Brake Pedal Lever With Biasing Beam for Progressive Pedal Feel
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Solution Overview
Problem
The complexity and cost of using progressive rate steel springs in brake pedal assemblies for both hydraulic and electrical brake systems pose challenges in fabrication and configuration within constrained spaces, affecting pedal feel and modulation control.
Innovation Solution
A user-manipulable signal generating apparatus featuring a base plate, elongate pedal lever, and resilient biasing beam that pivotally moves between a home and maximum pivot position, with sensors detecting pivotal motion to generate signals, providing a cost-effective and space-efficient alternative for brake pedal assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If progressive rate steel springs are used in brake pedal assemblies, then pedal feel and modulation control are improved, but fabrication complexity and cost increase
Solution Approach 1:
The patent replaces the traditional mechanical progressive rate steel spring system with an electrical actuation system. A motor-driven mechanism (such as a lead screw or rack and pinion) converts rotational motor motion into linear pedal movement, eliminating the need for complex progressive rate springs while maintaining pedal feel and modulation control through electronic control algorithms.
Solution Approach 2:
The invention changes the fundamental operating parameter of the brake pedal from mechanical spring-based force generation to electrical motor-driven position control. By using a motor to directly control pedal position and a force sensor to monitor applied force, the system achieves progressive rate spring characteristics through software control rather than mechanical spring design.
2Ease of operation
If progressive rate steel springs are used in brake pedal assemblies, then pedal return action is improved, but space requirements and configuration difficulty increase
Solution Approach 1:
The patent replaces the mechanical spring-based return mechanism with an electrical motor system. The motor, controlled by an electronic control unit, actively manages both pedal application and return phases. This eliminates the need for large progressive rate springs while providing precise control over pedal return characteristics through electronic timing and force management.
Solution Approach 2:
The motor-driven system serves multiple functions: it provides both the braking force application and the pedal return action that were previously separate mechanical functions. The single motor unit replaces what would have required multiple spring components, reducing space requirements while maintaining or improving return action performance.
3Ease of operation
If progressive rate steel springs are used in brake pedal assemblies, then modulation control is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces expensive, custom-fabricated progressive rate springs with standardized motor and sensor components. The modulation control function is achieved through electronic control algorithms that manage motor torque and speed, allowing precise force application without the need for costly progressive rate spring fabrication and tuning.
Solution Approach 2:
The invention transitions from mechanical parameter tuning (spring wire gauge, coil spacing, material selection) to electrical parameter control (motor voltage, current, PWM duty cycle). This allows modulation control to be adjusted via software rather than requiring expensive physical prototype iterations and custom manufacturing.
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 apparatus offers a cost-effective and space-efficient solution for brake pedal assemblies, providing a familiar pedal feel and modulation control similar to traditional systems, while reducing fabrication complexity and enhancing user interaction.
Implementation Method 1
Motion of the pedal lever in an apply direction, from the home position toward the maximum pivot position, causes elastic deformation of the beam body
Data Source
AI summary
A user-manipulable signal generating apparatus includes a base plate and an elongate pedal lever having first and second lever ends separated by a lever body. The first lever end is hingedly connected to the base plate. The second lever end is spaced apart from the base plate for pivotal movement with respect thereto. The lever body is configured to move pivotally between a predetermined home position and a maximum pivot position. An elongate resilient biasing beam has first and second beam ends longitudinally separated by a beam body. The first beam end is connected to the base plate. The second beam end is connected to the lever body. A sensor detects pivotal motion of the lever body and generate a signal responsive thereto. The beam body is biased toward an unflexed condition and, when in the flexed condition, urges the lever body in a return direction toward the home position.