Coil-Spring Pedal Force Emulator for e-Boost Brake Feedback
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Solution Overview
Problem
The transition from mechanical to e-boost braking systems in vehicles has reduced the need for mechanical braking by operators, necessitating a passive force emulator to provide haptic feedback during pedal deployment.
Innovation Solution
A pedal assembly incorporating a housing with cradles and springs that generate force feedback through compression energy, simulating the resistance felt in conventional hydraulic braking systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If e-boost braking system is used to provide active force, then braking efficiency is improved, but operator haptic feedback is lost
Solution Approach 1:
A passive force emulator assembly is introduced as an intermediary mechanical component between the operator and the e-boost braking system. This emulator uses spring elements to generate resistive force that mimics the feel of traditional hydraulic braking, allowing the operator to receive haptic feedback while the electronic system handles the actual braking power generation.
Solution Approach 2:
The passive force emulator creates a simplified mechanical copy of the traditional hydraulic braking feedback mechanism. By using springs to replicate the resistive force characteristics of hydraulic systems, the operator experiences a familiar tactile sensation without requiring the complex hydraulic infrastructure.
2Ease of operation
If passive force emulator is added to e-boost system, then operator haptic feedback is restored, but device complexity increases
Solution Approach 1:
The braking system is segmented into two independent functional modules: the electronic boost system for power generation and the passive force emulator for feedback provision. This segmentation allows each subsystem to be optimized independently and simplifies the overall control architecture, as the emulator operates autonomously without requiring electronic control.
Solution Approach 2:
The passive force emulator is a self-contained mechanical system that automatically generates resistive force through spring compression based on pedal displacement. It requires no external power source, control electronics, or active regulation, thereby adding minimal complexity to the overall system while reliably providing haptic feedback.
3Reliability
If multiple springs are used in series, then force feedback realism is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple spring elements are arranged in a nested configuration where inner springs are positioned within outer springs. This nested arrangement allows all spring elements to be housed within a compact cylindrical space, simplifying the housing design and reducing the overall footprint of the emulator assembly while maintaining the progressive force feedback characteristics.
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 assembly provides a realistic braking sensation by generating varying force feedback based on applied loads, ensuring a robust and reliable braking experience.
Implementation Method 1
at least a compression energy by the first pair of springs generates a first force feedback onto the pedal arm
Data Source
AI summary
The present disclosure is directed to a pedal assembly that includes a pedal arm configured to move based on a load applied thereon and a housing that includes a first housing member having a first cavity and a pushrod operably connected to the pedal arm and to the first housing member. A first cradle positioned within the first cavity. The first cradle includes a second cavity. A first pair of springs positioned to extend within the second cavity. A second housing member having a third cavity. A second pair of springs positioned to extend within the second cavity and the third cavity. When a first predetermined load is applied to the pedal arm, the pushrod moves which drives the first cradle against the first pair of springs such that at least a compression energy by the first pair of springs generates a first force feedback onto the pedal arm.