Vehicle Kick-Down Element Roller Actuator Travel Path
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Solution Overview
Problem
Existing kick-down elements for vehicles with automatic transmission often have limited actuator travel paths, which restrict the pedal's full throttle range, necessitating a more compact design that allows for a longer travel path without compromising structural integrity or operational safety.
Innovation Solution
A compact kick-down element design featuring a roller attached to the actuator's lower end, with symmetrical loading, adjustable wedge angles, and a coil spring for customizable force steps, along with a mandrel for precise alignment and ribs for secure housing, enabling a 0 mm to 12 mm movement range and preventing jamming or tipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a compact design is used for the kick-down element, then the device size is reduced, but the actuator travel path is limited
Solution Approach 1:
The patent repositions the roller from a side-mounted configuration to the lower end of the actuator, utilizing the vertical dimension more effectively. This dimensional change allows the actuator to achieve a longer travel path (0-12mm) within a compact housing volume, resolving the contradiction between device size and travel path length.
Solution Approach 2:
The actuator is nested within the housing such that it can move axially along the longitudinal axis, with the roller positioned at the lower end. This nested arrangement maximizes the use of internal space, allowing sufficient travel path while maintaining a compact overall device volume.
2Device complexity
If asymmetrical loading is applied to the kick-down element, then the structure is simpler, but parts may jam and service life is reduced
Solution Approach 1:
The patent employs two rollers positioned symmetrically at the lower end of the actuator, creating symmetrical loading conditions. This symmetrical arrangement distributes forces evenly, preventing jamming and extending service life, while the overall structure remains relatively simple.
3Ease of manufacture
If a fixed wedge angle is used in the force step element, then the manufacturing is simpler, but friction is increased and operational safety is reduced
Solution Approach 1:
The force step element incorporates a wedge-shaped extension with adjustable wedge angles, allowing the angle to be optimized for different operating conditions. This dynamic adjustability reduces friction during actuator movement while maintaining manufacturing feasibility through standardized components.
4Adaptability or versatility
If the elastic element is not precisely aligned, then the assembly is more flexible, but the elastic force becomes inconsistent and the element may kink
Solution Approach 1:
The patent introduces a mandrel as an intermediary component that precisely aligns the elastic element (coil spring) during assembly. The mandrel ensures the spring remains centered and prevents kinking, maintaining consistent elastic force while allowing assembly flexibility through the removable mandrel design.
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 a versatile, long actuator travel path, enhanced operational safety, reduced friction, and customizable force steps, ensuring reliable and extended service life while maintaining precise elastic force and preventing double force steps.
Implementation Method 1
an elastic element (10), in this case a coil spring, which can be pressed together in the longitudinal direction of the kick-down element
Implementation Method 2
the elasticity of coil springs remains constant over the long term
Implementation Method 3
reduced friction during operation
Data Source
AI summary
A kick-down element for a vehicle, complete with a housing, an actuator that is fastened in the housing such that it can be moved axially and a force surge element that can be moved axially in the actuator and which is axially loaded by an elastic element. There is a plate-shaped protruding part on at least one housing panel, which runs perpendicular to the movement direction and the upper end of which runs diagonally downward. The force step element interacts with at least one roller, which is located between the protruding part and a wedgeshaped (9) of the force surge element in a resting position. The kick-down element is intended to allow for a relatively long travel path for the actuator in the most compact design possible. This is achieved by keeping the roller attached to a lower end of the actuator.