Pedal Bracket with Nested Sensor and Integral U-Profile
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Solution Overview
Problem
Conventional pedal mechanisms with position sensors have limited angular motion range, inefficient sensor utilization, and increased risk of damage due to sensor protrusion, along with a complex and costly production process.
Innovation Solution
A pedal mechanism with a bracket comprising integral U-profiles and a sensor accommodated within the bracket's structure, providing enhanced protection and a flexible element system for increased angular detection range, combined with a simplified production method using a single piece of sheet material and reduced steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is mounted on the lateral surface of the bracket, then the sensor can detect the pedal position, but the sensor protrudes from the bracket which increases the risk of damage and reduces space utilization
Solution Approach 1:
The sensor is nested within the bracket structure by positioning it in the space between the first and second U-profiles. The sensor is at least partially received within the bracket, with its projection overlapping the pedal projection, effectively hiding the sensor within the bracket's structural space rather than mounting it externally.
Solution Approach 2:
The sensor is repositioned from a lateral surface mounting to a position within the bracket's internal space, utilizing the depth dimension created by the difference in base widths between the first and second U-profiles. This dimensional repositioning allows the sensor to be protected while maintaining detection functionality.
2Measurement precision
If the sensor is located on the rotational axis of the pedal, then the sensor can detect pedal position, but the angular motion range is limited to the pedal's rotation range which reduces measurement resolution
Solution Approach 1:
The system is segmented into two rotational components: the pedal's limited angular rotation for mechanical operation, and the sensor's extended rotational range achieved through the lever's larger arc movement. This segmentation allows the sensor to utilize a broader angular range than the pedal's direct rotation, improving measurement resolution.
Solution Approach 2:
The sensor detection range is extended by introducing a lever that converts the pedal's limited rotation into a larger angular sweep. The sensor rotates through a greater angle than the pedal's direct rotation, effectively utilizing the lever's mechanical advantage to expand the measurement range in the angular dimension.
3Ease of manufacture
If the bracket is made by combining separate parts for holding the pedal and sensor, then the bracket can be manufactured, but the production process requires three separate steps which increases labor and time cost
Solution Approach 1:
The bracket is designed as a single integrated piece formed from one continuous sheet material. The first and second U-profiles are integral with each other, eliminating the need to separately manufacture and assemble multiple bracket components. This merging of previously separate parts into a single monolithic structure reduces production steps and improves manufacturing efficiency.
Solution Approach 2:
The single sheet material bracket performs multiple functions simultaneously: it provides the first U-profile for pedal mounting, the second U-profile for sensor accommodation, and the structural framework for the entire assembly. This multi-functional design eliminates the need for separate specialized components, streamlining production.
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The present invention proposes a pedal mechanism comprising a pedal (1) for holding the pedal, a bracket (2) and a sensor (7) for sensing the position of the pedal, wherein the bracket (2) comprises a first U-profile with a base width of W1, and a second U-profile with a base width of W2, where W2 is greater than W1; the first U-profile (U1) and the second U-profile (U2) are integral with each other and are made from a single piece of a sheet material; and - the sensor (7) is attached to the first U-profile (U1). Also a bracket production method is proposed.