Modular Non-linear Spring System for Brake Pedal Feel
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Solution Overview
Problem
Advanced vehicle braking systems, such as electro-hydraulic systems, lack the traditional brake pedal feel experienced in hydraulic systems, and existing pedal feel simulator devices are complex and difficult to customize.
Innovation Solution
A modular non-linear spring system that simulates the traditional brake pedal feel by using a combination of mechanical springs with varying properties and spacers, allowing for sequential compression to provide a progressively increasing pedal force, which can be easily customized for different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electro-hydraulic braking systems are used, then braking control precision is improved, but brake pedal feel is degraded
Solution Approach 1:
A mechanical spring system is introduced as an intermediary component between the brake pedal and the electro-hydraulic control system. This spring system provides progressive mechanical resistance that simulates traditional hydraulic brake pedal feel, while the electro-hydraulic system separately provides precise digital control. The intermediary spring mechanism bridges the gap between digital control precision and analog tactile feedback.
2Ease of operation
If traditional hydraulic braking systems are used, then brake pedal feel is maintained, but braking control precision is reduced
Solution Approach 1:
The braking system is segmented into two independent functional components: a mechanical spring system that provides progressive resistance for realistic pedal feel, and an electro-hydraulic control system that provides precise digital control. This segmentation allows each component to optimize its specific function without compromising the other.
3Ease of operation
If complex pedal feel simulator devices are used, then brake pedal feel is improved, but device complexity is increased
Solution Approach 1:
The spring system uses progressive spring rates with varying stiffness parameters along the compression stroke to create realistic brake pedal feel. By carefully selecting and arranging springs with different rate parameters, the system achieves complex nonlinear force-displacement characteristics using simple mechanical components rather than complex active control systems.
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 modular non-linear spring system effectively replicates the traditional brake pedal feel in both hydraulic and electro-hydraulic braking systems, offering adjustable and customizable options for various driving styles, enhancing the braking experience.
Implementation Method 1
a first spring in abutting engagement with the first spacer, a second spring in abutting engagement with the first spacer, and wherein the first and second springs are sequentially compressible whereby compression of one or more of the mechanical springs in said modular non-linear spring system provides a non-linear, progressively increasing mechanical spring force
Data Source
AI summary
A modular non-linear spring system capable of simulating traditional brake pedal feel when incorporated into a hydraulic and/or electro-hydraulic vehicle braking system. The system can include a first spacer having a top surface and a bottom surface and an optional second spacer having a top surface and a bottom surface. In one arrangement, a first mechanical spring is in abutting engagement with the top surface of said first spacer, a second mechanical spring is in abutting engagement with the bottom surface of said first spacer and the top surface of said second spacer, and an optional third mechanical spring is in abutting engagement with the bottom surface of said second spacer. The springs are arranged to be progressively compressed using a brake pedal of the braking system.