Passive Pedal Force Emulator Assembly for E-Boost Brake Feedback
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Solution Overview
Problem
The increasing reliance on e-boost braking systems reduces the need for mechanical braking by operators, necessitating a passive force emulator to provide haptic feedback in pedal assemblies, as the mechanical resistance and hysteresis in traditional braking systems are no longer sufficient.
Innovation Solution
A pedal assembly with an emulator assembly that includes a housing, a pedal arm, an elongated member, a carrier, and compressible members, where the elongated member moves the carrier towards compressible members to generate force feedback, simulating the resistance of a hydraulic braking system, with distinct force vs travel sections to mimic the feel of different braking conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If e-boost braking systems are used to provide active braking force, then braking power and control precision are improved, but mechanical resistance and haptic feedback to the operator are reduced
Solution Approach 1:
A passive force emulator assembly is introduced as an intermediary mechanical component between the pedal and the e-boost system. This emulator includes compressible members (springs) that provide mechanical resistance and haptic feedback to the operator's foot, while the e-boost system independently provides the actual braking force through electronic actuation. The emulator thus mediates the tactile feedback without interfering with the active braking power.
Solution Approach 2:
The force emulator creates a simplified mechanical copy of traditional hydraulic braking system characteristics. By using compressible members that resist pedal depression, it replicates the feel and haptic feedback of hydraulic systems, allowing operators to maintain familiar braking sensations even though the actual braking function is performed by the electronic system.
2Ease of operation
If passive force emulator is added to provide haptic feedback, then operator feedback and realism are improved, but device complexity increases
Solution Approach 1:
The braking system is segmented into two independent functional modules: the passive force emulator assembly that handles haptic feedback, and the e-boost system that handles active braking. The emulator assembly itself is further segmented into distinct components including a housing, pedal arm, elongated member, carrier, and compressible members. This segmentation allows each component to perform its specific function independently, simplifying the overall system architecture despite the added complexity of the emulator.
Solution Approach 2:
The force emulator is designed as a passive, self-contained mechanical system that automatically provides haptic feedback without requiring external power or control systems. The compressible members inherently generate resistance forces based on their mechanical properties, eliminating the need for additional sensors, actuators, or control electronics to create the feedback effect.
3Manufacturing precision
If multiple compressible members with different stiffness are used, then force feedback differentiation and realism are improved, but manufacturing complexity increases
Solution Approach 1:
Different compressible members within the emulator assembly are assigned different local qualities in terms of stiffness and compression characteristics. The first compressible member has a first stiffness characteristic while the second compressible member has a second stiffness characteristic, allowing the system to provide differentiated haptic feedback for different braking conditions. Each compressible member is optimized for its specific function within the overall braking feedback profile.
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 emulator assembly provides a realistic haptic feedback to the driver, simulating the resistance and hysteresis of a hydraulic braking system, ensuring the driver feels distinct resistance based on pedal depression speed, enhancing the braking experience in e-boost systems.
Implementation Method 1
the compressible member is positioned in the space between the carrier and the end plate to be in contact with the carrier and the end plate. When the pedal pad is depressed, the elongated member moves the carrier in a direction towards the end plate which drives the carrier into the compressible member such that the compressible material compresses to generate a force feedback
Implementation Method 2
linear passive force emulators for pedal assemblies with a mechanical resistance for damping and hysteresis dependent on a pedal movement
Data Source
AI summary
Embodiments herein are directed to an emulator assembly. The assembly includes a housing with a cavity, a pedal arm, an elongated member, a carrier, an end plate and a compressible member. The pedal arm is at least partially received in the cavity and has a pedal pad on one end. The elongated member extends and couples to the pedal arm on one end and couples to a carrier on an opposite other end. The end plate is spaced apart from the carrier. The compressible member is positioned in the space between the carrier and the end plate. When the pedal pad is depressed, the elongated member moves the carrier in a direction towards the end plate which drives the carrier into the compressible member such that the compressible material compresses to generate a force feedback onto a foot positioned on the pedal pad.