Multi-Spring Brake Pedal Emulator for Realistic Brake-by-Wire Feedback
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Solution Overview
Problem
Brake-by-wire systems lack the tactile feedback that drivers are accustomed to in conventional brake systems, necessitating a reliable, compact, and cost-effective pedal emulator that replicates the feel of a mechanical brake pedal.
Innovation Solution
A brake pedal emulator system featuring multiple spring sets arranged along the pedal arm, providing variable feedback through different stages of actuation, including a friction device and position sensors for precise feedback and position tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake-by-wire systems are used, then system reliability and control precision are improved, but tactile feedback and driver familiarity are lost
Solution Approach 1:
A pedal emulator mechanism is introduced as an intermediary component between the brake pedal and the brake-by-wire system. This emulator includes springs and friction devices that mechanically replicate the tactile feedback and resistance characteristics of conventional brake systems, allowing drivers to maintain familiar tactile interaction while the underlying brake-by-wire system provides enhanced reliability and control precision.
Solution Approach 2:
The brake system is segmented into distinct functional components: the pedal emulator mechanism that handles tactile feedback, the sensor system that monitors pedal position, and the electronic control unit that manages brake actuation. This segmentation allows each component to optimize its specific function while working together as an integrated system.
2Ease of operation
If multiple spring sets are added to provide variable feedback, then tactile realism is improved, but device complexity increases
Solution Approach 1:
The spring system is segmented into multiple sets positioned at different locations along the pedal arm, with each spring set becoming engaged at specific points during pedal travel. This segmentation allows variable feedback characteristics throughout the pedal stroke while maintaining a modular structure that manages complexity through functional zoning.
Solution Approach 2:
The pedal emulator employs dynamic engagement of different spring sets based on pedal position. As the pedal moves through its range of motion, different spring sets are sequentially engaged or disengaged, providing dynamically varying tactile feedback that mimics the nonlinear characteristics of conventional brake systems while adapting to the operator's input stage.
3Measurement precision
If precise position tracking sensors are implemented, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The system replaces complex mechanical position sensing mechanisms with electronic sensors that provide precise pedal position tracking. This substitution enables accurate measurement of pedal travel and force application while reducing mechanical complexity and potentially lowering manufacturing costs through the use of solid-state sensing technologies.
Solution Approach 2:
Position sensors provide continuous feedback information about pedal position and travel distance to the control system. This feedback enables the system to accurately determine the operator's braking intent and adjust the brake-by-wire actuation accordingly, achieving precise measurement and control while maintaining cost-effectiveness through intelligent sensor utilization.
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 system effectively replicates the feel of a conventional brake pedal, offering variable operator feedback and precise position tracking, enhancing driver experience and system reliability.
Implementation Method 1
a first spring set engaged with the pedal arm at the unactuated position and operable to bias the pedal arm toward the unactuated position
Implementation Method 2
a friction device engaged with the first spring set for generating a resistance force against movement of the pedal, both toward and away from the unactuated position, through friction contact therewith
Data Source
AI summary
Examples provide a brake pedal assembly including a pedal housing, a bracket for securement within a vehicle, and a pedal arm having a proximal portion pivotally supported by the pedal housing and a distal portion including a foot pad spaced from the bracket. The pedal arm pivots from an unactuated position to a fully actuated position in response to application of a force to the foot pad. A pedal emulator system provides variable operator feedback as the pedal arm pivots in response to the application of force. The pedal emulator system includes a first spring set engaged with the pedal arm at the unactuated position and operable to bias the pedal arm toward the unactuated position, and a second spring set engaged with the pedal arm only after the pedal arm pivots from the unactuated position to a first intercept position between the unactuated and fully actuated positions.