Brake Pedal Stroke Sensor Integrating Hinge Shaft and Angle Sensor
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Solution Overview
Problem
Conventional brake pedal sensors face issues with durability and accuracy due to loose tolerances and increased manufacturing costs and weight caused by additional brackets, which deteriorate sensing performance over time.
Innovation Solution
A brake pedal stroke sensor design that integrates a hinge shaft with a sensor cover and a bracket supporting an angle sensor, eliminating the need for a separate bracket by using a drive pin and elongated slot mechanism to transmit rotary angles directly to the angle sensor, thereby improving accuracy and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate bracket is added to equalize the trace of operation between the brake pedal arm and the pedal stroke, then the sensing performance is improved, but the manufacturing cost and weight are increased
Solution Approach 1:
The patent combines the bracket function with the sensor cover by integrating the trace equalizing mechanism directly into the sensor cover structure. The sensor cover is designed with a specific geometry that simultaneously serves as both the protective cover and the trace equalizing component, eliminating the need for a separate bracket while maintaining sensing performance.
Solution Approach 2:
The sensor cover is designed to perform multiple functions: it protects the angle sensor, provides structural support, and equalizes the trace of operation between the brake pedal arm and pedal stroke. By making the sensor cover a multi-functional component, the patent eliminates the separate bracket and reduces overall weight.
2Measurement precision
If a separate bracket is added to equalize the trace of operation between the brake pedal arm and the pedal stroke, then the sensing performance is improved, but the manufacturing cost is increased
Solution Approach 1:
The patent merges the bracket's trace equalizing function with the sensor cover structure. This integration reduces the total number of parts that need to be manufactured, assembled, and quality-checked, thereby lowering manufacturing costs while maintaining the sensing performance improvement.
Solution Approach 2:
The patent extracts the trace equalizing function from the separate bracket and incorporates it directly into the sensor cover design. This eliminates the need for a additional component, simplifying the manufacturing process and reducing costs.
3Stability of the object's composition
If a separate bracket is added to equalize the trace of operation, then the operation trace is equalized, but the device complexity is increased
Solution Approach 1:
The patent combines the trace equalizing function with the sensor cover, reducing the number of separate components. This integration simplifies the overall device structure while maintaining the ability to equalize the operation trace between the brake pedal arm and pedal stroke.
Solution Approach 2:
By designing the sensor cover to simultaneously provide protection, structural support, and trace equalization, the patent reduces device complexity. The multi-functional sensor cover eliminates the need for a separate bracket, simplifying assembly and reducing the number of parts.
Data Source
AI summary
A brake pedal stroke sensor apparatus may include a frame, a hinge shaft fixed to the frame, a pedal arm pivotally coupled to the hinge shaft and rotating with respect to the hinge shaft, an angle sensor that is coaxially aligned to the hinge shaft and fixed to the frame, a sensor lever connected to a rotational shaft of the angle sensor and extending with a predetermined length, and a drive pin formed to the hinge shaft in a predetermined distance from a rotational axis of the hinge shaft and engaged to a distal end portion of the sensor lever so as to transmit change of a rotary angle of the pedal arm to the angle sensor in accordance with a rotation of the pedal arm.