Passive pedal force simulator assembly

Abstract

Embodiments herein relate to a pedal emulator assembly including a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall. A lower arm having a spring holding portion is formed therein. The pedal arm is pivotally coupled to the pedal arm and includes a pedal pad. A lever arm including a spring receiving portion is positioned within the cavity of the housing and pivotally coupled to the housing. A spring carrier including a compressible member extends between the spring receiving portion and the spring retaining portion. When a first predetermined load is applied to the pedal pad, the pedal arm drives the lever arm into the compressible member, and the compressible member compresses to an at least partially compressed state to generate a first restoring force on the pedal pad.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This utility model patent application claims priority to U.S. Provisional Patent Application No. 63 / 403,360 filed on September 2, 2022 and entitled "Passive Pedal Force Emulator Assemblies Having Friction and / or Lever Arms," ​​the entire contents of which are incorporated herein in their entirety. Technical Field

[0003] The present description relates generally to pedal assemblies for vehicles and, more particularly, to a passive force simulator for a pedal assembly having a mechanical resistance for damping and hysteresis depending on pedal movement. Background Art

[0004] Conventional vehicle pedal systems are used in vehicles to perform functions such as acceleration, braking, and clutch operation. Typically, these pedals are mechanically linked to the corresponding vehicle components they control, causing the driver of the vehicle to feel direct feedback when they press the pedal used in the pedal system. For example, a brake pedal can provide resistance when it pushes against the hydraulic fluid in the brake system. However, in many modern vehicles (such as electric vehicles and other autonomous vehicles), the direct mechanical linkage in the pedal system can be replaced by an electronic system. Although these electronic systems can provide easier integration, fewer mechanical parts, and weight reduction, they generally lack the tactile feedback for vehicle control that the driver expects and relies on. Therefore, a pedal simulator assembly that can reproduce the feel and feedback of a traditional mechanical pedal is needed. Summary of the invention

[0005] In an embodiment, a pedal simulator assembly is disclosed. The pedal simulator assembly includes a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall. A lower arm having a spring retaining portion is formed therein. A pedal arm is pivotally connected to the pedal arm and includes a pedal pad. A lever arm including a spring receiving portion is positioned within the cavity of the housing and is pivotally connected to the housing. A spring carrier including a compressible member extends between the spring receiving portion and the spring retaining portion. When a first predetermined load is applied to the pedal pad, the pedal arm drives the lever arm into the compressible member, and the compressible member is compressed to an at least partially compressed state to generate a first restoring force on the pedal pad.

[0006] In another embodiment, a pedal simulator assembly for a vehicle is disclosed. The pedal simulator assembly includes a housing mounted on a floor having a cavity defined by a pair of side walls, a first end wall, and a second end wall. A lower arm having a spring retaining portion formed therein is positioned in the cavity. A pedal arm is at least partially received in the cavity, the pedal arm having an inner surface, a pivot end, and an opposite pad end, and a pedal pad is attached to the pad end. A lever arm is positioned in the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising: a first end; a second end, which is positioned opposite to the first end; an apex, which is arranged at the first end; a hub, which is arranged at the second end; an upper frame portion and a lower frame portion, which are connected at the apex and the hub; and a spring receiving portion, which is positioned between the first end and the second end and within the lower frame portion. A spring carrier including a compressible member extends between the spring receiving portion and the spring retaining portion. When a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm drives the lever arm into the compressible member so that the compressible member is compressed to a compressed state to generate a first restoring force on the pedal pad.

[0007] In yet another embodiment, a pedal simulator assembly for a vehicle is disclosed. The pedal simulator assembly includes a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall. The pedal simulator assembly also includes a lower arm having a spring retaining portion formed therein. The pedal arm is at least partially received in the cavity, the pedal arm having a pivot end pivotally coupled to the housing, an opposite pad end to which a pedal pad is attached, and a nonlinear inner surface. A lever arm is positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm also including: a first end; a second end, which is positioned opposite to the first end; an apex, which is arranged at the first end; a hub, which is arranged at the second end; an upper frame and a lower frame, which are connected at the apex and the hub, the upper frame including an upper surface having a nonlinear profile; and a spring receiving portion, which is positioned in the lower frame between the first end and the second end. The pedal simulator assembly also includes a spring carrier, which includes a compressible member extending between the spring receiving portion and the spring retaining portion. When a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the upper surface of the upper frame of the lever arm, so that the lever arm is forced into the compressible member to generate a restoring force on the pedal pad.

[0008] These and additional features provided by the embodiments described herein will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The embodiments illustrated in the drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments may be understood when read in conjunction with the accompanying drawings, in which like structures are indicated by like reference numerals, and in which:

[0010] FIG. 1 schematically illustrates an example graphical representation of pedal travel versus applied force according to one or more embodiments shown and described herein;

[0011] FIG. 2 schematically illustrates an example graphical representation of pedal travel versus hysteresis force according to one or more embodiments shown and described herein;

[0012] 3A schematically depicts a left side perspective view of a first example pedal assembly according to one or more embodiments shown and described herein;

[0013] 3B schematically depicts a rear and left side perspective view of the pedal assembly of FIG. 3A according to one or more embodiments shown and described herein;

[0014] FIG3C schematically depicts an exploded perspective view of the pedal assembly of FIG3A according to one or more embodiments shown and described herein;

[0015] 3D schematically depicts a cross-sectional view of the pedal assembly of FIG. 3A taken along line 3 - 3 with the pedal arm in an undepressed state according to one or more embodiments shown and described herein;

[0016] 3E schematically depicts a cross-sectional view of the pedal assembly of FIG. 3A taken along line 3 - 3 with the pedal arm in a partially depressed state according to one or more embodiments shown and described herein;

[0017] 3F schematically depicts a cross-sectional view of the pedal assembly of FIG. 3A taken along line 3 - 3 with the pedal arm in a fully depressed state according to one or more embodiments shown and described herein;

[0018] 4A schematically depicts a left side perspective view of a second example pedal assembly according to one or more embodiments shown and described herein;

[0019] 4B schematically depicts a rear and left side perspective view of the pedal assembly of FIG. 4A according to one or more embodiments shown and described herein;

[0020] FIG4C schematically depicts an exploded perspective view of the pedal assembly of FIG4A according to one or more embodiments shown and described herein;

[0021] 4D schematically depicts a cross-sectional view of the pedal assembly of FIG. 4A taken along line 4 - 4 with the pedal arm in an undepressed state according to one or more embodiments shown and described herein;

[0022] 4E schematically depicts a cross-sectional view of the suspended pedal assembly of FIG. 4A taken along line 4 - 4 with the pedal arm in a partially depressed state according to one or more embodiments shown and described herein;

[0023] 4F schematically depicts a cross-sectional view of the suspended pedal assembly of FIG. 4A taken along line 4 - 4 with the pedal arm in a fully depressed state, according to one or more embodiments shown and described herein;

[0024] 5A schematically depicts a left perspective view of a third example pedal assembly utilizing friction within a slot to generate resistance according to one or more embodiments shown and described herein;

[0025] 5B schematically depicts a left side perspective view of the pedal assembly of FIG. 5A without the housing according to one or more embodiments shown and described herein;

[0026] FIG5C schematically depicts an exploded perspective view of the pedal assembly of FIG5A according to one or more embodiments shown and described herein;

[0027] 5D schematically depicts a cross-sectional view of the pedal assembly of FIG. 5A taken along line 5 - 5 with the pedal arm in an undepressed state according to one or more embodiments shown and described herein;

[0028] 5E schematically depicts a cross-sectional view of the pedal assembly of FIG. 5A taken along line 5 - 5 with the pedal arm in a partially depressed state according to one or more embodiments shown and described herein;

[0029] 5F schematically depicts a cross-sectional view of the suspended pedal assembly of FIG. 5A taken along line 5 - 5 with the pedal arm in a fully depressed state, according to one or more embodiments shown and described herein;

[0030] 6A schematically depicts a right side view of a fourth example pedal assembly utilizing a pivoting friction lever to generate resistance according to one or more embodiments shown and described herein;

[0031] 6B schematically depicts a perspective view of the pedal assembly of FIG. 6A with the pedal arm in an undepressed state according to one or more embodiments shown and described herein;

[0032] 6C schematically depicts a perspective view of the pedal assembly of FIG. 6A with the pedal arm in a partially depressed state according to one or more embodiments shown and described herein;

[0033] 6D schematically depicts a perspective view of the pedal assembly of FIG. 6A with the pedal arm in a fully depressed state according to one or more embodiments shown and described herein;

[0034] 7A schematically depicts a rear and right side perspective view of a fifth example pedal assembly utilizing rotating pedal arms to generate resistance according to one or more embodiments shown and described herein;

[0035] 7B schematically depicts a side view of the pedal assembly of FIG. 7A with the rotating pedal arm in an unengaged state according to one or more embodiments shown and described herein;

[0036] 7C schematically depicts a side view of the pedal assembly of FIG. 7A with the pedal arm in a partially engaged state according to one or more embodiments shown and described herein; and

[0037] 7D schematically depicts a side view of the pedal assembly of FIG. 7A with the pedal arm in a fully engaged state, according to one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0038] A brake pedal emulator (BPE) is a device that replaces the brake pedal and other hardware and is used on electromechanical brake systems where there is no direct mechanical or hydraulic connection between the brake pedal and the caliper. The BPE inputs are force and travel distance from the driver's foot, reference voltages for all sensors, ground for all sensors, reaction loads at all fastening points. The BPE outputs are force feedback / resistance of the driver's foot as a function of travel and speed, multiple pedal position sensor outputs as a function of travel, and error codes associated with the sensor outputs. An optional function is to adjust the output signal to provide the driver's expected brake input signal. The goal is for the BPE to behave as close to a conventional brake system as possible to the driver in terms of pedal feel and deceleration performance.

[0039] The BPE may be located in the driver's footwell area. The BPE needs to meet the same mechanical loads as a conventional pedal assembly and must function in a similar manner to a conventional pedal. For example, when considering applied load, lateral load, reverse load in relation to deflection and plastic deformation, the BPE needs to behave similarly to a conventional pedal.

[0040] Conventional brake pedal assemblies include a pedal mounting bracket with a pivotally attached pedal arm / lever that has certain pedal force characteristics that need to be met during the application stroke of the pedal. Therefore, the BPE needs to be constructed to meet these same certain pedal force characteristics. Further, in some embodiments, the BPE may also include a bottom dead center for the brake pedal stroke. Additionally, the BPE needs to be constructed to withstand emergency braking loads.

[0041] The BPE assembly disclosed herein meets the following criteria: The BPE function fails such that in the event of any failure, the driver is allowed to operate the brake system by applying the pedal and an appropriate sensor signal output is provided. The BPE is constructed to withstand the foreseeable conditions and abuse to which the pedal will be subjected. The BPE is scalable to automotive mass series production and is cost effective to manufacture and assemble.

[0042] Embodiments described herein relate to a pedal simulator assembly including a sensor adapted to sense the position and / or force of a pedal pad. The pedal simulator assembly is configured to simulate a brake fluid system based on a speed system, such as a hydraulic system. That is, the faster a driver depresses the pedal pad of a pedal, the harder the pedal is to depress, referred to herein as hepatic force.

[0043] When a pedal force (PE) is applied to the pedal, the pedal arm pivots to allow the pedal to travel. The pedal simulator assembly applies an opposing simulator force (EF) to provide the driver with a resistance that varies depending on the speed at which PE is applied. Typically, the pedal simulator assembly outputs three different force and travel segments corresponding to a specific range of travel, so that the driver feels a different resistance or tactile sensation based on the speed at which the pedal is depressed.

[0044] Various embodiments of the pedal simulator assembly are described in detail herein. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0045] As used herein, the term "communicatively connected" means that the connected components are able to exchange data signals and / or electrical signals with each other, for example, electrical signals via a conductive medium or a non-conductive medium (through a network such as via Wi-Fi, Bluetooth, etc.), electromagnetic signals via the air, optical signals via optical waveguides, etc.

[0046] As used herein, the term "longitudinal" refers to the front-to-back direction of an assembly (i.e., the + / -X direction depicted in FIG. 3A ). The term "lateral" refers to the direction across an assembly (i.e., the + / -Y direction depicted in FIG. 3A ), and is transverse to the longitudinal direction. The term "vertical" or "below" or "above" refers to the up-down direction of an assembly (i.e., the + / -Z direction depicted in FIG. 3A ).

[0047] Referring first to FIG. 1 , an example graphical representation of a desired force response curve for a pedal assembly, such as the various pedal assemblies depicted in FIGS. 3A to 7D , is depicted. It can be seen that as the pedal travels, the applied force required to generate tactile feedback increases. The force is non-linear and increases significantly near the end of the pedal travel. This type of force response is typically found in mechanical pedal designs where there is a connecting rod that is mechanically or hydraulically coupled to the brake caliper. When a pedal force (PE) is applied to the pedal, the pedal arm pivots to allow the pedal to travel. The simulator applies an opposite simulator force (EF) to provide the driver with a resistance that varies depending on the speed at which PE is applied.

[0048] For example, Figure 1 depicts three different forces corresponding to specific ranges of travel so that the driver of the vehicle feels varying resistance and / or tactile sensations based on the speed at which the pedal pad of the pedal assembly is depressed. In the first section, illustrated by bracket 102, the pedal arm is partially depressed by a first predetermined load or force, but minimal force is transmitted from the pedal arm to the other components of the simulator assembly discussed herein.

[0049] In the second section, as depicted by bracket 104, when the second predetermined amount of force is applied to the pedal assembly to have a stroke of approximately and not limited to 30-60 mm of the pedal arm, the slope needs to increase. Therefore, when the various pedal assemblies described herein are in multiple semi-compressed states or partially compressed states, this slope is desired. As illustrated, the upward slope of the curve depicted in Figure 1 indicates that the greater the distance traveled by the pedal pad of the pedal assembly, the greater the force acting on the pedal pad, so that the driver's foot feels the desired tactile response, such as force feedback. Bracket 102 depicts the first force feedback or the first restoring force, and bracket 104 depicts the second force feedback or the second restoring force, which is felt by the driver while applying the second predetermined amount of load to the pedal pad. Therefore, the second force feedback or the second restoring force is a force greater than the first force feedback or the first restoring force, which is felt by the driver while applying the second predetermined amount of load to the pedal pad. Further, the second predetermined amount of load to the pedal pad is greater than the first predetermined amount of load to the pedal pad.

[0050] In these embodiments, it should be understood that the pedal travel amount (depicted as the last 10 millimeters of travel, which may correspond to the third segment depicted by bracket 106) may produce the maximum increase in force when the third predetermined force is applied to the pedal pad. Therefore, bracket 106 depicts the third force feedback or third restoring force felt by the driver while the third predetermined amount of load is applied to the pedal pad. Therefore, the third force feedback or third restoring force is a greater force than the second force feedback or second restoring force, which is felt by the driver while the third predetermined amount of load is applied to the pedal pad. Further, the third predetermined amount of load to the pedal pad is greater than the second predetermined amount of load to the pedal pad.

[0051] Various pedal assemblies and their corresponding simulators will be described in greater detail herein with reference to FIGS. 3A-7D .

[0052] Referring now to FIG. 2 , an example graphical representation of the desired mechanical hysteresis force as a function of force as a function of pedal position is depicted. As can be seen in the figure, the curve has a shape similar to the applied force represented in FIG. 1 . For example, the restoring force depicted in FIG. 2 may have an upward slope corresponding to the upward slope of the target force per pedal travel distance depicted in FIG. 1 . It should be understood that in these embodiments, it is desirable to have such a force response in a drive-by-wire braking system without a mechanical linkage. Such a system would include a brake pedal simulator that replaces the mechanically linked brake pedal. As described above, various embodiments of the brake pedal simulator will be described in more detail herein with reference to FIGS. 3A to 7D .

[0053] Referring now to FIGS. 3A to 3F , a schematic representation of a first embodiment of a pedal simulator assembly 300 that utilizes sliding friction to generate resistance is shown. In this embodiment, the pedal simulator assembly 300 is depicted as a pedal assembly mounted on a base plate. This is non-limiting, and the pedal assembly can be a suspended, accordion-type, or other type of pedal assembly. The pedal simulator assembly 300 includes a pedal arm 302 and a housing 304. The pedal arm 302 includes a pivot end 306 and an opposing pad end 308, wherein a pedal pad 310 is attached to the pad end 308. The pedal arm 302 includes an outer surface 312a and an opposing inner surface 312b. The cavity 313 of the pedal arm 302 is defined by a pair of opposing walls 315a, 315b, an outer wall 315c, and an inner surface 312b of the pedal arm 302. The inner surface 312b is positioned to face the cavity 314 of the housing 304, and portions of the pair of opposing walls 315a, 315b are received within the cavity 314 of the housing 304. In some embodiments, the inner surface 312b of the pedal arm 302 may not be a uniform, linear, and / or smooth contour surface, and alternatively, the contour of the inner surface 312b may include an inclined portion 317a, an arcuate portion 317b, a protrusion 317c, a notch 317d, etc. In other embodiments, the inner surface 312b of the pedal arm 302 may be a linear or uniform contour. The cavity 314 of the housing 304 may be defined by a pair of side walls 316a, 316b, a first end wall 316c, and a second end wall 316d. Further, the cavity includes an inner surface 319 formed by the pair of side walls 316a, 316b, the first end wall 316c, and the second end wall 316d.

[0054] In the embodiments described herein, the housing 304 including the side walls 316, 316b, the first end wall 316c, and the second end wall 316d can be molded plastic. For example, the housing 304 can be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. can be added.

[0055] In other embodiments, the housing 304 and the pedal arm 302 may be formed by injection molding or other additive manufacturing techniques. For example, as provided herein, additive manufacturing techniques generally refer to manufacturing processes in which successive layers of material are placed on top of each other to "build up" a three-dimensional component layer by layer. Successive layers are typically fused together to form an integral component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building up objects typically point by point and layer by layer in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer additive process, a layer subtractive process, or a hybrid process.

[0056] Additionally, it should be understood that the housing 304 can be floor mounted. That is, in some embodiments, the housing 304 can be coupled or mounted to be positioned within or extend from a floor surface of a vehicle. Thus, the cavity 314 of the housing 304 accommodates the pedal arm 302 in a fully depressed state to allow full travel of the pedal pad 310.

[0057] Still referring to FIGS. 3A to 3F , the pedal simulator assembly 300 may also include a lever arm 318 positioned within the cavity 314 of the housing 304 and pivotally coupled between a pair of side walls 316a, 316b. The lever arm 318 includes a first end 322a and an opposite second end 322b. Further, the lever arm 318 includes an upper frame 330 and a lower frame 332 connected at a vertex 328 at the first end 322a and a hub 336 at the second end 322b. A plurality of support members 334 extend between the upper frame 330 and the lower frame 332 to ensure the integrity of the lever arm 318 when the pedal arm 302 is depressed.

[0058] As further depicted in FIGS. 3A to 3F , a hub 336 positioned at the second end 322b of the lever arm 318 is pivotally connected to the pair of side walls 316a, 316b of the housing 304 via an attachment portion 321 extending between the pair of side walls 316a, 316b. The attachment portion 321 may include a pair of receiving slots 323 configured to receive a circumferential wall 325 or a continuous circular wall of the lever arm 318 extending laterally (i.e., + / -Y direction) from the second end 322b. For example, the hub 336 may be coupled to the pair of side walls 316a, 316b using a press fit, a through pin, etc. In other embodiments, a protrusion may extend from each of the pair of side walls 316a, 316b to be received by the hub 336 so that the hub 336 may pivot relative to the pair of side walls 316a, 316b. However, it should be understood that the hub 336 may be coupled to the pair of side walls 316a, 316b via any suitable coupling that allows the hub 336 to pivot. By pivotally coupling the hub 336 between the pair of side walls 316a, 316b, the lever arm 318 may rotate about the hub 336 when the inner surface 312b of the pedal arm 302 contacts the upper frame 330 of the lever arm 318, as will be described in greater detail herein.

[0059] As further depicted in Figures 3A to 3F, the upper frame 330 includes a surface 331 having a nonlinear profile that extends between the first end 322a and the second end 322b of the lever arm 318 and through the vertex 340 of the upper frame 330. For example, as best depicted in Figures 3D to 3F, the first portion 327 of the upper frame 330 (e.g., the portion extending between the first end 322a and the vertex 340) can have a first slope, while the second portion 329 of the upper frame 330 (e.g., the portion extending between the vertex 340 and the second end 322b) can have a second slope different from the first slope, which can provide a nonlinear profile for the surface 331 of the upper frame 330. In these embodiments, the first slope of the first portion 327 can be greater than (e.g., steeper than) the second slope of the second portion 329, which can help ensure that the appropriate force is provided when the pedal is depressed. The operation of the pedal simulator assembly 300 will be described in more detail herein with reference to Figures 3D to 3F.

[0060] In the embodiments described herein, the lever arm 318 may further include a spring receiver 320 positioned in the lower frame 332 between the first end 322a and the second end 322b.

[0061] A spring carrier 343 including a compressible member such as at least one spring 326 may extend between a spring receiving portion 320 of the lever arm 318 and a spring retaining portion 324 formed in the lower arm 341. The lower arm 341 may be fixedly coupled to a floor surface and / or inner surface 319 of the cavity, etc.

[0062] The lower arm 341 also includes an upper portion 365a and an opposing lower portion 365b. The lower portion 365b is coupled to the housing 304 via a lower arm protrusion 366 extending from the lower portion 365b of the lower arm 341. In these embodiments, the lower arm protrusion 366 of the lower arm 341 is received in a recess 370 of the housing 304 formed in the second end wall 316d. The upper portion includes an engagement surface 367 that is configured to receive a portion of a vertex 328 of the junction of the upper frame 330 and the lower frame 332 of the lever arm 318 based on the amount of travel of the pedal arm 302. For example, as best illustrated in FIG. 3F , the vertex 328 is illustrated as abutting, engaging, or otherwise communicating with the engagement surface 367 of the lower arm 341 when the pedal arm 302 is in a fully compressed position, thereby increasing the pedal force felt by the driver.

[0063] The lower arm 341 may also include a recessed portion 361 configured to receive a pivot portion 363 rotatably or movably coupled to the pivot end 306 of the pedal arm 302 such that the pedal arm pivots or rotates or otherwise moves the pivot portion 363 within the recessed portion 361 of the lower arm 341 .

[0064] Thus, a portion of the spring carrier 343 may be received within the cavity 313 of the pedal arm 302, and a portion may be received within the cavity 314 of the housing 304. In some embodiments, the spring carrier 343 may be coupled to the spring receiving portion 320 of the lever arm 318 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded node, etc. In other embodiments, the spring carrier 343 may be coupled to the spring receiving portion 320 of the lever arm 318 via a press-fit configuration, a tension fit, etc. Further, in some embodiments, the spring carrier 343 may be coupled to the spring retaining portion 324 of the lower arm 341 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded node, etc. In other embodiments, the spring carrier 343 may be coupled to the spring retaining portion 324 of the lower arm 341 via a press-fit configuration, a tension fit, etc.

[0065] The spring carrier 343 also includes a concave spring guide 345 and a convex spring guide 347, which includes an elongated member 355 that is configured to extend and engage with the concave spring guide 345 and compress into a void or cavity in the convex spring guide 347 based on tension or force applied to the spring carrier 343. It should be understood that this is non-limiting and the elongated member 355 can be configured to extend and engage with the convex spring guide 347 and compress into a void or cavity in the concave spring guide 345 based on tension or force applied to the spring carrier 343.

[0066] The concave spring guide 345 and the convex spring guide 347 are coupled to each other (e.g., via the elongated member 355) within the inner diameter of the at least one spring 326, such that the at least one spring 326 extends between and contacts the spring receiving surface 349a of the concave spring guide 345 and the spring receiving surface 349b of the convex spring guide 347. This arrangement holds the at least one spring 326 while allowing the at least one spring 326 to expand and compress depending on the amount of travel of the pedal arm 302, as discussed in more detail herein.

[0067] The protrusion 351 extends from the male spring guide 347 to serve as a connection point to pivotally connect the male spring guide 347 to the corresponding slot 353 in the spring retaining portion 324 of the lower arm 341 in a press-fit or tension-fit connection. In other embodiments, the protrusion 351 of the male spring guide 347 can be connected to the corresponding slot 353 via a fastener (such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc.).

[0068] The tension caused by the at least one spring 326 disposed between the male spring guide 347 and the female spring guide 345, which are configured to move to compress the at least one spring 326, can keep the female spring guide 345 in contact with or seated in the spring receiving portion 320 of the lever arm 318, and keep the male spring guide 347 in contact with or seated in the spring holding portion 324 formed in the lower arm 341. Therefore, regardless of the amount of travel of the pedal arm 302, there is tension caused by the male spring guide 347 and the female spring guide 345, thereby maintaining the contact position of the spring carrier 343 extending between the lever arm 318 and the lower arm 341.

[0069] At least one spring 326 biases the lever arm 318 into the inner surface 312b (e.g., via the first end 322a as described herein) with sufficient force to maintain the pedal pad 310 in an initial or undepressed position so that the pedal pad 310 is accessible to the driver, as best illustrated in FIG. 3D.

[0070] Although the pedal simulator assembly 300 depicted in Figures 3A to 3F is illustrated as including a single spring as the at least one spring 326, it should be understood that in some embodiments, multiple springs may extend between the spring receiving portion 320 and the spring retaining portion 324 formed in the lower arm 341. The multiple springs can be coaxially aligned so that the at least one spring 326 has an outer diameter that is less than the inner diameter of the at least one spring 326 so as to be positioned within the inner diameter of the at least one spring 326, whichever is greater. For example, in some embodiments, the multiple springs can be used to ensure that the pedal simulator assembly 300 remains functional in the event of at least one of the springs failing (e.g., breaking, detaching from the spring retaining portion, etc.). In these embodiments, the at least one spring 326 can be a coil spring. In other embodiments, the at least one spring 326 can be a torsion spring, a tension spring, a conical spring, etc. The at least one spring 326 can be formed of a steel material, such as stainless steel, wire, carbon steel, alloy steel, Elgiloy non-magnetic alloy, Copper, nickel, etc.

[0071] The operation of the pedal simulator assembly 300 will now be discussed in detail with reference to FIGS. 3D to 3F . For example, as depicted in FIG. 3D , the pedal simulator assembly 300 is in an initial or undepressed position, and / or is subjected to a first predetermined load L1. In this position, the pedal pad 310 extends away from the housing 304 in the longitudinal direction (e.g., + / -X direction) such that the inner surface 312b of the pedal arm 302 contacts only the first end 322a of the lever arm 318. In these embodiments, the at least one spring 326 may be in a substantially unbiased (e.g., fully extended) position such that the at least one spring 326 applies only minimal resistance to maintain the positioning of the pedal arm 302. Thus, the first predetermined load L1 may be sufficient to force the at least one spring 326 to be compressed a predetermined distance, and the pedal arm may slidably contact or slidably engage a portion of the nonlinear profile of the surface 331 of the upper frame 330 of the lever arm 318 to achieve the desired curve illustrated by bracket 102 in FIG. 1 .

[0072] 3E , when a second predetermined load L2 is applied to the pedal pad 310 in the direction indicated by arrow A1, the pedal arm 302 moves or pivots about the pivot end 306, as indicated by arrow A2, to allow the pad end 308 to move into the housing 304 based on the amount of force applied to the pedal pad 310 and the current position of the pedal arm 302. For example, as depicted in FIG3E , the pad end 308 may partially move into the housing 304, causing the at least one spring 326 to be partially compressed and generate a restoring force or force feedback on the pedal pad 310 corresponding to the amount of force applied to the pedal pad 310 by the driver.

[0073] At the same time, in addition to compressing the at least one spring 326, the inner surface 312b of the pedal arm 302 may abut or ride against the surface 331 of the upper frame 330. In these embodiments, the amount of force applied to the pedal pad 310 (e.g., via the driver) may correspond to the pedal effort and / or resistance felt by the driver during depression of the pedal pad 310. More specifically, the mechanical advantage of the pedal arm 302 against the at least one spring 326 may determine the pedal effort and / or resistance felt by the driver during depression of the pedal pad 310. In these embodiments, the mechanical advantage between the pedal arm 302 and the at least one spring 326 refers to the ratio of the force applied by the at least one spring 326 relative to the force applied to the pedal arm 302 via contact between the driver and the pedal pad 310.

[0074] Still referring to FIG. 3E , a greater portion of the nonlinear profile of the surface 331 of the upper frame 330 of the lever arm 318 can further ride against or be in sliding contact or sliding engagement with the inner surface 312 b of the pedal arm 302, thereby generating a greater pedal force experienced by the driver, as illustrated by bracket 104 in FIG. 1 . Further, the at least one spring 326 can still be compressed, thereby providing additional pedal force. In these embodiments, the effective force applied by the at least one spring 326 can depend on the profile of the surface 331 of the upper frame 330 relative to the profile of the inner surface 312 b of the pedal arm 302 that contacts the upper frame 330.

[0075] For example, in the embodiments depicted in FIGS. 3D-3F , the profile of the inner surface 312 b of the pedal arm 302 may be similar to the profile of the first portion of the upper frame 330 (e.g., the portion between the first end 322 a and the apex 340). Thus, when the pedal arm 302 is partially depressed, as best depicted in FIG. 3E , the force applied to the driver's foot may be less because the similar profiles of the inner surface 312 b of the pedal arm 302 and the first portion of the upper frame 330 may be used to balance the force applied by the at least one spring 326. In these embodiments, the force applied to the driver's foot may simulate the reach or ease of a conventional brake pedal, which is depicted in bracket 104 of FIG. 1 .

[0076] As the pedal arm 302 is further depressed, the inner surface 312b of the pedal arm 302 may engage a different portion of the upper frame 330. As the profile of the upper frame 330 changes, the upper frame 330 may provide an increasing mechanical advantage against the at least one spring 326, thereby simulating a gradual increase in resistance or pedal effort felt by the driver.

[0077] When the profile of the upper frame 330 deviates from the profile of the inner surface 312b of the pedal arm 302, the mechanical advantage against the at least one spring 326 can be increased. For example, as depicted in Figures 3D-3F, the slope of the second portion 329 of the upper frame 330 (e.g., the portion between the vertex 340 and the second end 322b) can be significantly different from the slope of the inner surface 312b of the pedal arm 302. Therefore, when the inner surface 312b of the pedal arm 302 contacts the second portion 329 of the upper frame 330, the force provided by the at least one spring 326 acts at a certain angle, thereby increasing the mechanical advantage or pedal force against the pedal arm 302.

[0078] For example, when the pedal arm 302 moves from a partially depressed position (as depicted in FIG. 3E ) to a fully depressed position (as depicted in FIG. 3F ), ​​the inner surface 312 b of the pedal arm 302 may transition from engaging the first portion 327 of the upper frame 330 to engaging the second portion 329 of the upper frame 330. When the inner surface 312 b of the pedal arm 302 contacts the second portion 329 of the upper frame 330, the mechanical advantage and / or pedal force against the at least one spring 326 may be maximized, thereby maximizing the force applied back to the pedal arm 302 (and thereby the driver's foot).

[0079] Therefore, it should be understood that the various profiles of the inner surface 312b, the surface 331 of the upper frame 330 of the lever arm 318, and the at least one spring 326 provide the pedal force / resistance felt by the driver at the pedal pad 310. The force applied by the at least one spring 326 and the various profiles of the surface 331 of the inner surface 312b applied against the non-linear surface of the upper frame 330 of the lever arm 318 apply different forces at corresponding travel positions of the pedal arm 302, wherein the surface 331 with the non-linear profile applies a desired force to the pedal arm 302. The combination of the at least one spring 326 and the various profiles of the inner surface 312b applied against the surface 331 of the upper frame 330 of the lever arm 318 results in a synthesis of forces to provide a desired force curve.

[0080] Referring again to Fig. 3A to Fig. 3F, in the embodiments described herein, the pedal simulator assembly 300 may also include a sensor assembly 350. In these embodiments, the sensor assembly 350 may include a printed circuit board including at least one Hall effect chip and a magnet positioned at any position within the housing 304, which moves to detect the movement of the pedal arm 302 and / or at least one spring 326 via Hall effect sensing technology. Therefore, the sensor assembly 350 may be configured to track the position of the pedal arm 302 and the force applied to the driver's foot. In other embodiments, inductive sensing technology may be applied to sense a coupling member that moves to detect the movement of the pedal arm 302 and / or at least one spring 326.

[0081] Turning now to FIGS. 4A to 4E , a second example embodiment of a pedal simulator assembly 400 that utilizes friction to generate resistance is schematically depicted. In these embodiments, the pedal simulator assembly 400 includes a pedal arm 402 and a housing 404. The pedal arm 402 includes a pivot end 406 and an opposing pad end 408, wherein a pedal pad 410 is attached to the pad end 408. The pedal arm 402 includes an outer surface 412a and an opposing inner surface 412b. A protrusion 413 extends from the inner surface 412b of the pedal arm 402. In some embodiments, the protrusion 413 can be shaped to have a circular contact surface 415. In other embodiments, the protrusion 413 can be any shape, including but not limited to an octagon, a hexagon, a triangle, a cone, a square, etc. A portion of the pedal arm 402 can be received in a cavity 414 of the housing 404.

[0082] The cavity 414 of the housing 404 is defined by a pair of side walls 416a, 416b, an end wall 416c and a top wall 416d. The pivot end 406 of the pedal arm 402 is pivotally connected to the pair of side walls 416a, 416b via an elongated member 417, so that the pedal arm 402 can rotate around the pivot end 406 in the direction indicated by arrow A4. The housing 404 is configured to be mounted to an instrument panel, a bracket, etc., so that the housing 404 is supported above the floor of the vehicle. Within the cavity 414 of the housing 404 is a lever arm 418 pivotally connected between the pair of side walls 416a, 416b. The lever arm 418 includes a first end 420a and an opposite second end 420b. Further, the lever arm 418 includes an outer surface 419a and an opposite inner surface 419b, which are separated by a plurality of honeycomb members 419c. Further, the outer surface 419a includes an engagement surface 422 positioned to extend along the outer surface 419a from the first end 420a. The engagement surface 422 may be configured to abut and / or receive the contact surface 415 of the protrusion so that the protrusion 413 can be slidably engaged with the engagement surface 422. Both the outer surface 419a and the engagement surface 422 are non-linear and may have arcuate and / or curved portions.

[0083] Further, the lever arm 418 includes a protrusion 423 extending from the inner surface 419b, which is configured to be received within a recess 427 of the inner surface 429 of the end wall 416c within the cavity 414. Therefore, the interaction between the protrusion 423 and the recess 427 allows the lever arm 418 to pivot or otherwise move a predetermined amount within the cavity 414 based on the load applied to the pedal pad 410.

[0084] The spring carrier 426 includes a pedal end 428a and an opposing lever arm end 428b. The spring carrier 426 extends between the pivot end 406 of the pedal arm 402 and the first end 420a of the lever arm 418. The pedal end 428a is coupled to a hub receiver 430 coupled to the pivot end 406 of the pedal arm 402, and the lever arm end 428b is coupled to the first end 420a of the lever arm 418. The second end 420b of the lever arm 418 is adapted to receive at least one spring 436 extending between the lever arm 418 and the hub receiver 430.

[0085] In some embodiments, the spring carrier 426 can be coupled to the spring receiving portion 421 of the lever arm 418 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc. In other embodiments, the spring carrier 426 can be coupled to the spring receiving portion 421 of the lever arm 418 via a press fit configuration, a tension fit, etc. Further, in some embodiments, the spring carrier 426 can be coupled to the spring carrier retaining portion 438 of the pedal arm 402 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc. In other embodiments, the spring carrier 426 can be coupled to the spring carrier retaining portion 438 of the pedal arm 402 via a press fit configuration, a tension fit, etc.

[0086] The spring carrier 426 also includes a female spring guide 445 and a male spring guide 447, which includes an elongated member 455 that is configured to extend and engage with the female spring guide 445 and compress into a void or cavity in the male spring guide 447 based on tension or force applied to the spring carrier 426. It should be understood that this is non-limiting and the elongated member 455 can be configured to extend and engage with the male spring guide 447 and compress into a void or cavity in the female spring guide 445 based on tension or force applied to the spring carrier 426. The male spring guide 447 includes a first end 426a and an opposite second end 426b, the first end 426a being configured to engage with the pedal arm at the pivot end 406, and the second end 426 being positioned at the female spring guide 445.

[0087] The concave spring guide 445 and the convex spring guide 447 are coupled to each other (e.g., via the elongated member 455) within the inner diameter of the at least one spring 436, such that the at least one spring 436 extends between and contacts the spring receiving surface 449a of the concave spring guide 445 and the spring receiving surface 449b of the convex spring guide 447. This arrangement holds the at least one spring 436 while allowing the at least one spring 436 to expand and compress depending on the amount of travel of the pedal arm 402, as discussed in more detail herein.

[0088] The tension caused by the at least one spring 436 disposed between the male spring guide 447 and the female spring guide 445, which are configured to move to compress the at least one spring 436, can keep the female spring guide 445 in contact with or seated in the spring receiving portion 421 of the lever arm 418, and keep the male spring guide 447 in contact with or seated in the spring carrier holding portion 438 formed in the pedal arm 402. Therefore, regardless of the amount of travel of the pedal arm 402, there is tension caused by the male spring guide 447 and the female spring guide 445, thereby maintaining the contact position of the spring carrier 426 extending between the lever arm 418 and the pedal arm 402.

[0089] Still referring to Figures 4A to 4E, the pedal simulator assembly 400 also includes an elastomeric member 432 positioned within a recess 434 of the housing 404. The recess 434 is positioned below the cavity 414 so that the elastomeric member 432 is positioned to align with the inner surface 412b of the pedal arm 402 at the pad end 408 so that when the pedal arm 402 moves or rotates a predetermined distance, the inner surface 412b of the pedal arm 402 at the pad end 408 contacts to compress the elastomeric member 432.

[0090] In the embodiments described herein, the housing 404 and the pedal arm 402 may be molded plastic. For example, the housing 404 and the pedal arm 402 may be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0091] In other embodiments, the housing 404 and the pedal arm 402 may be formed by injection molding or other additive manufacturing techniques. For example, as provided herein, additive manufacturing techniques generally refer to manufacturing processes in which successive layers of material are placed on top of each other to "build up" a three-dimensional component layer by layer. Successive layers are typically fused together to form an integral component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building up objects typically point by point and layer by layer in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer additive process, a layer subtractive process, or a hybrid process.

[0092] The operation of the pedal simulator assembly 400 will now be described in detail with reference to FIGS. 4D to 4F . Initially, FIG. 4D depicts the pedal simulator assembly 400 in an uncompressed (e.g., initial or default) position and / or subjected to a first predetermined load L1. In these embodiments, the lever arm 418 is also positioned in the initial position such that the inner surface 412b of the pedal arm exerts only a minimal force on the lever arm 418. Thus, the first predetermined load L1 may be sufficient force to compress the pedal arm 402 a predetermined distance such that the pedal arm 402 slidably contacts or slidably engages the engagement surface 422 of the lever arm to achieve the desired curve illustrated by bracket 102 in FIG. 1 . Thus, it should also be understood that when the first predetermined load L1 is applied to the pedal arm, as depicted in FIG. 4D , at least one spring 436 and the elastomeric member 432 positioned within the recess 434 of the housing 404 are similarly uncompressed.

[0093] When a second predetermined load L2 greater than the first predetermined load L1 is applied to the pedal pad 410 in the direction indicated by arrow A3, the pedal arm 402 moves or pivots about the pivot end 406 based on the amount of force applied to the pedal pad 410, as indicated by arrow A4. In these embodiments, the coupling of the pivot end 406 to the pair of side walls 416a, 416b allows the pedal arm 402 to move in an arcuate trajectory. At the same time, the movement of the pedal arm 402 is transmitted via the spring carrier 426 to compress the at least one spring 436. In these embodiments, the second predetermined load L2 applied to the pedal (e.g., in the direction indicated by arrow A3) can cause the pedal pad 410 to move to a partially compressed position corresponding to the second bracket 104 depicted in FIG. 1.

[0094] Still referring to FIG. 4E , and as described herein, the outer surface 419a of the lever arm 418 can be configured to interact with the inner surface 412b of the pedal arm 402. Because each of the outer surface 419a of the lever arm 418 and the inner surface 412b of the pedal arm 402 are non-linear surfaces, different portions of the outer surface 419a of the lever arm 418 contact the inner surface 412b of the pedal arm 402 when the pedal arm 402 is depressed, wherein various portions of the inner surface 412b of the pedal arm provide variable amounts of friction on the engagement surface 422 of the lever arm 418.

[0095] In the embodiments described herein, it should be understood that the variability of the friction force acting on the outer surface 419a of the lever arm 418 can be used to produce a desired force curve. For example, when the pedal arm 402 is depressed, the resistance provided to the driver by the pedal arm 402 is not consistent and / or linear; instead, the resistance of the pedal arm 402 varies to mimic the feel of a traditional vehicle pedal. In these embodiments, the outer surface 419a of the lever arm 418 and the surface of the engagement surface 422 can be manipulated to obtain the desired force curve depicted in Figures 1 and 2, as will be described herein.

[0096] For example, when the pedal arm 402 is depressed, the pivotal motion of the pedal arm 402 is converted to pivot the lever arm 418. For example, when the pedal arm 402 rotates, the inner surface 412b of the pedal arm 402 slides against the engagement surface 422 of the pedal arm 402, causing the lever arm 418 to pivot. Therefore, it should be understood that the amount of contact between the outer surface 419a of the lever arm 418 and the inner surface 412b of the pedal arm can determine the friction force that exists between the two components, and in turn, the resistance provided by the pedal arm 402.

[0097] 1 and 2, the inner surface 412b of the pedal arm and the outer surface 419a of the lever arm 418 can be configured so that the two surfaces gradually contact each other when the pedal arm 402 is depressed. For example, a portion of the outer surface 419a of the lever arm 418 and / or the inner surface 412b of the pedal arm can be textured, include a plurality of ridges, or otherwise include a non-linear portion (e.g., curved) so that when the pedal arm 402 is depressed, the contact between the inner surface 412b of the pedal arm 402 and the outer surface 419a of the lever arm 418 increases. Therefore, the increase in friction between the inner surface 412b of the pedal arm 402 and the outer surface 419a of the lever arm 418 when the pedal arm 402 is depressed can similarly increase the resistance provided by the pedal arm 402, thereby generating the desired force curve depicted in FIGS. 1 and 2.

[0098] 4E , when the second predetermined load L2 is applied to the pedal arm 402, the second end 420b of the lever arm 418 (e.g., the end connected to the spring mechanism) may compress the spring to further increase the resistance provided by the pedal arm 402. As should be appreciated, as the pedal arm 402 is depressed and the lever arm 418 continues to pivot, the spring may become increasingly compressed, thereby increasing the resistance provided by the pedal arm 402. In these embodiments, variations in the type of spring and the compression characteristics of the spring may further affect the resistance provided by the pedal arm 402 when the pedal arm 402 is depressed.

[0099] Turning now to FIG. 4F , the pedal simulator assembly 400 is depicted in a fully compressed position, wherein a third predetermined load L3 is applied to the pedal arm 402. In these embodiments, when the third predetermined load L3 is applied to the pedal pad 410, the inner surface 412b of the pedal arm 402 contacts and compresses the elastomeric member 432. In these embodiments, when the pedal arm 402 contacts the elastomeric member 432, the elastomeric member 432 can resist compression, thereby providing additional resistance to the pedal arm 402. In particular, the additional resistance provided by the elastomeric member 432 can correspond to the third segment of the desired force curve depicted by bracket 106 shown in FIG. 1 .

[0100] Referring again to FIGS. 4A to 4F , in the embodiments described herein, the pedal simulator assembly 400 may also include a sensor assembly 450. In these embodiments, the sensor assembly 450 may include a printed circuit board including at least one Hall effect chip and a magnet positioned anywhere within the housing 404 that moves to detect movement of the pedal arm 402 and / or the lever arm 418 via Hall effect sensing techniques. In other embodiments, inductive sensing techniques may be applied to sense a coupling that moves to detect movement of the pedal arm 302 and / or at least one spring 326. Thus, the sensor assembly 450 may be configured to track the position of the pedal arm 402 and the force applied to the driver's foot.

[0101] In view of the above, it should be understood that the spring, the nonlinear profiles of the outer surface 419a and the engagement surface 422, and the elastomeric member 432 provide the pedal force / resistance felt by the driver during depression of the pedal pad 310. That is, the various profiles of the outer surface 419a and the engagement surface 422, at least one spring, and the elastomeric member 432 provide the pedal force / resistance felt by the driver at the pedal pad 410, and apply different forces at corresponding travel positions, wherein the elastomeric member 432 applies significant force to the pedal arm 402. The combination of the profiles of the outer surface 419a and the engagement surface 422, at least one spring, and the elastomeric member 432 results in a synthesis of forces to provide a desired force curve.

[0102] 5A-5F, a third example embodiment of a pedal simulator assembly 500 utilizing slots to generate frictional resistance is schematically depicted. The pedal simulator assembly 500 includes a pedal arm 502 and a housing 504. The pedal arm 502 includes a pivot end 506 and an opposing pad end 508, wherein a pedal pad 510 is attached to the pad end 508.

[0103] The pedal arm 502 includes an outer surface 512a and an opposite inner surface 512b. The cavity 513 of the pedal arm 502 is defined by a pair of opposite walls 515a, 515b of the pedal arm 502, an outer wall 515c, and the inner surface 512b. The inner surface 512b is positioned to face the cavity 514 of the housing, and portions of the pair of opposite walls 515a, 515b are received in the cavity 514 of the housing 504. The cavity 514 of the housing 504 is defined by a pair of side walls 516a, 516b, a first end wall 516c, and a second end wall 516d. Further, the cavity includes an inner surface 519 formed by the pair of side walls 516a, 516b, the first end wall 516c, and the second end wall 516d.

[0104] In some embodiments, housing 504 may be configured to be mounted to the floor of a vehicle. In other embodiments, housing 504 may be configured to be mounted to any component within the passenger compartment of a vehicle, such as an instrument panel, a firewall, etc.

[0105] In the embodiments described herein, the housing 504 and the pedal arm 502 may be molded plastic. For example, the housing 504 and the pedal arm 502 may be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0106] In other embodiments, the housing 504 and the pedal arm 502 may be formed by injection molding or other additive manufacturing techniques. For example, as provided herein, additive manufacturing techniques generally refer to manufacturing processes in which successive layers of material are placed on top of each other to "build up" a three-dimensional component layer by layer. Successive layers are typically fused together to form an integral component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building objects up point by point and layer by layer, typically vertically, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer additive process, a layer subtractive process, or a hybrid process.

[0107] Still referring to Figures 5A to 5F, the pedal simulator assembly 500 can also include a pair of slots 518, which extend through a pair of opposing walls 515a, 515b respectively between the pivot end 506 and the pad end 508 and below the inner surface 512b of the pedal arm 502 in the vertical direction (i.e., + / -Z direction). Each of the pair of slots 518 extends in the longitudinal direction (i.e., + / -X direction). In these embodiments, a link arm 520 having a support end 522 and a coupling end 524 is positioned in the cavities 513, 514 and movably coupled to the pair of slots 518. The coupling end 524 can be pivotally or movably coupled to the lower arm 526. The support end 522 includes a pair of ears 528 extending from the body 530. Each of the pair of ears 528 is spaced and / or sized to align with the pair of slots 518 in the lateral direction (i.e., + / -Y direction). Each of the pair of ears 528 includes an aperture 532 extending therethrough. The aperture 532 receives an elongated member 533 having a circumferential outer surface 535 having a smaller diameter than the aperture 532. The circumferential outer surface 535 can be a smooth contour and is configured to slidably engage with the pair of slots 518 and the upper lever arm 534, as discussed in more detail herein. The elongated member 533 has a pair of terminal ends 537 having a diameter greater than each of the pair of slots 518. In some embodiments, the elongated member 533 can be a through pin or other elongated type of member to slidably couple the support end 522 of the link arm 520 to the pedal arm 502. The coupling end 524 is pivotally coupled to the lower arm 526 so that the link arm 520 can pivot or otherwise move relative to the lower arm 526 depending on the amount of load applied to the pedal arm 502, as will be described in more detail herein with reference to FIGS. 5D-5F.

[0108] As further depicted in FIGS. 5A to 5F , the upper lever arm 534 is pivotally connected between a pair of side walls 516a, 516b. The upper lever arm 534 includes a first end 536a and an opposite second end 536b. Further, the upper lever arm 534 includes an upper frame portion 538 and a lower frame portion 540, which are separated and connected by a plurality of honeycomb support members 544. When the first predetermined load L1 is applied to the pedal pad 510, the upper frame portion 538 and the lower frame portion 540 may be connected or abutted at a vertex 542, which may be positioned at and / or between a pair of ears 528 of the support end 522 of the link arm 520. The second end 536b is pivotally connected to the pair of side walls 516a, 516b. In some embodiments, a through pin 543 may be used to pivotally connect or otherwise movably connect the second end 536b to a pair of side walls 516a, 516b. In other embodiments, a protrusion may extend from each of the pair of side walls 516a, 516b to be received by the second end 546b. The upper lever arm 534 also includes a spring receiving portion 546 positioned between the first end 536a and the second end 536b and extending within the lower frame portion 540.

[0109] 5A-5F, the upper frame portion 538 includes an engagement surface 549 and an upper surface 550. The engagement surface 549 may have a non-linear profile or reverse profile adapted to receive, abut, or otherwise slidably engage the circumferential outer surface 535 of the elongated member 533 such that the circumferential outer surface 535 rides along the engagement surface 549 based on the amount of load applied to the pedal pad 510, as will be described in greater detail herein.

[0110] The lower arm 526 includes a first end 546a extending from and pivotally coupled to the pivot end 506 of the pedal arm 502 and an opposite second end 546b. The lower arm 526 includes a spring retaining portion 547 positioned at or adjacent to the second end 546b. A spring carrier 570 including a compressible member, such as at least one spring 548, extends between the spring retaining portion 547 of the lower arm 526 and the spring receiving portion 546 of the upper lever arm 534 to bias the upper lever arm 534 in a direction opposite to the pedal depression force (e.g., in the opposite direction depicted by arrow A5 in FIGS. 5A and 5B ). In these embodiments, the lower arm 526 may be fixedly coupled to the floor surface and / or the inner surface 519 of the cavity 513, etc.

[0111] The lower arm 526 also includes an upper portion 526a and an opposing lower portion 526b. The lower portion 526b is coupled to the housing 504 via a lower arm protrusion 566 extending from the lower portion 526b of the lower arm 526. In these embodiments, the lower arm protrusion 566 of the lower arm 526 is received in a recess 571 of the housing 504 formed in the second end wall 516d. The upper portion includes an engagement surface 567 that is configured to receive a portion of the link arm 520, such as the coupling end 524 of the link arm 520, based on the amount of travel of the pedal arm 502. For example, as best illustrated in FIG. 5F , when the pedal arm 502 is in the fully compressed position, the coupling end 524 of the link arm 520 is illustrated as pivoting about or otherwise communicating with the engagement surface 567 of the lower arm 526, thereby increasing the pedal force felt by the driver.

[0112] The lower arm 526 may also include a recessed portion 561 configured to receive a pivot portion 563 rotatably or movably coupled to the pivot end 506 of the pedal arm 502 such that the pedal arm pivots or rotates or otherwise moves the pivot portion 563 within the recessed portion 561 of the lower arm 526 .

[0113] Thus, a portion of the spring carrier 570 may be received within the cavity 513 of the pedal arm 502, and a portion may be received within the cavity 514 of the housing 504. In some embodiments, the spring carrier 570 may be coupled to the spring receiving portion 546 of the linkage arm 520 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc. In other embodiments, the spring carrier 570 may be coupled to the spring receiving portion 546 of the linkage arm 520 via a press-fit configuration, a tension fit, etc. Further, in some embodiments, the spring carrier 570 may be coupled to the spring retaining portion 547 of the lower arm 526 via a fastener, such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc. In other embodiments, the spring carrier 570 may be coupled to the spring retaining portion 547 of the lower arm 526 via a press-fit configuration, a tension fit, etc.

[0114] The spring carrier 570 also includes a concave spring guide 575 and a convex spring guide 577, which includes an elongated member 555 that is configured to extend and engage with the concave spring guide 575 and compress into a void or cavity in the convex spring guide 577 based on tension or force applied to the spring carrier 570. It should be understood that this is non-limiting and the elongated member 555 can be configured to extend and engage with the convex spring guide 577 and compress into a void or cavity in the concave spring guide 575 based on tension or force applied to the spring carrier 570.

[0115] The concave spring guide 575 and the convex spring guide 577 are coupled to each other (e.g., via the elongated member 555) within the inner diameter of the at least one spring 548, such that the at least one spring 548 extends between and contacts the spring receiving surface 575a of the concave spring guide 575 and the spring receiving surface 577b of the convex spring guide 577. This arrangement holds the at least one spring 548 while allowing the at least one spring 548 to expand and compress depending on the amount of travel of the pedal arm 502, as discussed in more detail herein.

[0116] The protrusion 551 extends from the male spring guide 577 to serve as a connection point to pivotally connect the male spring guide 577 to the corresponding slot 553 in the spring retaining portion 547 of the lower arm 526 with a press fit or tension fit connection. In other embodiments, the protrusion 551 of the male spring guide 577 can be connected to the corresponding slot 553 via a fastener (such as a nut and bolt, a screw, a rivet, a shackle, an adhesive, a welded joint, etc.).

[0117] The tension caused by the at least one spring 548 disposed between the male spring guide 577 and the female spring guide 575, which are configured to move to compress the at least one spring 548, can keep the female spring guide 575 in contact with or seated in the spring receiving portion 546 of the upper lever arm 534, and keep the male spring guide 577 in contact with or seated in the spring retaining portion 547 formed in the lower arm 526. Therefore, regardless of the amount of travel of the pedal arm 502, there is tension caused by the male spring guide 577 and the female spring guide 575, thereby maintaining the contact position of the spring carrier 570 extending between the upper lever arm 534 and the lower arm 526.

[0118] As further depicted in FIGS. 5A to 5F , it should be understood that the at least one spring 548 may include a plurality of spring coils. For example, in some embodiments, the plurality of spring coils may be used to ensure that the pedal simulator assembly 500 remains functional in the event of at least one of the spring coils failing (e.g., breaking, detaching from a spring retaining portion, etc.). In these embodiments, the at least one spring 548 may be formed of a steel material, such as stainless steel, wire, carbon steel, alloy steel, Elgiloy non-magnetic alloy, Copper, nickel, etc.

[0119] The operation of the pedal simulator assembly 500 will now be discussed in detail with reference to FIGS. 5D to 5F. For example, as depicted in FIG. 5D, the pedal simulator assembly 500 is in an initial or undepressed position, and / or is subjected to a first predetermined load L1. In the undepressed position, the link arm 520 guided by a pair of slots 518 formed in the housing 504 is coupled to the pedal arm 502, as discussed in more detail herein. In these embodiments, the at least one spring 548 can be in a position that is almost unbiased (e.g., fully extended) such that the at least one spring 548 applies only minimal resistance to maintain the positioning of the pedal arm 502. Thus, the first predetermined load L1 can be sufficient force to compress the at least one spring 548 a predetermined distance, and the elongated member 533 can be slidably contacted or slidably engaged with a portion of the nonlinear profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 to achieve the desired curve illustrated by bracket 102 in FIG. 1.

[0120] 5E , when a second predetermined load L2 is applied to the pedal pad 510 in the direction indicated by arrow A5, the pedal arm 502 moves or pivots about the pivot end 506 in the direction indicated by arrow A6 to allow the pad end 508 to move in and out of the housing 504 based on the amount of force provided to the pad end 508 and the current position of the pedal arm 502. For example, as depicted in FIG5E , the pad end 508 may be partially moved into the housing 504 such that the at least one spring 548 is partially compressed and generates a restoring force or force feedback on the pedal pad 510 corresponding to the amount of force applied to the pedal pad 510 by the driver.

[0121] At the same time, in addition to the compression of the at least one spring 548, depressing the pedal arm 502 about the pivot end 506 can cause the slot 518 formed in the pedal arm 502 to contact the through pin extending through the support end 522 of the link arm 520. In these embodiments, the rotation of the pedal arm 502 about the pivot end 506 (e.g., in the direction indicated by arrow A2) and the contact between the slot 518 and the elongated member 533 can force the elongated member 533 to move in an upward direction along the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534. When the elongated member 533 rides along the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534, the link arm 520 can exert a downward force on the upper lever arm 534, which can in turn cause the upper lever arm 534 to rotate about its second end 536b and compress the at least one spring 548.

[0122] In these embodiments, the non-linear profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 can affect the resistance experienced by the driver against the pedal arm 502. For example, the profile of the engagement surface 549 of the upper frame portion 538 can affect the force that must be applied by the driver on the pedal pad 510 in order to advance the through pin upward through the slot 518 and, in turn, compress the at least one spring 548.

[0123] More specifically, the nonlinear profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 can produce a variable mechanical advantage between the link arm 520 and the upper lever arm 534, which can allow the pedal simulator assembly 500 to generate a desired force curve, as depicted in Figures 1 and 2. For example, as most clearly depicted in Figures 5D to 5F, the first portion of the engagement surface 549 of the upper frame portion 538 (e.g., the portion of the engagement surface 549 that the elongated member 533 contacts in the undepressed position depicted in Figure 5D) can include a relatively shallow or gentle slope. Because the slope of the first portion of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 is shallow, depressing the pedal pad 510 from the undepressed position (Figure 5D) to the partially depressed position (Figure 5E) may require a second predetermined load L2, which may be a relatively small force, which is depicted in brackets 104 of Figure 1.

[0124] As further depicted in FIGS. 5D-5F , the second portion of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 may have a slope that increases in steepness along the length of the second portion of the engagement surface 549 of the frame portion 538. As the slope of the engagement surface 549 of the upper frame portion 538 increases, depressing the pedal pad 510 may become increasingly difficult, such that a third predetermined load L3 greater than the second predetermined load L2 is required to move the elongated member 533 through the second portion of the engagement surface 549 of the upper frame portion 538 having the steeper slope. Because the force required to move the elongated member 533 through the slot 518 increases, the force applied by the link arm 520 on the upper lever arm 534 similarly increases, which may result in increased compression of the at least one spring 548, as depicted by bracket 106 of FIG. 1 .

[0125] In the embodiments described herein, it should also be understood that the elongated member 533 may not contact various portions of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 because the movement of the elongated member 533 along the engagement surface 549 of the upper frame portion 538 is limited by the slot 518. For example, the bottom surface and the upper surface of the slot 518 can define the distance that the elongated member 533 can travel, and in turn define the portion of the engagement surface 549 of the upper frame portion 538 that the elongated member 533 can contact. Therefore, it should be understood that the size of the slot can be configured to ensure that the elongated member 533 only contacts the intended portion of the engagement surface 549 of the upper frame portion 538. Furthermore, in these embodiments, the slot 518 ensures that the elongated member 533 rides accurately along the engagement surface 549 of the upper frame portion 538. Therefore, the guidance of the slot 518 helps ensure that the desired force curve of the pedal simulator assembly 500 is not disrupted.

[0126] 5F , the force required to depress the pedal arm 502 may be greatest when the elongated member 533 contacts the portion of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 having the greatest slope, which may correspond to the position of the pedal arm 502 when it is fully depressed. For example, when the pedal arm 502 is fully depressed, the at least one spring 548 may be fully compressed so that the pedal arm 502 (and thus the driver's foot) may experience the greatest resistance.

[0127] 5A-5F , the pedal simulator assembly 500 may also include a sensor assembly 560 configured to monitor the rotational movement of the second end 536b of the upper lever arm 534 to determine the exact force and position of the pedal pad 510 when the elongated member 533 of the main lever arm 520 traverses in the slot 518. In these embodiments, the sensor assembly 560 may also include a coupling 564 integrated into the second end 536B of the upper lever arm 534 such that the coupling 564 may rotate in conjunction with the second end 536b of the upper lever arm 534 and convert the mechanical movement (e.g., rotation) of the upper lever arm 534 into a measurable signal.

[0128] In particular, the rotation of the coupling 564 affects the orientation and position of the coupling 564 relative to the plurality of transmitting and receiving coils. For example, when the coupling 564 moves (e.g., rotates), it causes changes in the magnetic field emitted by the transmitting coil. The receiving coil detects these changes, and the changes in the received magnetic field can then be converted into electrical signals that are processed by an onboard controller or microprocessor. Therefore, the electrical signal indicating the changes in the received magnetic field can be directly related to the rotational position of the upper lever arm 534, and in turn, to the pedal pad 510.

[0129] As should be understood from the foregoing, the various profiles of the engagement surface 549 and the at least one spring 548 provide the pedal force / resistance felt by the driver at the pedal pad 510. That is, the force applied by the at least one spring 548 and the profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 apply different forces at corresponding travel positions, wherein the profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 is near the end of the slot 518 (full travel of the pedal arm 502), thereby applying significant force to the pedal arm 502. The combination of the at least one spring 548 and the profile of the engagement surface 549 of the upper frame portion 538 of the upper lever arm 534 results in a synthesis of forces to provide a desired force curve.

[0130] Turning now to FIGS. 6A to 6D , a fourth example embodiment of a pedal simulator assembly 600 that utilizes a pivoting friction lever to generate resistance is schematically depicted. In these embodiments, the pedal simulator assembly 600 can be a baseplate mounted accordion brake pedal simulator assembly. This is non-limiting, and the pedal simulator assembly 600 can be a suspended pedal assembly or any other type of pedal assembly. The pedal simulator assembly 600 includes a pedal arm 602 and a housing 604. The pedal arm 602 includes a pivot end 606 and an opposing pad end 608, wherein a pedal pad 610 is attached to the pad end 608. The pedal arm 602 includes an outer surface 612a and an opposing inner surface 612b. A connecting rod 614 is coupled to the inner surface 612b and a spring carrier assembly 616 positioned within a cavity 618 of the housing 604.

[0131] The spring carrier assembly 616 includes a lever arm 620 and a spring carrier 622. The lever arm 620 includes a hub portion 624 and a spring receiving portion 626. The spring carrier 622 includes a concave portion 628 and a spring retaining portion 630.

[0132] Still referring to FIGS. 6A to 6D , the housing 604 includes a friction member 632 integrally formed on the inner surface 634 of the side wall 636. The friction member 632 may be semi-annular or semi-circular. The hub 624 of the lever arm 620 abuts the friction member 632 of the housing 604 and the concave portion 628 of the spring carrier 622. When pressure is applied to the spring receiving portion 626, the hub 624 rotates within the concave portion 628 of the spring carrier 622 and against the friction member 632 of the housing 604. When the pedal pad 610 is depressed, pressure is received, which drives the connecting rod 614 into the lever arm 620. Therefore, the pedal force / resistance is generated by the friction generated by the hub 624 of the friction member 632 rotating against the housing 604 and the concave portion 628 of the spring carrier 622.

[0133] In the embodiments described herein, the housing 604 and the pedal arm 602 may be molded plastic. For example, the housing 604 and the pedal arm 602 may be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0134] In other embodiments, the housing 604 and the pedal arm 602 may be formed by injection molding or other additive manufacturing techniques. For example, as provided herein, additive manufacturing techniques generally refer to manufacturing processes in which successive layers of material are placed on top of each other to "build up" a three-dimensional component layer by layer. Successive layers are typically fused together to form an integral component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building up objects typically point by point and layer by layer in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer additive process, a layer subtractive process, or a hybrid process.

[0135] As further depicted in FIGS. 6A to 6D , the pedal simulator assembly 600 may also include a first compressible member, such as at least one first spring 638, positioned between the spring receiving portion 626 of the lever arm 620 and the spring retaining portion 630 of the spring carrier 622 to bias the lever arm 620 in a direction opposite to the pedal depression force. The connecting rod 614 is coupled to the spring receiving portion 626. When the pedal depression force is applied to the pedal arm 602, the connecting rod 614 moves into the spring receiving portion 626 of the lever arm 620, which in turn compresses the at least one first spring 638 into the spring retaining portion 630 of the spring carrier 622.

[0136] In these embodiments, the pedal simulator assembly 600 may also include a sensor assembly 652 that includes a coupling 654 mounted in the hub 624 and configured to rotate when the hub 624 rotates. The sensor assembly 652 may track or determine the movement of the coupling 654 via a transmitting coil and at least one receiving coil positioned on or within a circuit board, such as a printed circuit board. Thus, the sensor assembly 652 will sense the amount of force on the pedal pad 610 at any given time based on the position of the coupling 654. The operation of the sensor assembly 652 will be described in more detail herein.

[0137] Still referring to FIGS. 6A-6D , a second compressible member, such as at least one second spring 640, is at least partially positioned within a spring receiving cavity 642 of the housing 604. A portion of the at least one second spring 640 is positioned above the housing upper surface 644 and below the inner surface 612 b of the pedal arm 602. Thus, once the pedal pad 610 is depressed with sufficient force to move the connecting rod 614 a predetermined distance (the force being a force greater than the force required to move the at least one first spring 638), the upper surface 646 of the at least one second spring 640 contacts the inner surface 612 b of the pedal arm 602, thereby compressing the at least one second spring 640 into the spring receiving cavity 642. This compression provides the pedal force / resistance of the second segment of the desired force curve of FIG. 1 , as will be described further herein.

[0138] In these embodiments, the pedal simulator assembly 600 may further include an elastomeric member 648 or foam member positioned on and extending from the housing upper surface 644 and below the inner surface 612b of the pedal arm 602. When the inner surface 612b of the pedal arm 602 contacts the upper surface 650 of the elastomeric member 648, the elastomeric member 648 is configured to compress at a predetermined rate.

[0139] The operation of the pedal simulator assembly 600 will now be described in detail with reference to FIGS. 6B to 6D. For example, as depicted in FIG. 6B, when the pedal pad 610 receives a first predetermined load, the pedal pad 610 begins to pivot about its pivot end 606. This movement is transmitted via the link 614, causing the link 614 to move the lever arm 620, which compresses the at least one first spring 638 and rotates the hub 624. In these embodiments, the at least one first spring 638 applies only minimal resistance to maintain the positioning of the pedal arm 602. Thus, the first predetermined load L1 can be sufficient force to compress the at least one first spring 638 a predetermined distance so that the link 614 contacts the spring receiving portion 626 of the spring carrier assembly 616 to achieve the desired curve illustrated by bracket 102 in FIG. 1.

[0140] In these embodiments, when the first predetermined load L1 acts on the pedal arm 602, the hub 624 rotates within the concave portion 628 of the spring carrier 622, causing the hub 624 to contact the friction member 632 of the housing 604. Thus, the rotation of the hub 624 generates a frictional resistance that acts as part of the first segment of the pedal application force depicted as bracket 102 in the desired force curve depicted in FIG.

[0141] Referring now to FIG. 6C , when a second predetermined load L2, which is greater than the first predetermined load L1, is applied to the pedal arm 602, the link 614 continues to move (e.g., in the direction illustrated by arrow A7). In response, once the pedal arm 602 has moved the predetermined distance, the inner surface 612b of the pedal arm 602 contacts the upper surface 646 of the at least one second spring 640. In these embodiments, the force applied to the pedal arm 602 is sufficient to overcome the combined resistance of the at least one first spring 638 and the friction force acting between the hub 624 and the friction member 632, so that the at least one second spring 640 at least partially stored in the spring receiving cavity 642 begins to compress. As should be understood in light of the foregoing, the compression of the at least one second spring 640 can provide increased resistance to the pedal arm 602. Therefore, the second predetermined load L2 can be sufficient force to compress the at least one first spring 638 and the at least one second spring 640 by the predetermined distance, thereby achieving the desired curve illustrated by bracket 104 in FIG. 1 .

[0142] Turning now to FIG. 6D , as the driver continues to apply force on the pedal pad 610 , a third predetermined load L3 greater than the second predetermined load L2 and the first predetermined load L1 may be applied to the pedal arm 602 such that the inner surface 612 b of the pedal arm contacts the upper surface 650 of the elastomeric member 648 positioned on the housing upper surface 644 . The elastomeric member 648 , which is made of a flexible material such as rubber, polyurethane, or any other similar deformable material, may begin to compress under the force applied to the elastomeric member 648 by the pedal arm 602 . In these embodiments, the compression of the elastomeric member 648 may provide a significant resistance that may correspond to the third segment of the desired force curve depicted by bracket 106 in FIG. 1 . For example, the resistance provided by the compression of the elastomeric member 648 may be the highest resistance generated by the pedal simulator assembly 600 , which may indicate to the driver the end stop feel of the depression of the pedal arm 602 .

[0143] In view of the foregoing, it should be understood that the forces applied by the various springs (e.g., at least one first spring 638 and / or at least one second spring 640) and the elastomeric member 648 apply different forces at corresponding travel positions. The compression of the elastomeric member 648 applies significant forces to the pedal arm 602. The combination of the various springs (e.g., at least one first spring 638 and / or at least one second spring 640) and the elastomeric member 648 results in a synthesis of forces to provide a desired force curve.

[0144] 6B-6D , the sensor assembly 652 is configured to monitor the rotational movement of the hub 624 of the lever arm 620 to determine the exact force and position of the pedal pad 610 when the pedal arm 602 is depressed. In these embodiments, the coupling 654 can rotate in conjunction with the hub 624 of the lever arm 620, thereby converting the mechanical movement (e.g., rotation) of the hub 624 into a measurable signal.

[0145] In particular, the rotation of the coupling 654 affects the orientation and position of the coupling 654 relative to the transmitting and receiving coils. For example, when the coupling 654 moves (e.g., rotates), it causes changes in the magnetic field emitted by the transmitting coil. The receiving coil detects these changes, and the changes in the received magnetic field can then be converted into electrical signals, which are processed by an on-board controller or microprocessor. Therefore, the electrical signal indicating the changes in the received magnetic field can be directly related to the rotational position of the hub 624, and in turn, the pedal pad 610.

[0146] Referring now to FIGS. 7A to 7D , a schematic representation of a fifth embodiment of a pedal simulator assembly 700 is shown that utilizes rotating pedal arms, compression, and sliding friction to generate resistance. The pedal simulator assembly 700 includes a pedal arm 702 and a housing 704. The pedal arm 702 is configured to rotate or pivot about a pivot hub 706 at a first end 708a of the pedal arm 702. An opposing second end 708b includes a pedal pad 710 attached thereto. The pedal arm 702 includes an outer surface 712a and an opposing inner surface 712b. The housing 704 includes a friction member 714 integrally formed with and extending from an inner surface 716 of a sidewall 717. The friction member 714 may be arcuate and extend from a position below the inner surface 712b of the pedal arm 702 to the first end 708a or the pivot hub 706 and partially around it.

[0147] The housing 704 also includes a spring receiving cavity 718 positioned below the inner surface 712b of the pedal arm 702. Further, the inner surface 712b of the pedal arm includes a spring receiving portion 720 positioned between the first end 708a and the second end 708b. At least one compressible member, such as at least one spring 722, extends between the spring receiving portion 720 and the spring receiving cavity 718, such that when a force is applied to the pedal pad 710, the at least one spring is compressible between the housing 704 and the pedal arm 702.

[0148] In the embodiments described herein, the housing 704 and the pedal arm 702 may be molded plastic. For example, the housing 704 and the pedal arm 702 may be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0149] In other embodiments, the housing 704 and the pedal arm 702 may be formed by injection molding or other additive manufacturing techniques. For example, as provided herein, additive manufacturing techniques generally refer to manufacturing processes in which successive layers of material are placed on top of each other to "build up" a three-dimensional component layer by layer. Successive layers are typically fused together to form an integral component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building up objects typically point by point and layer by layer in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer additive process, a layer subtractive process, or a hybrid process.

[0150] The friction member assembly 724 is coupled to the inner surface 712b of the pedal arm 702 via a first linkage arm 726 between the spring receiving portion 720 and the first end 708a, and is connected to the friction shoe 728. The first linkage arm 726 can be rotatably received in a semi-annular receiving portion 730 of the friction shoe 728 at or adjacent to the proximal end 732. The second linkage arm 734 can be received in a receiving portion 736 at a distal end 738 of the friction shoe 728 and extend between the friction shoe 728 and the first end 708a of the pedal arm 702. Therefore, the friction member assembly 724 can include the friction shoe 728, the first linkage arm 726, and / or the second linkage arm 734.

[0151] The friction shoe 728 may also include a recess or notch 740 that receives a spring and / or cantilever member 742 extending between the notch 740 and the second linkage arm 734, the cantilever member 742 being fixed or coupled to the second linkage arm 734 and moving within the notch 740 based on the amount of rotation of the first end 708a about the pivot hub 706. The friction shoe 728 abuts or rides within the arcuate or non-linear friction member 714. That is, the friction shoe 728 may be arcuate or non-linear.

[0152] The operation of the pedal simulator assembly will now be described in detail with reference to FIGS. 7B to 7D . As depicted in FIG. 7B , when a first predetermined load L1 is applied to the pedal pad 710, the first end 708a and the pedal arm begin to rotate about the pivot hub 706. In these embodiments, the rotation of the pedal arm 702 about the pivot hub 706 causes the inner surface 712b of the pedal pad 710 to contact and compress the at least one spring 722. In these embodiments, the at least one spring 722 can be in a nearly unbiased position such that the at least one spring 722 applies only minimal resistance to maintain the position of the pedal arm 702. Thus, the first predetermined load L1 can be sufficient force to compress the at least one spring 722 a predetermined distance such that the spring receiving portion 720 of the pedal arm 702 contacts the at least one spring 722 to achieve the desired force curve illustrated by bracket 102 of FIG. 1 .

[0153] At the same time, the rotation of the pedal arm 702 actuates the first linkage arm 726, which in turn pushes the friction shoe 728 along the friction member 714. In these embodiments, the shape and / or material of the friction shoe 728 and the friction member 714 can allow for the introduction of sliding friction into the pedal simulator assembly 700, which forms part of the resistance force generated by the first predetermined load L1 and as depicted in bracket 102 of Figure 1. For example, and as will be appreciated in light of the foregoing, higher friction forces can be achieved between the friction shoe 728 and the friction member 714 by increasing the contact surface area between the two components.

[0154] 7A-7D , as the friction shoe 728 contacts various portions of the friction member 714, the contact angle between the friction shoe 728 and the friction member 714 may change due to the nonlinear or arcuate profile of the friction member 714. Thus, when the friction shoe 728 contacts a portion of the friction member 714 having a steeper curvature, the friction shoe 728 may generate a larger normal force (e.g., a force perpendicular to the surface of the friction member 714), which may in turn result in an increase in friction force.

[0155] 7B , when the pedal pad 710 receives the first predetermined load L1, the first link arm 726 and the second link arm 734 may act as a connector between the pedal arm 702 and the friction shoe 728. Thus, in these embodiments, the first link arm 726 and the second link arm 734 may convert the rotational motion of the pedal arm 702 into the linear motion of the friction shoe 728. In these embodiments, the nonlinear profile of the friction member 714 may cause friction forces to be generated between the friction shoe 728 and the friction member 714 when the friction shoe is linearly actuated, as has been described in detail herein.

[0156] Turning now to FIG. 7C , as the pedal arm 702 continues to rotate about the pivot hub 706, the pedal arm 702 may receive a second predetermined load L2. In these embodiments, when the second predetermined load L2 is applied to the pedal arm, the inner surface 712b of the pedal arm 702 may further compress the at least one spring 722, thereby increasing the resistance within the pedal simulator assembly 700 and making the pedal arm 702 more difficult to depress (e.g., rotate). In addition, as the pedal arm 702 rotates, the friction shoe 728 continues to traverse the friction member 714. As already described herein, when the friction shoe 728 interacts with the portion of the friction member 714 having a steeper curve, the resistance due to friction increases. Therefore, it should be understood that the gradual increase in friction caused by the nonlinear profile of the friction member 714 can simulate the braking force in a traditional brake pad and provide tactile feedback to the driver.

[0157] Still referring to FIG. 7C , when the second predetermined load L2 acts on the pedal arm 702, the position of the cantilever member 742 within the recess 740 may also change. For example, and as described herein, the rotation of the pedal arm 702 may cause the first linkage arm 726 to move the friction shoe 728 along the friction member 714. As the friction shoe 728 moves, the cantilever member 742 may experience displacement due to the connection between the cantilever member 742 and the second linkage arm 734. Therefore, as the pedal arm 702 continues to rotate, the cantilever member 742 may become increasingly displaced, which may cause the cantilever member 742 to bend. In these embodiments, the bending of the cantilever member 742 and the connection between the cantilever member 742 and the second linkage arm 734 may provide a lever effect that applies a force on the second linkage arm 734. More specifically, the force applied by the cantilever member 742 on the second linkage arm is directed toward the pivot hub 706 of the pedal arm 702, thereby resisting the rotation of the pedal arm 702. Thus, the force exerted by the cantilever member 742 on the second linkage arm 734 may further contribute to the resistance of the pedal pad 710 and the tactile feedback experienced by the driver.

[0158] In the embodiments described herein, it will be appreciated that the resistance generated by cantilever member 742 , friction member 714 , and at least one spring 722 when second predetermined load L2 acts on pedal arm 702 may produce a greater pedal effort experienced by the driver, as illustrated by bracket 104 of FIG. 1 .

[0159] Turning now to FIG. 7D , the pedal simulator assembly 700 is depicted in a fully compressed position, wherein a third predetermined load L3 greater than the first predetermined load L1 and the second predetermined load L2 is applied to the pedal arm. In these embodiments, the pedal arm 702 may be fully rotated such that the inner surface 712 b of the pedal pad 710 fully compresses the at least one spring 722. In addition, the friction shoe 728 may interact with a portion of the friction member 714 having the most aggressive curve (e.g., the steepest slope), which results in a maximum level of friction force being applied to the pedal pad 710. Similarly, the first linkage arm 726 actuates the friction shoe 728 at a maximum distance along the friction member 714, while the cantilever member 742 applies a maximum force on the second linkage arm 734. In these embodiments, the combination of forces may result in a peak resistance being achieved within the pedal simulator assembly 700, which may correspond to the third segment depicted as bracket 106 in the desired force curve illustrated in FIG. 1 .

[0160] In view of the foregoing, it should be understood that the forces applied by the at least one spring 722, the friction shoe 728, the curvature of the friction member 714, and the respective linkage arms 726, 734 apply different forces at corresponding travel positions. The compression of the second linkage arm 734 and the bending of the friction member 714 and the friction shoe 728 at this particular point apply a significant force to the pedal arm 702. The combination of the at least one spring 722, the friction shoe 728, the curvature of the friction member 714, and the respective linkage arms 726, 734 produces a composite of forces to provide a desired force curve.

[0161] 7A-7D , the pedal simulator assembly 700 may also include a sensor assembly 750 configured to monitor the rotational movement of the hub portion 624 of the pivot hub 706 to determine the exact force and position of the pedal pad 710 when the pedal arm 702 is depressed. In these embodiments, the sensor assembly 750 may also include a coupling 754 that may be integrated into the pivot hub 706 such that the coupling 756 may rotate in conjunction with the pivot hub 706 of the pedal arm 702 and convert the mechanical movement (e.g., rotation) of the pivot hub 706 into a measurable signal.

[0162] In particular, the rotation of the coupling 754 affects the orientation and position of the coupling 754 relative to a plurality of transmitting and receiving coils (not depicted). For example, when the coupling 754 moves (e.g., rotates), it causes changes in the magnetic field emitted by the transmitting coil. The receiving coil detects these changes, and the changes in the received magnetic field can then be converted into electrical signals that are processed by an onboard controller or microprocessor. Therefore, the electrical signal indicating the changes in the received magnetic field can be directly related to the rotational position of the pivot hub 706, and in turn, to the pedal pad 710.

[0163] 1. A pedal simulator assembly, comprising: a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm pivotally connected to the pedal arm and having a pedal pad; a lever arm positioned in the cavity of the housing and pivotally connected to the housing, the lever arm further comprising a spring receiving portion; and a spring carrier comprising a compressible member extending between the spring receiving portion and the spring retaining portion; wherein, when a first predetermined load is applied to the pedal pad, the pedal arm drives the lever arm into the compressible member so that the compressible member is compressed to an at least partially compressed state to generate a first restoring force on the pedal pad.

[0164] 2. A pedal simulator assembly according to any of the preceding clauses, wherein the lever arm further comprises an upper frame portion comprising an engagement surface having a non-linear profile extending between the first end of the lever arm and the second end of the lever arm.

[0165] 3. A pedal simulator assembly according to any of the preceding clauses, wherein the upper frame portion comprises a first portion extending between the first end of the lever arm and the apex of the lever arm.

[0166] 4. A pedal simulator assembly according to any of the preceding clauses, wherein the upper frame portion comprises a second portion extending between the apex of the lever arm and the second end of the lever arm.

[0167] 5. A pedal simulator assembly according to any of the preceding clauses, wherein the first portion of the upper frame portion has a first slope and the second portion of the upper frame portion has a second slope different from the first slope.

[0168] 6. A pedal simulator assembly according to any of the preceding clauses, wherein, when a second predetermined load is applied to the pedal pad, the pedal arm further contacts the first portion of the upper frame portion to generate a second restoring force on the pedal pad, the second predetermined load being a load greater than the first predetermined load and the second restoring force being a force greater than the first restoring force.

[0169] 7. A pedal simulator assembly according to any of the preceding clauses, wherein, when a third predetermined load is applied to the pedal pad, the pedal arm further contacts the second portion of the upper frame to generate a third restoring force on the pedal pad, the third predetermined load being a load greater than the second predetermined load and the third restoring force being a force greater than the second restoring force.

[0170] 8. A pedal simulator assembly according to any preceding clause, wherein the lower arm is fixedly coupled to the cavity of the housing.

[0171] 9. A pedal simulator assembly according to any one of the preceding clauses, wherein the lower arm further comprises a concave portion configured to receive the pivot portion of the pivot end of the pedal arm such that the pedal arm pivots about the pivot portion within the concave portion of the lower arm.

[0172] 10. A pedal simulator assembly according to any of the preceding clauses, wherein the compressible member comprises a plurality of springs coaxially arranged around a spring carrier.

[0173] 11. A pedal simulator assembly according to any of the preceding clauses, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: a circuit board; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to at least one Hall effect chip; wherein the sensor assembly is configured to detect movement of the pedal arm.

[0174] 12. A pedal simulator assembly for a vehicle, comprising: a baseplate mounted housing having a cavity defined by a pair of side walls, a first end wall and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm at least partially received in the cavity, the pedal arm having an inner surface, a pivot end and an opposite pad end, a pedal pad attached to the pad end; a lever arm positioned in the cavity of the housing and pivotally connected to the housing, the lever arm further comprising: a first end; a second end positioned opposite the first end; an apex disposed at the first end; a hub disposed at the second end; an upper frame portion and a lower frame portion connected at the apex and the hub; and a spring receiving portion positioned between the first end and the second end and within the lower frame portion; and a spring carrier including a compressible member extending between the spring receiving portion and the spring retaining portion; wherein, when a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm drives the lever arm into the compressible member so that the compressible member is compressed to a compressed state to generate a first restoring force on the pedal pad.

[0175] 13. A pedal simulator assembly according to any preceding clause, wherein the inner surface of the pedal arm is non-linear.

[0176] 14. A pedal simulator assembly according to any of the preceding clauses, wherein the upper frame portion comprises a surface having a non-linear profile, the surface extending between the first end of the lever arm and the second end of the lever arm.

[0177] 15. A pedal simulator assembly according to any of the preceding clauses, wherein the upper frame portion comprises a first portion extending between the first end of the lever arm and the apex of the lever arm and a second portion extending between the apex of the lever arm and the second end of the lever arm.

[0178] 16. A pedal simulator assembly according to any of the preceding clauses, wherein a first portion of the upper frame portion has a first slope and a second portion of the upper frame portion has a second slope different from the first slope.

[0179] 17. A pedal simulator assembly according to any of the preceding clauses, wherein, when a second predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the first portion of the upper frame portion to generate a second restoring force on the pedal pad, the second predetermined load being a load greater than the first predetermined load and the second restoring force being a force greater than the first restoring force.

[0180] 18. A pedal simulator assembly according to any of the preceding clauses, wherein, when a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the second portion of the upper frame portion to generate a third restoring force on the pedal pad, the third predetermined load being a load greater than the second predetermined load and the third restoring force being a force greater than the second restoring force.

[0181] 19. A pedal simulator assembly according to any of the preceding clauses, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: a circuit board; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to at least one Hall effect chip; wherein the sensor assembly is configured to detect movement of the pedal arm.

[0182] 20. A pedal simulator assembly for a vehicle, comprising: a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end pivotally coupled to the housing, an opposite pad end to which a pedal pad is attached, and a non-linear inner surface; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising: a first end; a second end positioned opposite the first end; a vertex arranged at a first end; a hub arranged at a second end; an upper frame and a lower frame connected at a vertex and the hub, the upper frame including an upper surface having a nonlinear profile; and a spring receiving portion positioned in the lower frame between the first end and the second end; a spring carrier including a compressible member extending between the spring receiving portion and the spring retaining portion; and wherein, when a first predetermined load is applied to the pedal pad, an inner surface of the pedal arm contacts an upper surface of the upper frame of the lever arm, so that the lever arm is forced into the compressible member to generate a restoring force on the pedal pad.

[0183] 21. A pedal simulator assembly, comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a protrusion extending from an inner surface of the pedal arm; a lever arm positioned in the cavity of the housing and pivotally connected to the housing, the lever arm also including an engagement surface configured to engage a contact surface of the engagement protrusion; and a spring carrier including a compressible member extending between the pivot end of the pedal arm and the lever arm; wherein, when a first predetermined load is applied to the pedal pad, the contact surface of the protrusion of the pedal arm slidably engages against the engagement surface of the lever arm and generates a first restoring force on the pedal pad.

[0184] 22. A pedal simulator assembly according to any preceding clause, wherein the outer surface of the lever arm is a non-linear surface.

[0185] 23. A pedal simulator assembly according to any preceding clause, wherein the engagement surface of the housing is a non-linear surface.

[0186] 24. A pedal simulator assembly according to any of the preceding clauses, wherein the engagement surface of the lever arm and the contact surface of the projection are configured such that contact between the engagement surface of the lever arm and the contact surface of the projection increases when a second predetermined load is applied to the pedal arm.

[0187] 25. A pedal simulator assembly according to any of the preceding clauses, wherein, when a second predetermined load is applied to the pedal arm, rotation of the pedal arm compresses the compressible member to generate a second restoring force on the pedal pad.

[0188] 26. A pedal simulator assembly according to any of the preceding clauses, further comprising an elastomeric member positioned within a recess formed in the housing.

[0189] 27. A pedal simulator assembly according to any one of the preceding clauses, wherein when a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm at the pad end contacts and compresses the elastomeric member.

[0190] 28. A pedal simulator assembly according to any of the preceding clauses, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: a circuit board; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to at least one Hall effect chip; wherein the sensor assembly is configured to detect movement of the pedal arm.

[0191] 29. A pedal simulator assembly according to any preceding clause, wherein the housing and pedal arm are formed from moulded plastic.

[0192] 30. A pedal simulator assembly comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a protrusion extending from an inner surface of the pedal arm; a lever arm positioned in the housing cavity and pivotally connected to the housing, the lever arm further comprising an outer surface configured to engage a contact surface of the protrusion; and a spring carrier having a pedal end and an opposing lever arm end, the spring carrier extending between the pivot end of the pedal arm and the lever arm; and an elastomeric member positioned in a recess formed in the housing; wherein, when a first predetermined load is applied to the pedal pad, the contact surface of the protrusion of the pedal arm slides against the engagement surface of the lever arm and generates a first restoring force on the pedal pad.

[0193] 31. A pedal simulator assembly according to any of the preceding clauses, wherein the outer surface of the lever arm is a non-linear surface.

[0194] 32. A pedal simulator assembly according to any preceding clause, wherein the engagement surface of the housing is a non-linear surface.

[0195] 33. A pedal simulator assembly according to any of the preceding clauses, wherein the inner surface of the pedal arm and the outer surface of the lever arm are constructed so that contact between the outer surface of the lever arm and the inner surface of the pedal arm increases when the pedal pad is depressed from an initial position to a fully depressed position.

[0196] 34. A pedal simulator assembly according to any one of the preceding clauses, wherein when a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm at the pad end contacts and compresses the elastomeric member.

[0197] 35. A pedal simulator assembly according to any of the preceding clauses, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: a circuit board; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to at least one Hall effect chip; wherein the sensor assembly is configured to detect movement of the pedal arm.

[0198] 36. A pedal simulator assembly according to any preceding clause, wherein the pedal arm and housing are formed from moulded plastic.

[0199] 37. A pedal simulator assembly according to any of the preceding clauses, wherein the lever arm further comprises a protrusion which engages a recess formed in the cavity of the housing.

[0200] 38. A pedal simulator assembly according to any preceding clause, wherein the elastomeric member is formed from rubber or plastic.

[0201] 39. A pedal simulator assembly according to any preceding clause, wherein the housing is configured to be mounted to a dashboard.

[0202] 40. A pedal simulator assembly for a vehicle, comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a protrusion extending from an inner surface of the pedal arm; a lever arm positioned in the cavity of the housing and pivotally coupled to the housing, the lever arm also including an engagement surface configured to engage a contact surface of the protrusion of the pedal arm; and a spring carrier having a pedal end and an opposing lever arm end, the spring carrier extending between the pivot end of the pedal arm and the lever arm; an elastomeric member positioned in a recess formed in the housing; and a sensor assembly positioned in the housing and configured to detect movement of the pedal arm, the sensor assembly also including: a circuit board; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to at least one Hall effect chip; wherein, when a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm slides against the engagement surface of the lever arm and generates a friction force on the pedal pad.

[0203] 41. A pedal simulator assembly comprising: a housing having a cavity defined by a pair of opposing side walls; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end, a pedal pad attached to the pad end; a pair of slots formed in the housing, the pair of slots extending through the pair of opposing side walls of the cavity; a lower arm having a first end and an opposing second end, the first end pivotally coupled to the pivot end of the pedal arm, the lower arm including a spring retainer; a link arm including a support end having an aperture extending therethrough, and a spring retainer pivotally coupled to the support end; a connecting end of the lower arm; an upper lever arm pivotally connected to the housing, the upper lever arm including a spring receiving portion; a slender member extending through a pair of slots and an orifice of the link arm and contacting the upper lever arm; and a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, contact between the pair of slots and the slender member drives the slender member along the upper lever arm so that the upper lever arm is forced to contact and compress the compressible member to generate a first restoring force on the pedal pad.

[0204] 42. A pedal simulator assembly according to any of the preceding clauses, wherein the upper lever arm comprises an upper frame having an engagement surface having a non-linear profile extending between a first end of the upper lever arm and an apex of the upper frame of the upper lever arm.

[0205] 43. A pedal simulator assembly according to any of the preceding clauses, wherein the engagement surface comprises a first portion extending partially between the first end of the upper lever arm and an apex of the upper lever arm.

[0206] 44. A pedal simulator assembly according to any of the preceding clauses, wherein the first portion of the engagement surface has a first slope that varies along the length of the first portion of the upper frame portion.

[0207] 45. A pedal simulator assembly according to any of the preceding clauses, wherein when a second predetermined load is applied to the pedal pad, the elongated member contacts the first portion of the engagement surface to generate a second restoring force on the pedal pad.

[0208] 46. ​​A pedal simulator assembly according to any preceding clause, wherein the engagement surface comprises a second portion extending between the first portion of the engagement surface and the apex of the upper lever arm.

[0209] 47. A pedal simulator assembly according to any preceding clause, wherein the second portion of the engagement surface has a second slope, the steepness of the second slope increasing along the length of the second portion of the upper frame.

[0210] 48. A pedal simulator assembly according to any of the preceding clauses, wherein when a third predetermined load is applied to the pedal pad, the elongated member contacts the second portion of the engagement surface to generate a third restoring force on the pedal pad.

[0211] 49. A pedal simulator assembly according to any of the preceding clauses, wherein the elongated member further comprises a pair of terminal ends having a first diameter greater than a second diameter of each of the pair of slots.

[0212] 50. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the second end of the upper lever arm.

[0213] 51. A pedal simulator assembly according to any of the preceding clauses, wherein the sensor assembly further comprises a coupling member integrated into the second end of the upper lever arm such that the coupling member rotates in conjunction with the second end of the upper lever arm.

[0214] 52. A pedal simulator assembly according to any preceding clause, wherein the housing and pedal arm are formed from moulded plastic.

[0215] 53. A pedal simulator assembly according to any of the preceding clauses, wherein the compressible member comprises a spring extending between a spring receiving portion of the upper lever arm and a spring retaining portion of the lower arm.

[0216] 54. A pedal simulator assembly for a vehicle, comprising: a housing mounted on a base plate, having a cavity defined by a pair of opposing side walls; a pedal arm, which is at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end, a pedal pad being attached to the pad end; a pair of slots formed in the housing, the pair of slots extending through the pair of opposing side walls of the cavity; a lower arm, which has a first end and an opposing second end, the first end being pivotally connected to the pivot end of the pedal arm, the lower arm including a spring retaining portion; a link arm, which includes a support end having an aperture extending therethrough, and a connecting end pivotally connected to the lower arm; an upper lever arm, which is pivotally connected to the housing, the upper lever arm including: a first end and a second end positioned opposite the first end; a top a spring receiving portion positioned in the lower frame between the first end and the second end; an elongated member extending through a pair of slots and an orifice of the link arm and contacting the upper lever arm; and a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, the contact between the pair of slots and the elongated member drives the elongated member along the joint surface of the upper lever arm, so that the lower frame of the upper lever arm is forced to contact the compressible member and compress the compressible member to generate a first restoring force on the pedal pad.

[0217] 55. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the second end of the upper lever arm.

[0218] 56. A pedal simulator assembly according to any of the preceding clauses, wherein the sensor assembly further comprises a coupling member integrated into the second end of the upper lever arm such that the coupling member rotates in conjunction with the second end of the upper lever arm.

[0219] 57. A pedal simulator assembly according to any preceding clause, wherein the support end of the linkage arm comprises a pair of ears, each of the pair of ears comprising an aperture for receiving an elongate member.

[0220] 58. A pedal simulator assembly according to any of the preceding clauses, wherein the compressible member comprises a spring having a plurality of coils, each of the plurality of coils extending between a spring receiving portion of the upper lever arm and a spring retaining portion of the lower arm.

[0221] 59. A pedal simulator assembly according to any preceding clause, wherein the steepness of the slope of the engagement surface of the upper frame increases along the length from the first end of the upper frame to the apex.

[0222] 60. A pedal simulator assembly for a vehicle, comprising: a baseplate-mounted housing having a cavity defined by a pair of opposing side walls; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end, a pedal pad being attached to the pad end; a pair of slots formed in the housing, the pair of slots extending through the pair of opposing side walls of the cavity; a lower arm having a first end and an opposing second end, the first end being pivotally coupled to the pivot end of the pedal arm, the lower arm including a spring retaining portion; a link arm including a support end having a pair of ears and a coupling end pivotally coupled to the lower arm, each of the pair of ears having an aperture extending therethrough; an upper lever arm pivotally coupled to the housing, the upper lever arm including: a first end and a second end positioned opposite the first end; a vertex having a first end and an opposing second end; and a spring receiving portion positioned in the lower frame between the first end and the second end; an elongated member extending through a pair of slots and an orifice of the link arm and contacting the engaging surface of the upper lever arm; and a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, the contact between the pair of slots and the elongated member drives the elongated member along the engaging surface of the upper lever arm, so that the lower frame of the upper lever arm is forced to contact the compressible member and compress the compressible member to generate a first restoring force on the pedal pad.

[0223] 61. A pedal simulator assembly, comprising: a shell having a cavity and a friction member formed on an inner surface of the shell; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposite pad end, a pedal pad attached to the pad end; a spring carrier assembly, comprising: a lever arm having a spring receiving portion and a hub portion that abuts the friction member of the shell; and a spring carrier, comprising a spring retaining portion; a connecting rod connected to the pedal arm and the lever arm of the spring carrier assembly; and a compressible member positioned between the spring receiving portion of the lever arm and the spring retaining portion of the spring carrier; wherein, when a first predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the compressible member, causing the compressible member to compress and the hub portion to rotate against the friction member to generate a first restoring force on the pedal pad.

[0224] 62. A pedal simulator assembly according to any preceding clause, wherein the housing is mounted to the floor of a vehicle.

[0225] 63. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing has a semi-annular or semi-circular profile.

[0226] 64. A pedal simulator assembly according to any of the preceding clauses, wherein the housing further comprises a spring receiving cavity.

[0227] 65. A pedal simulator assembly according to any of the preceding clauses, wherein the second compressible member is at least partially positioned within the spring receiving cavity.

[0228] 66. A pedal simulator assembly according to any of the preceding clauses, wherein when a second predetermined load is applied to the pedal pad, the pedal arm contacts the second compressible member and compresses the second compressible member into the spring receiving cavity.

[0229] 67. A pedal simulator assembly according to any of the preceding clauses, further comprising an elastomeric member extending from the housing.

[0230] 68. A pedal simulator assembly according to any of the preceding clauses, wherein when a third predetermined load is applied to the pedal pad, the pedal arm contacts the elastomeric member and compresses the elastomeric member against the housing.

[0231] 69. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

[0232] 70. A pedal simulator assembly according to any of the preceding clauses, wherein the sensor assembly further comprises a coupling member integrated into the hub of the lever arm such that the coupling member rotates in conjunction with the hub of the lever arm.

[0233] 71. A pedal simulator assembly comprising: a housing having a cavity, a spring receiving cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end, a pedal pad attached to the pad end; a spring carrier assembly comprising: a lever arm having a spring receiving portion and a hub portion that abuts the friction member of the housing; and a spring carrier including a spring retaining portion; a connecting rod coupled to the pedal arm and the lever arm of the spring carrier assembly; a first compressible member positioned between the spring receiving portion of the lever arm and the spring retaining portion of the spring carrier; and a second compressible member at least partially positioned in the spring receiving cavity, wherein when a first predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the first compressible member, and when a second predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the first compressible member and the second compressible member, so that the first compressible member and the second compressible member are compressed and the hub portion rotates against the friction member to generate a second restoring force on the pedal pad.

[0234] 72. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing has a semi-annular or semi-circular profile.

[0235] 73. A pedal simulator assembly according to any of the preceding clauses, further comprising an elastomeric member extending from the housing.

[0236] 74. A pedal simulator assembly according to any of the preceding clauses, wherein when a third predetermined load is applied to the pedal pad, the pedal arm contacts the elastomeric member and compresses the elastomeric member against the housing.

[0237] 75. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

[0238] 76. A pedal simulator assembly according to any of the preceding clauses, wherein the sensor assembly further comprises a coupling member integrated into the hub of the lever arm such that the coupling member rotates in conjunction with the hub of the lever arm.

[0239] 77. A pedal simulator assembly comprising: a housing having a cavity, a spring receiving cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposite pad end, a pedal pad attached to the pad end; a spring carrier assembly comprising: a lever arm having a spring receiving portion and a hub portion abutting the friction member of the housing; and a spring carrier including a spring retaining portion; a connecting rod coupled to the pedal arm and the lever arm of the spring carrier assembly; a first compressible member positioned at the lever arm between a spring receiving portion and a spring retaining portion of a spring carrier; a second compressible member, which is at least partially positioned in the spring receiving cavity; and an elastomeric member, which extends from the housing; wherein, when a first predetermined load is applied to the pedal pad, the pedal arm rotates so that the connecting rod drives the lever arm into the first compressible member, and when a second predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the second compressible member, and when a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm compresses the elastomeric member to generate a restoring force on the pedal pad.

[0240] 78. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing has a semi-annular or semi-circular profile.

[0241] 79. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

[0242] 80. A pedal simulator assembly according to any of the preceding clauses, wherein the sensor assembly further comprises a coupling member integrated into the hub of the lever arm such that the coupling member rotates in conjunction with the hub of the lever arm.

[0243] 81. A pedal simulator assembly, comprising: a shell having a spring receiving cavity and a friction member formed on an inner surface of the shell; a pedal arm at least partially received in the shell, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiving portion, the spring receiving portion being positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; and a friction member assembly, comprising: a friction shoe abutting the friction member of the shell; a first link arm extending between the spring receiving portion of the pedal arm and a proximal end of the friction shoe; and a second link arm extending between the pivot end of the pedal arm and a distal end of the friction shoe; wherein, when a first predetermined load is applied to the pedal pad, the pedal arm compresses the compressible member to generate a first restoring force on the pedal pad.

[0244] 82. A pedal simulator assembly according to any of the preceding clauses, wherein when a second predetermined load is applied to the pedal pad, the friction shoe rotates against the friction member to generate a second restoring force on the pedal pad.

[0245] 83. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing is arcuate in shape.

[0246] 84. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing extends from a position below the inner surface of the pedal arm to and partially surrounds the pivot end of the pedal arm.

[0247] 85. A pedal simulator assembly according to any preceding clause, wherein the friction shoes are arcuate in shape.

[0248] 86. A pedal simulator assembly according to any of the preceding clauses, wherein the friction shoe further comprises a recess.

[0249] 87. A pedal simulator assembly according to any of the preceding clauses, wherein the friction assembly further comprises a cantilever member coupled to the second linkage arm and extending between the second linkage arm and the recess of the friction shoe such that the cantilever member moves within the recess.

[0250] 88. A pedal simulator assembly according to any of the preceding clauses, wherein when a second predetermined load is applied to the pedal pad, the cantilever member displaces within the recess causing the cantilever member to bend and exert a force on the second linkage arm.

[0251] 89. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

[0252] 90. A pedal simulator assembly according to any preceding clause, wherein the sensor assembly further comprises a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in conjunction with the pivot end of the pedal arm.

[0253] 91. A pedal simulator assembly, comprising: a housing having a spring receiving cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the housing, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiving portion positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; and a friction assembly, comprising: a friction shoe abutting the friction member of the housing; A link arm extending between a spring receiving portion of the pedal arm and a proximal end of the friction shoe; a second link arm extending between a pivot end of the pedal arm and a distal end of the friction shoe; a recess; and a cantilever member connected to the second link arm and extending between the second link arm and the recess of the friction shoe so that the cantilever member moves within the recess; wherein when a first predetermined load is applied to the pedal pad, the pedal arm compresses the compressible member, and when a second predetermined load is applied to the pedal pad, the friction shoe rotates against the friction member to generate a restoring force on the pedal pad.

[0254] 92. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing is arcuate in shape.

[0255] 93. A pedal simulator assembly according to any of the preceding clauses, wherein the friction member of the housing extends from a position below the inner surface of the pedal arm to and partially surrounds the pivot end of the pedal arm.

[0256] 94. A pedal simulator assembly according to any preceding clause, wherein the friction shoe is arcuate in shape.

[0257] 95. A pedal simulator assembly according to any preceding clause, wherein when a third predetermined load is applied to the pedal pad, the cantilever member displaces within the recess such that the cantilever member bends and exerts a force on the second linkage arm.

[0258] 96. A pedal simulator assembly according to any preceding clause, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

[0259] 97. A pedal simulator assembly according to any preceding clause, wherein the sensor assembly further comprises a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in conjunction with the pivot end of the pedal arm.

[0260] 98. A pedal simulator assembly for a vehicle, comprising: a baseplate mounted housing having a spring receiving cavity and an arcuate friction member formed on an inner surface of the housing; a pedal arm at least partially received in the housing, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiving portion positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; and a friction assembly comprising: an arcuate friction shoe abutting the friction member of the housing; a first link arm, which extends between a spring receiving portion of the pedal arm and a proximal end of the friction shoe; a second link arm which extends between a pivot end of the pedal arm and a distal end of the friction shoe; a recess; and a cantilever member connected to the second link arm and extending between the second link arm and the recess of the friction shoe so that the cantilever member moves within the recess; wherein, when a first predetermined load is applied to the pedal arm, the pedal arm compresses the compressible member, when a second predetermined load is applied to the pedal arm, the friction shoe rotates against the friction member, and when a third predetermined load is applied to the pedal arm, the cantilever member is displaced within the recess to generate a restoring force on the pedal pad.

[0261] 99. A pedal simulator assembly according to any of the preceding clauses, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

[0262] 100. A pedal simulator assembly according to any preceding clause, wherein the sensor assembly further comprises a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in conjunction with the pivot end of the pedal arm.

[0263] It should be understood now that the embodiments described herein relate to embodiments of pedal simulator assemblies, which include sensors suitable for sensing the position and / or force of pedal pads. Various pedal assemblies are constructed to simulate brake fluid systems based on speed systems, such as hydraulic systems, such as the faster the driver presses down the pedal pad of the pedal, the harder the pedal is pressed, referred to herein as hepatic force. Pedal simulator assemblies described herein apply opposite simulator forces to provide the driver with resistance that changes according to the speed at which PE is applied. Typically, the simulator assembly outputs three different forces and sections of travel corresponding to a specific range of travel, so that the driver feels different resistances or tactile sensations based on the speed at which the pedal is pressed down.

[0264] The terms used herein are only used for the purpose of describing specific aspects and are not intended to be limiting. As used herein, the singular forms "one", "an" and "the" are intended to include plural forms, including "at least one", unless the content explicitly indicates otherwise. "Or" means "and / or". As used herein, the term "and / or" includes any and all combinations of one or more associated listed items. It should also be understood that when used in this specification, the terms "include" and / or "comprise" or "contain" specify the presence of the features, regions, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, parts and / or their groups. The term "or a combination thereof" means a combination including at least one of the aforementioned elements.

[0265] It is noted that the terms "substantially" and "approximately" may be used herein to represent the inherent uncertainty that may be attributed to any false comparison, value, measurement or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

[0266] Although specific embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, these aspects need not be used in combination. Therefore, the appended claims are intended to cover all such changes and modifications within the scope of the claimed subject matter.

Claims

1. A pedal simulator assembly, comprising: a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm pivotally coupled to the pedal arm and having a pedal pad; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising a spring receiving portion; and a spring carrier including a compressible member extending between the spring receiving portion and the spring retaining portion, Wherein, when a first predetermined load is applied to the pedal pad, the pedal arm drives the lever arm into the compressible member such that the compressible member is compressed to an at least partially compressed state to generate a first restoring force on the pedal pad.

2. The pedal simulator assembly according to claim 1, wherein: The lever arm also includes an upper frame portion including an engagement surface having a non-linear profile extending between a first end of the lever arm and a second end of the lever arm.

3. The pedal simulator assembly according to claim 2, wherein: The upper frame portion includes a first portion extending between the first end of the lever arm and an apex of the lever arm.

4. The pedal simulator assembly according to claim 3, wherein: The upper frame portion includes a second portion extending between the apex of the lever arm and the second end of the lever arm.

5. The pedal simulator assembly according to claim 4, wherein: The first portion of the upper frame portion has a first slope, and the second portion of the upper frame portion has a second slope different from the first slope.

6. The pedal simulator assembly according to claim 5, wherein: When a second predetermined load is applied to the pedal pad, the pedal arm further contacts the first portion of the upper frame portion to generate a second restoring force on the pedal pad, the second predetermined load being a load greater than the first predetermined load and the second restoring force being a force greater than the first restoring force.

7. The pedal simulator assembly according to claim 5, wherein: When a third predetermined load is applied to the pedal pad, the pedal arm further contacts the second portion of the upper frame to generate a third restoring force on the pedal pad, the third predetermined load being a load greater than the second predetermined load and the third restoring force being a force greater than the second restoring force.

8. The pedal simulator assembly according to claim 1, wherein: The lower arm is fixedly coupled within the cavity of the housing.

9. The pedal simulator assembly according to claim 1, wherein: The lower arm also includes a concave portion configured to receive a pivot portion of the pivot end of the pedal arm such that the pedal arm pivots about the pivot portion within the concave portion of the lower arm.

10. The pedal simulator assembly of claim 1, wherein: The compressible member includes a plurality of springs coaxially arranged around the spring carrier.

11. The pedal simulator assembly of claim 1 , further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: Circuit boards; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to the at least one Hall effect chip; Wherein, the sensor assembly is configured to detect movement of the pedal arm.

12. A pedal simulator assembly for a vehicle, comprising: a base mounted housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm at least partially received in the cavity, the pedal arm having an inner surface, a pivot end, and an opposing pad end to which a pedal pad is attached; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising: First end; a second end positioned opposite to the first end; an apex disposed at the first end; a hub disposed at the second end; an upper frame portion and a lower frame portion connected at the apex and the hub; and a spring receiving portion positioned between the first end and the second end and within the lower frame portion; and a spring carrier including a compressible member extending between the spring receiving portion and the spring retaining portion, Wherein, when a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm drives the lever arm into the compressible member such that the compressible member is compressed into a compressed state to generate a first restoring force on the pedal pad.

13. The pedal simulator assembly according to claim 12, wherein: The inner surface of the pedal arm is non-linear.

14. The pedal simulator assembly of claim 12, wherein: The upper frame portion includes a surface having a non-linear profile extending between the first end of the lever arm and the second end of the lever arm.

15. The pedal simulator assembly of claim 12, wherein: The upper frame portion includes a first portion extending between the first end of the lever arm and the apex of the lever arm and a second portion extending between the apex of the lever arm and the second end of the lever arm.

16. The pedal simulator assembly of claim 15, wherein: The first portion of the upper frame portion has a first slope, and the second portion of the upper frame portion has a second slope different from the first slope.

17. The pedal simulator assembly of claim 15, wherein: When a second predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the first portion of the upper frame portion to generate a second restoring force on the pedal pad, the second predetermined load being a load greater than the first predetermined load and the second restoring force being a force greater than the first restoring force.

18. The pedal simulator assembly of claim 17, wherein: When a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the second portion of the upper frame portion to generate a third restoring force on the pedal pad, the third predetermined load being a load greater than the second predetermined load and the third restoring force being a force greater than the second restoring force.

19. The pedal simulator assembly of claim 12, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: Circuit boards; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to the at least one Hall effect chip, Wherein, the sensor assembly is configured to detect movement of the pedal arm.

20. A pedal simulator assembly for a vehicle, comprising: a housing having a cavity defined by a pair of side walls, a first end wall, and a second end wall; a lower arm having a spring retaining portion formed therein; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end pivotally coupled to the housing, an opposing pad end to which a pedal pad is attached, and a non-linear inner surface; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising: First end; a second end positioned opposite to the first end; an apex disposed at the first end; a hub disposed at the second end; an upper frame and a lower frame connected at the apex and the hub, the upper frame including an upper surface having a nonlinear profile; and a spring receiving portion positioned in the lower frame between the first end and the second end; and a spring carrier including a compressible member extending between the spring receiving portion and the spring retaining portion, wherein when a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm contacts the upper surface of the upper frame of the lever arm such that the lever arm is forced into the compressible member to generate a restoring force on the pedal pad.

21. A pedal simulator assembly comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a projection extending from an inner surface of the pedal arm; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising an engagement surface configured to engage the contact surface of the projection; as well as a spring carrier including a compressible member extending between the pivot end of the pedal arm and the lever arm; wherein, when a first predetermined load is applied to the pedal pad, the contact surface of the protruding portion of the pedal arm slidably engages against the engagement surface of the lever arm and generates a first restoring force on the pedal pad.

22. The pedal simulator assembly of claim 21, wherein: The outer surface of the lever arm is a non-linear surface.

23. The pedal simulator assembly of claim 21, wherein: The engagement surface of the housing is a non-linear surface.

24. The pedal simulator assembly of claim 21, wherein: The engagement surface of the lever arm and the contact surface of the protrusion are configured such that contact between the engagement surface of the lever arm and the contact surface of the protrusion increases when a second predetermined load is applied to the pedal arm.

25. The pedal simulator assembly of claim 21, wherein: When a second predetermined load is applied to the pedal arm, rotation of the pedal arm compresses the compressible member to generate a second restoring force on the pedal pad.

26. The pedal simulator assembly of claim 21, further comprising an elastomeric member positioned within a recess formed in the housing.

27. The pedal simulator assembly of claim 26, wherein: When a third predetermined load is applied to the pedal pad, an inner surface of the pedal arm at the pad end contacts and compresses the elastomeric member.

28. The pedal simulator assembly of claim 21, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: Circuit boards; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to the at least one Hall effect chip, Wherein, the sensor assembly is configured to detect movement of the pedal arm.

29. The pedal simulator assembly of claim 21, wherein: The housing and the pedal arm are formed from molded plastic.

30. A pedal simulator assembly comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a projection extending from an inner surface of the pedal arm; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising an outer surface configured to engage a contact surface of the projection; as well as a spring carrier having a pedal end and an opposing lever arm end, said spring carrier extending between said pivot end of said pedal arm and said lever arm; as well as an elastomeric member positioned within a recess formed in the housing, Wherein, when a first predetermined load is applied to the pedal pad, the contact surface of the protruding portion of the pedal arm slides against the engagement surface of the lever arm and generates a first restoring force on the pedal pad.

31. The pedal simulator assembly of claim 30, wherein: The outer surface of the lever arm is a non-linear surface.

32. The pedal simulator assembly of claim 30, wherein: The engagement surface of the housing is a non-linear surface.

33. The pedal simulator assembly of claim 30, wherein: The inner surface of the pedal arm and the outer surface of the lever arm are configured such that contact between the outer surface of the lever arm and the inner surface of the pedal arm increases as the pedal pad is depressed from an initial position to a fully depressed position.

34. The pedal simulator assembly of claim 30, wherein: When a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm at the pad end contacts and compresses the elastomeric member.

35. The pedal simulator assembly of claim 30, further comprising: a sensor assembly positioned within the housing, the sensor assembly further comprising: Circuit boards; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to the at least one Hall effect chip, Wherein, the sensor assembly is configured to detect movement of the pedal arm.

36. The pedal simulator assembly of claim 30, wherein: The pedal arm and the housing are formed of molded plastic.

37. The pedal simulator assembly of claim 30, wherein: The lever arm also includes a protrusion that engages a recess formed in the cavity of the housing.

38. The pedal simulator assembly of claim 30, wherein: The elastic member is formed of rubber or plastic.

39. The pedal simulator assembly of claim 30, wherein: The housing is configured to be mounted to an instrument panel.

40. A pedal simulator assembly for a vehicle, comprising: a housing including a cavity; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end, an opposing pad end to which a pedal pad is attached, and a projection extending from an inner surface of the pedal arm; a lever arm positioned within the cavity of the housing and pivotally coupled to the housing, the lever arm further comprising an engagement surface configured to engage a contact surface of the projection of the pedal arm; as well as a spring carrier having a pedal end and an opposing lever arm end, said spring carrier extending between said pivot end of said pedal arm and said lever arm; an elastomeric member positioned within a recess formed in the housing; as well as a sensor assembly positioned within the housing and configured to detect movement of the pedal arm, the sensor assembly further comprising: Circuit boards; at least one Hall effect chip communicatively coupled to the circuit board; and a magnet communicatively coupled to the at least one Hall effect chip, Wherein, when a first predetermined load is applied to the pedal pad, the inner surface of the pedal arm slides against the engagement surface of the lever arm and generates friction force on the pedal pad.

41. A pedal simulator assembly comprising: a housing having a cavity defined by a pair of opposing side walls; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; a pair of slots formed in the housing, the pair of slots extending through the pair of opposing side walls of the cavity; a lower arm having a first end and an opposite second end, the first end being pivotally coupled to the pivot end of the pedal arm, the lower arm including a spring retainer; a link arm including a support end having an aperture extending therethrough, and a coupling end pivotally coupled to the lower arm; an upper lever arm pivotally coupled to the housing, the upper lever arm including a spring receiving portion; an elongated member extending through the pair of slots and the aperture of the linkage arm and contacting the upper lever arm; as well as a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, contact between the pair of slots and the elongated member drives the elongated member along the upper lever arm such that the upper lever arm is forced to contact the compressible member and compress the compressible member to generate a first restoring force on the pedal pad.

42. A pedal simulator assembly according to claim 41, wherein The upper lever arm includes an upper frame having an engagement surface having a non-linear profile extending between a first end of the upper lever arm and an apex of the upper frame of the upper lever arm.

43. A pedal simulator assembly according to claim 42, wherein The engagement surface includes a first portion extending partially between the first end of the upper lever arm and the apex of the upper lever arm.

44. A pedal simulator assembly according to claim 43, wherein The first portion of the engagement surface has a first slope that varies along a length of the first portion of the upper frame portion.

45. A pedal simulator assembly according to claim 44, wherein When a second predetermined load is applied to the pedal pad, the elongated member contacts the first portion of the engagement surface to generate a second restoring force on the pedal pad.

46. ​​The pedal simulator assembly of claim 42, wherein: The engagement surface includes a second portion extending between the first portion of the engagement surface and the apex of the upper lever arm.

47. A pedal simulator assembly according to claim 46, wherein The second portion of the engagement surface has a second slope, the steepness of the second slope increasing along a length of the second portion of the upper frame.

48. A pedal simulator assembly according to claim 47, wherein When a third predetermined load is applied to the pedal pad, the elongated member contacts the second portion of the engagement surface to generate a third restoring force on the pedal pad.

49. The pedal simulator assembly of claim 41, wherein: The elongated member also includes a pair of terminal ends having a first diameter greater than a second diameter of each of the pair of slots.

50. The pedal simulator assembly of claim 41, further comprising a sensor assembly configured to monitor rotational movement of the second end of the upper lever arm.

51. A pedal simulator assembly according to claim 50, wherein The sensor assembly also includes a coupling integrated into the second end of the upper lever arm such that the coupling rotates in unison with the second end of the upper lever arm.

52. The pedal simulator assembly of claim 41, wherein: The housing and the pedal arm are formed from molded plastic.

53. The pedal simulator assembly of claim 41, wherein: The compressible member includes a spring extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm.

54. A pedal simulator assembly for a vehicle, comprising: a base mounted housing having a cavity defined by a pair of opposing side walls; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; a pair of slots formed in the housing, the pair of slots extending through the pair of opposing side walls of the cavity; a lower arm having a first end and an opposite second end, the first end being pivotally coupled to the pivot end of the pedal arm, the lower arm including a spring retainer; a link arm including a support end having an aperture extending therethrough, and a coupling end pivotally coupled to the lower arm; an upper lever arm pivotally coupled to the housing, the upper lever arm comprising: a first end and a second end positioned opposite the first end; an apex disposed at the first end; a hub disposed at the second end; an upper frame and a lower frame connected at the apex and the hub, the upper frame including an engagement surface having a non-linear profile; and a spring receiver positioned in the lower frame between the first end and the second end; an elongated member extending through the pair of slots and the aperture of the linkage arm and contacting the upper lever arm; and a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, contact between the pair of narrow slots and the slender member drives the slender member along the engagement surface of the upper lever arm so that the lower frame of the upper lever arm is forced to contact the compressible member and compress the compressible member to generate a first restoring force on the pedal pad.

55. The pedal simulator assembly of claim 54, further comprising a sensor assembly configured to monitor rotational movement of the second end of the upper lever arm.

56. A pedal simulator assembly according to claim 55, wherein The sensor assembly also includes a coupling integrated into the second end of the upper lever arm such that the coupling rotates in unison with the second end of the upper lever arm.

57. The pedal simulator assembly of claim 54, wherein: The support end of the linkage arm includes a pair of ears, each of the pair of ears including an aperture for receiving the elongated member.

58. The pedal simulator assembly of claim 54, wherein: The compressible member includes a spring having a plurality of coils, each of the plurality of coils extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm.

59. The pedal simulator assembly of claim 54, wherein: The steepness of the slope of the joint surface of the upper frame increases along the length from the first end to the apex of the upper frame.

60. A pedal simulator assembly for a vehicle, comprising: a base mounted housing having a cavity defined by a pair of opposing side walls; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; a pair of slots formed in the housing; a lower arm having a first end and an opposite second end, the first end being pivotally coupled to the pivot end of the pedal arm, the lower arm including a spring retainer; a link arm including a support end having a pair of ears, each of the pair of ears having an aperture extending therethrough, and a coupling end pivotally coupled to the lower arm; an upper lever arm pivotally coupled to the housing, the upper lever arm comprising: a first end and a second end positioned opposite the first end; an apex disposed at the first end; a hub disposed at the second end; an upper frame and a lower frame connected at the apex and the hub, the upper frame including an engagement surface having a slope that increases in steepness from the first end of the upper lever arm to the apex; and a spring receiver positioned in the lower frame between the first end and the second end; an elongated member extending through the pair of slots and the aperture of the link arm and contacting the engagement surface of the upper lever arm; and a compressible member extending between the spring receiving portion of the upper lever arm and the spring retaining portion of the lower arm; wherein, when a first predetermined load is applied to the pedal pad, contact between the pair of narrow slots and the slender member drives the slender member along the engagement surface of the upper lever arm so that the lower frame of the upper lever arm is forced to contact the compressible member and compress the compressible member to generate a first restoring force on the pedal pad.

61. A pedal simulator assembly comprising: a housing having a cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; A spring carrier assembly comprising: a lever arm having a spring receiving portion and a hub portion that abuts the friction member of the housing; and a spring carrier including a spring retaining portion; a connecting rod coupled to the pedal arm and the lever arm of the spring carrier assembly; and a compressible member positioned between the spring receiving portion of the lever arm and the spring retaining portion of the spring carrier, Wherein, when a first predetermined load is applied to the pedal pad, the link drives the lever arm into the compressible member so that the compressible member compresses and the hub rotates against the friction member to generate a first restoring force on the pedal pad.

62. A pedal simulator assembly according to claim 61, wherein The housing is mounted to the floor of the vehicle.

63. The pedal simulator assembly of claim 61, wherein: The friction member of the housing has a semi-annular or semi-circular profile.

64. The pedal simulator assembly of claim 61, wherein: The housing also includes a spring receiving cavity.

65. A pedal simulator assembly according to claim 64, wherein A second compressible member is at least partially positioned within the spring receiving cavity.

66. A pedal simulator assembly according to claim 65, wherein When a second predetermined load is applied to the pedal pad, the pedal arm contacts the second compressible member and compresses the second compressible member into the spring receiving cavity.

67. The pedal simulator assembly of claim 61 further comprising an elastomeric member extending from the housing.

68. A pedal simulator assembly according to claim 67, wherein When a third predetermined load is applied to the pedal pad, the pedal arm contacts the elastomeric member and compresses the elastomeric member against the housing.

69. The pedal simulator assembly of claim 61, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

70. The pedal simulator assembly of claim 69, wherein: The sensor assembly also includes a coupling integrated into the hub of the lever arm such that the coupling rotates in unison with the hub of the lever arm.

71. A pedal simulator assembly comprising: A housing having an inner surface, the housing further comprising: Cavity; a spring receiving cavity; as well as a friction member formed on the inner surface of the housing; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; A spring carrier assembly comprising: a lever arm having a spring receiving portion and a hub portion that abuts the friction member of the housing; and a spring carrier including a spring retaining portion; a connecting rod coupled to the pedal arm and the lever arm of the spring carrier assembly; a first compressible member positioned between the spring receiving portion of the lever arm and the spring retaining portion of the spring carrier; and a second compressible member at least partially positioned within the spring receiving cavity, wherein, when a first predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the first compressible member, and when a second predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the first compressible member and the second compressible member, so that the first compressible member and the second compressible member are compressed and the hub rotates against the friction member to generate a second restoring force on the pedal pad.

72. A pedal simulator assembly according to claim 71, wherein The friction member of the housing has a semi-annular or semi-circular profile.

73. The pedal simulator assembly of claim 71 further comprising an elastomeric member extending from the housing.

74. A pedal simulator assembly according to claim 73, wherein: When a third predetermined load is applied to the pedal pad, the pedal arm contacts the elastomeric member and compresses the elastomeric member against the housing.

75. The pedal simulator assembly of claim 71, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

76. A pedal simulator assembly according to claim 75, wherein: The sensor assembly also includes a coupling integrated into the hub of the lever arm such that the coupling rotates in unison with the hub of the lever arm.

77. A pedal simulator assembly comprising: a housing having a cavity, a spring receiving cavity, and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the cavity, the pedal arm having a pivot end and an opposing pad end to which a pedal pad is attached; A spring carrier assembly comprising: a lever arm having a spring receiving portion and a hub portion that abuts the friction member of the housing; and a spring carrier including a spring retaining portion; a connecting rod coupled to the pedal arm and the lever arm of the spring carrier assembly; a first compressible member positioned between the spring receiving portion of the lever arm and the spring retaining portion of the spring carrier; a second compressible member positioned at least partially within the spring receiving cavity; and an elastomeric member extending from the housing, wherein, when a first predetermined load is applied to the pedal pad, the pedal arm rotates so that the connecting rod drives the lever arm into the first compressible member, and when a second predetermined load is applied to the pedal pad, the connecting rod drives the lever arm into the second compressible member, and when a third predetermined load is applied to the pedal pad, the inner surface of the pedal arm compresses the elastomeric member to generate a restoring force on the pedal pad.

78. A pedal simulator assembly according to claim 77, wherein The friction member of the housing has a semi-annular or semi-circular profile.

79. The pedal simulator assembly of claim 77, further comprising a sensor assembly configured to monitor rotational movement of the lever arm.

80. The pedal simulator assembly of claim 79, wherein: The sensor assembly also includes a coupling integrated into the hub of the lever arm such that the coupling rotates in unison with the hub of the lever arm.

81. A pedal simulator assembly comprising: a housing having a spring receiving cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the housing, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiver positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; as well as A friction member assembly comprising: a friction shoe abutting against the friction member of the housing; a first linkage arm extending between the spring receiving portion of the pedal arm and a proximal end of the friction shoe; and a second linkage arm extending between the pivot end of the pedal arm and a distal end of the friction shoe, Wherein, when a first predetermined load is applied to the pedal pad, the pedal arm compresses the compressible member to generate a first restoring force on the pedal pad.

82. A pedal simulator assembly according to claim 81, wherein When a second predetermined load is applied to the pedal pad, the friction shoe rotates against the friction member to generate a second restoring force on the pedal pad.

83. The pedal simulator assembly of claim 81, wherein: The friction member of the housing is arcuate in shape.

84. The pedal simulator assembly of claim 81, wherein: The friction member of the housing extends from a position below an inner surface of the pedal arm to the pivot end of the pedal arm and partially surrounds the pivot end of the pedal arm.

85. The pedal simulator assembly of claim 81, wherein: The friction shoe is arcuate in shape.

86. The pedal simulator assembly of claim 81, wherein: The friction shoe also includes a recess.

87. A pedal simulator assembly according to claim 86, wherein The friction assembly also includes a cantilever member coupled to the second linkage arm and extending between the second linkage arm and the recess of the friction shoe such that the cantilever member moves within the recess.

88. A pedal simulator assembly according to claim 87, wherein When a second predetermined load is applied to the pedal pad, the cantilever member displaces within the recess, causing the cantilever member to bend and exert a force on the second linkage arm.

89. The pedal emulator assembly of claim 81, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

90. The pedal simulator assembly of claim 89, wherein: The sensor assembly also includes a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in unison with the pivot end of the pedal arm.

91. A pedal simulator assembly comprising: a housing having a spring receiving cavity and a friction member formed on an inner surface of the housing; a pedal arm at least partially received in the housing, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiver positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; as well as A friction assembly comprising: a friction shoe abutting against the friction member of the housing; a first linkage arm extending between the spring receiving portion of the pedal arm and a proximal end of the friction shoe; a second linkage arm extending between the pivot end of the pedal arm and a distal end of the friction shoe; Notches; and a cantilever member coupled to the second linkage arm and extending between the second linkage arm and the recess of the friction shoe such that the cantilever member moves within the recess, wherein when a first predetermined load is applied to the pedal pad, the pedal arm compresses the compressible member, and when a second predetermined load is applied to the pedal pad, the friction shoe rotates against the friction member to generate a restoring force on the pedal pad.

92. A pedal simulator assembly according to claim 91, wherein The friction member of the housing is arcuate in shape.

93. The pedal simulator assembly of claim 91, wherein: The friction member of the housing extends from a position below an inner surface of the pedal arm to the pivot end of the pedal arm and partially surrounds the pivot end of the pedal arm.

94. The pedal simulator assembly of claim 91, wherein: The friction shoe is arcuate in shape.

95. The pedal simulator assembly of claim 91, wherein: When a third predetermined load is applied to the pedal pad, the cantilever member displaces within the recess, causing the cantilever member to bend and exert a force on the second linkage arm.

96. The pedal emulator assembly of claim 95, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

97. A pedal simulator assembly according to claim 96, wherein The sensor assembly also includes a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in unison with the pivot end of the pedal arm.

98. A pedal simulator assembly for a vehicle, comprising: a baseplate mounted housing having a spring receiving cavity and an arcuate friction member formed on an inner surface of the housing; a pedal arm at least partially received in the housing, the pedal arm having a pivot end, an opposite pad end to which a pedal pad is attached, and a spring receiver positioned between the pivot end and the opposite pad end to which the pedal pad is attached; a compressible member extending between the spring receiving cavity and the spring receiving portion of the pedal arm; as well as A friction assembly comprising: an arcuate friction shoe abutting against the friction member of the housing; a first linkage arm extending between the spring receiving portion of the pedal arm and a proximal end of the friction shoe; a second linkage arm extending between the pivot end of the pedal arm and a distal end of the friction shoe; Notches; and a cantilever member coupled to the second linkage arm and extending between the second linkage arm and the recess of the friction shoe such that the cantilever member moves within the recess, wherein when a first predetermined load is applied to the pedal arm, the pedal arm compresses the compressible member, when a second predetermined load is applied to the pedal arm, the friction shoe rotates against the friction member, and when a third predetermined load is applied to the pedal arm, the cantilever member displaces within the recess to generate a restoring force on the pedal pad.

99. The pedal emulator assembly of claim 98, further comprising a sensor assembly configured to monitor rotational movement of the pedal pad.

100. The pedal simulator assembly of claim 99, wherein: The sensor assembly also includes a coupling member integrated into the pivot end of the pedal arm such that the coupling member rotates in unison with the pivot end of the pedal arm.

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