Brake Pedal Simulator Link Mechanism for Continuous Force Sensation
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Solution Overview
Problem
Conventional brake pedal simulators for vehicles fail to accurately replicate the changing foot effort sensation with stroke, leading to a sudden increase in reaction force and sensitivity issues due to fixed spring constants or temperature-dependent rubber hardness.
Innovation Solution
A brake pedal simulator utilizing a link structure and elastic member, specifically a spring, to dynamically adjust foot effort based on stroke, forming a rhombus shape with hinge connections and snap rings to ensure continuous mechanical reaction force increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed spring constant is used inside the master cylinder, then the structure is simple, but the foot effort sensation becomes discontinuous and suddenly increases
Solution Approach 1:
The spring is divided into multiple segments (first spring and second spring) with different spring constants. The first spring has a smaller spring constant for initial stroke, and the second spring has a larger spring constant for subsequent stroke. This segmentation allows continuous and natural increase of foot effort sensation without sudden jumps, resolving the contradiction between structural simplicity and pedal feel continuity.
Solution Approach 2:
The system transitions from a static fixed spring constant to a dynamic multi-stage spring constant system. The spring constant changes dynamically based on the stroke position, providing small resistance initially and increasing resistance as stroke progresses. This dynamic adjustment maintains pedal feel continuity while keeping the mechanical structure relatively simple.
2Device complexity
If rubber is used as the elastic member, then the structure is simple, but the foot effort changes with temperature
Solution Approach 1:
The invention changes the material parameter from temperature-sensitive rubber to temperature-insensitive metal springs. The spring constant is adjusted through material selection and geometric design rather than relying on rubber hardness, which varies with temperature. This parameter change eliminates temperature dependency while maintaining structural simplicity.
3Device complexity
If a single spring is used, then the device is simple, but the foot effort inclination cannot change from small to high
Solution Approach 1:
The single spring is segmented into multiple springs (first spring and second spring) arranged in sequence along the stroke direction. Each spring provides a different spring constant for different stroke phases, enabling the foot effort inclination to transition from small to high. This segmentation achieves adaptability while maintaining relatively simple device structure.
Solution Approach 2:
Different regions of the spring system are assigned different local qualities (spring constants). The first spring region has a smaller spring constant for initial soft feel, while the second spring region has a larger spring constant for subsequent firm feel. This local quality differentiation enables the system to adapt to changing foot effort requirements throughout the stroke.
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 solution effectively replicates the changing foot effort sensation of an actual vehicle, reducing manufacturing costs and preventing discontinuous reaction force increases, thereby enhancing pedal feel sensitivity.
Implementation Method 1
an elastic member elastically supporting the link unit and configured to form reaction force by elastic force
Implementation Method 2
A brake pedal simulator utilizing a link structure and elastic member, specifically a spring
Data Source
AI summary
A brake pedal simulator apparatus for a vehicle for implementing a change in a foot effort applied to a brake pedal for each stroke, may include a pedal arm including one end hinge-connected to one side of a frame and the other end in which a pad may be mounted, a link unit including a plurality of links mutually connected between the frame and the pedal arm, and an elastic member elastically supporting the link unit and configured to form reaction force by elastic force in the pedal arm according to the each stroke by the foot effort applied to the pedal arm.