Brake Pedal Feel Test Apparatus Using Hydraulic Pressure Monitoring
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Solution Overview
Problem
Existing methods for testing brake pedal feel in vehicle brake systems are subjective and time-consuming, making it difficult to quantify and ensure consistency in brake pedal performance, particularly in manufacturing environments.
Innovation Solution
A method and apparatus that monitor hydraulic system pressure in relation to brake pedal travel and load, using position transducers and load cell transducers to compare data against predefined metrics, providing graphical indicators to guide users in matching target pedal travel and load, and determining if the brake system meets these metrics for consistent performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If subjective assessment methods are used to evaluate brake pedal feel, then the assessment can capture human perception, but the testing process becomes time-consuming and difficult to quantify
Solution Approach 1:
The patent replaces subjective human sensory assessment with objective electronic measurement systems. Position transducers measure pedal displacement, load cells measure applied force, and pressure sensors measure hydraulic pressure. These electronic sensors substitute for human perception, providing quantifiable data that eliminates the time-consuming nature of subjective evaluation while maintaining measurement accuracy.
Solution Approach 2:
The system provides real-time feedback through graphical indicators displayed on a screen. The target indicator shows the desired pedal travel or load, while the measured indicator shows actual performance. This visual feedback loop allows operators to quickly assess whether the brake system meets specifications without time-consuming manual evaluation, enabling rapid iteration and adjustment during testing.
2Reliability
If manual testing methods are used to assess brake pedal behavior, then flexibility in evaluation is maintained, but consistency and repeatability of results deteriorate
Solution Approach 1:
The testing system is divided into distinct functional modules: position transducers for measuring pedal displacement, load cells for measuring applied force, pressure sensors for measuring hydraulic pressure, and a control system for coordinating measurements. This segmentation allows each component to perform its specific function reliably, ensuring consistent and repeatable results while making the overall system manageable despite its complexity.
Solution Approach 2:
The testing apparatus is designed to measure multiple parameters simultaneously (pedal position, load, and hydraulic pressure) using a integrated system. This multi-functionality ensures that all relevant aspects of brake pedal behavior are captured in a single test sequence, improving reliability by capturing complete system behavior without requiring multiple separate manual tests.
3Manufacturing precision
If graphical indicators are displayed to guide brake pedal actuation, then user guidance and precision are improved, but the complexity of the testing system increases
Solution Approach 1:
The system creates a visual copy or representation of the target brake pedal travel or load as a graphical indicator on the display. Instead of requiring complex mechanical guidance mechanisms, the system projects a graphical target that the operator aims to match by actuating the brake pedal. This copying approach simplifies the physical system while maintaining high precision in achieving the target parameters.
Solution Approach 2:
The graphical display acts as an intermediary between the control system and the operator. Rather than the control system directly manipulating the brake mechanism, it provides visual guidance through graphical indicators that mediate the operator's actions. This intermediary layer simplifies the interaction while improving precision, as the graphical feedback makes it easier for the operator to achieve the desired pedal travel or load.
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
This approach allows for objective assessment and quantification of brake pedal feel, reducing testing time and ensuring consistency in brake system behavior, facilitating efficient quality control during vehicle assembly.
Implementation Method 1
The brake pedal travel can be measured by one or more position transducers
Implementation Method 2
The brake pedal load (i.e. the load applied to the pedal) can be measured by a load cell transducer coupled to the brake pedal
Implementation Method 3
a hydraulic system pressure is monitored as the brake pedal is displaced
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present disclosure relates to a method of testing behaviour of a vehicle brake system in dependence on operation of a brake pedal (P). A first graphical indicator (45) is displayed on a display screen (9) to indicate a target brake pedal travel or a target brake pedal load. A second graphical indicator (55) is displayed on the display screen (9) to represent the measured brake pedal travel or the brake pedal load. The brake pedal (P) is displaced at least substantially to match the measured brake pedal travel to the target brake pedal travel or to match the measured brake pedal load to the target brake pedal load. A hydraulic system pressure is monitored as the brake pedal is displaced to determine if the vehicle brake system satisfies one or more predefined metrics. The present disclosure also relates to a test apparatus (1); a pedal measurement apparatus (7); and a method of measuring pedal travel.