Pedal unit for triggering a vehicle function

Abstract

The invention relates to a pedal unit (10) for triggering a vehicle function, having a modularly configured pedal head (12), which is subjected to a manipulation force of a driver's foot; a fixable, open housing (20) toward the pedal head (12); a pedal piston (25), which is arranged at least partially in the housing (20), is supported in the housing (20), can be moved axially over a small stroke against the force of a return spring (27), passes through an opening of the housing (20), and is detachably connected to the pedal head (12); and at least one sensor assembly (30), which comprises at least one measurement value provider (38), which is coupled to the pedal piston (25), and at least one sensor (37), wherein the at least one sensor (37) is configured to contactlessly detect a stroke movement of the movable pedal piston (25) caused by the manipulation force of the driver's foot.

Description

Technical Field

[0001] This invention relates to a pedal unit for triggering vehicle functions. Background Technology

[0002] Drive-by-wire systems with pedal assemblies are known in the prior art, transmitting driver commands solely through electrical or electronic means. Such systems include, for example, pedal assemblies with so-called electronic throttle pedals or accelerator pedals for drive control or acceleration, and brake pedals for brake-by-wire systems to perform braking functions. Another known drive-by-wire system is a steer-by-wire system for steering control. Drive-by-wire refers to driving or controlling a vehicle without mechanical force transmission from vehicle operating elements, such as the accelerator pedal, brake pedal, or steering wheel, to corresponding adjusting elements of the vehicle, such as the throttle, brakes, and / or steering mechanism. This means that for such drive-by-wire systems, the corresponding pedal units are decoupled from force flow, and instead, the functions are controlled via electrical wiring and servo motors or electromechanical actuators. Typically, the sensor array of a drive-by-wire system detects the driver's intent using force-based sensor units to determine the required braking or acceleration intensity of the vehicle, and adjusts accordingly through the drivetrain and braking system. By eliminating the mechanical connection, a novel pedal design can be achieved, as large pedal displacements are no longer required to decelerate or accelerate the vehicle.

[0003] A device for accelerating or decelerating a motor vehicle is known from document DE 103 12 547 A1. This device includes two operating elements. A first operating element is used to accelerate the motor vehicle, and a second operating element is used to decelerate the motor vehicle. These operating elements are operated by applying a hand or foot force. Here, both operating elements operate with minimal displacement, and after the hand or foot force is removed from the first or second operating element, the speed of the motor vehicle remains constant according to the last applied hand or foot force until further operation of the first or second operating element.

[0004] A pedal assembly having two pedal units (one pedal unit for triggering a vehicle function) is known from document DE 10 2023 204 205 A1, along with a method for assembling such pedal units and a method for removing pedal heads from such pedal units. The pedal unit includes a modularly constructed pedal head comprising a pad carrier and a replaceable pedal pad for bearing the operating force of the driver's foot, and the pedal head is connected to a housing cover that is movable with a small stroke along the height direction of the pedal unit. The pedal pad is detachably connected to the pad carrier. Here, a fastening assembly detachably and form-fittingly and / or force-transmittingly connects the pad carrier to the movable housing cover. The pedal assembly includes a first pedal unit designed as a brake pedal and a second pedal unit designed as an accelerator pedal. Summary of the Invention

[0005] The pedal unit for triggering vehicle functions, having the features of independent claim 1, has the advantage of enabling an improved, space-optimized sensor scheme with a small travel range of 0 to 10 mm, compact structural dimensions, low mass, and reduced CO2 footprint. Preferably, inductive measurement technology and / or magnetic measurement technology can be employed. Furthermore, the implementation of the pedal unit allows for easy mounting on the vehicle floor or bracket assembly to optimize driver protection in the event of a collision. Additionally, convenient electrical connections with lateral wiring can be achieved for easier cable laying.

[0006] In the implementation of the pedal unit, each sensor assembly can use multiple parallel-operating measurement systems or sensor systems with the same or different measurement principles. Furthermore, the implementation of the pedal unit achieves high sensor resolution to provide a comfortable pedal feel for the driver.

[0007] Embodiments of the present invention provide a pedal unit for triggering vehicle functions, comprising: a modularly constructed pedal head that receives the operating force of a driver's foot; a lockable housing open toward the pedal head; a pedal piston at least partially disposed within the housing, supported within the housing, capable of axially moving a small stroke against the force of a return spring, passing through an opening in the housing, and detachably connected to the pedal head; and at least one sensor assembly including at least one measurement provider coupled to the pedal piston and at least one sensor. Here, the at least one sensor is configured to non-contactly detect the stroke movement of the movable pedal piston caused by the operating force of the driver's foot.

[0008] The housing can preferably be constructed as a thin-walled injection-molded plastic part or a metal component, such as an aluminum component. The external shape and electrical connections of the housing can be advantageously tailored to customer interface requirements. The housing preferably includes separate chambers for the individual sensor assemblies, so as to achieve spatial separation of the sensor assemblies in addition to electrical isolation when using multiple sensor assemblies. Thus, the continued operation of the pedal unit can be guaranteed when a sensor assembly in one chamber fails, for example, due to leakage.

[0009] The pedal piston is used for axial movement of the pedal head, which can then be detachably mounted on the upper end of the pedal piston and can move between an initial position and a final state. Here, the pedal piston may have a quick-lock assembly and surrounding grooves for securing the sealing element. The return spring can be designed according to customer requirements and has different spring characteristics in the brake pedal used for braking or in the accelerator pedal used for acceleration. The return spring generates a driving force perceived by the driver. Depending on the application, the return spring may or may not be preloaded. Preferably, the final preload of the return spring can be adjusted after at least one sensor assembly is installed.

[0010] To convert driver intentions into corresponding electrical signals for vehicle functions, at least one contactless sensor assembly is employed, which has at least one sensor. This at least one sensor assembly may be optionally designed redundantly, or according to applicable regulations. Some regulations require four sensors with two different measurement principles, all of which are considered "redundant," when the pedal unit is configured as a brake pedal. When the pedal unit is configured as an accelerator pedal, two redundant sensors with the same measurement principle are sufficient.

[0011] Currently, at least one sensor can be understood as a circuit or structural unit having at least one sensor element, which is accordingly positioned to measure the stroke of a movable pedal piston caused by the operating force of the driver's foot without contact. Here, the at least one sensor is configured to detect the small stroke of the movable pedal piston. For this purpose, there are various feasible measurement principles that can be used to measure the stroke of the movable pedal piston. For example, magnetic measurement methods and / or inductive measurement methods known from the prior art can be used to detect the small stroke of the movable pedal piston.

[0012] The at least one sensor assembly may have a circuit board serving as a circuit carrier on which at least one sensor can be mounted. Furthermore, the at least one sensor assembly may have an external electrical interface through which measurement signals can be output to a higher-level control system, and through which power can be supplied to the at least one sensor. An evaluation and control unit mounted on the circuit carrier can be used for further analysis, such as data comparison, feasibility checks, etc. Additionally or alternatively, evaluation can be performed in one or more redundant external evaluation and control units. For this purpose, the at least one sensor may preprocess the measurement signal and convert it into a signal usable by the subsequent evaluation and control unit. Examples of this include analog data output in the range of, for example, 0.5 to 4.5 volts, and digital data output, such as a PWM signal or a SENT signal. For this purpose, at least one evaluation and control unit of the at least one sensor assembly may be, for example, a so-called ASIC component or a microcontroller, which may contain various functions for detecting and evaluating sensor signals. However, the evaluation and control unit may also be constructed as an integrated circuit or a discrete component. For example, a software module present on the microcontroller may also be used to evaluate and / or further process the detected signal. Computer program products containing program code stored on a machine-readable medium (such as semiconductor memory, hard disk memory, or optical memory) are also advantageous and are used for evaluation when the program is executed.

[0013] Advantageous improvements to the pedal unit for triggering vehicle functions as given in independent claim 1 can be achieved through the measures and improvements listed in the dependent claims.

[0014] Particularly advantageously, the pedal piston can be guided in at least two support bushings connected to the housing. Here, the first support bushing can be configured as a through bushing, positioned at the opening of the housing. The second support bushing can be configured as an end bushing connected to the bottom of the housing, accommodating the end region of the pedal piston opposite the pedal head, and forming a stop for the pedal piston. The mounting position and length of the pedal piston can be configured such that when the pedal unit reaches its maximum stroke or end position, the lower end of the pedal piston rests against the support bushing, and even higher axial forces, which might occur in cases of misuse or panic, can be discharged through the housing. The support bushings can be, for example, placed in a mold as plastic injection molding parts during the manufacture of the housing. Alternatively, the support bushings can be press-fitted, bonded, laser-welded, or otherwise connected to the housing in a suitable manner. Furthermore, the support bushing configured as a through bushing can have the possibility of fixation, for example, with surrounding grooves for subsequent assembly of sealing elements.

[0015] In an advantageous design of the pedal unit, the pedal piston can be constructed in a stepped shape and have a locating shoulder. Here, the return spring can be supported on the edge of the end bushing and on the locating shoulder of the pedal piston. To protect the edge of the end bushing from excessive wear caused by the directly abutting return spring, a locating disc can be arranged between the return spring and the edge of the end bushing.

[0016] In another advantageous design of the pedal unit, at least one sensor assembly may include at least two redundant sensors that apply the same measurement principle to detect the movement of the pedal piston.

[0017] In another advantageous design of the pedal unit, at least one sensor assembly may include at least one measurement provider coupled to the pedal piston via a follower and movable with the pedal piston. Here, the follower may preferably be configured as a mating pin, with one end coupled to at least one measurement provider and the other end inserted into a corresponding radial mating hole cut into the pedal piston. The mating pin may, for example, be pressed, screwed, or glued into the corresponding radial mating hole. The follower may perform multiple functions. For example, the follower may act as a stop for the piston's axial movement in its initial state, thereby fixing the piston in position within the housing. Furthermore, the follower may provide anti-rotation functionality, ensuring that the movement of the pedal piston is purely axial and does not simultaneously involve rotation, which could distort the measurement. Additionally, the follower may transmit the movement of the pedal piston to at least one measurement provider.

[0018] In another advantageous design of the pedal unit, at least one sensor component can be configured as a magnetic displacement sensor or an inductive displacement sensor.

[0019] In another advantageous design of the pedal unit, the magnetic displacement sensor may include a measurement provider configured as a magnet and at least one magnetic field sensor arranged on a circuit carrier, spaced apart from the magnet within the range of movement of the magnet, and for detecting and evaluating the magnetic field or magnetic field changes of the magnet.

[0020] In another advantageous design of the pedal unit, a cover element can be arranged between the measuring value provider, which is constructed as a magnet, and at least one magnetic field sensor. Here, the cover element is preferably constructed as a cover and is sealed by bonding or laser or ultrasonic welding. Here, the external interface and the cover can enclose a space in which the magnetic field sensor is arranged. With the corresponding connectors inserted, this achieves a seal against moisture or water. The external interface can be sealed securely to the housing by bonding or laser or ultrasonic welding.

[0021] In another advantageous design of the pedal unit, the magnet can be arranged within a magnet slider movably supported in a guide plate, coupled to the pedal piston via a follower. Here, the follower passes through a through guide portion in the guide plate and inserts into a receiving opening in the magnet slider. A compensation spring can be arranged in the receiving opening of the magnet slider to compensate for the gap between the follower and the magnet slider. This gap compensation improves measurement accuracy and repeatability. The compensation spring can be constructed, for example, as a helical spring, a leaf spring, an elastic wire, or a clamp. The magnet can be positionally positioned within the magnet slider, for example, by bonding or thermal filling.

[0022] In an alternative design for the pedal unit, the follower can pass through the through guide portion in the guide plate and be connected in a shape that matches the magnetic slider.

[0023] In another advantageous design of the pedal unit, the slider guide between the guide plate and the magnetic slider can be configured as a dovetail guide or a longitudinal guide. The magnetic slider can be moved by a follower after assembly. Furthermore, the magnetic slider can move against the force of another return spring, which is used for clearance compensation relative to the follower, as this other return spring always presses the slider against the follower. In the event of a breakage in the pedal piston's return spring, this other return spring can push the pedal piston back to its initial state via the magnetic slider and the follower, and the magnetic slider can also press the pedal head back to its initial position. Thus, in the event of a breakage in the pedal piston's return spring, the corresponding pedal unit can be reset. When configured as a longitudinal guide, the magnetic slider is only laterally guided to provide lateral support and suppress resonance during external vibrations.

[0024] In another advantageous design of the pedal unit, the inductive displacement sensor may include a measurement provider configured as a conductive target and at least one inductive sensor arranged on a circuit carrier and spaced apart from the conductive target within the range of movement of the conductive target. Here, the at least one inductive sensor may include at least one excitation structure, at least one receiving structure, and an evaluation and control unit. The at least one excitation structure is coupled to the evaluation and control unit, which couples a periodic alternating signal to the at least one excitation structure during operation. The conductive target is configured to influence the inductive coupling between the at least one excitation structure and the at least one receiving structure. The evaluation and control unit is configured to receive and evaluate the signal sensed in the at least one receiving structure and determine the current position of the movable pedal piston. The target may be constructed, for example, as an aluminum plate, copper plate, or stainless steel plate, and is fixed to the follower non-rotatably by riveting, bonding, or pressing. Alternatively, a printed circuit board (PCB) with a copper surface on its upper surface may be used as the target instead of a sheet metal. The circuit carrier may be assembled with a small gap relative to the range of movement of the target and fixed, for example, by bonding, hot stamping, or riveting.

[0025] In another advantageous design of the pedal unit, a cover element is arranged between the measuring value provider, configured as a conductive target, and at least one inductive sensor. Here, the cover element can preferably be configured as a cover plate and is sealed to the housing by adhesive bonding or laser or ultrasonic welding. The external interface and the cover plate can enclose a space in which the inductive sensor is arranged. With the corresponding connector inserted, this achieves a seal against moisture or water. The external interface can be securely fastened to the housing by adhesive bonding or laser or ultrasonic welding.

[0026] In another advantageous design of the pedal unit, two redundant sensor assemblies are arranged spatially and electrically apart within the housing and sealed relative to each other and externally to the external medium. Here, these two redundant sensor assemblies apply different measurement principles to detect the movement of the pedal piston. With this design of two redundant sensor assemblies, the pedal unit can be constructed as a brake pedal with both a magnetic displacement sensor and an inductive displacement sensor. Here, the magnetic displacement sensor has two redundant magnetic field sensors, and the inductive displacement sensor has two inductive sensors, each also having its own independent power supply. Optionally, additional measurement circuits can be implemented. For example, a "pedal wake-up" function can be optionally implemented. This means that with slight manipulation of the pedal unit, the controller can be "wake up" by an additional sensor, i.e., put into operating mode, so that braking can be triggered, for example, even if the vehicle was previously closed. Such an additional sensor can, for example, be soldered onto the circuit carrier of the magnetic displacement sensor or the inductive displacement sensor. If necessary, another magnet can be fitted for this purpose.

[0027] In another advantageous design of the pedal unit, two redundant sensor assemblies can be arranged offset from each other by 90 degrees or 180 degrees.

[0028] In another advantageous design of the pedal unit, the modularly constructed pedal head may include a pad carrier and a replaceable pedal pad detachably connected to the pad carrier. Here, the pad carrier has a receiving opening on its side facing the pedal piston, which receives the end region of the pedal piston facing the pedal head. A quick-release fastener is provided, which detachably connects the pad carrier to the pedal piston. Thus, the pedal head can be subsequently assembled and replaced. This means that the pedal unit can be mounted under the vehicle carpet without the pedal head, and then the pedal head can be assembled later. This allows for a very aesthetically pleasing design, especially for vehicles with autonomous driving capabilities. For pedal units with a small travel, the pedal head, coupled with the movable pedal piston, has only a small travel along the height direction of the pedal unit. The advantage of a pedal unit with a small travel and a retractable housing is that, apart from the movable pedal head and the connection area with the movable pedal piston, the corresponding pedal unit can be positioned in the vehicle interior, more specifically under the carpet, so that only the pedal head is visible. The carpet can then be positioned on a support plate or a manufacturer's bracket. This means that the cutout in the carpet is limited to the size of the connection area between the pedal head and the movable pedal piston. If the carpet also needs to accommodate the larger profile of the pedal head, the cutout must be larger, which is detrimental to the overall appearance. With a pedal head that can be installed subsequently, the cutout in the carpet is reduced to the minimum necessary size, and it is almost completely covered by the subsequently installed pedal head.

[0029] In another advantageous design of the pedal unit, the quick-release mechanism may include at least one retaining opening in the pedal piston and / or the pad carrier, and at least one retaining element inserted into the retaining opening and detachably connecting the pad carrier to the pedal piston. Here, the quick-release mechanism may include a radial retaining opening in the pedal piston and a radial retaining opening in the pad carrier of the pedal head, oriented flush with the aforementioned radial retaining opening. The retaining element may be inserted into the radial retaining opening of the pad carrier and pass through the radial retaining opening in the pedal piston, detachably connecting the pad carrier to the pedal piston.

[0030] In an alternative design for the pedal unit, the quick-release mechanism may include an axial fixing opening on the end side of the pedal piston, an axial fixing opening in the pad carrier, and an axial opening in the pedal pad, all flush with each other. Here, the fixing element can pass through the axial opening in the pedal pad and the axial fixing opening in the pad carrier, and be inserted into the axial fixing opening in the pedal piston, thus detachably connecting the pad carrier to the pedal piston.

[0031] In an alternative design of the pedal unit, the quick-release mechanism may include an axial fixing opening located on the end side of the pedal piston and a fixing element disposed on the pedal head, which protrudes from the pedal head toward the pedal piston and has a stepped radial through opening. Furthermore, a radial, through sleeve receiving portion may be provided in the pedal piston to accommodate a spring-loaded locking sleeve. Here, with the pedal head in the assembled state, the spring-loaded locking sleeve can at least partially extend into the stepped radial through opening, locking the fixing element in the axial fixing opening.

[0032] In another alternative design of the pedal unit, a torsion stop can be provided between the pedal head and the pedal piston. This stop includes an axial locking opening located on the end side of the pedal piston and a locking pin arranged on the pedal head, which protrudes from the pedal head toward the pedal piston and is at least partially accommodated by the axial locking opening in the pedal piston.

[0033] Embodiments of the present invention are shown in the accompanying drawings and will be explained in more detail in the following description. In the drawings, the same reference numerals denote parts or elements that perform the same or similar functions. Attached Figure Description

[0034] Figure 1 A schematic perspective view of a portion of the foot space on the driver's side of a vehicle is shown, featuring a pedal assembly that includes two embodiments of a pedal unit for triggering vehicle functions according to the invention.

[0035] Figure 2 It shows Figure 1 The schematic perspective view of the pedal unit according to the present invention is shown in the figure. The pedal unit is configured as a brake pedal.

[0036] Figure 3 It shows Figure 1 The schematic perspective view of the pedal unit according to the present invention is shown in the figure. The pedal unit is configured as an accelerator pedal.

[0037] Figure 4 A schematic perspective partial cross-sectional view of a pedal unit according to the present invention is shown, the pedal unit being configured as a brake pedal.

[0038] Figure 5 A schematic perspective transverse sectional view of the housing of a pedal unit according to the present invention is shown, the pedal unit being configured as a brake pedal.

[0039] Figure 6 A schematic exploded perspective view of a magnetic field sensor in a first sensor assembly configured as a magnetic displacement sensor in a pedal unit according to the present invention is shown. The pedal unit is configured as a brake pedal.

[0040] Figure 7 A schematic perspective longitudinal sectional view is shown of a first embodiment of a measurement value provider for a first sensor assembly configured as a magnetic displacement sensor, the measurement value provider being arranged in a housing of a pedal unit configured as a brake pedal according to the invention.

[0041] Figure 8 A schematic perspective view of a second embodiment of a measurement value provider for a first sensor assembly configured as a magnetic displacement sensor in a pedal unit according to the present invention is shown, wherein the pedal unit is configured as a brake pedal.

[0042] Figure 9 A schematic perspective longitudinal sectional view of a second sensor assembly configured as an inductive displacement sensor is shown, the second sensor assembly being arranged in the housing of a pedal unit configured as a brake pedal according to the invention.

[0043] Figure 10 A schematic perspective cross-sectional view of a first embodiment of a pedal head of a pedal unit according to the present invention is shown, wherein the pedal unit is configured as a brake pedal.

[0044] Figure 11 A schematic perspective cross-sectional view of a second embodiment of a pedal head of a pedal unit according to the present invention is shown, wherein the pedal unit is configured as a brake pedal.

[0045] Figure 12 A schematic perspective cross-sectional view of a third embodiment of a pedal head according to the invention is shown, wherein the pedal unit is configured as a brake pedal.

[0046] Figure 13 The disassembly process was shown. Figure 11 The figure shows a schematic perspective cross-sectional view of the pedal head of the pedal unit according to the present invention, wherein the pedal unit is configured as a brake pedal. Detailed Implementation

[0047] from Figures 1 to 13 As can be seen, the illustrated embodiment of the pedal unit 10 for triggering vehicle functions according to the present invention includes: a modularly constructed pedal head 12 that bears the operating force of the driver's foot; a lockable housing 20 open toward the pedal head 12; a pedal piston 25 at least partially disposed in the housing 20, supported within the housing 20, capable of axially moving a small stroke against the force of the return spring 27, passing through the opening of the housing 20, and detachably connected to the pedal head 12; and at least one sensor assembly 30, which includes at least one measurement provider 38 coupled to the pedal piston 25 and at least one sensor 37. Here, the at least one sensor 37 is configured to detect the stroke movement of the movable pedal piston 25 caused by the operating force of the driver's foot without contact.

[0048] from Figures 1 to 3 It can also be seen that in the shown portion of the footwell on the driver's side of the vehicle, a pedal assembly 1 is arranged on the corresponding vehicle body 3. This pedal assembly has two embodiments of the pedal unit 10 for triggering vehicle functions according to the present invention. Both pedal units 10 are arranged and fastened to the partition wall 3A between the vehicle interior space and the engine compartment. Here, the left pedal unit 10 in the figure is configured as a brake pedal 10A for performing the braking function, and the right pedal unit 10 in the figure is configured as an accelerator pedal 10B for performing the acceleration function. For fastening, the housing 20A of the brake pedal 10A and the housing 20B of the accelerator pedal 10B each have a plurality of screw-connecting lugs 20.1, through which the corresponding housing 20 is screwed to the vehicle body 3. In addition, an elastic seal 18 configured as a corrugated structure 18A is arranged between each housing 20 and the corresponding pedal head 12. For the two embodiments of the pedal unit 10, the small stroke of the movable pedal piston 25 is in the range of 0 to 10 mm. In an alternative embodiment (not shown), two pedal units 10 are arranged and secured to the vehicle floor 3B. Figure 1 It can also be seen that the partition wall 3A and the bottom of the vehicle 3B are covered with carpet 5.

[0049] To convert driver intentions into corresponding electrical signals for the corresponding vehicle functions, contactless measurement sensor assemblies 30 are employed. Each of these sensor assemblies 30 is redundantly designed according to applicable regulatory guidelines. In the illustrated embodiment, the pedal unit 10 configured as a brake pedal 10A has two redundant sensor assemblies 30, which apply different measurement principles to detect the movement of the pedal piston 25. These two redundant sensor assemblies 30 are spatially and electrically separated from each other in the first housing 20A and are sealed relative to each other and externally relative to the external medium. Here, each of the two sensor assemblies 30 for detecting the movement of the pedal piston 25 has two redundant sensors 37, which are respectively arranged on the circuit carrier 36.

[0050] Especially from Figure 4 It can also be seen that the first housing 20A includes two separate chambers 22 for the two sensor assemblies 30, each of which is externally sealed by a cover 32 to prevent fluid penetration. Each cover 32 has a connector housing 34, which is part of the external interface of the corresponding sensor assembly 30. Therefore, in the illustrated embodiment of the brake pedal 10A, the first sensor assembly 30 is configured as a magnetic displacement sensor 30A and is arranged in the first chamber 22A of the housing 20A, located on the first circuit carrier 36A. The first chamber 22A of the housing 20A is externally sealed by the first cover 32A. Here, the first connector housing 34A allows for convenient electrical connection and lateral wiring of the magnetic displacement sensor 30A, facilitating easier cable laying. The second sensor assembly 30 is configured as an inductive displacement sensor 30B and is arranged in the second chamber 22B of the housing 20A, located on the second circuit carrier 36B. The second chamber 22B of the housing 20A is externally covered and sealed by the second cover 32B. Here, the second connector housing 34B allows for convenient electrical connection and lateral wiring of the inductive displacement sensor 30B, facilitating easier cable laying. In the illustrated embodiment of the brake pedal 10A, the two redundant sensor assemblies 30 are arranged 90 degrees offset from each other. In an alternative embodiment of the brake pedal 10A (not shown), the two redundant sensor assemblies 30 are arranged 180 degrees offset from each other.

[0051] For the pedal unit 10 configured as accelerator pedal 10B, only one sensor assembly 30 is used, which has two redundant sensors 37 employing the same measurement principle. Therefore, for accelerator pedal 10B, a housing 20 with two chambers 22, identical to that of brake pedal 10A, can be used. In this embodiment, only one chamber 22 can be used to house the sensor assembly 30. The other chamber 22 can be covered by a cover 32 without a connector housing 34. In the illustrated embodiment, alternatively, a second housing 20B with only one chamber 22 is used to house the sensor assembly 30. In the illustrated embodiment of accelerator pedal 10B, the sensor assembly 30 is configured as a magnetic displacement sensor 30A and is arranged in a chamber of housing 20B (not shown in detail). This chamber of housing 20B is externally covered and sealed by a first cover 32A. Here, the first connector housing 34A allows for convenient electrical connection and lateral wiring of the magnetic displacement sensor 30A, facilitating easier cable laying. In an alternative embodiment (not shown) of the accelerator pedal 10B, the sensor assembly 30 is configured as an inductive displacement sensor 30B and is arranged in a chamber (not shown in detail) of the housing 20B. This chamber of the housing 20B is externally covered and sealed by a second cover 32B. Here, the second connector housing 34B allows for convenient electrical connection of the inductive displacement sensor 30B and lateral wiring for easier cable laying.

[0052] Especially from Figure 4 It can also be seen that the pedal piston 25 is guided in at least two support bushings 24, which are connected to the housing 20. Here, the uppermost first support bushing 24 in the figure is constructed as a through bushing 24A, which is arranged at the opening of the housing 20. The lowermost second support bushing 24 in the figure is constructed as an end bushing 24B connected to the bottom of the housing 20, which accommodates the end region of the pedal piston 25 opposite to the pedal head 12 and forms a stop 24.2 for the pedal piston 25. Inside the housing 20, the pedal piston 25 extends in a piston receiving portion 23, which accommodates the end bushing 24B at its lower end in the figure.

[0053] Especially from Figure 4 , Figure 7 and Figure 9It can also be seen that the pedal piston 25 is constructed in a stepped shape and has a positioning shoulder 25.2. Here, the return spring 27 is supported on the edge of the end bushing 24B and the positioning shoulder 25.2 of the pedal piston 25. To protect the end bushing 24B from wear, a positioning disc 28 is arranged between the return spring 27 and the edge of the end bushing 24B. The pedal piston 25 is used for axial movement of the pedal head 12, which is mounted on the upper end of the pedal piston 25. At least one sensor assembly 30 includes at least one measurement value provider 38, which is coupled to the pedal piston 25 via a follower 29 and can move with the pedal piston 25. For this purpose, in the illustrated embodiment, the follower 29 is constructed as mating pins 29A, 29B, which are coupled to at least one measurement value provider 38 at a first end and inserted into a corresponding radial mating hole 26 carved in the pedal piston 25 at a second end. The pedal piston 25 is positioned and lengthened such that when the pedal head 12 is pressed to reach its maximum stroke, the lower end of the pedal piston 25 rests against the end bushing 24B, and even higher axial forces can be discharged through the housing 20. Furthermore, the pedal piston 25 has a surrounding first sealing groove 14.1 at its upper end, which receives the uppermost first sealing lip 18.1 of the seal 18, which is constructed as a corrugated portion 18A, to secure the seal 18. Additionally, the first support bushing 24, constructed to pass through the bushing 24A, has a surrounding second sealing groove 25.1, which receives the lowermost second sealing lip 18.2 of the seal 18, which is constructed as a corrugated portion 18A, to secure the seal 18.

[0054] Especially from Figures 4 to 8 It can also be seen that the magnetic displacement sensor 30A includes a measurement value provider 38 configured as a magnet 38A and at least one magnetic field sensor 37A, which is arranged on the first circuit carrier 36A, spaced apart from the magnet 38A within the range of movement of the magnet 38A, and detects and evaluates the magnetic field or magnetic field changes of the magnet 38A. In the illustrated embodiment, the magnetic field sensor 37A is configured as an integrated Hall sensor component, which is soldered to the first circuit carrier 36A. In addition, two redundant magnetic field sensors 37A configured as integrated Hall sensor components are arranged on the first circuit carrier 36A. The signal of the integrated Hall sensor component is output through the connection pin 35 of the external interface. The magnet 38A is magnetized so that the integrated Hall sensor component can detect the magnetic field and thereby detect and measure the movement of the magnet 38A. A cover element 33 configured as a cover 33A is arranged between the measurement value provider 38A configured as the magnet 38A and the magnetic field sensor 37A, which can protect the magnetic field sensor 37A from external influences.

[0055] from Figure 4 , Figure 5 and Figure 7It can also be seen that, in the illustrated embodiment, the magnet 38A is arranged in a magnet slider 50 movably supported in the guide plate 52, and the magnet slider is coupled to the pedal piston 25 via a follower 29. Here, the slider guide portion 53 between the guide plate 52A and the magnet slider 50A is constructed as a dovetail guide portion 53A. Furthermore, the follower 29, constructed as a mating pin 29A, passes through the through guide portion 52.1 in the guide plate 52A and is inserted into the receiving opening 50.1 of the magnet slider 50A. In addition, a compensation spring 55 is arranged in the receiving opening 50.1 of the magnet slider 50A to compensate for the gap between the follower 29 and the magnet slider 50A. When the guide plate 52 is fixed, the compensation spring 55 presses against the follower 29 and presses the magnet slider 50A against the slider guide portion 53. Simultaneously, the compensating spring 55 presses the follower 29 against the wall of the through guide portion 52.1, thereby achieving gap compensation between the magnetic slider 50A and the follower 29. After assembly, the magnetic slider 50A is moved by the follower 29.

[0056] In the illustrated embodiment, the magnetic slider 50A moves against the force of another return spring 54, which is partially accommodated by a spring receiving portion 56 formed on the guide plate 52A and supported on the magnetic slider 50A. This other return spring 54 is used for clearance compensation relative to the follower 29, as it continuously presses the magnetic slider 50A against the follower 29. When the return spring 27 of the pedal piston 25 breaks, this other return spring 54 can push the pedal piston 25 back to its initial state via the magnetic slider 50A and the follower 29, and also press the pedal head 12 back to its initial position using the magnetic slider 50A. Thus, in the event of the breakage of the return spring 27 of the pedal piston 25, the corresponding pedal unit 10 can be reset. Furthermore, the dovetail guide portion 53 has a deformable portion at the end of the guide plate 52A, created by hot stamping or hot filling, as an anti-loss portion, thereby locking the magnetic slider 50A in a form-fitting manner within the dovetail guide portion 53. This allows the magnet component to be assembled as a single part and transported to the production line.

[0057] from Figure 8 It can also be seen that, in the illustrated embodiment, the slider guide portion 53 between the guide plate 52B and the magnetic slider 50B is configured as a longitudinal guide portion 53B. Here, the follower 29, configured as a mating pin 29A, passes through the through guide portion 52.1 in the guide plate 52B and is connected to the magnetic slider 50B in a form-fitting manner. The longitudinal guide portion 53B includes two guide bars 58, in which the guide element 59 of the magnetic slider 50B is laterally guided.

[0058] from Figure 4 and Figure 9It can also be seen that the inductive displacement sensor 30B includes a measurement value provider 38 configured as a conductive target 38B and at least one inductive sensor 37B, which is arranged on the second circuit carrier 36B and spaced apart from the conductive target 38B within the range of movement of the conductive target 38B.

[0059] The at least one inductive sensor 37B includes at least one excitation structure (not shown in detail), at least one receiving structure (not shown in detail), and an evaluation and control unit 39. Here, the at least one excitation structure is coupled to the evaluation and control unit 39, which during operation couples a periodic alternating signal to the at least one excitation structure. A conductive target 38A is configured to influence the inductive coupling between the at least one excitation structure and the at least one receiving structure. The evaluation and control unit 39 is configured to receive and evaluate the signal induced in the at least one receiving structure and determine the current position of the target 38A or the movable pedal piston 25. The at least one excitation structure and the at least one receiving structure are preferably configured as planar coils located on a preferably multilayered second circuit carrier 36B.

[0060] In the illustrated embodiment, two redundant inductive sensors 37B are arranged on the circuit carrier 36B. This means that two excitation structures, two receiving structures, and two evaluation and control units 39 are constructed or arranged on the second circuit carrier 36B. The signals of the evaluation and control units 39 are output through the connection pin 35 of the external interface. Between the excitation and receiving structures of the second circuit carrier 36B and the measurement value provider 38 configured as a target 38B, a cover element 33 configured as a cover plate 33B is arranged to protect the inductive sensors 37B from external influences.

[0061] Especially from Figure 5 It can also be seen that the two sensor assemblies 30 are constructed such that the follower 29 of the mating pins 29A and 29B and the corresponding mating holes 26 for the mating pins 29A and 29B have different diameters, so that the incorrect rotation position of the pedal piston 25 can be immediately noticed during assembly (error prevention). Therefore, the diameter of the first mating pin 29A and the first mating hole 26A is smaller than the diameter of the second mating pin 29B and the second mating hole 26B.

[0062] In the illustrated embodiment of the pedal unit 10, the pedal head 12 is modularly constructed and includes a pad carrier 14 and a replaceable pedal pad 16. In the illustrated embodiment, the pedal pad 16 of the pedal head 10 correspondingly has a curved deep-drawn shell 16.1 made of stainless steel, which is combined with a curved rubber member 16.2 to form a strip-shaped abutment structure 16.3 protruding from the deep-drawn shell 16.1 on its upper side. The abutment structure 16.3 prevents the driver's foot from slipping or at least makes it more difficult to slip. The pedal pad 16 is fixedly mounted to the pad carrier 14. The rubber member 16.2 has an invisible surrounding receiving groove 12.4 into which the invisible surrounding edge of the pad carrier 14 is inserted, such that the wall of the receiving groove, configured as a flexible lip, surrounds the edge of the pad carrier 14.

[0063] from Figure 4 and Figures 10 to 13 It can also be seen that the pad carrier 14 has a receiving opening 15 on its side facing the pedal piston 25, which receives the end region of the pedal piston 25 facing the pedal head 12. Here, a quick-fastening member 40 is designed to detachably connect the pad carrier 14 to the pedal piston 25. For this purpose, embodiments of the quick-fastening member 40 have at least one fixing opening 14.1, 42 provided in the pedal piston 25 and / or the pad carrier 14, and at least one corresponding fixing element 44, which is inserted into at least one fixing opening 14.1, 42 to secure the pad carrier 14 or the pedal head 12, and detachably connects the pad carrier 14 to the pedal piston 25.

[0064] from Figure 4 and Figure 10 It can also be seen that the first embodiment of the quick-fixing member 40A includes a radial fixing opening 42A provided in the pedal piston 25 and a radial insertion opening 14.1A provided in the pad carrier 14, which are flush with the radial fixing opening 42. Here, the fixing element 44, configured as a fixing screw 44A, is inserted into the radial fixing opening 14.1A of the pad carrier 14 and passes through the radial fixing opening 42A in the pedal piston 25, and detachably connects the pad carrier 14 to the pedal piston 25.

[0065] from Figure 11It can also be seen that the second embodiment 40B of the quick-fixing component includes an axial fixing opening 42B provided in the end side of the pedal piston 25, an axial fixing opening 14.1B provided in the pad carrier 14, and an axial opening 16.4 provided in the pedal pad 16, which are flush with each other. The fixing element 44, configured as a fixing screw 44A, passes through the axial opening 16.4 in the pedal pad 16 and through the axial fixing opening 14.1B in the pad carrier 14, and is inserted into the axial fixing opening 42B in the pedal piston 25, thereby detachably connecting the pad carrier 14 to the pedal piston 25. To tighten and loosen the fixing screw 44A, a screwdriver can be inserted into the head of the fixing screw 44A through the axial opening 16.4 in the pedal pad 16.

[0066] from Figure 12 and Figure 13 It can also be seen that the third embodiment 40C of the quick-fixing component includes an axial fixing opening 42C provided in the end side of the pedal piston 25 and a fixing element 44 arranged on the pedal head 12 and configured as a fixing pin 44B. The fixing element protrudes from the pedal head 12 toward the pedal piston 25 and is fastened to the fixing plate 43. In the illustrated embodiment, the fixing plate 43 is at least partially injection-encapsulated by the pad carrier 14. Furthermore, the fixing pin 44B has a stepped radial through opening 44.1. A radially through sleeve receiving portion 49 is provided in the pedal piston 25, which accommodates a spring-loaded locking sleeve 47. In the assembled state of the pedal head 12, the spring-loaded locking sleeve 47 extends at least partially into the stepped radial through opening 44.1 and locks the fixing element 44 in the axial fixing opening 42C. To prevent the pedal head 12 from falling off, during assembly, the laterally positioned locking sleeve 47 is pressed against the spring force of the locking spring 48 into the stepped sleeve receiving portion 49, and engages at the end position of the retaining element 44, which is configured as a retaining pin 44B, in its stepped radial through opening 44.1. The locking spring 48 is supported here on the closing element 49.1, which is, for example, pressed, glued, or packed into the sleeve receiving portion 49.

[0067] from Figure 13It can also be seen that, in order to disassemble the pedal head 12, the upper sealing lip 18.1 of the seal 18, which is constructed as a corrugated structure 18A, is pried out of the second sealing groove 25.1 and pushed downward. The disassembly tool 60 has a head 62 and a stepped rod portion 64 formed on the head. Here, the stepped rod portion 64 is inserted into the stepped through hole 44.1 of the retaining pin 44B through the stepped sleeve receiving portion 49 in the pedal piston 25 in the direction of arrow R1, and the locking sleeve 47 is pressed back against the spring force of the locking spring 48. At the same time, the pedal head 12 is pulled upward in the direction of arrow R2 until the movement is stopped by the laterally placed stepped rod portion 64. Then the stepped rod portion 64 is carefully pulled backward, at which point the locking sleeve 47 is held by self-locking on the retaining element 44 constructed as the retaining pin 44B, so that the pedal head 12 can be pulled out further and separated from the pedal piston 25.

[0068] In the second embodiment 40B and the third embodiment 40C of the quick-locking mechanism, the pedal head 12 is protected against rotation to prevent rotation. For this purpose, a torsion stop 46 is arranged between the pedal head 12 and the pedal piston 25, comprising an axial locking opening 46.2 provided in the end side of the pedal piston 25 and a locking pin 46.1 arranged on the pedal head 12, the locking pin protruding from the pedal head 12 toward the pedal piston 25 and at least partially received by the axial locking opening 46.2 in the pedal piston 25. The locking pin 46.1 can be welded or pressed into the pad carrier 14 or the fixing plate 43, for example. Alternatively, two fixing screws 44A can be used to secure the pedal head 12. Optionally, the fixing screws 44A can have an adhesive safety mechanism or similar mechanism to prevent loosening, thereby providing better retention.

Claims

1. A pedal unit (10) for triggering vehicle functions, the pedal unit having: A modularly constructed pedal head (12) that bears the operating force of the driver's foot; A lockable housing (20) that opens toward the pedal head (12); A pedal piston (25) is arranged at least partially in the housing (20), the pedal piston being axially supported in the housing (20) with a small stroke against the force of the return spring (27), passing through an opening in the housing (20) and being detachably connected to the pedal head (12); as well as At least one sensor assembly (30) includes at least one measurement provider (38) coupled to the pedal piston (25) and at least one sensor (37). The at least one sensor (37) detects, without contact, the travel movement of the movable pedal piston (25) caused by the operating force of the driver's foot.

2. The pedal unit (10) according to claim 1, characterized in that, The pedal piston (25) is guided in at least two support bushings (24) connected to the housing (20).

3. The pedal unit (10) according to claim 2, characterized in that, The first support bushing (24) is constructed as a through bushing (24A) arranged at the opening of the housing (20), and the second support bushing (24) is constructed as an end bushing (24B) connected to the bottom of the housing (20), the end bushing accommodating the end region of the pedal piston (25) opposite to the pedal head (12), and forming a stop (24.2) for the pedal piston (25).

4. The pedal unit (10) according to claim 3, characterized in that, The pedal piston (25) is stepped and has a positioning shoulder (25.2), wherein the return spring (27) is supported on the edge of the end bushing (24B) and on the positioning shoulder (25.2) of the pedal piston (25).

5. The pedal unit (10) according to claim 4, characterized in that, A positioning disc (28) is arranged between the edge of the return spring (27) and the end bushing (24B).

6. The pedal unit (10) according to any one of claims 1 to 5, characterized in that, The at least one sensor assembly (30) includes at least two redundant sensors (37) that apply the same measurement principle to detect the movement of the pedal piston (25).

7. The pedal unit (10) according to any one of claims 1 to 6, characterized in that, The at least one sensor assembly (30) includes at least one measurement provider (38) which is coupled to the pedal piston (25) via a follower (29) and is movable together with the pedal piston (25).

8. The pedal unit (10) according to claim 7, characterized in that, The follower (29) is configured as a mating pin (29A, 29B), which is coupled at a first end to the at least one measuring value provider (38) and inserted at a second end into a corresponding radial mating hole (26) carved in the pedal piston (25).

9. The pedal unit (10) according to any one of claims 1 to 8, characterized in that, The at least one sensor component (30) is configured as a magnetic displacement sensor (30A) or an inductive displacement sensor (30B).

10. The pedal unit (10) according to claim 9, characterized in that, The magnetic displacement sensor (30A) includes a measurement provider (38) configured as a magnet (38A) and at least one magnetic field sensor (37A) arranged on a circuit carrier (36), spaced apart from the magnet (38A) within the range of movement of the magnet (38A), and detecting and evaluating the magnetic field or magnetic field changes of the magnet (38A).

11. The pedal unit (10) according to claim 10, characterized in that, A cover element (33) is arranged between the measurement value provider (38) configured as a magnet (38A) and the at least one magnetic field sensor (37A).

12. The pedal unit (10) according to claim 10 or 11, characterized in that, The magnet (38A) is arranged in a magnet slider (50) movably supported in a guide plate (52), and the magnet slider is coupled to the pedal piston (25) via the follower (29).

13. The pedal unit (10) according to claim 12, characterized in that, The follower (29) passes through the through guide portion (52.1) in the guide plate (52) and is inserted into the receiving opening (50.1) of the magnet slider (50), wherein a compensation spring (55) is arranged in the receiving opening (50.1) of the magnet slider (50), and the compensation spring realizes the gap compensation between the follower (29) and the magnet slider (50).

14. The pedal unit (10) according to claim 12, characterized in that, The follower (29) passes through the through guide portion (52.1) in the guide plate (52) and is connected to the magnet slider (50) in a shape-matching manner.

15. The pedal unit (10) according to any one of claims 12 to 14, characterized in that, The slider guide (53) between the guide plate (52) and the magnet slider (50) is constructed as a dovetail guide (53A) or a longitudinal guide (53B).

16. The pedal unit (10) according to any one of claims 12 to 15, characterized in that, The movably supported magnetic slider (50) can move against the force of another return spring (54).

17. The pedal unit (10) according to claim 9, characterized in that, The inductive displacement sensor (30B) includes a measurement provider (38) configured as a conductive target (38B) and at least one inductive sensor (37B) arranged on a circuit carrier (36) and spaced apart from the conductive target (38B) within the range of motion of the conductive target (38B).

18. The pedal unit (10) according to claim 17, characterized in that, The at least one inductive sensor (37B) includes at least one excitation structure, at least one receiving structure, and an evaluation and control unit, wherein the at least one excitation structure is coupled to the evaluation and control unit (39), which during operation couples a periodic alternating signal to the at least one excitation structure, wherein the conductive target (38A) affects the inductive coupling between the at least one excitation structure and the at least one receiving structure, wherein the evaluation and control unit (39) receives and evaluates the signal sensed in the at least one receiving structure and determines the current position of the movable pedal piston (25).

19. The pedal unit (10) according to claim 17 or 18, characterized in that, A cover element (33) is arranged between the measurement value provider (38) configured as a conductive target (38B) and the at least one inductive sensor (37B).

20. The pedal unit (10) according to any one of claims 1 to 19, characterized in that, Two redundant sensor assemblies (30) are arranged spatially and electrically separated from each other in the housing (20) and sealed relative to each other and to the external medium, wherein the two redundant sensor assemblies (30) apply different measurement principles to detect the movement of the pedal piston (25).

21. The pedal unit (10) according to claim 20, characterized in that, Two redundant sensor assemblies (30) are arranged at 90 or 180 degrees offset from each other.

22. The pedal unit (10) according to any one of claims 1 to 21, characterized in that, The modularly constructed pedal head (12) includes a pad carrier (14) and a replaceable pedal pad (16) detachably connected to the pad carrier (14), wherein the pad carrier (14) has a receiving opening (15) on its side facing the pedal piston (25), the receiving opening accommodating the end region of the pedal piston (25) facing the pedal head (12), wherein a quick-release fastener (40) is provided, the quick-release fastener allowing the pad carrier (14) to be detachably connected to the pedal piston (25).

23. The pedal unit (10) according to claim 22, characterized in that, The quick-release fastener (40) includes at least one fixing opening (14.1, 42) disposed in the pedal piston (25) and / or the pad carrier (14) and at least one fixing element (44), the at least one fixing element being inserted into the at least one fixing opening (14.1, 42) and detachably connecting the pad carrier (14) to the pedal piston (25).

24. The pedal unit (10) according to claim 23, characterized in that, The quick-fixing member (40) includes a radial fixing opening (42A) disposed in the pedal piston (25) and a radial fixing opening (14.1A) disposed in the pad carrier (14) of the pedal head (12), the radial fixing opening being flush with the radial fixing opening (42), wherein the fixing element (44) is inserted into the radial fixing opening (14.1A) of the pad carrier (14) and passes through the radial fixing opening (42A) in the pedal piston (25), and detachably connects the pad carrier (14) to the pedal piston (25).

25. The pedal unit (10) according to claim 23, characterized in that, The quick-fixing member (40) includes an axial fixing opening (42B) disposed on the end side of the pedal piston (25), an axial fixing opening (14.1B) disposed on the pad carrier (14), and an axial opening (16.4) disposed on the pedal pad (16). These openings are flush with each other. The fixing element (44) passes through the axial opening (16.4) in the pedal pad (16) and through the axial fixing opening (14.1B) in the pad carrier, and is inserted into the axial fixing opening (42B) in the pedal piston (25), thereby detachably connecting the pad carrier (14) to the pedal piston (25).

26. The pedal unit (10) according to claim 23, characterized in that, The quick-fixing component (40) includes an axial fixing opening (42C) disposed on the end side of the pedal piston (25) and a fixing element (44) disposed on the pedal head (12), the fixing element protruding from the pedal head (12) toward the pedal piston (25) and having a stepped radial through opening (44.1), wherein a radial, through sleeve receiving portion (49) is provided in the pedal piston (25), the sleeve receiving portion accommodating a spring-loaded locking sleeve (47).

27. The pedal unit (10) according to claim 26, characterized in that, The spring-loaded locking sleeve (47) extends at least partially into the stepped radial through opening (44.1) in the assembled state of the pedal head (12) and locks the fixing element (44) in the axial fixing opening (42C).

28. The pedal unit (10) according to any one of claims 25 to 27, characterized in that, A torsion stop (46) is provided between the pedal head (12) and the pedal piston (25). The torsion stop includes an axial locking opening (46.2) disposed in the end side of the pedal piston (25) and a locking pin (46.1) disposed on the pedal head (12). The locking pin protrudes from the pedal head (12) toward the pedal piston (25) and is at least partially accommodated by the axial locking opening (46.2) in the pedal piston (25).

29. The pedal unit (10) according to any one of claims 1 to 28, characterized in that, The vehicle functions that can be triggered are braking or acceleration.

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