Accelerator Pedal Sensor Gearing for Excess Torque Protection

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Solution Overview

Problem

Existing accelerator pedals are prone to damage due to excessive force applied by panicked drivers, particularly when the force is applied further away from the rotational axis, increasing torque and risk of damage.

Innovation Solution

The accelerator pedal design incorporates a gearing system between the actuation element and the rotor in the rotational position sensor, which converts pivotal movement into rotational movement, reducing the forces that could cause damage. This gearing system includes at least one gearwheel and/or a lever, with a stop mechanism to prevent excessive rotation and absorb forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the force application point is moved further from the rotational axis to increase leverage, then the ease of operation is improved, but the torque increases causing higher risk of damage to the accelerator pedal

Engineering Contradiction:

Improveease of operationVSAvoidstrength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent introduces an intermediary lever system between the actuation element and the rotor. The first lever receives force from the actuation element and transmits it to the second lever, which then drives the rotor. This intermediary mechanism allows force application at a distance from the rotational axis while distributing and reducing the torque load on critical components, resolving the contradiction between ease of operation and structural strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If a direct connection between the actuation element and rotor is used, then the device complexity is reduced, but the reliability decreases due to higher risk of damage from excessive forces

Engineering Contradiction:

Improvedevice complexityVSAvoidreliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent segments the direct connection into multiple components: the actuation element, first lever, second lever, and rotor. This segmentation allows each component to be optimized for its specific function and enables the system to handle excessive forces more reliably. The modular lever system can absorb and distribute stress, preventing catastrophic failure while maintaining acceptable complexity.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If the actuation element is directly attached to the rotor with aligned rotational axes, then the manufacturing precision requirements are reduced, but the object-generated harmful factors increase due to higher torque transmission

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidobject-generated harmful factors

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent employs an intermediary lever mechanism that decouples the actuation element from direct rotor attachment. The levers serve as mediators that convert the pivotal movement of the actuation element into rotational movement of the rotor while reducing the transmitted torque. This allows for less precise manufacturing alignment while minimizing harmful torque effects on the rotor and stator.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 gearing system effectively reduces the forces that could result in damage to the accelerator pedal, ensuring that safety-related parts are protected from excessive torque, thereby enhancing the pedal's durability and reliability.

Implementation Method 1

there is a gearing between the actuation element and the rotor, which converts a pivoting of the actuation element into a rotation of the rotor

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Implementation Method 2

The gearing can contain at least one gearwheel and/or a lever

Methodology Applied

Scientific EffectGear: Gear

Implementation Method 3

The first and second levers can interact with one another such that pivoting of the first lever in a first direction results in pivoting of the second lever

Methodology Applied

Scientific EffectLever: Lever

Implementation Method 4

with which a torque or force can be transferred from the first lever to the second

Methodology Applied

Scientific EffectTorque: Torque

Implementation Method 5

The stop prevents the rotor from rotating further than necessary in relation to the stator for detecting the position of the actuation element

Methodology Applied

Scientific EffectImpact Force: Impact Force

Data Source

PatentUS20250050733A1Accelerator pedal comprising a rotational position sensor with a rotational axis sensor and a pivotal actuation element with an actuation rotational axis

Publication Date: 2025.02.13 HELLA GMBH & CO KGAA

AI summary

An accelerator pedal includes a rotational position sensor, and a pivotal actuation element coupled to a rotor in the rotational position sensor to rotate the rotor in the rotational position sensor in relation to a stator in the rotational position sensor. The actuation element is pivotally supported such that it can pivot about am actuation rotational axis. The rotor in the rotational position sensor is rotationally supported such that it can rotate about a sensor rotational axis. The actuation rotational axis and the sensor rotational axis are different axes, and there is a gearing between the actuation element and the rotor that converts a pivoting of the actuation element into a rotation of the rotor.