Vehicle Brake Pedal Cam Block Gap Management
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Solution Overview
Problem
Conventional vehicle braking assemblies, particularly those with clevis assemblies, are complex and costly to install and maintain, and they often require additional parts that increase production and manufacturing costs, while also presenting challenges in managing the gap between the brake pedal arm and hydraulic booster interface, which can delay hydraulic braking system activation in by-wire systems.
Innovation Solution
A by-wire braking assembly that eliminates the need for a clevis and clevis pin by using a cam block to manage the spatial distance between the pedal arm and power booster, allowing for adjustable gap management and simpler engagement, reducing part complexity and costs, and ensuring quicker hydraulic braking system response in case of by-wire system failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clevis assembly is used to connect the pedal arm and power booster, then the connection is reliable and guides proper alignment, but the part complexity and manufacturing costs increase
Solution Approach 1:
The cam block is integrated directly with the pedal arm as a single unit, eliminating the need for separate clevis components. The cam block combines the functions of connection, alignment guidance, and gap management that were previously distributed across multiple clevis parts, thereby reducing part complexity while maintaining connection reliability
Solution Approach 2:
The cam block serves multiple functions simultaneously: it connects the pedal arm to the power booster, guides the pedal arm into proper alignment during engagement, manages the gap between components, and enables by-wire system operation. This multi-functionality replaces the specialized clevis assembly, reducing the total number of parts required
2Reliability
If a clevis assembly is used to connect the pedal arm and power booster, then the connection is secure, but the manufacturing and installation costs increase
Solution Approach 1:
By integrating the cam block with the pedal arm as a single component, the manufacturing process is simplified. Instead of producing multiple separate clevis parts and assembling them with fasteners, the single integrated part reduces manufacturing steps, material usage, and assembly operations, thereby lowering production costs while maintaining secure connection
Solution Approach 2:
The invention extracts and eliminates the unnecessary clevis components from the system, retaining only the essential connection and alignment functions through the cam block. This reduction in part count directly decreases manufacturing complexity and installation time, reducing overall system cost
3Adaptability or versatility
If a gap is maintained between the pedal arm and hydraulic booster in by-wire systems, then regenerative braking can function, but hydraulic braking activation is delayed in case of system failure
Solution Approach 1:
The cam block is designed to be movable relative to the pedal arm, allowing it to dynamically adjust its position. During normal by-wire operation, the cam block maintains a gap that enables regenerative braking. Upon detection of hydraulic system failure, the cam block moves to close the gap, immediately engaging the hydraulic booster for emergency braking, thus providing dynamic adaptability to different operational modes
Solution Approach 2:
The cam block acts as an intermediary mechanism between the pedal arm and hydraulic booster. It mediates the interaction by controlling the gap distance, allowing the system to switch between regenerative braking mode (gap present) and emergency hydraulic braking mode (gap closed), thereby enabling both operational modes without compromise
4Adaptability or versatility
If the cam block is made movable with respect to the pedal arm, then the gap can be adjusted for different operating modes, but the mechanism complexity increases
Solution Approach 1:
The cam block is designed with movable capability through simple mechanical means such as sliding surfaces or pivots, allowing it to adjust its position relative to the pedal arm. This dynamic movement enables gap adjustment for different operating modes without requiring complex actuation systems, maintaining mechanism simplicity while achieving adaptability
Data Source
AI summary
The present disclosure relates to various vehicle braking assemblies with gap management devices to manage the distance between the pedal arm and power booster under predetermined conditions.