Inductive Pedal Sensor Layout for Accurate Short-Stroke Detection
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Solution Overview
Problem
Existing sensors for vehicle pedals, particularly those with short-stroke movements, face challenges such as limited accuracy, sensitivity, robustness, and flexibility, as well as difficulties in miniaturization and meeting stringent safety and interference immunity requirements.
Innovation Solution
A sensor design featuring a first and second wing structure, a sensor circuit board, and a sleeve that connects the wing structures, allowing for detection of short-stroke movements. The sensor circuit board is positioned between the wing structures and is stationary, while the wing structures and sleeve move relative to it, enabling precise measurement of short strokes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If known sensors are designed for large stroke (approximately 60 mm), then the sensor can detect larger movements, but the sensor cannot achieve accurate detection for short strokes (less than 10 mm)
Solution Approach 1:
The sensor is divided into separate functional modules: a sensor circuit board for detection, a first wing structure, a second wing structure, and a sleeve. This segmentation allows the sensor to be optimized for short-stroke detection while maintaining modularity and flexibility for different applications.
Solution Approach 2:
The patent transitions from angular measurement to linear path measurement by positioning the sensor circuit board between two wing structures that move linearly relative to each other. This dimensional change enables accurate detection of short linear strokes (less than 10 mm) rather than rotational angles.
2Volume of moving object
If sensors are miniaturized for short stroke detection, then the sensor size is reduced, but mechanical tolerances become very exacting and difficult to manufacture
Solution Approach 1:
The sensor design uses universal components that can serve multiple functions. The sleeve both connects the wing structures and provides guiding functionality. The sensor circuit board serves as both the detection element and the structural base. This multi-functionality reduces the number of separate precision components needed.
Solution Approach 2:
The sleeve acts as an intermediary component that mediates between the first and second wing structures. It provides the guiding function and mechanical connection while allowing relative linear movement, thereby reducing the need for extremely precise direct mating between the wing structures and sensor board.
3Measurement precision
If specialized sensor circuit boards are designed for specific applications (angular or path measurement), then the sensor performance for that application is optimized, but the components cannot be modularly exchanged and flexibility is reduced
Solution Approach 1:
The sensor circuit board is designed with universal mounting features and standardized interfaces that allow it to be used in different configurations. The same basic circuit board design can serve angular measurement, linear path measurement, or other sensing applications by simply changing the wing structure attachments, enabling modular exchangeability while maintaining application-specific optimization.
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 achieves improved accuracy, robustness, and cost-effectiveness for short-stroke sensors, allowing for precise detection of pedal movements with minimal installation space and weight, while also enhancing resistance to interference and misalignment.
Implementation Method 1
sensor-based detection of a movement of the first wing structure and/or second wing structure
Data Source
AI summary
A sensor for detecting a short-stroke movement, in particular for a pedal of a vehicle. The sensor has a first wing structure. A second wing structure is spaced apart from the first wing structure along a stroke direction. A sensor circuit board is provided for sensor-based detection of a movement of the first wing structure and/or second wing structure, the sensor circuit board being situated between the first wing structure and the second wing structure. A sleeve connects the first wing structure and the second wing structure, the sleeve being situated so that it is movable with respect to the sensor circuit board.