Compact Vehicle Pedal with Integrated Sensor Housing
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Solution Overview
Problem
Existing vehicle pedals are not compact or lightweight enough to fit within smaller vehicle floor spaces, and they lack efficient mechanisms for sensing pedal position using compact contacting and non-contacting assemblies.
Innovation Solution
A compact vehicle pedal design featuring a pedal base with a sensor housing and a pivotable pedal arm, utilizing strain gages, Hall Effect sensors, or resistive elements to generate electrical signals for position determination, along with return springs for resetting the pedal arm to its idle position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional vehicle pedal designs are used, then the pedal structure is robust and reliable, but the pedal occupies excessive floor space and has high weight
Solution Approach 1:
The pedal is divided into separate functional modules: pedal arm, pedal base, sensor housing, and mounting bracket. This segmentation allows each component to be optimized independently for size and strength, reducing overall floor space while maintaining structural robustness through precise component design and positioning.
Solution Approach 2:
The sensor housing is positioned in a vertical dimension above the pedal base rather than extending horizontally. This vertical arrangement allows the sensing mechanism to be compact in the floor plane while maintaining adequate sensing capability, effectively moving the sensor function to another spatial dimension.
2Measurement precision
If traditional sensor assemblies are used, then the sensing mechanism is reliable, but the overall pedal size and weight increase
Solution Approach 1:
The patent employs electrical and magnetic sensing mechanisms (strain gages, Hall Effect sensors) instead of traditional mechanical position sensing systems. This substitution eliminates the need for heavy mechanical linkages and components, significantly reducing pedal weight while maintaining or improving position sensing accuracy through electronic detection methods.
Solution Approach 2:
The sensor housing serves multiple functions: it houses the sensing mechanism, provides structural support for the pedal assembly, and acts as a mounting point for the pedal arm. This multi-functionality consolidates several components into one, reducing overall weight while maintaining sensing precision.
3Volume of moving object
If compact sensor assemblies are used, then the pedal fits smaller vehicle spaces, but the sensing mechanism complexity increases
Solution Approach 1:
The sensor housing combines multiple sensing elements (strain gages, Hall Effect sensors, magnets) and structural components into a single integrated assembly. This merging reduces the number of separate parts and simplifies installation while maintaining compact dimensions suitable for smaller vehicle spaces.
Solution Approach 2:
The sensing mechanism is nested within the sensor housing, which itself is mounted on the pedal base. This nested arrangement allows the complex sensing components to be contained within a compact external envelope, fitting smaller vehicle floor spaces while housing the necessary complexity internally.
4Volume of moving object
If the pedal arm is positioned close to the pedal base, then the pedal is compact, but the sensor positioning and calibration become more difficult
Solution Approach 1:
The sensor housing acts as an intermediary component between the pedal arm and the pedal base. It provides a standardized mounting interface that maintains consistent sensor positioning relative to the pedal arm's pivot point, simplifying installation and calibration procedures even when the overall pedal size is reduced.
Solution Approach 2:
The sensor housing is designed with adjustable mounting features that allow precise positioning of the sensing elements. This adjustability compensates for the reduced space between pedal arm and base, enabling proper sensor alignment and calibration while maintaining the compact overall pedal dimensions.
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 design allows for precise position sensing of the pedal arm, enabling efficient operation in smaller vehicle spaces while maintaining compactness and light weight, enhancing the integration of sensing technologies within the pedal mechanism.
Implementation Method 1
the sensor additionally comprises a strain gage located in the sensor housing in the pedal base, a moveable actuator defining the moveable sensor element, the actuator being located between the strain gage and the pedal arm
Implementation Method 2
the sensor additionally comprises a Hall Effect sensor located in the sensor housing in the pedal base, and a moveable magnet defining the moveable sensor element
Implementation Method 3
a bias spring located between the actuator and the pedal arm, the spring including a first end abutting against the actuator and a second opposed end abutted against the pedal arm
Implementation Method 4
a return spring has a first end abutted against the pedal arm and a second opposed end abutted against the pedal base and adapted for returning the pedal arm to an idle position
Data Source
AI summary
A vehicle pedal with a pedal base defining a sensor housing and a pedal arm overlying and spaced from and pivotally coupled to the pedal base. A sensor in the sensor housing includes a sensor element that moves in the direction of the pedal base in response to the movement of the pedal arm to generate an electrical signal used to determine to position of the pedal arm. In one embodiment, the sensor includes a strain gage and the sensor element is an actuator that flexes the strain gage. In another embodiment, the sensor includes a Hall Effect sensor and the sensor element is a magnet whose movement results in a magnetic field change sensed by the Hall Effect sensor. In a further embodiment, the sensor element is a cap with wipers that slide against a resistive element.