Accelerator Pedal Active Control Mechanism Design
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Solution Overview
Problem
Existing accelerator pedal devices with active control mechanisms for drive-by-wire systems have complex structures, leading to inferior responsiveness and difficulty in miniaturization, as they combine hysteresis generation and active control mechanisms, which often interfere with each other.
Innovation Solution
A simplified accelerator pedal device design featuring a pedal arm with a hysteresis generation mechanism and an active control mechanism, where the active control mechanism includes a drive source and a return lever that rotates with the pedal arm, allowing independent operation and improved responsiveness, with the return lever detachably engaging with the pedal arm to provide stable push back force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex active control mechanism with multiple transmission components (worm gear, gear, lead screw, slider, rod) is used to generate push back force, then the control function is achieved, but the device size increases and responsiveness deteriorates
Solution Approach 1:
The invention separates the active control mechanism from the hysteresis generation mechanism into independent functional modules. The active control mechanism directly applies push back force to the pedal arm without passing through multiple transmission stages, while the hysteresis mechanism operates independently through its own friction elements. This segmentation eliminates the chain of worm gear→gear→lead screw→slider→rod and achieves direct force application for rapid response.
Solution Approach 2:
The invention extracts the essential function of generating push back force from the complex transmission system and implements it through a simplified direct-acting mechanism. The active control motor directly drives a control lever that applies force to the pedal arm, taking out the unnecessary intermediate transmission components (worm gear, gear, lead screw, slider) while preserving the core control function.
2Reliability
If multiple transmission components (worm gear, gear, lead screw, slider, rod) are used in the active control mechanism, then push back force is generated, but the structure becomes complex and device size increases
Solution Approach 1:
The invention segments the overall pedal mechanism into distinct functional zones: the hysteresis generation mechanism with its friction elements and adjustment means, and the active control mechanism with its motor and control lever. This segmentation allows each mechanism to be optimized independently and simplifies the overall structure by eliminating the need for complex interconnections between transmission components.
Solution Approach 2:
The invention takes out the essential function of force transmission from the complex multi-component system and replaces it with a direct-acting control lever mechanism. The control lever directly transmits force from the active control motor to the pedal arm, eliminating the worm gear, gear, lead screw, and slider while maintaining reliable push back force generation.
3Reliability
If the rod reciprocates linearly while the pedal arm swings rotationally, then the active control mechanism operates, but the contact status changes with pedal arm angle and preferable restraining force cannot be obtained
Solution Approach 1:
Instead of having the control element (rod) move linearly while the pedal arm rotates, the invention inverts the approach by having both the control lever and pedal arm rotate about fixed pivot points. This inversion ensures that the contact point between the control lever and pedal arm maintains a stable geometric relationship throughout the range of motion, eliminating the variable contact status problem.
Solution Approach 2:
The invention employs rotational motion (circular arc trajectories) instead of linear reciprocation for the control lever. Both the control lever and pedal arm rotate about pivot points, creating curved motion paths that naturally maintain consistent contact geometry. This spherical/curved motion approach ensures stable contact status regardless of the pedal arm angle.
4Adaptability or versatility
If the hysteresis generation mechanism and active control mechanism are combined in existing designs, then both functions are present, but the structure becomes even more complex and independent operation cannot be ensured
Solution Approach 1:
The invention clearly segments the pedal mechanism into two independent functional modules: (1) the hysteresis generation mechanism comprising friction elements, friction adjustment means, and return spring, and (2) the active control mechanism comprising the active control motor and control lever. Each module operates independently with its own control and force transmission paths, eliminating interference while maintaining dual functionality.
Solution Approach 2:
The invention extracts the hysteresis generation function and active control function into separate mechanical subsystems. The hysteresis mechanism uses friction elements and a return spring independent of the active control motor, while the active control mechanism uses its own motor and control lever independent of the hysteresis components. This extraction ensures independent operation while maintaining both functions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a more responsive and reliable active control mechanism while simplifying the device structure, reducing component count, and enabling miniaturization, ensuring independent operation of both hysteresis and active control mechanisms, and providing stable push back force.
Implementation Method 1
a return spring (30) that generates resilient force to return the pedal arm (20) to the rest position
Implementation Method 2
a hysteresis generation mechanism (40) that comes in contact with the vicinity of an upper end (23) of the pedal arm (20) to generate hysteresis in a pedal force (20P) of the accelerator pedal (22)
Implementation Method 3
an active control mechanism (60) to perform control to push back the pedal arm (20) toward the rest position under prescribed conditions between the pivot axis line (L1) and the hysteresis generation mechanism (40). The active control mechanism (60) includes a drive source (61), and a return lever (62) that is rotated in the same direction as the direction of the swinging of the pedal arm (20) in conjunction with the drive source (61)
Data Source
AI summary
An accelerator pedal device having a pedal arm working in conjunction with an accelerating pedal, a housing to rotatably support the pedal arm around a prescribed pivot axis line between a rest position and a maximum applied position, a hysteresis generation mechanism that comes in contact with the vicinity of an upper end of the pedal arm to generate hysteresis in a pedal force of the accelerator pedal, and an active control mechanism to push back the pedal arm toward the rest position under prescribed conditions between the pivot axis line and the hysteresis generation mechanism. The active control mechanism includes a drive source provided in the housing, and a return lever that is rotated in the same direction as the direction of the swinging of the pedal arm in conjunction with the drive source and is detachably engaged with the vicinity of the upper end of the pedal arm.