Vehicle Pedal Arm Break Detection Using an Integrated Conductor Loop

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Solution Overview

Problem

Existing brake pedals made of plastic are prone to undetectable partial breakage, which can lead to failure during strong braking, posing a safety risk due to undetected loss of braking functionality.

Innovation Solution

Incorporating a first electrical conductor loop into the pedal arm, which is guided from the holder to the footplate and back, allowing for detection of breakage by interrupting the current flow, and combining it with an inductive rotation angle sensor to determine the pivot angle and generate a signal for breakage detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a pedal arm made from plastic is used, then weight is reduced and manufacturing cost is lowered, but the risk of undetectable partial breakage increases

Engineering Contradiction:

Improvepedal arm weightVSAvoidbreakage detection capability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent replaces mechanical breakage detection with an electrical detection system. A conductor loop is integrated into the pedal arm structure, and its electrical continuity is monitored to detect breakages. This substitution allows plastic pedal arms to be used while providing reliable breakage detection through electrical means rather than mechanical indicators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductor loop serves multiple functions: it is part of the electrical system of the pedal and simultaneously acts as a sensor for detecting pedal arm breakage. This multi-functionality allows the detection system to be integrated without adding separate components, maintaining the weight advantages of plastic construction while enabling reliable monitoring.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a pedal arm made from metal is used, then breakage resistance is improved, but weight increases and manufacturing cost rises

Engineering Contradiction:

Improvebreakage resistanceVSAvoidpedal arm weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces the need for metal construction with an electrical detection system integrated into the plastic pedal arm. The conductor loop embedded in or attached to the plastic structure provides breakage detection capability, eliminating the requirement for metal pedal arms while maintaining safety through electrical monitoring of structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a conductor loop is integrated into the pedal arm, then breakage detection capability is improved, but device complexity increases

Engineering Contradiction:

Improvebreakage detection capabilityVSAvoiddetector system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the conductor loop with the pedal arm structure itself, either by embedding it during molding or by integrating it as a structural component. This merging eliminates the need for separate detection hardware and reduces system complexity by making the electrical conductor serve dual purposes: electrical function and structural integrity sensing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductor loop is designed to serve multiple functions simultaneously: it is part of the electrical circuitry of the pedal and acts as a sensor for detecting structural breakage. This multi-functionality reduces the need for additional components and simplifies the overall system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables detection of both complete and partial breakage of the pedal arm, ensuring safety by preventing undetected failures and maintaining braking functionality.

Implementation Method 1

a first electrical conductor loop, which is guided at least from a region adjacent to the holder to a region adjacent to the pedal plate, and from there back to the region adjacent to the holder. A breakage of the pedal arm also results in a breakage of the conductor, which is electrically detectable.

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

combining it with an inductive rotation angle sensor to determine the pivot angle and generate a signal for breakage detection

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12429897B2Motor vehicle pedal with a detector for detecting a pedal arm breakage

Publication Date: 2025.09.30 HELLA GMBH & CO KGAA

AI summary

A motor vehicle pedal comprising a footplate and a pedal arm to which the footplate is attached. A holder is provided on which the pedal arm is pivotably mounted. The motor vehicle pedal has a detector to detect a pedal arm break. The detector has a first electrical conductor loop that is guided from at least one region of the pedal arm adjacent to the holder to a region of the pedal arm adjacent to the pedal plate and from there back to the region of the pedal arm adjacent to the holder.