Accelerator Pedal Support Wall Geometry for Breakage-Resistant Assembly
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Solution Overview
Problem
The existing accelerator devices face issues with support wall breakage due to stress concentration during assembly and reduced assembly strength against pull-up loads, as high rigidity support walls are prone to failure under assembly loads and subsequent deformation.
Innovation Solution
The accelerator device incorporates a pair of support walls with a thickening portion where the root side is thicker than the tip side, featuring a curved or slope surface with a broader surface area further from the bearing portion, dispersing stress and maintaining rigidity without compromising elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high rigidity support walls are used, then assembly strength is improved, but stress concentration causes breakage during assembly
Solution Approach 1:
The support wall is designed with non-uniform thickness, featuring a thickening portion at the root side and a thinner tip side. This local quality variation allows the root portion to bear high assembly loads while the tip portion remains flexible, preventing stress concentration-induced breakage while maintaining overall assembly strength
Solution Approach 2:
The thickening portion includes a curved surface that gradually increases in surface area as distance from the bearing portion increases. This curvature design smoothly distributes stress away from the bearing portion, preventing stress concentration and reducing the risk of breakage during assembly operations
2Ease of manufacture
If uniform thickness support walls are used, then manufacturing is simplified, but stress concentration occurs at the root portion
Solution Approach 1:
Instead of uniform thickness, the support wall incorporates a localized thickening portion at the root side. This targeted modification addresses stress concentration at the critical root area while keeping the rest of the structure simpler, balancing manufacturing feasibility with stress distribution requirements
3Stability of the object's composition
If thicker support walls are used throughout, then rigidity is improved, but elasticity is compromised
Solution Approach 1:
The support wall features localized thickening at the root portion to provide rigidity where structural stability is critical, while the thinner tip side maintains elasticity for flexible operation. This spatial differentiation of thickness allows simultaneous optimization of both rigidity and elasticity in different functional zones
Solution Approach 2:
The curved surface of the thickening portion creates a gradual transition in thickness, providing smooth stress distribution that maintains structural rigidity at the root while preserving elastic deformation capability in the thinner tip region
Data Source
AI summary
In an accelerator device, a pedal is rotatable in an accelerator opening direction by a pedaling force of a pad. An arm connects the pedal to the pad. A biasing member biases the pedal in an accelerator closing direction via the arm. The arm has a shaft portion that is assembled to the pad, and the pad has a pair of support walls that rotatably support the shaft portion. The pair of support walls have wall surfaces facing each other, each of the which is provided with a bearing portion and a thickening portion. The thickening portion includes a curved surface or a slope surface having a surface area broader as a distance from the bearing portion increases.