Vehicle Pedal Index Assembly Using Plastic Pin Locking
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Solution Overview
Problem
Existing vehicle pedal systems with contacting position sensors lack a simple and cost-effective method for setting and locking the index position of the rotor arm, which is crucial for accurate throttle control and tactile feedback.
Innovation Solution
A vehicle pedal assembly that includes a housing with a drum and rotor, a contacting position sensor with a resistive material strip, and an index position locking assembly using a plastic pin or clip mechanism to securely set and lock the rotor arm's position, allowing for precise adjustment and locking of the index position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal pin is used to lock the rotor arm index position, then the locking reliability is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces the traditional metal pin with a plastic index positioning pin that is integral to the rotor arm. This disposable-like approach uses a cheaper material (plastic instead of metal) and simplifies the assembly by eliminating the need for separate fastening operations, while still providing sufficient locking reliability for the application.
Solution Approach 2:
The patent integrates the index positioning pin directly into the rotor arm structure as an integral feature. This merging of the positioning function into the existing component eliminates the need for separate metal pins and fastening hardware, reducing both complexity and cost while maintaining the necessary locking function.
2Strength
If a complex fastening mechanism is used to lock the rotor arm, then the locking strength is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The index positioning pin is merged with the rotor arm as an integral feature, eliminating the need for separate fastening operations. This single-piece design maintains sufficient locking strength through proper geometric design while dramatically improving ease of manufacture by reducing assembly steps and component count.
Solution Approach 2:
The rotor arm design allows the index positioning pin to automatically engage with the drum feature during assembly without requiring additional fastening actions. The component essentially fastens itself through its geometric design, improving manufacturability while maintaining locking strength.
3Duration of action of stationary object
If traditional metal fastening components are used, then the durability is improved, but the cost-effectiveness deteriorates
Solution Approach 1:
The patent adopts a cost-effective approach by using a plastic index positioning pin instead of metal fastening components. This disposable-like component is cheaper to manufacture and assemble, while its design ensures sufficient durability for the application lifecycle through proper material selection and geometric design.
Solution Approach 2:
The patent uses composite construction by integrating the plastic index positioning pin into the rotor arm structure. This composite approach combines the advantages of plastic (cost-effectiveness, ease of manufacturing) with sufficient mechanical properties (durability, locking strength) through intelligent design of the integral feature.
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
This solution provides a reliable, cost-effective method for setting and locking the index position of the rotor arm, enhancing the accuracy of throttle control and providing improved tactile feedback to the driver.
Implementation Method 1
friction between the Bowden cable and its protective sheath reduced the foot pressure required from the driver to hold a given throttle position
Data Source
AI summary
A vehicle pedal comprising a housing for a pedal arm with a drum, a rotor coupled to the drum and including a contactor that slides against a strip of resistive material in the housing, and an assembly for setting and locking the index position of the rotor. In one embodiment, the rotor extends through a window that is defined in the housing and limits the movement of the rotor during the index setting operation. In one embodiment, a plastic pin that is either separate from or unitary with the rotor is fitted into a slot defined in the drum. In another embodiment, a potting material is deposited and cured in the slot in the drum for locking the pin in the slot. In another embodiment, the pin is unitary with the drum of the pedal arm and is press-fitted into a slot in the rotor. In a further embodiment, the drum and rotor include respective plates and the pin is a clip that locks the plates together.