Pedal Feel Emulator Assembly with Nested Piston and Elastic Members
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Solution Overview
Problem
Electronic brake systems lack a realistic pedal feel due to the absence of hydraulic pressure, leading to operator disorientation, and existing pedal feel emulators face challenges in compactness, assembly ease, and thermal stability.
Innovation Solution
A pedal feel emulator assembly with a housing, multiple pistons, and elastic members arranged in series and parallel configurations to provide three stages of compression, allowing for flexible tuning and overcoming thermal instability, simulating the feedback characteristics of traditional brake systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pedal feel emulator is constructed with multiple elastic members in series and parallel configurations, then the device provides three stages of compression with flexible tuning capability, but the device complexity increases
Solution Approach 1:
The emulator assembly is segmented into multiple elastic members (first elastic member, second elastic member, third elastic member) arranged in series and parallel configurations. Each elastic member can be independently tuned to provide different compression stages, enabling flexible pedal feel adjustment while maintaining a modular structure that manages complexity through functional decomposition
Solution Approach 2:
Different elastic members are positioned at specific locations within the housing to create localized compression zones. The first elastic member is positioned to provide initial compression, the second elastic member provides intermediate compression, and the third elastic member provides final compression. This local differentiation of properties allows tailored pedal feel characteristics across different compression stages
2Volume of moving object
If a compact pedal feel emulator assembly is designed, then the volume is reduced, but the assembly ease and manufacturing precision may be compromised
Solution Approach 1:
The emulator assembly employs a nested configuration where the first piston is disposed within the housing, the second piston is disposed within the first piston, and elastic members are nested between these pistons and the housing walls. This nesting arrangement achieves compact volume by utilizing internal spaces efficiently, while the modular nested structure facilitates assembly by allowing components to be installed in a systematic sequence
Solution Approach 2:
Multiple functional elements are merged into a single integrated assembly. The housing simultaneously serves as the outer container, the mounting structure for elastic members, and the fluid communication pathway. The pistons combine multiple functions: they transmit force, define fluid pathways, and provide mounting surfaces for elastic members. This merging reduces the number of separate components, decreasing overall volume while simplifying assembly
3Ease of manufacture
If an elastomer-only design is used for the pedal feel emulator, then the device is simpler to manufacture, but thermal instability issues occur causing fluctuation in spring constant
Solution Approach 1:
The emulator assembly uses multiple elastic members that can be made from different materials with complementary properties. While elastomers provide good manufacturing simplicity and elasticity, they can be combined with metal springs or other temperature-stable elastic materials. This composite approach maintains ease of manufacture through established elastomer molding processes while compensating for thermal instability by using materials that maintain consistent spring constants across temperature variations
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 solution provides a compact, easy-to-assemble pedal feel emulator that effectively simulates the feedback of traditional brake systems, enhancing operator control and stability by incorporating three stages of compression, thus addressing thermal instability and improving the realism of pedal feel in electronic brake systems.
Implementation Method 1
A first elastic member is located in the chamber extending between the spring seat and the closed end. A second elastic member is located in the compartment and extending between the spring seat and the first piston. A third elastic member is located between the second piston and the first piston.
Data Source
AI summary
A pedal feel emulator comprises a housing extending along a center axis between a closed end and an opened end and defining a chamber extending therebetween. A first piston is slidably disposed in the chamber. The first piston defines a compartment in fluid communication with the chamber. A second piston is slidably disposed in the compartment. A spring seat extends radially outwardly from the second piston. A first elastic member is located in the chamber extending between the spring seat and the closed end. A second elastic member is located in the compartment and extending between the spring seat and the first piston. A third elastic member is located between the second piston and the first piston. A brake system including the pedal feel emulator is also disclosed herein.