Microswitch for ebps applications, in particular mounted in a brake pedal absorber

Abstract

The present invention relates to a microswitch (1500) for eBPS applications, comprising in sequence along a direction of axial extension into a cylindrical housing (1580) : - a movable pin (1520); - elastic biasing means (1530) for the movable pin (1520); - a fixed element (1540) with an abutment end of said elastic biasing means (1530); - electrical connection means (1510) which start from the inside of the elastic biasing means (1530) and exit from said fixed element (1540) along said direction of axial extension; wherein the end of the movable pin (1520) facing the elastic biasing means (1530) comprises an electrical contact (1525) configured to contact said electrical connection means (1510) as a function of the compression state of the elastic biasing means (1530). In an embodiment, the invention comprises a brake pedal assembly in which a position sensor device (100) with a poka-yoke arrangement and the microswitch is included.

Description

[0001] Microswitch for eBPS applications , in particular mounted in a brake pedal absorber

[0002] To : Brembo N . V.

[0003] Inventors : Martina Truffello, Andrea Milanesi, Manlio

[0004] Della Rossa, Francesco Saverio Mastropierro

[0005] The present invention relates to a microswitch for eBPS ( electronic Brake Pedal Simulator) applications , in particular mounted in a brake pedal absorber .

[0006] Background art

[0007] There are standard applications , such as that shown in Fig . 1 , in which a microswitch is mounted outside the rear brake master cylinder, which is activated when the driver applies a braking request to the pedal lever . Such a design requires mounting a component outside the brake master cylinder, which must be installed directly by the customer on the assembly line . Furthermore, since it is an exposed component , it impacts the overall dimensions of the system and is subject to external agents (mud, water, salt , etc . ) which can compromise the service life and proper operation thereof .

[0008] A possible solution is an arrangement like that in Fig . 2 , which however has the following limitations :

[0009] - Increase in the axial overall dimensions of the system;

[0010] - Increase in the number of components which affect the position of the piston and thus the free stroke ( in the case of eBPS, the impact is directly on the brake pedal curve ) .

[0011] Indeed, a microswitch is here directly integrated on the brake master cylinder . With respect to Fig . 1 , there is no longer a need for the customer to perform in-line integration . The design of the brake master cylinder becomes here more complex because the microswitch is actuated by a plastic tab preloaded by a spring against the float . This increases the overall dimensions and the complexity of the design of the brake master cylinder, and impacts the idle stroke which will be subject to the tolerances of the added components , worsening the variability thereof and the driver' s feeling . Furthermore, since the microswitch is not sealed here, it is also necessary to implement a dedicated structure which ensures tightness to atmospheric agents and moisture . The addition of these components causes an increase in cost and in the overall dimensions of the brake master cylinder itself .

[0012] With reference to Fig . 3 , the microswitch has here the design of a conical interface tip which can be actuated not only in the direction of the rotation axis thereof , but also in a perpendicular direction (e . g . , sliding on a piston) . Such a design is improved with respect to that in Fig . 2 because it can be activated by modifying the geometry of the float of the brake master cylinder, thereby avoiding the addition of extra components for activation . However, this system does not ensure tightness between the brake master cylinder and the microswitch; accordingly, it is necessary to provide a sealed cover suitable for the purpose . Furthermore, the prior art generally has the following problems :

[0013] - Need for a microswitch to activate not only the brake light switch, but also the brake signal from the eBPS, in the event of damage to the position sensor;

[0014] - Need to comply with a critical constraint in terms of available space ;

[0015] - Need to provide a braking system without the pedal lever, and therefore to find a space in which to install the microswitch, with a reduction in the available space .

[0016] Moreover, the microswitch is an external component and therefore is exposed to the external environment and to damage due to impacts and drops .

[0017] For the eBPS pro ject , the microswitch is a safety- critical component which provides a redundant signal for the braking request in the event of position sensor failure .

[0018] KR 100867719 Bl relates to a microswitch for automotive applications , in particular for the detection of the position of the brake pedal . The document describes a microswitch structure which allows precisely detecting the pedal actuation, improving the reliability of the brake signal transmitted to the electronic systems of the vehicle . The microswitch described in KR 100867719 Bl is integrated close to the brake pedal, but the suggested solution does not specifically address the issue of reducing space requirements within the brake system . The integration of the microswitch near the pedal can require additional components and a dedicated mounting space, which is disadvantageous in applications in which space is limited, such as in eBPS systems or in two-wheeled vehicles . Furthermore, the document does not suggest solutions for optimizing the air gap between sensor and magnet , nor for blocking all the mechanical degrees of freedom of the sensor .

[0019] DE 10 2018 209261 relates to a position sensor for brake control systems , in particular for automotive applications . The document describes a sensor device which detects the position of a movable element , such as a pedal or a piston, and transmits a corresponding electrical signal to the vehicle control system . The suggested solution is based on a magnetic sensor, in which the position of the movable element is detected by the variation of the magnetic field generated by a magnet connected to the element itself . The sensor is integrated so as to ensure stable assembly and protection against external agents , such as dust , moisture, and vibrations . The document also highlights the possibility of an easy replacement of the sensor and the compatibility with different types of braking systems . Such a magnetic position sensor is designed to ensure robustnes s and environmental protection, but its integration into the braking system requires a dedicated housing and a minimum distance between sensor and magnet (air gap) , which can be disadvantageous in terms of space . The solution does not include a fastening system which allows minimizing the axial space requirement and does not offer a mounting mode which blocks all the mechanical degrees of freedom of the sensor, as would instead be desirable . Furthermore, the document does not address the issue of the ease of disassembly and reuse of the sensor, nor the anti-tampering function of the connectors , which elements help meet a desirable, critical constraint of space and safety .

[0020] The microswitch can also be used in combination with the known ePedal technology, which comprises the use of a brake pedal position sensor . Indeed, braking power boosters are used to reduce the actuation force of a brake of a vehicle with at least two wheels , in particular a motorcar, but also a motorcycle or a heavy vehicle, e . g . , a truck, in order to obtain a braking effect desired by the user . For such a purpose, vacuum brake boosters are usually installed on vehicles . Meanwhile, however, electric brake boosters have also been increasingly used in the respective braking systems . While in the case of vacuum brake boosters the actuation of a brake pedal as a signal transmitter is transmitted mechanically to the brake booster, this is no longer the case with electric brake boosters (Brake- By-Wire ("BBW" ) ) . Therefore, sensor devices intended to detect the position or movement of the signal transmitter, in particular contactless , are provided . Usually, one or more linearly movable permanent magnets are used for this purpose, the magnetic field of which is detected by a fixed position sensor .

[0021] Within the ePedal design, the position of the position sensor plays an important role : it tracks the movement of the floating piston and sends an electrical signal to the components of the control unit ; this electrical input is then converted into mechanical power through the action of the pads on the disc . Therefore, the position of the sensor is responsible for the functionality of the entire braking system . Furthermore, a fundamental parameter in the design of the sensor position is the air gap, defined as the space between the sensing element of the sensor and the magnet : this parameter is responsible for the correct operation of the sensor ; the closer the sensing element is to the magnet , the higher the accuracy of the sensor and therefore the greater the braking performance . For all these reasons , it is important to properly secure the position of the sensor to the ePedal housing . In this context , the fastening method shall also take into account the fact that the sensor must not be easily tampered with .

[0022] Usually, the assembly of the sensor ( for example, but without limitation, made of plastic, aluminum, resin, steel ) on the ePedal housing ( for example, but without limitation, made of aluminum, steel, cast iron) is irreversible ; for this reason, the sensor cannot be reused for another ePedal . Furthermore, the suggested sensor fastening method is highly temperature-dependent , thus making the type of mounting not sufficiently reliable from a mechanical point of view; therefore, this solution is not suitable for a safety-critical component ( such as the position sensor) , which is usually characterized by precise tolerances .

[0023] Moreover, in known solutions , there is only one contact plane on one side of the sensor housing, where there is the fastening screw : this means that the sensor is more exposed to loads on this side, especially during mounting . The distance between the sensing element and the magnet is then determined by the thread length of the fastening screw hole, and has a direct impact on the air gap .

[0024] Furthermore, the anti-rotation feature is designed within a cavity in the housing itself and directly affects the machining step .

[0025] In the solution of application WO 2024 / 013593 , a drawing of which is shown in Fig . 9, two screws must be used for fastening the sensor ( indicated by reference numeral 21 in the figure ) , and there is no integrated microswitch .

[0026] On this basis , the need remains for a solution which solves the following problems :

[0027] - All mechanical degrees of freedom of the sensor must be constrained;

[0028] - The air gap (defined as the distance between position sensor and magnet ) must be optimized : the shorter the air gap, the greater the electromagnetic performance of the sensor;

[0029] - The fastening method should take into account that the sensor connectors must not be easily disconnectable ;

[0030] - The sensor fastening method should involve a simple and cost-effective manufacturing process and a poka- yoke design;

[0031] - An anti-tampering requirement for sensor and connectors must be met ;

[0032] - The position sensor must be easily disassemblable on the assembly line ; thus , in the event of a compromised mechanical part , the sensor can be reused and assembled on another ePedal .

[0033] Purpose and object of the invention

[0034] It is an object of the present invention to provide a microswitch which solves the problems and overcomes the drawbacks of the prior art .

[0035] The present invention relates to a microswitch according to the appended claims .

[0036] Such a microswitch, which is actuated when the driver applies a braking request to the pedal lever, is mounted outside the brake master cylinder, preferably but not exclusively the rear one . The microswitch can additionally be mounted in a brake pedal absorber .

[0037] Such a vehicle can be a motorcycle with at least two wheels , or a motorcar or heavy vehicle (e . g . , truck) , with at least four wheels .

[0038] Detailed description of embodiments of the invention

[0039] List of drawings

[0040] The invention will now be described by way of a nonlimiting illustration, with particular reference to the figures in the accompanying drawings , in which :

[0041] - Fig . 1 shows a motorcycle brake pedal with a microswitch, according to the prior art (no eBPS ) ;

[0042] - Fig . 2 shows a further brake pedal with a microswitch according to the prior art ;

[0043] - Fig . 3 shows a microswitch according to the prior art ;

[0044] - Fig . 4 shows a pedal component with a microswitch according to a preferred embodiment of the invention;

[0045] - Fig . 5 shows in (a) a detail of Fig . 4 and in (b) a three-dimensional view of the microswitch in (a) ;

[0046] - Fig . 6 shows a possible positioning of the microswitch according to the invention;

[0047] - Fig . 7 shows a vertical section of an embodiment of the microswitch according to the invention;

[0048] - Fig . 8 shows a perspective view with axial section of an embodiment of the brake pedal device according to the invention;

[0049] - Fig . 9 shows a solution of position sensor on an ePedal, according to the prior art ;

[0050] - Fig . 10 shows a section view of a reference embodiment of the sensor housing device of the invention, corresponding in detail to that in Fig .

[0051] 4 , in which the support surface on the ePedal housing and outside the cavity into which the sensor housing is inserted, is highlighted;

[0052] - Fig . 11 shows a first embodiment of the system according to the present invention;

[0053] - Fig . 12 shows a second embodiment of the system according to the present invention;

[0054] - Fig . 13 shows a third embodiment of the system according to the present invention;

[0055] - Fig . 14 shows a fourth embodiment of the system according to the present invention; - Fig . 15 shows an embodiment of a motorcar brake pedal assembly which includes the position sensor according to the invention;

[0056] - Fig . 16 shows the positioning of the device of the invention with respect to a motorcycle frame ;

[0057] - Fig . 17 shows a further embodiment of a motorcycle brake pedal assembly which includes the position sensor, the microswitch, and the anti-rotation pin, according to the invention .

[0058] It is specified here that elements of different embodiments can be combined together to provide further embodiments , without restrictions , by respecting the technical concept of the invention, as those ordinarily skilled in the art will effortlessly understand from the description .

[0059] The present description also makes reference to the prior art for the implementation thereof in relation to the detail features not described, such as elements of minor importance usually used in the prior art in solutions of the same type, for example .

[0060] When an element is introduced, it is always understood that there can be "at least one" or "one or more" .

[0061] When a list of elements or features is given in this description, it is understood that the finding according to the invention " comprises" or alternatively " consists of" such elements .

[0062] When listing features within the same sentence or bullet list , one or more of the single features can be included in the invention without connection with the other features on the list . Two or more of the parts (elements , devices , systems ) described above can be freely associated and considered as a kit of parts according to the invention .

[0063] Embodiment s

[0064] With reference to Fig . 4 , according to an embodiment , an arrangement 1000 is shown, in which the brake pedal (not shown) is connected to the absorber 1100 by means of a mechanical connection 1200 , 1250 , shown in the form of a push rod . Reference numeral 1300 indicates a dust cuff (optional ) . Reference numeral 1700 indicates a floating element moved by the push rod .

[0065] To the side of the absorber 1100 , a position sensor 1400 and, separately, a vertically open housing 1600 to house a microswitch 1500 are fastened .

[0066] An embodiment of the microswitch 1500 is better shown in Fig . 5 , in which the fixed connections 1510 and the movable pin 1520 are shown, i . e . , the element of the microswitch which is moved by the moving counterpart to open / close the electrical circuit , transmitting the activation / deactivation signal to a control unit . The element 1550 is an elastic biasing means ( in particular, a spring) of the movable pin 1520 .

[0067] Reference numeral 1750 indicates an anti-rotation cavity, which is the seat where the microswitch of the invention is engaged . This component has the dual function of preventing the rotation of the float and of generating the signal to apply the braking request and activate the lights . The geometry of the cavity has a step 1755 adapted to actuate the microswitch . When the driver applies the load to the pedal, the float slides and the microswitch is actuated from the change in slope on the cavity . The function of signaling the onset of braking and preventing the rotation on the float , necessary to ensure the reading of the position sensor, are thus carried out by the same component .

[0068] The anti-rotation feature is more apparent in Fig . 8 , in which the cavity 1750 is shown as a cavity along the longitudinal movement axis of the float 1700 . The antirotation is achieved by the lateral walls of the cavity . More precisely, the float 1700 moves along the Y axis , the microswitch extends along the Z axis , and the seat 1750 prevents the microswitch from displacing along the X axis , e . g . , due to vibrations .

[0069] Fig . 5 shows a possible positioning of the microswitch 1500 . As indicated above, such a positioning allows preventing the rotation and ensuring the activation of the microswitch . Furthermore, such a design ensures tightness between the component and the eBPS housing, whereby no external structure needs to be provided to ensure isolation from environmental agents and moisture . The fastening method is here a press-fitting operation which allows , once the electrical connection has been established with respect to an external reference located on the eBPS housing, the system to be fastened, avoiding such a connection from rotating, due to vibrations , about the axis of the microswitch . Such an embodiment is shown in Fig . 6, in which the microswitch with knurling 1555 , suitable for press-fitting, is shown . The anti-rotation cavity 1750 provided on the piston has a width such as to ensure a limited clearance with respect to the anti-rotation microswitch, and has a difference in height such as to ensure the activation thereof during sliding, when the lever reaches a stroke agreed with the customer . The inclined plane 1755 which serves as a connection between the two heights of the cavity, Fig . 5 , is designed so as to prevent fatigue wear of the tip of the microswitch, ensuring a controlled surface finish . The inclination angle of the plane 1755 can vary from 15 ° to 30 ° based on the tolerance on the lever stroke accepted to send the braking signal, whereas the height depends on the design of the microswitch . It must not be exces sively reduced, to ensure that possible vibrations during on-vehicle use do not produce unwanted activation signals (avoiding the brake lights from coming on when braking or, in case of a position sensor fault , an unintentional braking request to the control unit ) . With reference to Fig . 7 , it is seen that the biasing means 1530 can comprise a spring which, on one side, bears against the movable pin 1520 and, on the other, against a fixed, preferably molded polymeric element 1540 . The fixed connections 1510 cross the device up to the movable pin, in which there are electrical contact means for activation when the movable pin rises .

[0070] Reference numeral 1570 indicates a sealing O-ring (optional ) . Reference numeral 1580 indicates the outer wall of the microswitch, on the outer surface of which there is optionally a thread 1550 . Reference numeral 1586 indicates an external hexagon for mounting the microswitch .

[0071] An inner wall 1560 is interposed between the outer wall 1580 and the contacts and the elastic means . It is an optional cylindrical wall, which has the purpose of ensuring the orientation of the electrical contacts 1510 once the microswitch has been fastened to the eBPS housing . In this case, fastening by means of screwing is provided; therefore, it is not possible to pre-orient the contacts . Upon completion of assembly, this is rotated to orient it according to preference . Such a position could vary due to vibrations on the vehicle, but it is expected that this rotation will be prevented or considerably limited once connected to the vehicleside wiring . Reference numeral 1570 indicates a sealing O-ring (optional ) .

[0072] Reference numeral 1590 indicates an optional upper hexagonal seat, useful for mounting the microswitch .

[0073] Reference numeral 1585 indicates an external sealing zone on the cone .

[0074] The solution according to the invention is designed with the following steps :

[0075] - The microswitch is integrated in almost the same space as the anti-rotation section;

[0076] - It has a diameter which provides the anti-rotation feature ;

[0077] - In the lowermost part , a conical shape is implemented, which can slide directly into the anti-rotation cavity of the absorber piston; - The cavity of the anti-rotation piston is designed to ensure both the orientation of the magnetic piston and the activation of the microswitch when the driver presses the pedal ;

[0078] - The microswitch ensures sealing directly with a conical shape and can be fastened to the eBPS housing by clamping, crimping, or another integration solution .

[0079] This solution can be implemented for standard front and rear master cylinders for motorcycle applications and generally for all boosters , eBPS and BPS for cars . This solution can be integrated together with the linear position sensor to improve assembly and use one connector instead of two .

[0080] The main advantages of this solution are :

[0081] - Improving the integration of the components in the eBPS solution;

[0082] - Suggesting a value proposition for standard rear pumps ;

[0083] - Improving assembly on customer side ;

[0084] - No impact on the free stroke for standard master cylinders, or no impact on the eBPS pedal sensitivity .

[0085] Embodiment with a system for fastening a position sensor in an ePedal application

[0086] In a different embodiment , there is described a system for fastening a position sensor in an ePedal application, which can be understood as independent or combined with the previous embodiment . The solutions that will be suggested below resolve the main issues associated with the previous design, making the system also suitable for motorcycle applications . Indeed, the size of the ePedal is the most critical issue for the design of motorcycle applications , because it is necessary that it remains as close as possible to the actual pedal pumps .

[0087] With reference to Fig . 10 , all embodiments comprise a sensor 100 with one or more cavities 110 for housing respective one or more connectors or sensing elements , such as a position sensor and a microswitch, a sensor body 120 with at least one flat lower surface, and an element 130 projecting from said flat lower surface , for example, the element 130 being configured to be inserted into a corresponding cavity 155 of a sensor housing or seat 150 , the element 150 being configured to be integrated into the housing 600 of the ePedal . Said element 150 could be of one piece with the housing 600 , or be a separate insert inserted into the housing 600 , also made of a different material from that of the housing . The one or more cavities 110 for housing one or more connectors are provided on the opposite side of said flat lower surface on said sensor body 120 .

[0088] The ends 121 and 122 (end 122 is optional ) of the sensor body 120 along the direction of longitudinal extension Y are outside the cavity 155 of the housing 150 and are flush with the surface of the housing 150 in the ePedal housing 600 , so as to have a single support plane P . The end 121 can conveniently house the hole 125 for screw fastening, whereas the end 122 can be a poka- yoke element .

[0089] Generally, the projecting element 130 has a section along a plane parallel to plane P , which could (without limitation) be non-circular, in particular quadrangular, with or without chamfered edges .

[0090] In the first two specific embodiments described below, in addition to the fastening screw, there is an anti-rotation element 122 consisting of a rectangular element in Solution #1 and of a "T-shaped" element in Solution #2 .

[0091] Embodiment #1

[0092] More in particular, in embodiment #1 in Fig . 11 , the degrees of rotation freedom are blocked not only by the rectangular element forming the projecting element 130 , but also by the fastening end 121 . The end 122a has a flat surface configured to rest on a corresponding flat surface of the ePedal housing, in the same manner as the other end 121 ( in which there is a hole for the fastening screw) . This applies to all embodiments that have such an end .

[0093] Embodiment #2

[0094] In contrast to the preceding embodiment , in embodiment # 2 in Fig . 12 , the same clearance in the cavity 155 is now greater, which makes it necessary to have the T-shaped element 122b pro jecting from the upper surface (opposite to the flat lower surface ) of the housing body 120 . The T-shaped element preferably has the same horizontal section (parallel to the plane P ) at all heights along the direction perpendicular to the plane P . The lugs 157 projecting from the upper surface form a seat where the T-shaped end 122b is inserted, so as to block the two movements on the plane P ( see Fig . 10 ) .

[0095] Embodiments #3 and #4

[0096] Embodiments # 3 and 4 , shown in Figs . 13 and 14 , respectively, are two alternative solutions of solution # 1 and solution # 2 , respectively . They further have a screw hole at the end 121 and an anti-rotation element represented by an element having the shape of a semicircle or an arc of a circle (which fits into a corresponding seat 156 of the ePedal housing 600 ) and by the inclined faces of the sensor, respectively, i . e . , in the latter case the projecting element 130 has a dovetail-shaped cross-section (perpendicular to the longitudinal direction Y) and the corresponding seat 656 has a section along Y adapted to accommodate the dovetail .

[0097] In the case of the element 122c the shape of a semicircle, it projects from the lateral surface of the housing body 120 , and preferably has the same horizontal section (parallel to the plane P ) at all heights along the direction perpendicular to the plane P . The seat 156 can project with respect to the plane P .

[0098] Although embodiments # 3 and #4 are very similar to the first two, they however represent different advantageous embodiments . In particular, embodiment #4 has a reduced longitudinal extension, because it has no end 122 .

[0099] Although embodiment # 4 does not have the second end and comprises the dovetail-shaped projecting element 130 , the latter can be provided with the shape of the preceding embodiments , because movement on the plane P is however blocked by the non-circular shape of the same projecting element .

[0100] Brake pedal assembly

[0101] With reference to Fig . 15 , there is shown a portion of a braking system, known per se, where the sensor 100 according to the invention is applied in the cavity 155 of the housing 150 . The braking system comprises a float 300 ( functionally equal to the element 1700 described above ) with a cavity 350 for housing the magnet (not shown) , the float being inserted into the ePedal housing 600 .

[0102] Also referring to the previous figures , the ePedal housing 600 comprises a sensor housing or seat 150 , comprising a recess 155 , 151 configured to accommodate said sensor 100 , said recess 155 , 151 including a cavity of shape corresponding to said pro jecting element 130 . Furthermore, the sensor housing or seat 150 of the ePedal housing 600 has a flat surface which is configured to abuttingly receive said sensor 100 .

[0103] The above-described absorber 1100 and the housing 600 perform the same function of containing the float and housing one or more sensors or active elements (e . g . , a position sensor and a microswitch) . Note that Fig . 17 also shows an anti-rotation pin 360 , which slides longitudinally in the cavity 370 , e . g . , as in Italian patent application No . 812024000189966 dd . 19 . 11 . 2024 , which is hereby included by reference in its entirety . The anti-rotation pin 360 prevents rotation between absorber 600 and float 300 about the longitudinal axis (brake actuation axis ) .

[0104] The device 100 can house a position sensor and possibly a microswitch . Alternatively, it is possible to position the above-described microswitch (Figs . 5 and 8 ) instead of the anti-rotation pin 360 , so that the microswitch also performs the anti-rotation function, being capable of sliding in the cavity 370 . In this configuration, the cavity 370 coincides with the seat 1750 . A variant is also possible, in which there are two microswitches , one in the device 100 and one in the antirotation feature, as described . The two microswitches do not need to be identical because the one in the device 100 is not required to perform an anti-rotation function .

[0105] In the case of the sensor 100 according to embodiment #2 or #3 , with a second end 122b, 122c, respectively, the sensor seat 150 of the ePedal housing 600 comprises a seat 156, 157 , 158 of corresponding shape, configured to accommodate said second end 122b, 122c so as to oppose the movement thereof in the longitudinal direction Y and in the direction X perpendicular thereto . Such an interference can also be achieved with a calibrated clearance between the parts , which allows displacements that are negligible for the operation of the sensor . Instead, in the case of embodiment #4 for the sensor 100 , the recess 151 is configured to accommodate the projecting element 130 with a dovetail-shaped section . The insertion of the sensor 100 does not occur here from above, as in the other embodiments , but in the longitudinal direction Y . For this reason, the second end 122 is not present .

[0106] With reference to Fig . 16, the positioning of the position sensor 100 with respect to the vehicle frame 2000 is shown . At the ends of the cavities 110 , two male connectors 800 are secured, with tabs 850 arranged towards the frame and therefore inaccessible, so as to implement an anti-tampering function .

[0107] In all embodiments , the sensor according to the invention could also have a microswitch configured to act as " secondary braking" in the event of a fault of the position sensor itself .

[0108] Referring now to Fig . 17 , a brake pedal assembly 3000 is shown, in which there are :

[0109] - brake lever 200 ;

[0110] - float 300 with cavity 350 ;

[0111] - magnetic sensor 400 ( similar to 1400 above but in a different position) ;

[0112] - elastic elements 500 ;

[0113] - housing 600 of the ePedal 3000 ;

[0114] - sensor seat 150 with recess 155 .

[0115] The device according to the invention can be used for both a motorcar or a vehicle having at least four wheels , and a motorcycle or a vehicle having at least two wheels . List of reference numerals

[0116] 100 Sensor device (position sensor installable on ePedal housing)

[0117] 110 Cavity for housing connectors or sensing elements

[0118] 120 Sensor body

[0119] 121 First end of the sensor body (with screw hole )

[0120] 122 Second end of the sensor body (optional, can be 122a, 122b, 122c)

[0121] 125 Hole for screw fastening

[0122] 130 Element projecting from the sensor body

[0123] 1400 Magnetic position sensor ( in some embodiments )

[0124] 150 Housing / seat of the sensor in the ePedal housing

[0125] 151 Recess for the sensor in the housing

[0126] 155 Cavity for inserting the proj ecting element of the sensor

[0127] 156 Seat of corresponding shape to accommodate the second end of the sensor

[0128] 157 Seat of corresponding shape to accommodate the second end of the sensor

[0129] 158 Seat of corresponding shape to accommodate the second end of the sensor

[0130] 1700 Float (movable element inside the absorber)

[0131] 1750 Anti-rotation cavity on the float

[0132] 1755 Step in the anti-rotation cavity

[0133] 200 Brake lever

[0134] 300 Float (movable element , equal to 1700 )

[0135] 350 Magnet cavity in the float

[0136] 360 Anti-rotation pin or position of a possible microswitch serving the anti-rotation pin function 370 Groove for anti-rotation pin or for a possible microswitch serving the anti-rotation pin function400 Magnetic sensor ( in some embodiments )

[0137] 500 Elastic biasing elements ( springs or other elastic means )

[0138] 600 ePedal housing (or absorber in some embodiments )

[0139] 800 Male connectors

[0140] 850 Tabs of the anti-tampering male connectors

[0141] 1000 Brake pedal / ePedal assembly (example of complete device )

[0142] 1100 Absorber ( cylindrical casing)

[0143] 1200 , 1250 Push rod (mechanical connection between pedal and absorber)

[0144] 1300 Dust cuff (optional )

[0145] 1400 Position sensor ( in some embodiments )

[0146] 1500 Microswitch

[0147] 1510 Electrical connection means of the microswitch

[0148] 1520 Movable pin of the microswitch

[0149] 1525 Electrical contact on the movable pin

[0150] 1530 Elastic biasing means of the movable pin ( spring)

[0151] 1540 Fixed element of the microswitch

[0152] 1550 Thread on the outer wall of the cylindrical housing of the microswitch

[0153] 1555 Knurling for press-fitting the microswitch

[0154] 1560 Inner wall of the cylindrical housing of the microswitch

[0155] 1570 Sealing O-ring (optional )

[0156] 1580 Outer wall of the cylindrical housing of the microswitch 1585 Outer sealing zone on the cone of the microswitch

[0157] 1586 Outer hexagon for mounting the microswitch

[0158] 1590 Upper hexagonal seat for mounting the microswitch

[0159] 2000 Vehicle frame (e . g . , motorcycle )

[0160] 3000 Brake pedal assembly ( in some embodiments )

[0161] Advantages of the invention

[0162] The advantages offered by the invention are many and effectively meet the technical and functional requirements of the electronic braking systems , in particular for eBPS applications and vehicles with critical space constraints .

[0163] Firstly, the microswitch according to the invention is designed to be integrated in a highly compact manner inside the cylindrical housing, minimizing the axial dimensions and allowing installation even in very limited spaces , as required by modern automotive and motorcycle applications . The configuration of movable pin, elastic biasing means , and fixed element allows obtaining a robust and reliable structure, capable of withstanding the mechanical stresses and the vibrations typical of the vehicle environment .

[0164] A further advantage is the presence of the antirotation cavity, which allows blocking of all the mechanical degrees of freedom of the microswitch, avoiding undesired movements and ensuring the precision of the activation signal . The internal stepped shape of the float cavity ensures that the microswitch is actuated only upon reaching a specific position, preventing accidental actuations due to vibrations or assembly tolerances .

[0165] The suggested solution also allows the optimization of the air gap between position sensor and magnet , improving the electromagnetic performance and the precision of braking detection . The fastening method, which can include press-fitting, screwing, or crimping, ensures an effective tightness to external agents , such as dust , moisture, and contaminants, without the need for additional structures for isolation .

[0166] From a safety point of view, the microswitch provides a redundant signal for the braking request , thus being a critical component for the functional safety of the eBPS system . The ease of disassembly and re-use of the sensor allows reducing maintenance costs and optimizing the management of components on the assembly line .

[0167] Finally, the solution according to the invention is readily adaptable to various types of vehicles , both two- and four-wheeled, and can be integrated with linear position sensors for greater application versatility . Compact design, mechanical robustness, functional safety, and ease of assembly make the microswitch according to claims 1 to 8 a superior technical solution as compared to the prior art .

[0168] The main advantages of the embodiment with the sensor device installable on a housing of an ePedal are :

[0169] - Improvement of the mechanical fastening concerning both the modes of blocking the degrees of freedom of the sensor, and the tolerances which can be dealt more easily in terms of mechanical and thermal stresses .

[0170] - From a mechanical design point of view, the sensor no longer functions in a manner similar to a cantilever beam, thus making the entire component more robust from a design point of view .

[0171] - In the case of a re jected ePedal as sembly, the sensor can be easily disassembled on the assembly line and reused for another ePedal assembly : the position sensor costs up to 40% of the entire ePedal project , therefore this advantage is fundamental .

[0172] - Guarantee of the anti-tampering function; the connectors face the motorcycle . The anti-tampering function is provided here by the tabs of the male connector which face the inside of the motorcycle : therefore, the sensor is mounted to the pedal, then the pedal is mounted to the motorcycle, and at this point the tabs (which must be released to tamper with the connectors ) are not reachable .

[0173] - The electromagnetic performance of the sensor is improved : indeed, since the lower part of the sensor is not completely flat , the sensor is now closer to the magnet inside the cylindrical casing, thus improving the electromagnetic performance of the sensor .

[0174] - The machining process for obtaining the sensor seat on the casing does not cause any problem, because it is simple and cost-effective . — All the solutions involve a simple process for assembling the sensor to the ePedal housing (poka- yoke design) .

[0175] Preferred embodiments have been described above and variations of the present invention have been suggested, but it should be understood that those skilled in the art may make modifications and changes without departing from the related scope of protection, as defined by the appended claims .

Claims

CLAIMS1. A microswitch (1500) for electronic Brake PedalSimulator, eBPS, applications , comprising in sequence along a direction of axial extension into a cylindrical housing (1580) :- a movable pin (1520) ;- elastic biasing means (1530) for the movable pin (1520) ;- a fixed element (1540) with an abutment end of said elastic biasing means (1530) ;- electrical connection means (1510) which start from the inside of the elastic biasing means (1530) and exit from said fixed element (1540) along said direction of axial extension; wherein the end of the movable pin (1520) facing the elastic biasing means (1530) comprises an electrical contact (1525) configured to contact said electrical connection means (1510) as a function of the compression state of the elastic biasing means (1530) .

2. A microswitch (1500) according to claim 1, wherein said elastic biasing means (1530) consist of a helical spring .

3. A microswitch (1500) according to claim 1 or 2, wherein the outer wall of the cylindrical housing (1580) comprises a thread (1550) .

4. A microswitch (1500) according to one of claims 1 to 3, wherein the fixed element (1540) has, at the end opposite to the abutment end, a seat (1590) configured for a microswitch assembly key.

5. A microswitch (1500) according to one of claims 1 to 4, wherein an inner wall (1560) is interposed between the outer wall of the cylindrical housing (1580) and the set comprising the elastic biasing means and the fixed element (1540) , which inner wall (1560) is configured so that said set is rotatable.

6. A brake pedal assembly (1000; 3000) , which extends in a longitudinal direction (Y) , comprising an absorber (1100; 600) connectable to a brake pedal by means of a push rod (1200,1250) , wherein the absorber comprises a cylindrical casing in which a floating element (1700; 300) connected to said push rod slides, wherein a microswitch (1500) is mounted (360) in an opening in said cylindrical casing, and wherein:- the microswitch (1500) is defined by one of claims1 to 5 and has a direction of axial extension perpendicular to the longitudinal direction (Y) , being configured to send a braking signal;- said movable pin (1520) penetrates into a cavity (1750;370) of said floating element (1700;300) ;- said cavity (1750; 370) has an extension along the movement axis of the floating element (1700; 300) coincident with the longitudinal direction (Y) and has an internal shape with a step (1755) configured so that the movable pin (1520) is pushed towards the elastic biasing means (1550) when the floating element (1700) slides in said cylindrical casing along said movement axis;- said cavity (1750; 370) is configured to prevent a displacement of the movable pin (1520) along adirection perpendicular to said direction of axial extension and to said movement axis.

7. A brake pedal assembly (1000; 3000) according to claim 6, wherein said step (1755) consists of a ramp having a slope between 15° and 30°, based on the tolerance on the predetermined stroke of the floating element to send a braking signal.

8. A brake pedal assembly (1000; 3000) according to one of the preceding claims, wherein the sensor device (100) comprises:- a sensor body (120), with a first surface extending along said longitudinal direction (Y) and along a direction (X) perpendicular thereto defining a plane (P) and a second surface opposite to the first surface along a direction perpendicular to said plane;- a first end (121) of the sensor body (120) along the longitudinal direction (Y) provided with a hole (125) for the passage of a fastening screw and with a first end surface in said plane (P) ;- a projecting element (130) , which protrudes from said first surface in the direction perpendicular to said plane (P) ; wherein the projecting element (130) has a non-circular section parallel to said plane (P) ; wherein there is also provided a sensor device (100) fixed in a corresponding sensor housing (150) on said absorber (1100; 600) , which comprises a recess (155,151) configured to accommodate said sensor device (100) , saidrecess (155,151) including a cavity of shape corresponding to said projecting element (130) , and wherein said absorber (1100; 600) has a flat surface which is configured to abuttingly receive said first surface of said sensor housing device (100) .

9. A brake pedal assembly (1000; 3000) according to one of the preceding claims, wherein the sensor device (100) comprises:- a sensor body (120), with a first surface extending along said longitudinal direction (Y) and along a direction (X) perpendicular thereto defining a plane (P) and a second surface opposite to the first surface along a direction perpendicular to said plane;- a first end (121) of the sensor body (120) along the longitudinal direction (Y) provided with a hole (125) for the passage of a fastening screw and with a first end surface in said plane (P) ;- a projecting element (130) , which protrudes from said first surface in the direction perpendicular to said plane (P) ; wherein the projecting element (130) has a circular section parallel to said plane (P) ; wherein there is also provided a sensor device (100) fixed in a corresponding sensor housing (150) on said absorber (1100; 600) , which comprises a recess (155,151) configured to accommodate said sensor device (100) , said recess (155,151) including a cavity of shape corresponding to said projecting element (130) ,and wherein said absorber (1100; 600) has a flat surface which is configured to abuttingly receive said first surface of said sensor housing device (100) .

10. An assembly (1000; 3000) according to claim 8 or 9, wherein there is provided a second end ( 122a, 122b, 122c) opposite to the first end (121) along the longitudinal direction (Y) , the second end having a second end surface on said plane (P) .

11. An assembly (1000; 3000) according to claim 10, wherein the second end (122b) has a section parallel to said plane (P) in the shape of a T or in the shape of a semicircle or an arc of a circle.

12. An assembly (1000; 3000) according to claim 11, wherein said absorber (600) comprises a seat (156,157,158) of corresponding shape configured to accommodate said second end (122b, 122c) abutting along a direction perpendicular to the plane (P) , and shaped so as to oppose the movement thereof in the longitudinal direction (Y) and in the direction (X) perpendicular thereto by interference with said second end.

13. An assembly (1000; 3000) according to any one of claims 8 to 12, wherein said non-circular section is a quadrangular section, and wherein the projecting element (130) has a dovetail-shaped section perpendicular to said plane (P) .

14. An assembly (1000; 3000) according to claim 12, wherein the recess (151) is configured to accommodate the projecting element (130) with a dovetail-shaped section, with insertion along the longitudinal direction (Y) •15. An assembly (1000; 3000) according to one of claims 8 to 12, wherein the sensor device (100) comprises the microswitch, configured to activate braking in the event of a fault of the sensor device (100) , or the microswitch is mounted (360,370) so as to cross said absorber and said floating element and so as to act as an anti-rotation pin of the float.

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