A pedal feel simulator for a brake-by-wire system
By employing a piston sliding structure and disc spring assembly in the pedal feel simulator for stable operation, combined with dual signal monitoring of the magnet assembly and displacement sensor, the signal error problem caused by the deviation of the elastic component is solved, thus achieving stable and accurate signal acquisition for the pedal simulator.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DAOZHI (SHANGHAI) TECH CO LTD
- Filing Date
- 2025-08-15
- Publication Date
- 2026-07-21
AI Technical Summary
In existing pedal feel simulation devices, the elastic component is prone to deviation from its track, which leads to pressure sensor error and affects the accuracy of signal acquisition.
It adopts a structure in which the piston can be slidably set in the inner cavity of the housing, combined with a disc spring assembly and a pressure sensor. Stable axial movement is achieved through the cooperation of the disc spring push rod and the disc spring cavity, and it is equipped with a magnet assembly and a displacement sensor for dual signal monitoring.
This improves the structural stability and signal acquisition accuracy of the pedal simulator, avoids component damage and signal errors, and ensures the safety and reliability of the braking process.
Smart Images
Figure CN224528638U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to vehicle braking technology, specifically to a pedal feel simulator for a brake-by-wire system. Background Technology
[0002] Electromechanical brake-by-wire systems eliminate the master cylinder and booster mechanism of traditional hydraulic braking systems. Therefore, an additional pedal feel simulator is needed to receive the driver's braking intention and simulate the braking feel of the hydraulic brake pedal to adapt to the driver's long-term braking habits, which relates to the pedal feel simulator mentioned in this application.
[0003] Pedal-feel simulation devices typically require external force from the pedal, causing axial movement of the push rod. This movement, along with the shape change of an elastic component, detects the pressure changes during this process, generating a pressure signal that is transmitted to a controller (chip) to control subsequent processes such as electric braking. In existing technologies, the elastic component is relatively simple, usually consisting of a spring or a spring push rod. This simple structure is prone to deviation from its intended path, which can easily damage components and cause inaccuracies in the pressure sensor's readings, resulting in errors in signal acquisition. Utility Model Content
[0004] Therefore, the technical problem to be solved by this utility model is to overcome the shortcomings of the prior art, thereby providing a technology to solve the problem of unstable force on the spring assembly and easy deviation from the motion track.
[0005] To achieve the above objectives, this utility model provides a pedal feel simulator for a brake-by-wire system, including a housing, a piston, a push rod, a disc spring assembly, and a pressure sensor;
[0006] The piston is slidably disposed within the cavity of the housing;
[0007] The push rod is used to receive external force from the pedal, and the inner end of the push rod cooperates with the piston;
[0008] The disc spring assembly has a disc spring cavity, a disc spring push rod, and a disc spring; the disc spring push rod has an outer end and a push plate portion, the outer end of the disc spring push rod cooperates with a piston, and the disc spring is disposed between the push plate portion and the bottom wall of the disc spring cavity;
[0009] The pressure sensor is located on the adjacent side of the bottom wall of the disc spring cavity.
[0010] Preferably, the system further includes a magnet assembly and a displacement sensor, the displacement sensor being used to sense movement of the magnet assembly; the magnet assembly is fixed to the side of the piston.
[0011] Preferably, the magnet assembly includes a magnet bracket and a fixing hole. The magnet bracket has a placement groove for placing magnets, and the fixing hole is connected to the side of the piston by a magnet fixing bolt.
[0012] Preferably, the displacement sensor is mounted on a support structure located on the side of the housing.
[0013] Preferably, the piston has an outer rod and an inner groove, the outer rod being slidably engaged with the front sidewall of the housing;
[0014] Preferably, the plane containing the push plate is perpendicular to the extending direction of the disc spring cavity;
[0015] The end of the inner groove is fitted onto the outer wall of the disc spring cavity, and the central region of the inner groove engages with the outer end of the disc spring push rod.
[0016] Preferably, a portion of the disc spring cavity engages with the piston.
[0017] Preferably, a sealing ring is provided between the piston and the housing.
[0018] Preferably, a buffer pad is provided between the front sidewall of the housing and the piston.
[0019] Preferably, it also has an end cap, which is fixed to the housing on the side away from the push rod by end cap bolts.
[0020] Preferably, the disc spring includes a plurality of disc spring units arranged axially in sequence; it also includes a spring shaft, one end of which is fixed to the end cover, and the other end of which passes through the disc spring cavity and is coaxially arranged with the disc spring unit at the end.
[0021] The beneficial effects of this utility model are as follows:
[0022] 1. This application achieves stable piston movement and uniform force distribution by allowing the piston to slide into the inner cavity of the housing. This design makes the longitudinal structure of the pedal simulator more compact. Unlike previous multi-segment springs, which had a relatively high possibility of jamming and more complex parts, this design is simpler.
[0023] 2. Furthermore, the disc spring assembly, through the cooperation of the disc spring cavity, disc spring push rod, and disc spring, achieves structural stability. During compression deformation, the disc spring push rod and disc spring can move stably axially within the disc spring cavity, achieving precise acquisition of braking signals and avoiding the problems of component damage and instability during axial movement. The piston has a cylindrical structure (the inner groove of the piston), and its lateral guiding effect provides greater stability. The large contact area between the disc spring push rod and the disc spring plane results in more uniform pressure.
[0024] 3. Dual redundancy of displacement and pressure sensors: The magnet's movement is sensed by the sensors, providing dual sensing signals for improved accuracy and safety. The magnet, identified by the displacement sensor, is directly mounted on the piston for added stability. The pressure sensor is fixedly placed at the bottom, minimizing the risk of damage. Attached Figure Description
[0025] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0026] Figure 1 This is a schematic diagram of the structure of a pedal feel simulator for a brake-by-wire system according to the present invention;
[0027] Figure 2 This is a schematic diagram of the structure of a pedal feel simulator for observing the top angle of a brake-by-wire system according to this utility model;
[0028] Figure 3 This utility model relates to a pedal feel simulator for a brake-by-wire system. Figure 2 A schematic diagram of the structure in the AA sectional view;
[0029] Figure 4 This is a schematic diagram of the disc spring unit of a pedal feel simulator for a brake-by-wire system according to the present invention.
[0030] Figure 5 This is a schematic diagram of the housing of a pedal feel simulator for a brake-by-wire system according to the present invention;
[0031] Figure 6 This is a schematic diagram of the disc spring assembly of a pedal feel simulator for a brake-by-wire system according to the present invention.
[0032] Figure 7 This is a schematic diagram of the structure of a magnet assembly for a pedal feel simulator in a brake-by-wire system according to this utility model.
[0033] Figure 8 This is a schematic diagram of the piston structure of a pedal feel simulator for a brake-by-wire system according to this utility model;
[0034] Explanation of reference numerals in the attached figures:
[0035] 10-Housing; 20-Piston; 21-Outer rod; 22-Inner groove; 221-Central area; 23-Sealing ring; 24-Buffer pad; 30-Push rod;
[0036] 40 - Disc spring assembly; 41 - Disc spring cavity; 411 - Bottom wall; 412 - Outer wall surface; 42 - Disc spring push rod; 421 - Outer end; 422 - Push plate part; 423 - Disc spring unit; 43 - Disc spring;
[0037] 50-Pressure sensor; 60-Magnet assembly; 61-Magnet bracket; 62-Fixing hole; 63-Magnet fixing bolt; 64-Placement slot; 70-Displacement sensor;
[0038] 80 - Bracket structure; 90 - End cap; 91 - End cap bolt; 100 - Spring shaft. Detailed Implementation
[0039] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0040] Example 1:
[0041] like Figures 1 to 6 As shown,
[0042] This utility model provides a pedal feel simulator for a brake-by-wire system, including a housing 10, a piston 20, a push rod 30, a disc spring assembly 40, and a pressure sensor 50;
[0043] The piston 20 is slidably disposed within the cavity of the housing 10;
[0044] The outer end of the push rod 30 is used to receive the external force from the pedal, and the inner end of the push rod 30 cooperates with the piston 20;
[0045] The disc spring assembly 40 has a disc spring cavity 41, a disc spring push rod 42, and a disc spring 43; the disc spring push rod 42 has an outer end 421 and a push plate portion 422, the outer end 421 of the disc spring push rod 42 cooperates with the piston 20, the push plate portion 422 is located inside the disc spring cavity 41, and the disc spring 43 is disposed between the push plate portion 422 and the bottom wall 411 of the disc spring cavity 41; the spring 43 provides a specific relationship between resistance and piston 20 displacement to satisfy the comfort of pedal feel.
[0046] The disc spring cavity 41, disc spring push rod 42, and disc spring 43 have a tight fit, making it less prone to misalignment and slippage. Specifically, the disc spring cavity 41 and disc spring 43 form an external fit, while the disc spring push rod 42 and disc spring 43 form an internal fit. In this way, when the disc spring 43 is compressed and deformed, a stable support relationship is formed both internally and externally, making it less prone to positional deviation and resulting in a smoother and more accurate movement process.
[0047] A pressure sensor 50 is disposed on the adjacent side of the bottom wall 411 of the disc spring cavity 41. The bottom wall 411 of the disc spring cavity 41 can contact the pressure sensor 70 to generate a pressure signal. The force transmission process is as follows: when the user's foot applies external force to the pedal, the piston 20 moves, which in turn pushes the disc spring push rod 42 to move. The disc spring push rod 42 then causes the disc spring 43 to compress and deform. The disc spring 43 transmits the pressure to the pressure sensor 70 on the adjacent side by squeezing the bottom wall 411 of the disc spring cavity 41. When the pedal is released, the disc spring 43 automatically returns to its original position, causing the disc spring push rod 42 and the piston 20 to move in the opposite direction to their initial positions.
[0048] Preferably, such as Figure 7 As shown, the system also includes a magnet assembly 60 and a displacement sensor 70. The displacement sensor 70 is used to sense the movement of the magnet assembly 60. The magnet assembly 60 is fixed to the side of the piston 20. The displacement sensor 70 is fixed in one position, and when the magnet assembly 60 moves with the piston 20, a movement signal is generated, which is detected by the displacement sensor 70. This signal and the signal detection from the pressure sensor 70 achieve dual redundancy, ensuring signal sensing and avoiding problems caused by a single signal failure.
[0049] Preferably, the magnet assembly 60 includes a magnet bracket 61 and a fixing hole 62. The magnet bracket 61 has a placement groove 64 for placing magnets, and the fixing hole 62 is connected to the side of the piston 20 by a magnet fixing bolt 63. This structure facilitates the fixing and installation of the magnet assembly 60 and makes it easy to use.
[0050] Preferably, the displacement sensor 70 is mounted on the bracket structure 80, which is located on the side of the housing 10.
[0051] The braking process is as follows:
[0052] When the driver presses the brake pedal, the push rod 30 pushes the piston 20 to compress the disc spring assembly 40. The resistance of the spring assembly 40 is fed back to the pedal and sensed by the driver. During the pushing process of the piston 20, the magnet is displaced and detected by the displacement sensor 70, which generates a displacement signal. At the same time, the disc spring assembly 40 transmits the force to the pressure sensor 50, which generates a signal and outputs it to the outside through the signal processing module.
[0053] Release process: This process is the opposite of the braking process and outputs force and displacement signals in real time.
[0054] Example 2:
[0055] Preferably, such as Figure 3 , 8 As shown, the piston 20 has an outer rod 21 and an inner groove 22. The outer rod 21 is slidably engaged with the front side wall of the housing 10. The piston 20 and the disc spring cavity 41 form a good fit relationship, that is, a rigid contact is formed at the middle position so that the force is transmitted from the piston 20 to the outer end 421 of the disc spring push rod 42. At the same time, the outer wall of the disc spring cavity 41 and the inner groove 22 of the piston 20 form a sliding fit relationship so that the disc spring cavity 41 is restricted in a certain axial direction and the structure is kept stable.
[0056] The end of the inner groove 22 is sleeved onto the outer wall 412 of the disc spring cavity 41, and the central region 221 of the inner groove 22 cooperates with the outer end 421 of the disc spring push rod 42.
[0057] Preferably, a portion of the disc spring cavity 41 engages with the piston 20.
[0058] Preferably, the plane (end plane or extended plane) where the push plate portion 422 is located is perpendicular to the extension direction of the disc spring cavity 41. This structure ensures efficient thrust transmission.
[0059] Preferably, a sealing ring 23 is provided between the piston 20 and the housing 10, and the sealing ring serves to seal.
[0060] Preferably, a buffer pad 24 is provided between the front sidewall of the housing 10 and the piston 20, and the buffer pad plays a role in buffering and protection.
[0061] Preferably, it also has an end cap 90, which is fixed to the side of the housing 10 away from the push rod 30 by an end cap bolt 91.
[0062] Preferably, such as Figure 3 , 4 As shown, the disc spring 43 includes a plurality of disc spring units 423 arranged axially in sequence; it also includes a spring shaft 100, one end of which is fixed to the end cap 90, and the other end of which passes through the disc spring cavity 41 and is coaxially arranged with the disc spring unit 423 at the end. The disc spring unit 423 is a disc-shaped elastic sheet structure, which is formed by sequentially arranging adjacent units. In a specific embodiment, the disc spring unit 423 can be an existing disc spring (also known as a Belleville spring washer, invented by the Frenchman Belleville).
[0063] Spring shaft 100 supports disc spring assembly 40, making the assembly coaxial with piston 20. Spring shaft 100 can be a rubber rod or other elastic rod. Through the action of spring shaft 100, disc spring cavity 41 can be better axially positioned, thus avoiding misalignment.
[0064] The specific beneficial effects of the above embodiments are as follows:
[0065] 1. In this application, the piston 20 is slidably engaged with the inner cavity of the housing 10, which makes the movement of the piston 20 and the engagement structure with the inner cavity stable and achieves uniform force distribution. In this solution, the longitudinal structure of the pedal simulator is more compact. Unlike previous multi-segment springs, which have a relatively high possibility of jamming and more complex parts, this solution is simpler.
[0066] 2. Furthermore, the disc spring assembly, through the cooperation of the disc spring cavity 41, the disc spring push rod 42, and the disc spring 43, has a stable structure. When undergoing compression deformation, the disc spring push rod 42 and the disc spring 43 can move stably axially within the disc spring cavity 41, achieving the purpose of accurately acquiring braking signals and avoiding the problems of component damage and unstable axial movement. The piston 20 has a cylindrical structure (the inner groove 22 of the piston 20), and its lateral guiding effect provides greater stability. The disc spring push rod 42 has a large contact area, resulting in more uniform pressure.
[0067] 3. The displacement sensor 70 and pressure sensor are dual-redundant; the position of the magnet is sensed by the sensor during its movement, thus providing dual sensing signal monitoring, improving the accuracy and safety of the detection results. The magnet identified by the displacement sensor 70 is directly mounted on the piston 20, making it more stable. The pressure sensor 50 is fixedly placed at the bottom, making it less prone to damage.
[0068] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the protection scope of this invention.
Claims
1. A pedal feel simulator for a brake-by-wire system, characterized in that, include: Shell (10); Piston (20) is slidably disposed in the inner cavity of the housing (10); A push rod (30) is used to receive external force from the pedal, and the inner end of the push rod (30) cooperates with the piston (20); The disc spring assembly (40) has a disc spring cavity (41), a disc spring push rod (42), and a disc spring (43); the disc spring push rod (42) has an outer end (421) and a push plate (422), the outer end (421) of the disc spring push rod (42) cooperates with the piston (20), the push plate (422) is located inside the disc spring cavity (41), and the disc spring (43) is disposed between the push plate (422) and the bottom wall (411) of the disc spring cavity (41); A pressure sensor (50) is disposed on the adjacent side of the bottom wall (411) of the disc spring cavity (41).
2. The pedal feel simulator for a brake-by-wire system according to claim 1, characterized in that, It also includes a magnet assembly (60) and a displacement sensor (70), the displacement sensor (70) being used to sense the movement of the magnet assembly (60); the magnet assembly (60) is fixed to the side of the piston (20).
3. The pedal feel simulator for a brake-by-wire system according to claim 2, characterized in that, The magnet assembly (60) includes a magnet bracket (61) and a fixing hole (62). The magnet bracket (61) has a placement groove (64) for placing magnets. The fixing hole (62) is connected to the side of the piston (20) by a magnet fixing bolt (63).
4. The pedal feel simulator for a brake-by-wire system according to claim 2, characterized in that, The displacement sensor (70) is mounted on a bracket structure (80), which is located on the side of the housing (10).
5. The pedal feel simulator for a brake-by-wire system according to claim 1, characterized in that, The piston (20) has an outer rod (21) and an inner groove (22), the outer rod (21) being slidably engaged with the front sidewall of the housing (10); The end of the inner groove (22) is sleeved onto the outer wall (412) of the disc spring cavity (41), and the central region (221) of the inner groove (22) is engaged with the outer end (421) of the disc spring push rod (42).
6. The pedal feel simulator for a brake-by-wire system according to claim 1, characterized in that, A portion of the disc spring cavity (41) engages with the piston (20); The plane containing the push plate (422) is perpendicular to the extension direction of the disc spring cavity (41).
7. The pedal feel simulator for a brake-by-wire system according to claim 1, characterized in that, A sealing ring (23) is provided between the piston (20) and the housing (10).
8. The pedal feel simulator for a brake-by-wire system according to claim 1, characterized in that, A buffer pad (24) is provided between the front sidewall of the housing (10) and the piston (20).
9. A pedal feel simulator for a brake-by-wire system according to any one of claims 1 to 8, characterized in that, It also has an end cap (90), which is fixed to the side of the housing (10) away from the push rod (30) by an end cap bolt (91).
10. The pedal feel simulator for a brake-by-wire system according to claim 9, characterized in that, The disc spring (43) includes a plurality of disc spring units (423) arranged axially in sequence; it also includes a spring shaft (100), one end of which is fixed to the end cap (90), and the other end of which passes through the disc spring cavity (41) and is coaxially arranged with the disc spring unit (423) at the end.