Mechanical Pedal Emulator With Nonlinear Counterforce Feedback

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Solution Overview

Problem

Existing pedal emulators for vehicles, such as brake-by-wire systems, lack a compact and simple design, often requiring complex hydraulic or pneumatic systems that involve handling fluids, which is costly and problematic.

Innovation Solution

A pedal emulator utilizing solely mechanical means, including springs and levers, to generate a non-linear counterforce progression along the pedal travel, allowing for a flexible and modular design without the need for hydraulic or pneumatic systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If hydraulic or pneumatic systems are used in pedal emulators, then force generation capability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecounterforce generation capabilityVSAvoidsystem complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent replaces hydraulic or pneumatic systems with a purely mechanical force generation unit comprising springs and levers. The first and second springs provide elastic forces that are transmitted through levers to generate the required counterforce on the pedal lever, eliminating the need for fluid-based systems while maintaining force generation capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The force generation unit is divided into separate functional components: a first spring for initial force generation, a second spring for additional force support, and levers for force transmission. This segmentation allows each component to be optimized independently and simplifies the overall system architecture compared to integrated hydraulic systems.

Inventive Principle:

Principle #1Segmentation

2Force

If hydraulic or pneumatic systems are used in pedal emulators, then force generation capability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecounterforce generation capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent employs standard, commercially available springs and levers that are inexpensive to manufacture and replace. These mechanical components can be produced using conventional manufacturing processes without requiring specialized equipment or materials needed for hydraulic systems, significantly reducing manufacturing costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

By substituting expensive hydraulic or pneumatic systems with simple mechanical springs and levers, the patent eliminates the need for fluid handling infrastructure, seals, hoses, and associated safety systems, thereby dramatically reducing both manufacturing complexity and cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If hydraulic or pneumatic systems are used in pedal emulators, then force progression control is improved, but handling of fluids becomes problematic

Engineering Contradiction:

Improveforce progression controlVSAvoidfluid handling problems

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces fluid-based force progression control with a mechanical system using springs and levers. The non-linear force progression is achieved through the geometric arrangement of levers and the characteristics of springs, eliminating all fluid handling issues while maintaining adaptability in force progression control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical means automatically generate and regulate the counterforce progression without requiring external fluid supply systems, pressure regulators, or fluid management infrastructure. The springs and levers self-regulate the force output based on pedal lever position, providing adaptive control without the complexity of fluid handling.

Inventive Principle:

Principle #25Self-service

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 mechanical design provides a compact, simple, and adaptable solution for simulating the haptic feedback of a conventional pedal, reducing complexity and costs associated with fluid handling while enabling flexible force progression and modular integration.

Implementation Method 1

the plurality of mechanical means features at least one spring

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11999337B2Pedal emulator for a vehicle

Publication Date: 2024.06.04 HELLA GMBH & CO KGAA

AI summary

A pedal emulator for a vehicle is provided comprising a base part for mounting the pedal emulator to a structure of the vehicle. A pedal lever is pivotable around a rotary axis of the base part. A force generation unit exerts a counterforce on the pedal lever by means of at least one coupling element for mechanically coupling the force generation unit with the pedal lever. The counterforce works counter to an actuating force exerted on the pedal lever. The force generation unit and the coupling element are designed and arranged in such a way that a progression of the counterforce along a pedal travel of the pedal lever (6) takes the form of a non-linear progression in a pedal travel-counterforce diagram.