Shaftless vehicle pedal with contact position sensor

Abstract

Vehicle pedal, comprising: a pedal housing (20) having an inner housing wall (26) dividing the housing (20) into first and second inner housing chambers, the inner housing wall (26) defining a through bore (32); a pedal arm (22) having a drum (44) extending into the first inner housing chamber of the pedal housing (20), the drum (44) having a neck (49) projecting outwardly from a first side surface of the drum (44) and defining a recess (50) extending into a second side surface of the drum (44), the neck (49) of the drum (44) extending through the through-bore (32) defined in the inner housing wall (26) of the pedal housing (20) for mounting the drum (44) for rotation in the first inner housing chamber relative to the pedal housing (20); a rotor (74) located in the second inner housing chamber of the pedal housing (20), the rotor (74) having a base (78) attached to one of the sides of the drum (44) extending through the through-bore (32) defined in the inner housing wall (26) of the pedal housing (20); a first cover attached to the pedal housing (20) and covering the first inner housing chamber, the cover (90) comprising a plate (90) having a collar (95) projecting inwardly from a surface thereof and extending into the recess (50) of the drum (44) for mounting the drum (44) for rotation in the first inner housing chamber relative to the pedal housing (20); a second cover attached to the pedal housing (20) and covering and sealing the second inner housing chamber of the pedal housing (20), wherein the base (78) of the rotor (74) defines at least a first through-bore and a second through-bore, wherein one of the sides of the drum (44) defines at least a first and a second slot, wherein the drum (44) defines an inner shoulder (51a), wherein the vehicle pedal has a retaining plate (84), a first pin protruding from the retaining plate (84) and a clamp (86) protruding from the retaining plate (84), the pin and clamp extending through the first and second through-bores defined in the base (78) of the rotor (74) and into the first and second slots defined in the drum (44), wherein the clamp (86) engages the inner shoulder (51a) in the drum (44) to lock the index position of the rotor (74) to the drum (44) of the pedal arm (22).

Description

Field of the invention

[0001] The present invention relates generally to a vehicle pedal and, more particularly, to a shaftless vehicle accelerator pedal having a contact position sensor. Background of the invention

[0002] Vehicle accelerator pedals typically include a pedal arm extending into a pedal housing and mounted for rotation on a shaft that also extends into the housing, as disclosed, for example, in U.S. Patent No. 8,042,430 B2 entitled "Accelerator Pedal for a Vehicle."

[0003] Vehicle accelerator pedals with contact position sensors further include a sensor rotor that is locked to the pedal arm after adjusting the idle initial position of the sensor rotor.

[0004] WO 2006 / 040 339 A1 discloses a device comprising a support structure and a lever rotatable about an axis (AA) with respect to the support structure and having a first arm partially projecting from the structure and serving as a pedal, and a second arm extending from the first arm on the opposite side of the axis (AA). Elastic biasing means tend to urge the lever toward a predetermined rest position. An electrical position sensor is connected to the structure and provides electrical signals indicative of the angular position of the lever. The elastic biasing means comprise first and second springs arranged on opposite sides of the axis (AA) between the structure and the first and second arms of the lever, respectively. These springs both tend to rotate the lever in the same direction about the axis (AA).

[0005] DE 199 24 410 A1 describes an accelerator pedal sensor with a housing, a pedal lever connected to a pedal plate at one end and mounted in the housing at the opposite end, and an electrical rotary sensor consisting of a sensor board and an actuating element driven by the pedal lever. The accelerator pedal sensor according to the invention is distinguished from known designs by eliminating the metal shaft that connects the pedal lever to the actuating element of the rotary sensor. This is achieved by the pedal lever being made of a plastic and integrally forming a first connecting element that is directly connected to a second connecting element of the actuating element.

[0006] EP 1 428 715 A2 describes an accelerator pedal module for controlling the power of a drive motor, in particular an internal combustion engine of a vehicle, comprising a pedal lever rotatably mounted on a bearing block by means of a pivot connection about a pivot axis, which pedal lever can be abutted against an associated bearing block stop by at least one pedal lever stop. The invention provides that in the region of the pedal lever stop and / or the bearing block stop, such elasticities are present that during a relative rotational movement about the pivot axis between the pedal lever and the bearing block to establish the pivot connection, the pedal lever stop slides past the bearing block stop due to elastic deformation and engages behind it after springing back.

[0007] DE 195 17 172 A1 discloses a foot-operated accelerator pedal of a road vehicle mounted at the end of a lever pivotally mounted on a spindle in a housing and having a bearing insert. When foot pressure is applied to the pedal, it moves against the force of a coil spring. Axially in line with the pivot mount is a potentiometer that provides feedback on the pedal position to the engine controller. This has a track on the moving part with a sliding contact pickup on the fixed housing. Inside is a small friction brake pad insert that acts against the pedal lever projection to maintain the end position.

[0008] The present invention is directed to a new and lower cost vehicle pedal with a contact position sensor that includes features that allow the pedal arm to be supported in the pedal housing without the use of a shaft.

[0009] The present invention is further directed to a bracket having a pin and clamp feature for holding and locking the sensor rotor on the pedal arm after adjusting the idle home position of the sensor rotor. Brief description of the invention

[0010] The invention is defined in the claims.

[0011] The present invention is directed to a vehicle pedal comprising a pedal housing having an inner housing wall dividing the housing into first and second inner housing chambers, the inner housing wall defining a through-bore, a pedal arm having a drum extending into the first inner housing chamber of the pedal housing, the drum having a neck projecting outwardly from one of the side surfaces thereof and defining a recess extending into the other of the side surfaces thereof, the neck of the drum extending through the through-bore defined in the inner housing wall of the pedal housing for mounting the drum for rotation in the first inner housing chamber relative to the pedal housing, a rotor located in the second inner housing chamber of the pedal housing, the rotor having a base attached to one of the sides of the drum,which extends through the through-bore defined in the inner housing wall of the pedal housing, a first cover which is attached to the pedal housing and covers the first inner housing chamber, the cover comprising a plate with a collar which projects outwardly from an inner surface thereof and extends into the recess in the other of the sides of the drum for mounting the drum for rotation in the first inner housing chamber relative to the pedal housing, and a second cover which is attached to the pedal housing and covers and seals the second inner housing chamber of the pedal housing.

[0012] The base of the rotor defines at least first and second through-bores, one of the sides of the drum defines at least first and second slots, and the drum defines an internal shoulder, wherein at least a first pin and a clamp project from a retaining plate and extend through the first and second through-bores defined in the base of the rotor and into the respective first and second slots defined in the drum, the clamp engaging the internal shoulder in the drum to lock the index position of the rotor to the drum of the pedal arm.

[0013] In one embodiment, a first bearing is located between the neck of the drum and the inner partition wall and a second bearing is located between the collar of the first cover and the drum for supporting the drum for rotation relative to the pedal housing.

[0014] There are further advantages and features of this invention which will become more apparent from the following detailed description of the embodiment of the invention, the drawings and the appended claims. Brief description of the drawings

[0015] In the accompanying drawings, which form an integral part of the specification and in which like reference numerals are used to identify like parts therein, Fig. 1 is a perspective view of a vehicle pedal according to the present invention; Fig. 2 is an exploded perspective view of the vehicle pedal according to the present invention; Fig. 3 is a perspective view of the rotor mount of the vehicle pedal of the present invention; Fig. 4 is a fragmentary, partly horizontal, partly vertical cross-sectional view of the vehicle pedal of the present invention; Fig. 5 is a broken-away side view of one side of the vehicle pedal of the present invention without the mechanism chamber cover, depicting the interior of the mechanism chamber of the pedal housing; Fig. 6 is a broken-away side view of the other side of the vehicle pedal of the present invention without the electrical element chamber cover, depicting the interior of the electrical element chamber of the pedal housing; Fig. Figure 7 is a broken-away, partly perspective, partly vertical cross-sectional view of the vehicle pedal of the present invention, showing the rotor prior to attachment to the drum of the pedal arm; Fig. Figure 8 is a broken-away, partly perspective, partly vertical cross-sectional view of the vehicle pedal of the present invention in which the bracket fixes the rotor in its index position to the drum of the pedal arm; Fig. 9 is a broken-away, enlarged perspective view of the pedal housing and pedal drum illustrating the rotor retainer pin slots defined in the side of the pedal drum of the vehicle pedal of the present invention; Fig. 10 is a broken-away, partly perspective, partly vertical cross-sectional view of the vehicle pedal of the present invention with an alternate retaining pin embodiment, showing the rotor prior to attachment to the drum of the pedal arm; and Fig. 11 is a broken-away, partly perspective, partly vertical cross-sectional view of the vehicle pedal with the Fig. 10, in which the rotor is in its fixed index position on the drum of the pedal arm. Detailed description of the embodiments

[0016] The Fig. 1-9 illustrate a shaftless contact sensor vehicle pedal 10 according to the present invention, partially comprising a pedal housing 20 and a pedal arm 22 extending into the pedal housing 20. Both the housing 20 and the pedal arm 22 may be made of a suitable molded plastic material.

[0017] The pedal housing 20 includes a generally circumferentially extending outer housing wall 24 and an inner separating or dividing housing wall 26 projecting outwardly from the inner surface of the outer wall 24 and separating and dividing the interior of the pedal housing 20 into a first inner mechanical element chamber 28 and a second inner sensor or electrical element chamber 30. The outer wall 24 and the separating wall 26 are in a generally perpendicular relationship relative to one another, and the chambers 28 and 30 are arranged in a side-by-side relationship. The inner separating wall 26 defines a generally circular through-bore or opening 32. A collar 34 surrounds the opening 32 and projects generally perpendicularly outwardly from the outer surface of the inner wall 26 and into the first mechanical chamber 28. The outer wall 24 of the housing 20 defines a front opening 36 that communicates with and opens toward the interior of the first interior chamber 28.

[0018] A plurality of mounting tabs 38 and a mounting clamp 40 protrude from the outer surface of the housing wall 24 and are designed to enable the pedal housing 20 to be attached to the floor or to the mounting plate of the vehicle.

[0019] The elongated pedal arm 22 has a tread plate 42 ( Fig. 1) at a distal end thereof and a drum 44 at a proximal end thereof. The pedal arm 22 is attached to the pedal housing 20, the pedal arm 22 extending through the front opening 36 of the pedal housing 20, and the drum 44 of the pedal arm 22 is arranged and adapted for rotation within the first interior chamber 28 of the pedal housing 20.

[0020] With particular reference to the Fig. 2 and Fig. 4, the drum 44 of the pedal arm 22 has opposite outer side surfaces 46 and 48. The drum 44 has an inner peripheral surface defining a through-bore 51 extending centrally through the interior of the drum 44. The inner peripheral surface of the drum 44 has two portions of different diameters, and thus, the drum 44 further includes a circumferentially extending inner shoulder 51a. A generally cylindrical recess or groove 50 is defined and extends inwardly into the side surface 46 of the drum 44. The recess or groove 50, in turn, defines an open collar 45 projecting outwardly from the side surface 46 of the drum 44. The drum through-bore 51 terminates in an annular opening 51b that communicates with and opens toward the recess or groove 50 in the side surface 46 of the drum 44.The through hole 51 has a diameter that is smaller than the diameter of the recess or groove 50.

[0021] With reference to the Fig. 4 and Fig. 9, a sleeve or neck or collar 49, which is generally cylindrical in shape, projects outwardly from the opposite side surface 48 of the drum 44 and terminates in a radial end surface 49a. The through bore 51 in the drum 44 terminates in a circular opening 51c in the radial end surface 49a of the sleeve or neck or collar 49. A collar 53 projects outwardly from the radial end surface 49a of the collar 49 and, more specifically, from the peripheral edge of the opening 51c in the radial end surface 49a. The through bore 51 extends through the collar 53. A plurality of generally arcuate and oval elongated slots 55 extend into the radial end surface 49a of the sleeve or neck or collar 49 in a spaced-apart relationship from the collar 53 and the opening 51c. A plurality of teeth or ribs 57 project outwardly from the inner surface defining the respective slots 55.

[0022] A spring platform 53 protrudes and extends integrally outwardly from the front of the drum 44.

[0023] With reference to the Fig. 2 and Fig. 5, the vehicle pedal 10 further includes a pedal arm friction hysteresis assembly comprising a molded plastic friction lever or arm 60, a pair of elongated nested coil springs 62 and 64, and a spring damper 66. The friction lever 60 is mounted in the first interior mechanical chamber 28 of the pedal housing 20 above the drum 44 and, more specifically, between the top of the drum 44 and the inner surface of an upper portion of the outer housing wall 24 in a manner against a pin or rib 61 ( Fig. 5) arranged and pivoted in a manner resembling a projection extending integrally outwardly from the inner surface of the housing wall 24. The pin or rib 61 has and terminates in a convexly curved, arcuate distal tip.

[0024] The friction lever 60 has opposite ends 60a and 60b and defines a centrally disposed groove or recess or indentation 60c extending into the outer top surface of the lever or arm 60. The groove or recess 60c is centrally disposed on the lever or arm 60 between the two ends 60a and 60b. The groove or recess 60c has a concavely curved arcuate shape and configuration corresponding to the convexly curved arcuate shape and configuration of the distal tip of the housing pin or rib 61. As shown in Fig. 5, the friction lever 60 has a curved central body portion which follows the contour and shape of the central recess or concavity 60c.

[0025] The pin or rib 61 on the housing wall 24 extends into the groove or recess 60c in abutting and intermeshing relationship with the outer surface of the distal tip thereof, in abutting and intermeshing relationship with the outer surface of the friction lever 60 defining the concavity 60c thereof, and defines a cantilevered or rocker-like principal axis or point for pivoting the lever 60 about and relative to the housing 20 and, more particularly, a principal pivot axis or point for the lever 60 about and relative to the housing wall 24. A friction block 70 on the end 66 of the friction lever 60 is adapted for abutting frictional contact with respective outer surfaces of the drum 44 of the pedal arm 22, such as disclosed in U.S. Patent No. 8,042,430, the disclosure and contents of which are incorporated herein by reference.

[0026] The spring 62 extends through the interior of the spring 64. The spring damper 66 surrounds the inner spring 62 and is designed to dampen the noise generated when the springs 62 and 64 contact each other during actuation of the pedal 10. The springs 62 and 64 are arranged and mounted in the first interior chamber 28 of the pedal housing 20 in front of the drum 44 and in a relationship where the springs 62 and 64 each extend between the inner surface of the drum spring platform 50 and the end 60b of the friction lever 60, and the respective ends thereof are in abutting contact therewith.

[0027] In accordance with the operation of the vehicle pedal assembly 10, rotation of the pedal arm 22 causes rotation of the drum 44 and drum platform 50 in a counterclockwise direction, causing the springs 62 and 64 to contract and exert a force against one end 60b of the friction lever 60, which in turn causes the opposite end 60a and the friction block 70 thereon to exert a frictional force against the surface of the drum 44 to create and transmit a pedal resistance or hysteresis force to the pedal arm 22.

[0028] Further details regarding the use, construction and function of the pedal friction and hysteresis assembly of pedal 10 can be found in U.S. Patent No. 8,042,430 entitled "Accelerator Pedal for a Vehicle," the disclosure and contents of which are incorporated herein by reference.

[0029] With reference to the Fig. 2 and Fig. 5, the vehicle pedal 10 further comprises a pedal arm kickdown assembly or module 100 mounted within the first interior housing chamber 28 and, more specifically, mounted within a kickdown module receptacle 28a defined within the interior housing chamber 28. Further details regarding the use, structure, and function of the kickdown module 10 can be found in U.S. Patent No. 6,418,813 B1 entitled "Kickdown Mechanism for a Pedal," the disclosure and contents of which are incorporated herein by reference.

[0030] With reference to the Fig. 2 and Fig. 6, the vehicle pedal 10 further includes a pedal contact position sensor assembly comprising an elongated strip of flexible Kapton film 72 having a series of resistive and conductive traces (not shown), a metal foil terminal 73, a contact potentiometer assembly in the form of an adjustable elongated contact rotor 74 of molded plastic, and terminals (not shown) within a terminal housing or box 76.

[0031] The rotor 74 has a generally circular base 78, an elongated contact arm 80 projecting outwardly from the base 78, and metal contact pieces 82 at the distal end of the arm 80 of the rotor 74. The rotor base 78 has a generally cylindrical and centrally located through-bore 77 ( Fig. 2). The rotor base 78 further defines one or more arcuate and generally oval through-bores or slots 79. The illustrated embodiment includes three separate generally arcuate and oval through-bores 79 extending around the central through-bore 77 in a spaced-apart relationship. The through-bores 79 are radially spaced from the central through-bore 77.

[0032] The strip of flexible film 72 is in the second inner chamber 30 of the pedal housing 20 against the inner surface of a back part of the housing wall 24 ( Fig. 6). The terminal housing or terminal box 76 projects outwardly from the outer surface of the back portion of the housing wall 24. Terminals (not shown) extend through the terminal housing 76 into the second interior housing chamber 30 and into contact with the strip of flexible Kapton film 72. The rotor 74 is arranged and mounted within the second interior chamber 30 of the pedal housing 20, with the base 78 of the rotor 74 secured to the neck 49 of the drum 44 of the pedal arm 22 and the metal contact pieces 82 in abutting and sliding contact against the surface of the film 72.

[0033] Further details regarding the use, structure and function of the contact position sensor assembly 70 can be found in U.S. Patent No. 8,042,430 B2 entitled “Accelerator Pedal for a Vehicle,” the disclosure and contents of which are incorporated herein by reference.

[0034] The vehicle pedal 10 further includes one or more elongated, arcuate, and generally oval plastic retaining pins 81 configured to retain and fix the rotor 74 to the drum 44 of the pedal arm 22 after setting the index idle home position of the rotor 74. The illustrated embodiment includes three retaining pins 81. The respective retaining pins 81 each have a width less than the length of the respective slots 55 defined in the drum 44 of the pedal arm 22.

[0035] Further, in the illustrated embodiment, the retaining pins 81 are part of a bracket 85, and the retaining pins 81 project generally perpendicularly and integrally from the lower outer surface of a generally circular support or retaining plate 84. An elongated central clamp 86 further projects generally perpendicularly and integrally outwardly and centrally from the lower outer surface of the support or retaining base plate 84. The elongated clamp 86 is centrally located on the support or retaining base plate 84, and the retaining pins 81 extend around the clamp 86 in a spaced and parallel relationship to each other and to the clamp 86. The clamp 86 consists of a plurality of elongated and flexible clamp arms 86a terminating in respective slanted and stepped clamp ends or fingers 86b.

[0036] The vehicle pedal 10, and more specifically, the pedal housing 20, further includes a first cover plate 90 for the mechanical element chamber and a second cover plate 92 for the sensor element chamber. The plates 90 and 92 define respective side walls of the housing 20 when the plates 90 and 92 are connected to the housing wall 26. The inner surfaces of the respective housing plates or side walls 90 and 92 are located opposite the outer surface of the respective sides 46 and 48 of the drum 44.

[0037] The cover plate 90 is made of the same plastic material as the plastic housing 20 and has a plurality of spaced-apart mounting clips or snap tabs 94 projecting generally perpendicularly from the peripheral edge thereof, and a sleeve or collar or neck 95 ( Fig. 2), which is generally cylindrical in shape and integrally projects outwardly from the inner surface of the cover plate 90. The cover plate 90 is designed to snap over and cover the first inner mechanism element chamber 28 of the pedal housing 20. Specifically, the mounting clips 94 on the cover plate 90 are inserted into corresponding mounting clip receiving openings 97 ( Fig. 2, Fig. 4 and Fig. 5) defined in the radial peripheral edge of the outer wall 24 of the pedal housing 20, for securing the cover plate 90 to the pedal housing 20 and snapped into place.

[0038] The cover plate 92 is preferably made of a metal material and is adapted to be ultrasonically welded and attached to the opposite peripheral edge of the housing wall 24 to cover the second internal sensor element chamber 30 of the pedal housing 20. The use of a pedal housing 20 having a cover plate 92 ultrasonically welded to the housing wall 24, in combination with an internal housing wall 26, creates and defines an internal electrical and sensor element chamber 30 that is protected not only from the environment outside the cover plate 92, but also from the environment inside the mechanical element housing chamber 28.

[0039] According to the present invention and as described in the Fig. 2 and Fig. 3, the pedal arm 22 is mounted to the pedal housing 20 and, more specifically, the drum 44 of the pedal arm 22 is mounted in the first interior housing chamber 28 of the pedal housing 20 in a relationship where the neck or collar 49 of the pedal arm drum 44 extends and is located in the collar 34 and the through-bore 32 defined in the interior partition 26 of the pedal housing 20.

[0040] An annular polymer bearing 110 surrounds the neck or collar 49 of the drum 44 and supports the drum 44 for rotation relative to the inner partition 26, and thus supports the drum 44 for rotation within the first interior housing chamber 28 relative to the pedal housing 20. Thus, in the illustrated embodiment, the bearing 110 surrounds and abuts the outer surface of the drum collar 49, and the housing collar 34 surrounds and abuts the outer surface of the bearing 110. The drum collar 49 is thus rotatable relative to the housing collar 34, and the drum 44 is thus rotatable relative to the housing 20 in response to rotation of the pedal arm 22.

[0041] Thereafter, the elements of the friction hysteresis assembly 59 and the vehicle pedal kickdown assembly 100 are arranged and mounted in the first inner housing chamber 28.

[0042] The cover plate 90 is then attached and secured to the pedal housing 20 in a relationship where the neck or collar or sleeve 95 on the cover plate 90 extends into the collar 45 and the recess 50 in the side 48 of the drum 44 of the pedal arm 22.

[0043] An annular polymer bearing 120 surrounds the neck 95 on the cover 90 and supports the drum 44 for rotation relative to the cover plate 90, and thus supports the drum 44 for rotation within the first interior housing chamber 28 relative to the pedal housing 20. Thus, the bearing 120 surrounds and abuts the outer surface of the housing or cover collar 95, and the drum collar 45 surrounds and abuts the outer surface of the bearing 120. The drum 44 is thus rotatable relative to the housing or cover collar 95.

[0044] Therefore, and as described above, the respective collars 34 and 95 on the respective housing cover plate 90 and inner partition wall 26 of the housing 20 extend into the respective opposite sides of the drum 44 to support the drum 44 and thus the pedal arm 22 for rotation about and relative to the pedal housing 20.

[0045] In other words, the use of a drum 44, a pedal housing wall 26, and a housing cover 90 having the features described above enables the drum 44 of the pedal arm 22 to be mounted and supported for rotation relative to the pedal housing 20 without the use of a separate shaft extending through the drum, such as disclosed in U.S. Patent No. 8,042,430 entitled "Accelerator Pedal for a Vehicle," and therefore defines and provides a shaftless pedal 10.

[0046] The elements of the contact position sensor assembly 70 are arranged and mounted within the second interior housing chamber 30 of the pedal housing 20. More specifically, the base 78 of the rotor 74 is disposed in a relationship overlying and abutting the radial end surface 49a of the neck 49 of the drum 44 extending through the through-bore 32 in the inner wall 26 of the pedal housing 20, and more specifically, in a relationship such that the through-bores 79 in the base 78 of the rotor 74 overlie and are in collinear relationship with the respective slots 55 defined in the neck 49 of the drum 44.

[0047] Thereafter, the index starting position of the rotor 74 is adjusted by rotating the rotor 74 by + / - 2 degrees to the desired index starting position, with the contact pieces 82 resting on the surface of the resistance foil 72.Once the idle home position has been set, the bracket 85 and, more specifically, the retainer plate 84 and the retainer pins 81 thereof are pushed or pressed axially downward or inward through the respective through-holes 79 in the rotor base 78 and into the respective slots 55 in the neck 49 of the drum 44 in a relationship where the bracket 85 and, more specifically, the retainer plate 84 thereof abut the outer surface of the base 78 of the rotor 74 and the outer surface of the respective pins 81 abut and are pressed against the plurality of ribs or teeth 57 in the respective slots 55 in the neck 49 of the drum 44 for fixing and locking the respective pins 81 in the respective slots 55 in the drum 44, which in turn fixes and locks the rotor 74 to the drum 44, which in turn fixes and locks the rotor 74 in its index position on the drum 44 and is locked.

[0048] Furthermore, the clamp 86 on the retainer plate 84 is pushed or pressed axially downward first through the through hole 77 defined in the rotor base 78 and then through the through hole 51 extending through the interior of the drum 44 of the pedal arm 22, causing the clamp arms 88 to move first inwardly toward each other and then subsequently outwardly away from each other after the clamp fingers 89 have disengaged from the inner drum shoulder 51a, thereby locking the clamp 86 to the drum 44 of the pedal arm 22, thereby locking the bracket 85 to the drum 44, which in turn locks the rotor 74 to the drum 44 of the pedal arm 22.

[0049] The length of the respective slots 55 in the neck 49 on the side 48 of the drum 44 limits the idle output setting of the rotor 74 to a maximum of + / -2 degrees.

[0050] The cover plate 92 is then applied to the pedal housing 20 in a relationship covering the second inner housing chamber 30 and secured to the radial end peripheral edge of the wall 24 of the pedal housing 20 by ultrasonic welding or a similar method to cover and protect the electrical and sensor elements located in the electrical or sensor element chamber 30 of the housing 20.

[0051] The Fig. 10 and Fig. 11 show the vehicle pedal 10 of the present invention, which includes a rotor mount embodiment in which the retaining pins 81 are not part of a mount 85, but are instead of the individual shear type shown, for example, in the Fig. 10, Fig. 11 and Fig. 12 of the co-pending US patent publication US 2014 / 0 090 512 A1, the disclosure and contents of which are incorporated herein by reference.

[0052] In particular, the design of the Fig. 10 and Fig. 11 of the present application, each of the retaining pins 81 is a shear-type pin which is one-piece and integrated and formed as part of the base 78 of the rotor 74 by a thin section or region of plastic material (not shown) extending between the base 78 of the rotor 74 and the outer surface of each of the pins 81.

[0053] Once the idle position of the rotor 74 has been adjusted as described above with respect to the Fig. 7 and Fig. 8 and incorporated herein by reference, the pins 81 are pushed or pressed axially downward to shear and tear the pins 81 away from the plastic material that fixes the pins 81 to the base 78 of the rotor 74, and the pins 81 are then pushed further axially downward through the respective slots 79 defined in the base 78 of the rotor 74 and into and through the respective slots 55 defined in the collar 53 in the side 48 of the drum 44 in the same manner as described above with respect to the Fig. 7 and Fig. 8 and incorporated herein by reference, are pushed or pressed to couple the rotor 74 to the drum 44.

Claims

[1] Vehicle pedal, comprising: a pedal housing (20) having an inner housing wall (26) dividing the housing (20) into first and second inner housing chambers, the inner housing wall (26) defining a through bore (32); a pedal arm (22) having a drum (44) extending into the first inner housing chamber of the pedal housing (20), the drum (44) having a neck (49) projecting outwardly from a first side surface of the drum (44) and defining a recess (50) extending into a second side surface of the drum (44), the neck (49) of the drum (44) extending through the through-bore (32) defined in the inner housing wall (26) of the pedal housing (20) for mounting the drum (44) for rotation in the first inner housing chamber relative to the pedal housing (20); a rotor (74) located in the second inner housing chamber of the pedal housing (20), the rotor (74) having a base (78) attached to one of the sides of the drum (44) extending through the through-bore (32) defined in the inner housing wall (26) of the pedal housing (20); a first cover attached to the pedal housing (20) and covering the first inner housing chamber, the cover (90) comprising a plate (90) having a collar (95) projecting inwardly from a surface thereof and extending into the recess (50) of the drum (44) for mounting the drum (44) for rotation in the first inner housing chamber relative to the pedal housing (20); a second cover attached to the pedal housing (20) and covering and sealing the second inner housing chamber of the pedal housing (20), wherein the base (78) of the rotor (74) defines at least a first through-bore and a second through-bore, wherein one of the sides of the drum (44) defines at least a first and a second slot, wherein the drum (44) defines an inner shoulder (51a), wherein the vehicle pedal has a retaining plate (84), a first pin protruding from the retaining plate (84) and a clamp (86) protruding from the retaining plate (84), the pin and clamp extending through the first and second through-bores defined in the base (78) of the rotor (74) and into the first and second slots defined in the drum (44), wherein the clamp (86) engages the inner shoulder (51a) in the drum (44) to lock the index position of the rotor (74) to the drum (44) of the pedal arm (22). [2] The vehicle pedal of claim 1, further comprising a first bearing located between the neck (49) of the drum (44) and the inner partition (26), and a second bearing located between the collar (95) of the first cover and the drum (44) for supporting the drum (44) for rotation relative to the pedal housing (20).

Images