Pedal Reaction Force Actuator With Intermediate Gear Angle Sensing
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Solution Overview
Problem
Existing actuators that apply a reaction force to accelerator pedals face challenges in maintaining consistent output load due to varying contact angles of the lever, leading to fluctuations in torque and operational noise.
Innovation Solution
An actuator system comprising an electric motor, a speed reducer mechanism, an actuator lever, and an angle detector device, where the speed reducer mechanism includes a motor gear, an output gear, and an intermediate gear with a large and small gear portion, and the angle detector device monitors the rotational angle of the intermediate gear to adjust operation accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a speed reducer mechanism with a lever is used to apply reaction force to the accelerator pedal, then the reaction force can be generated, but the output load fluctuates due to varying contact angles of the lever
Solution Approach 1:
A reaction force application amount detector detects the actual reaction force applied to the accelerator pedal, and a controller adjusts the motor output based on this feedback to maintain the reaction force within a target range, compensating for load fluctuations caused by varying contact angles
Solution Approach 2:
The controller dynamically changes the motor output parameter based on the detected reaction force and contact angle variations, adjusting the motor torque to compensate for the fluctuating mechanical advantage in the speed reducer mechanism
2Adaptability or versatility
If the lever contact angle varies during pedal operation, then the actuator can accommodate different pedal positions, but torque fluctuations and operational noise occur
Solution Approach 1:
The system continuously detects the reaction force and contact angle, and the controller uses this feedback to adjust motor output, maintaining smooth operation and reducing torque fluctuations and noise across different pedal positions
Solution Approach 2:
The controller dynamically adjusts the motor output in real-time based on the varying contact angle and detected reaction force, adapting the actuator's behavior to maintain consistent performance throughout the pedal's range of motion
3Measurement precision
If an angle detector device is added to monitor the intermediate gear rotational angle, then detection accuracy and responsiveness improve, but device complexity increases
Solution Approach 1:
The angle detector device monitors the intermediate gear's rotational angle, providing an indirect but accurate measurement of the actuator's position and state, which the controller uses to optimize reaction force application
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 system effectively controls the reaction force applied to the pedal lever, reducing torque fluctuations and operational noise, while improving detection accuracy and responsiveness.
Implementation Method 1
an electric motor
Implementation Method 2
a speed reducer mechanism including: a motor gear that is configured to rotate integrally with the electric motor; an output gear that is configured to rotate integrally with an output shaft; and an intermediate gear that is installed between the motor gear and the output gear
Data Source
AI summary
An actuator applies a reaction force to a pedal lever to be depressed by a human driver. The actuator includes an electric motor, a speed reducer mechanism, an actuator lever and an angle detector device. The speed reducer mechanism includes: a motor gear that rotates integrally with the electric motor; an output gear that rotate integrally with an output shaft; and an intermediate gear installed between the motor gear and the output gear. The actuator lever is driven by the output shaft and contacts the pedal lever. The angle detector device detects a rotational angle of the intermediate gear. The intermediate gear has: a large gear portion, which meshes with the motor gear; and a small gear portion, which meshes with the output gear. The small gear portion is integrally formed in one-piece with the large gear portion.