Brake-by-wire pedal simulator device

Abstract

The invention discloses a brake-by-wire pedal simulator device, and relates to the field of pedal braking, the brake-by-wire pedal simulator device comprises an outer shell and a brake handle, the lower end of the brake handle is connected with a force hysteresis assembly which gradually improves damping force along with increase of a treading stroke, the force hysteresis assembly comprises an outer cover and a spring seat, and an upper spring column is installed in an inner cavity of the spring seat; the upper end of the spring seat is fixedly connected with a connecting part, the connecting part is hinged to the brake handle, the lower end of the spring seat is provided with an upper force hysteresis block and a lower force hysteresis block, and the upper force hysteresis block and the lower force hysteresis block are in sliding connection with the side wall of the inner cavity of the outer cover. The vacuum booster provides familiar and reliable pedal feedback for a driver, is compact in structure, has extremely high interchangeability and adaptability, can directly replace a traditional vacuum booster, effectively reduces the arrangement difficulty and manufacturing cost of a whole vehicle, and achieves unification of performance, safety and economic benefits.

Description

Technical Field

[0001] This invention relates to the field of pedal braking, specifically to a pedal simulator device for brake-by-wire. Background Technology

[0002] Traditional automotive braking systems widely use vacuum boosters as power assistance devices. These boosters utilize the vacuum generated by the engine intake manifold or the vacuum pressure difference generated by an electric vacuum pump to assist the driver in pressing the brake pedal. While this mechanical-hydraulic structure is technically mature, it has many inherent drawbacks: For pure electric vehicles or range-extended electric vehicles, since there is no traditional engine, obtaining a stable vacuum source requires the addition of an electric vacuum pump. This not only increases the system's energy consumption and occupies valuable engine compartment space, but also introduces new noise and potential points of failure. At the same time, the mechanical connection method has a response delay, and the pedal force curve is relatively fixed, making it difficult to make fine adjustments and failing to provide the driver with an ideal and consistent pedal feel.

[0003] With the development of brake-by-wire technology, the aim is to eliminate mechanical or hydraulic backups and directly transmit driver intentions via electrical signals. However, accurately replicating or even optimizing the force feedback characteristics of the traditional brake pedal in the brake-by-wire system has become a key challenge. Early brake-by-wire pedal simulators had simple structures, often using a single spring or rubber block. The damping force they provided was linearly related to the travel, failing to simulate the "rigid" pedal feel required in the later stages of traditional braking. This resulted in a false braking feel and insufficient feedback force, affecting driver confidence and comfort. Summary of the Invention

[0004] The purpose of this invention is to provide a pedal simulator device with brake-by-wire to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a pedal simulator device with brake-by-wire, comprising an outer housing and a brake lever, wherein the lower end of the brake lever is connected to a damping component that gradually increases the damping force as the pedal stroke increases, the damping component comprising an outer cover and a spring seat, wherein an upper spring post is installed in the inner cavity of the spring seat, and a connecting part is fixedly connected to the upper end of the spring seat, the connecting part being hinged to the brake lever; and an upper damping block and a lower damping block are provided at the lower end of the spring seat, the upper damping block and the lower damping block being connected to the brake lever. The slidable connection between the slack block and the inner cavity sidewall of the outer cover is achieved. The bottom end of the upper spring column abuts against the top end of the upper slack block. An elastic component one is connected between the upper end face of the upper slack block and the inner cavity top wall of the spring seat. A lower spring column is installed at the bottom of the inner cavity of the outer cover. The top end of the lower spring column is connected to the bottom end of the lower slack block. An elastic component two is connected between the bottom end of the lower slack block and the inner cavity bottom wall of the outer cover. This achieves a smooth pedaling force in the front section and a sharp increase in pedaling force in the rear section.

[0006] Preferably, a mounting plate is fixedly connected to the outer cover, and a sensor connector is mounted on the mounting plate.

[0007] Preferably, a strip groove is provided on the outer end face of the outer cover, and a protrusion is provided on the spring seat, the upper force block and the lower force block respectively, and the protrusion is slidably connected in the strip groove.

[0008] Preferably, the protrusion on the spring seat has an opening groove, and a magnetic component is disposed in the opening groove. The sensing circuit board in the sensor connector is parallel to and opposite to the magnetic component.

[0009] Preferably, a wedge-shaped structure is formed between the lower end face of the upper force lag block and the upper end face of the lower force lag block.

[0010] Preferably, a torsion spring is fitted on the brake rotating shaft, with one end of the torsion spring connected to the brake handle and the other end abutting against the outer casing.

[0011] Preferably, the bottom of the inner cavity of the outer cover is provided with a cylindrical protrusion, and the bottom of the lower spring column abuts against the cylindrical protrusion.

[0012] Preferably, a support is fixedly provided on the outer casing, a brake rotating shaft is rotatably mounted on the support, and a brake handle is fixedly connected to the brake rotating shaft.

[0013] Preferably, a brake pedal is fixedly mounted on the brake handle, and the surface of the brake pedal is provided with grooves.

[0014] Preferably, the outer casing has a recessed cavity at the position corresponding to the brake handle to accommodate the brake handle.

[0015] In summary, the beneficial effects of this invention are:

[0016] This invention, through a wedge-shaped hysteresis structure, accurately simulates the "smooth initial braking and firm subsequent braking" feel of traditional braking systems, providing drivers with familiar and reliable pedal feedback. Simultaneously, its integrated dual-sensor redundancy design ensures high reliability and safety of signal output, and combined with a low-power wake-up function, significantly reduces system standby power consumption. Furthermore, the device is compact, highly interchangeable and adaptable, and can directly replace traditional vacuum boosters, effectively reducing the difficulty of vehicle layout and manufacturing costs, achieving a balance between performance, safety, and economic benefits. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of a pedal simulator device for brake-by-wire control according to the present invention;

[0019] Figure 2 This is a schematic diagram of the pedal simulator device for brake-by-wire according to the present invention from another perspective.

[0020] Figure 3 This is a schematic diagram of the force lag component in a pedal simulator device for brake-by-wire control according to the present invention.

[0021] Figure 4 This is a schematic diagram of the force lag component in a pedal simulator device for brake-by-wire control according to the present invention from another perspective.

[0022] Figure 5 This is a schematic diagram showing the unfolded structure of the lower and upper hysteresis blocks in a pedal simulator device for brake-by-wire control according to the present invention.

[0023] Figure 6 This is a schematic diagram of the protruding part of the spring seat in a pedal simulator device with wire braking according to the present invention.

[0024] The markings in the attached drawings are described as follows: outer casing 10; support part 11; brake rotating shaft 12; brake handle 13; brake pedal 14; connecting part 15; connector 16; mounting plate 17; sensor connector 18; outer cover 19; lower spring column 20; lower force stabilizing block 21; upper force stabilizing block 22; spring seat 23; upper spring column 24; elastic component one 25; elastic component two 26. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by drivers of ordinary skill in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0026] To facilitate understanding of the present invention, a more complete description of the invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of the invention will be more thorough and complete.

[0027] All features disclosed in this specification, or all steps in all disclosed methods or processes, may be combined in any way, except for mutually exclusive features and / or steps.

[0028] Any feature disclosed in this specification (including any appended claims, abstract, and drawings) may be replaced by other equivalent or similar features for a similar purpose, unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is merely one example of a series of equivalent or similar features.

[0029] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of at least two elements or the interaction relationship of at least two elements, unless otherwise explicitly limited. For drivers skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0030] Please see Figures 1-5 The present invention provides an embodiment of a pedal simulator device with wire braking, comprising an outer housing 10, a brake lever 13, and a force lag assembly that gradually increases damping force with increasing pedal travel. Three support portions 11 are fixedly disposed on the outer housing 10, and a brake rotating shaft 12 is rotatably mounted between the three support portions 11. The brake lever 13 is fixedly connected to the brake rotating shaft 12, and the force lag assembly is connected to the brake lever 13. A torsion spring is sleeved on the brake rotating shaft 12, one end of which is connected to the brake lever 13, and the other end abuts against the outer housing 10. Therefore, the force lag assembly can be driven to brake by stepping on a brake pedal 14 mounted on the brake lever 13. An inner cavity is provided on the outer housing 10 at a position corresponding to the brake lever 13 to accommodate the brake lever 13 during pedaling.

[0031] It is worth mentioning that, in this embodiment, the force lag assembly includes an outer cover 19 and a spring seat 23. The outer cover 19 is fixedly installed on the outer casing 10, and the spring seat 23 is slidably connected in the inner cavity of the outer cover 19. A connecting part 15 is fixedly connected to the upper end of the spring seat 23, and the connecting part 15 is hinged to the brake handle 13. Thus, the spring seat 23 can slide up and down along the outer cover 19 by stepping on the brake pedal 14. An upper spring post 24 is installed in the inner cavity of the spring seat 23, and an upper force lag block 22 and a lower force lag block 21 are provided at the lower end of the spring seat 23. The slidable connection between the slack block 22 and the lower slack block 21 and the inner cavity sidewall of the outer cover 19 is achieved. The bottom end of the upper spring column 24 abuts against the top end of the upper slack block 22. An elastic component 25 is connected between the upper end face of the upper slack block 22 and the inner cavity top wall of the spring seat 23. A lower spring column 20 is installed at the bottom of the inner cavity of the outer cover 19. The top end of the lower spring column 20 is connected to the bottom end of the lower slack block 21. An elastic component 26 is connected between the bottom end of the lower slack block 21 and the inner cavity bottom wall of the outer cover 19. This achieves a smooth pedaling force in the front section and a sharp increase in pedaling force in the rear section.

[0032] To further control the pedal travel, in this embodiment, a mounting plate 17 is fixedly connected to the outer cover 19, and a sensor connector 18 is mounted on the mounting plate 17. A strip-shaped groove is provided on the outer end face of the outer cover 19. A protrusion is provided on the spring seat 23, the upper force lag block 22, and the lower force lag block 21, respectively. The protrusion is slidably connected in the strip-shaped groove. An opening slot is provided in the protrusion on the spring seat 23, and a magnetic component is provided in the opening slot. The sensing circuit board in the sensor connector 18 is parallel to and opposite to the magnetic component. The Hall sensor sends the driver signal to the vehicle control unit, and the vehicle receives the signal and transmits it to the braking terminal to realize the driver's intention to decelerate, i.e., brake-by-wire.

[0033] In another embodiment, a wedge-shaped structure is formed between the lower end face of the upper force stabilizing block 22 and the upper end face of the lower force stabilizing block 21, and a cylindrical protrusion is provided at the bottom of the inner cavity of the outer cover 19, with the bottom of the lower spring column 20 abutting against the cylindrical protrusion.

[0034] In another embodiment, the surface of the brake pedal 14 is provided with grooves to increase friction when pedaled.

[0035] During actual operation, the vehicle is initially locked and in standby mode. The pedal simulator's electronic control unit is in sleep mode, consuming very little power.

[0036] The driver opens the car door, sits in the driver's seat, and his foot naturally rests on the brake pedal 14. He subconsciously and gently presses down a very small amount (e.g., 2mm). This tiny pressure causes the brake lever 13 to move slightly, resulting in a slight movement between the hinged connection 15 and the spring seat 23. The magnetic component on the spring seat 23 moves accordingly. Although the displacement is very small, the Hall circuit in the sensor connector 18 detects the change in magnetic field and immediately outputs a high-level signal. This high-level signal serves as a "wake-up" command and is sent to the vehicle control unit (VCU). The VCU is then activated, notifying the relevant vehicle systems (including the braking system) to enter the operational readiness mode from sleep mode. At this point, the braking system is ready to engage, but no actual braking force has yet been generated.

[0037] When the driver needs to slowly pull out of the parking space, he smoothly depresses the brake pedal to approximately 40% of its total travel. The brake lever 13 rotates, pushing the spring seat 23 downwards within the outer casing 19 via the connecting part 15. The spring seat 23 compresses the upper spring post 24 and the upper hysteresis block 22. At this stage, the wedge-shaped structure between the upper and lower hysteresis blocks 22 and 21 is not fully engaged, with gaps or only slight friction present. The main resistance comes from the torsional resistance of the torsion spring, the compression of elastic components 25 and 26, and the compression of the upper and lower spring posts 24 and 20. These springs work together to provide a linear, smooth, and gradually increasing pedal feel. The movement of the spring seat 23 is precisely captured by two redundant Hall effect sensors, which continuously output a signal or PWM signal proportional to the pedal travel (e.g., a voltage value corresponding to 40% of the travel). The VCU receives the signal, identifies it as a "light braking" intention, and transmits it to the brake terminal. The brake terminal controls the motor to generate appropriate braking force, allowing the vehicle to decelerate smoothly. The driver's foot feel is very similar to the initial feel of a traditional vacuum-assisted brake, making it easy to control.

[0038] Suddenly, a car approaches from the side, and the driver needs to brake immediately. He presses the brake pedal all the way down (entering the last 50% of the travel, for example, from 50% to 100%), and the spring seat 23 continues to descend, pushing the wedge-shaped surfaces of the upper force-lock block 22 and the lower force-lock block 21 into close contact. As the travel increases, the wedge-shaped structure is forcefully pressed into the inner cavity of the outer cover 19. Due to the design of the wedge angle, the upper force-lock block 22 and the lower force-lock block 21 are subjected to a huge normal force from the side wall, thus generating very significant sliding friction damping.

[0039] This frictional damping force increases dramatically and non-linearly, superimposed on the forces of all the previous springs, making the pedal force instantly become very "heavy".

[0040] This "soft at the beginning, firm at the end" pedal feel perfectly simulates the characteristic of traditional hydraulic brakes where the pedal force increases sharply during emergency braking, giving the driver ample confidence and feedback. Despite the surge in pedal force, the displacement of the spring seat 23 is still precisely measured by the sensor, outputting a maximum signal representing 100% travel. Upon receiving the maximum braking signal, the VCU immediately issues a "full braking" command to the braking terminal. The braking terminal then activates maximum pressure or torque to achieve emergency braking of the vehicle until systems such as ABS intervene.

[0041] Once the danger is averted, the driver releases the brake pedal. All compressed springs (torsion spring, elastic component 25, elastic component 26, upper / lower spring posts) release energy, pushing the spring seat 23 back to its original position. The upper and lower force-locking blocks 22 and 21 separate under the action of the springs, eliminating wedge friction. The entire mechanism smoothly returns to its initial position under the force of the springs, and the sensor signal smoothly drops from its maximum value to zero. After the pedal has fully returned to its original position, the system enters a low-power sleep mode after a preset delay, awaiting the next wake-up.

[0042] In summary, this invention, through its innovative wedge-shaped hysteresis structure, accurately simulates the "smooth initial braking and firm subsequent braking" feel of traditional braking systems, providing drivers with familiar and reliable pedal feedback. Simultaneously, its integrated dual-sensor redundancy design ensures high reliability and safety of signal output, and combined with a low-power wake-up function, significantly reduces system standby power consumption. Furthermore, the device is compact, highly interchangeable and adaptable, and can directly replace traditional vacuum boosters, effectively reducing the difficulty of vehicle layout and manufacturing costs, achieving a balance between performance, safety, and economic benefits.

[0043] The above description is merely a specific embodiment of the invention, but the scope of protection of the invention is not limited thereto. Any variations or substitutions conceived without inventive effort should be included within the scope of protection of the invention. Therefore, the scope of protection of the invention should be determined by the scope defined in the claims.

Claims

1. A pedal simulator device with brake-by-wire, comprising an outer housing (10) and a brake lever (13), characterized in that: The lower end of the brake lever (13) is connected to a damping component that gradually increases the damping force as the pedal stroke increases. The damping component includes an outer cover (19) and a spring seat (23). An upper spring column (24) is installed in the inner cavity of the spring seat (23). A connecting part (15) is fixedly connected to the upper end of the spring seat (23). The connecting part (15) is hinged to the brake lever (13). An upper damping block (22) and a lower damping block (21) are provided at the lower end of the spring seat (23). The upper damping block (22) and the lower damping block (21) slide against the inner cavity sidewall of the outer cover (19). The upper spring column (24) is connected to the top of the upper force block (22), and an elastic component (25) is connected between the upper end face of the upper force block (22) and the inner cavity top wall of the spring seat (23). A lower spring column (20) is installed at the bottom of the inner cavity of the outer cover (19), and the top of the lower spring column (20) is connected to the bottom of the lower force block (21). An elastic component (26) is connected between the bottom of the lower force block (21) and the inner cavity bottom wall of the outer cover (19), so that the pedaling force in the front part is smooth and the pedaling force in the rear part increases sharply.

2. The pedal simulator device with brake-by-wire according to claim 1, characterized in that: An mounting plate (17) is fixedly connected to the outer cover (19), and a sensor connector (18) is mounted on the mounting plate (17).

3. The pedal simulator device for brake-by-wire according to claim 2, characterized in that: A strip groove is provided on the outer end face of the outer cover (19), and a protrusion is provided on the spring seat (23), the upper force block (22) and the lower force block (21), respectively. The protrusion is slidably connected in the strip groove.

4. The pedal simulator device with brake-by-wire according to claim 3, characterized in that: An opening groove is provided in the protrusion on the spring seat (23), and a magnetic component is provided in the opening groove. The sensing circuit board in the sensor connector (18) is parallel to and opposite to the magnetic component.

5. The pedal simulator device for brake-by-wire according to claim 4, characterized in that: A wedge-shaped structure is formed between the lower end face of the upper force stabilizing block (22) and the upper end face of the lower force stabilizing block (21).

6. The pedal simulator device for brake-by-wire according to claim 1, characterized in that: A torsion spring is fitted on the brake rotating shaft (12), one end of which is connected to the brake handle (13), and the other end abuts against the outer casing (10).

7. The pedal simulator device for brake-by-wire according to claim 1, characterized in that: The bottom of the inner cavity of the outer cover (19) is provided with a cylindrical protrusion, and the bottom of the lower spring column (20) abuts against the cylindrical protrusion.

8. The pedal simulator device for brake-by-wire according to claim 1, characterized in that: A support part (11) is fixedly provided on the outer casing (10), and a brake rotating shaft (12) is rotatably mounted on the support part (11). The brake handle (13) is fixedly connected to the brake rotating shaft (12).

9. The pedal simulator device for brake-by-wire according to claim 1, characterized in that: A brake pedal (14) is fixedly installed on the brake handle (13), and the surface of the brake pedal (14) is provided with grooves.

10. A pedal simulator device for brake-by-wire according to claim 9, characterized in that: The outer casing (10) has a recessed cavity at the position corresponding to the brake handle (13) to accommodate the brake handle (13).

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