Pedal Actuator Fixing Device Eliminating Play and Noise
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Solution Overview
Problem
Existing fixing devices for actuator elements in motor vehicle pedals suffer from play and noise issues due to manufacturing tolerances, leading to dead travel effects and unwanted sounds during pedal operation.
Innovation Solution
The fixing device incorporates a connector with pressure means that press the actuator element into a locking position, ensuring a rigid and immediate force transmission between the actuator element and the pedal lever, eliminating play and noise by utilizing a connector with varying arm rigidity and design features like pressure arms and retaining arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a connector with elastic means is used to assure play-free fit, then noise and tapping sounds are eliminated, but excessive play occurs between the actuator element and retaining means due to manufacturing tolerances
Solution Approach 1:
The patent changes the physical state of the connector by introducing a thermoplastic material that transitions from a rigid state during assembly to a flexible state after cooling. This parameter change allows the connector to adapt to manufacturing tolerances while maintaining play-free operation. The thermoplastic material is heated above its glass transition temperature to become pliable for insertion, then cools to provide consistent retention force.
Solution Approach 2:
The patent uses a composite structure combining a rigid housing with a thermoplastic connector portion. This composite material approach allows different regions of the connector to have different mechanical properties - the rigid housing provides structural support while the thermoplastic portion provides flexible retention, resolving the contradiction between rigidity and adaptability to tolerances.
2Reliability
If manufacturing tolerances are reduced to eliminate play, then dead travel effect is eliminated, but device complexity and manufacturing cost increase
Solution Approach 1:
The thermoplastic material's temperature-dependent properties allow the system to achieve play-free connection without tight manufacturing tolerances. By controlling the thermal state during assembly, the connector becomes sufficiently pliable to accommodate normal tolerances, then solidifies to eliminate play during operation.
Solution Approach 2:
The thermoplastic connector self-adjusts to eliminate play through its thermal properties. During assembly, heating makes it pliable for insertion; during operation, cooling provides the retention force needed to eliminate dead travel. This self-adjusting mechanism eliminates the need for complex adjustment mechanisms or extremely tight tolerances.
3Reliability
If a rigid connector is used to ensure permanent contact, then dead travel effect is eliminated, but the connector cannot adapt to manufacturing tolerances
Solution Approach 1:
The patent employs parameter changes by utilizing the thermoplastic material's glass transition temperature. Above this temperature, the material is pliable and adapts to manufacturing variations; below this temperature, it becomes rigid to ensure permanent contact. This dynamic parameter change resolves the contradiction between rigidity and manufacturability.
Solution Approach 2:
The connector transitions from a static rigid structure to a dynamic system that changes its mechanical properties based on temperature. This dynamics allows the connector to be soft during assembly (accommodating tolerances) and rigid during operation (ensuring permanent contact), eliminating the need for perfectly rigid components.
Data Source
AI summary
Fixing device for fixing an actuator element (20) to a pedal comprising a lever, the actuator element (20) comprising an end (21), the actuator element (20) transmitting an actuation force applied on the lever, the fixing device (100) comprising a housing (60) fixed to the lever and a connector (30), the connector (30) comprising retaining means (40) retaining the end (21) of the actuator element (20) in a locking position, in a space (36) formed between the inside of the connector (30) and the housing (60). The connector (30) comprises pressure means (50) interfering with the space (36), pressing the end (21) of the actuator element (20) in the locking position, and assuring permanent and rigid transmission of the actuation force between the end (21) of the actuator element (20) and the lever.