Electronic Throttle Control Rack and Pinion Integration
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Solution Overview
Problem
Current electronic throttle control (ETC) systems face challenges in packaging size, cost, complexity, and longevity, particularly in vehicles where operator controls are integrated with the throttle mechanism, requiring a compact, cost-effective, and reliable solution that provides precise control and user feedback.
Innovation Solution
The ETC assembly incorporates a rack and pinion gear mechanism with compression springs that provide a safe return force and adjustable haptic feedback, allowing for a compact design that integrates auxiliary controls and electronics, reducing component count and simplifying the supply chain, while enabling customizable resistive forces and reduced wear compared to cam interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional ETC packaging is used, then the system is simple to manufacture, but the package size is large and aesthetics are compromised
Solution Approach 1:
The patent combines the ETC assembly with auxiliary vehicle controls into a single integrated housing structure. The operator controls are positioned on the housing of the ETC packaging, merging multiple functions into one compact unit that reduces overall package size while maintaining manufacturability
Solution Approach 2:
The housing structure serves multiple functions: it encloses the ETC sensor assembly, provides mounting for auxiliary operator controls, and acts as the structural interface with the handle bar. This multi-functionality reduces the need for separate components and packaging elements
2Adaptability or versatility
If more operator controls are added near the throttle, then control accessibility is improved, but device complexity increases
Solution Approach 1:
Multiple operator controls are integrated into the single ETC housing structure, allowing higher quantity of controls to be reachable by the operator while their hand is on the throttle control. This merging approach provides versatile control accessibility without proportionally increasing overall device complexity
Solution Approach 2:
The housing structure is designed to accommodate multiple types of operator controls (buttons, switches, dials) in addition to the throttle mechanism itself, creating a universal control hub that maximizes functionality within a single integrated unit
3Reliability
If a rack and pinion gear with compression springs is used, then haptic feedback and reliability are improved, but manufacturing precision requirements increase
Solution Approach 1:
Compression springs are incorporated into the rack and pinion gear mechanism to provide beforehand cushioning and controlled resistance during throttle operation. The springs are positioned to engage with the gear teeth, providing smooth haptic feedback and ensuring a safe return force to the closed throttle position, thereby improving reliability while managing precision requirements through elastic compliance
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 solution enables a more compact, cost-effective, and aesthetically pleasing ETC system with improved user feedback and reduced wear, allowing for a higher quantity of accessible controls and easier customization, while maintaining reliability and precision in throttle control.
Implementation Method 1
compression springs that provide a safe return force
Implementation Method 2
compression springs that provide a safe return force and adjustable haptic feedback
Implementation Method 3
rack and pinion gear mechanism
Implementation Method 4
rack and pinion gear mechanism with compression springs
Data Source
AI summary
An electronic throttle control assembly for a vehicle has a housing that mounts to a handlebar of the vehicle and defines an interior. A rack gear is mounted in the interior for movement in a linear, translational, and/or radial direction. A pinion gear within the interior moves the rack gear upon rotation of the pinion gear. A sensor target is coupled to the rack gear. A sensor detects a position of the sensor target and generates an electric signal for a vehicle control unit. A grip is coupled to the pinion gear, rotation of the grip moving the rack gear and sensor target in a linear, translational, and/or radial direction, the electric signal varying based on the change in position of the sensor target. Opposing springs within the housing resist movement of the rack gear and rest in a normally preloaded state.