Passive Brake Pedal Emulator for Speed-Sensitive Force Feedback
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Solution Overview
Problem
The reduction in mechanical braking demand due to the rise of e-boost braking systems in vehicles has led to a need for passive force emulators to provide haptic feedback to operators, as the operator's need for mechanical braking decreases and the system's need to perform braking on behalf of the operator increases.
Innovation Solution
A pedal assembly with an emulator assembly that includes a housing, a pedal arm, an elongated member, a carrier, and compressible members, where the elongated member moves the carrier towards a compressible member to generate force feedback when the pedal is depressed, providing distinct resistance levels based on the speed of pedal depression, simulating a braking fluid system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If e-boost braking systems are used to provide active braking force, then braking performance and system capability are improved, but the need for mechanical braking by the operator decreases and haptic feedback is lost
Solution Approach 1:
A passive force emulator mechanism is introduced as an intermediary component between the operator's foot and the e-boost braking system. This emulator includes a pedal arm, elongated member, carrier, and compressible members that mechanically generate haptic feedback without requiring active electronic control, thus preserving tactile sensation while working within the e-boost system framework
Solution Approach 2:
The force emulator is designed to be self-regulating through passive mechanical means. The compressible members (springs or dampers) automatically provide resistance force proportional to pedal depression speed and distance, eliminating the need for electronic sensors, controllers, or power sources while still delivering adaptive haptic feedback
2Ease of operation
If passive force emulator is introduced to provide haptic feedback, then operator feedback and braking intuition are improved, but device complexity increases
Solution Approach 1:
The haptic feedback function is extracted from the complex e-boost electronic control system and implemented through a separate, dedicated passive mechanical emulator. This separation allows the emulator to focus solely on providing tactile feedback through simple mechanical components, reducing the complexity burden on the overall braking system while maintaining feedback quality
Solution Approach 2:
The force emulator replicates the haptic characteristics of traditional mechanical braking systems using simplified passive components. By copying the essential tactile feedback behavior of hydraulic systems through spring and damper mechanisms, the emulator achieves realistic braking sensation without requiring the complex electronic control architecture of modern e-boost systems
3Manufacturing precision
If multiple compressible members with different stiffness are used, then force feedback precision and braking simulation accuracy are improved, but manufacturing complexity increases
Solution Approach 1:
The force emulator divides the braking force feedback into multiple segments using different compressible members (e.g., first and second springs with different stiffness values). Each segment handles a specific range or aspect of the braking force characteristic, allowing precise control over the overall haptic response while using simple, standardized components that are easy to manufacture and assemble
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 emulator assembly effectively provides a resistive force that changes with the speed of pedal depression, offering three distinct force vs travel sections, enhancing the haptic feedback and making the braking experience more intuitive and responsive.
Implementation Method 1
the carrier is driven into the compressible member such that the compressible material compresses to generate a force feedback onto a foot positioned on the pedal pad
Implementation Method 2
the compressible member positioned in the space between the carrier and the end plate to be in contact with the carrier and the end plate
Data Source
AI summary
Embodiments herein are directed to an emulator assembly. The assembly includes a housing with a cavity, a pedal arm, an elongated member, a carrier, an end plate and a compressible member. The pedal arm is at least partially received in the cavity and has a pedal pad on one end. The elongated member extends and couples to the pedal arm on one end and couples to a carrier on an opposite other end. The end plate is spaced apart from the carrier. The compressible member is positioned in the space between the carrier and the end plate. When the pedal pad is depressed, the elongated member moves the carrier in a direction towards the end plate which drives the carrier into the compressible member such that the compressible material compresses to generate a force feedback onto a foot positioned on the pedal pad.