Modular Vehicle Pedal Head for Safe Tool-Free Pad Replacement
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Solution Overview
Problem
Existing drive-by-wire systems for vehicle control lack a modular design that allows easy replacement of pedal pads without damaging the sensor housing or applying undefined lever forces, which can lead to misuse and potential damage to sensor arrangements.
Innovation Solution
A modular pedal unit design with a releasable and form-fit/friction-fit connection between the pedal head and the movable housing cover, enabling easy assembly and disassembly without tools, and using a sensor arrangement to detect small stroke movements contactlessly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pedal pad is fixed to the pad support with a strong connection, then the pedal pad remains secure during use, but the pedal pad cannot be easily replaced without damaging the sensor housing or applying undefined lever forces
Solution Approach 1:
The pedal head is divided into separable components: the pedal pad, pad support, and movable housing cover. The fastening arrangement enables the pedal head to be detached from the movable housing cover, allowing the pedal pad to be replaced independently without applying forces to the sensor housing. This segmentation resolves the contradiction by making replacement easy while maintaining secure attachment during normal use.
Solution Approach 2:
The connection between the pedal head and movable housing cover is designed to be dynamically changeable - securely attached during operation but easily releasable when replacement is needed. The fastening arrangement with latching elements provides a dynamic state that transitions from locked (secure attachment) to unlocked (easy removal), resolving the contradiction between security and ease of replacement.
2Ease of repair
If the pedal head is permanently attached to the movable housing cover, then the sensor housing is protected from damage, but the pedal pad cannot be replaced without risking damage to the sensor arrangement
Solution Approach 1:
The pedal head is segmented as a separate, removable component from the movable housing cover that contains the sensor arrangement. This segmentation allows the pedal pad to be replaced by detaching and reattaching the pedal head, eliminating the need to apply forces directly to the sensor housing and thus preventing damage to the sensor arrangement.
Solution Approach 2:
The fastening arrangement acts as an intermediary mechanism between the pedal head and movable housing cover. It provides a controlled interface that allows secure attachment during use but enables easy, tool-free removal when replacement is needed, preventing direct force application to the sensor arrangement while maintaining operational security.
3Ease of operation
If a modular design with releasable connection is used, then easy replacement of pedal pads is enabled, but the device complexity increases
Solution Approach 1:
The pedal head is segmented into modular components (pedal pad, pad support, movable housing cover) connected by a fastening arrangement. While this segmentation enables easy replacement, the fastening arrangement with latching elements adds structural complexity to achieve the releasable connection.
Solution Approach 2:
The fastening arrangement is designed to be self-latching and self-releasing without requiring external tools. The latching elements automatically engage when the pedal head is attached and can be released by simple manual manipulation, reducing the operational complexity despite the increased structural complexity of the modular 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
Facilitates quick, secure, and tool-free assembly of pedal units, reduces carpet cut-out size, and prevents misuse by allowing safe disassembly and replacement of pedal pads without exerting force on the sensor housing, enhancing both functionality and aesthetics.
Implementation Method 1
using a sensor arrangement to detect small stroke movements contactlessly
Implementation Method 2
A fastening arrangement is configured to connect the pad support to the movable housing cover in a releasable and form-fit and/or friction-fit manner
Data Source
AI summary
A pedal unit for controlling a vehicle function has a modularly constructed pedal head which includes a pad support and a replaceable pedal pad for receiving an actuation force of a driver's foot and connected to a small stroke movable housing cover along a vertical direction of the pedal unit. The pedal pad is releasably connected to the pad support. A fastening arrangement is configured to connect the pad support to the movable housing cover in a releasable and form-fit and/or friction-fit manner as well. A method for assembling such a pedal unit and a method for disassembling a pedal head from such a pedal unit is also disclosed.