Pedal Pad Elastic Contact Design for Load Sensor Clearance
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Solution Overview
Problem
The conventional pedal devices require manual clearance adjustment to ensure the pressing portion of the pedal plate abuts the load sensor in a non-depression state, increasing manufacturing man-hours due to dimensional variations of components.
Innovation Solution
Incorporating an elastically deformable pedal pad that absorbs dimensional variations, ensuring the pressing portion consistently contacts the load sensor without manual adjustment through elastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual clearance adjustment is performed to ensure consistent contact between the pressing portion and load sensor, then measurement precision is improved, but manufacturing time increases
Solution Approach 1:
The pedal pad is designed to automatically adjust and maintain optimal contact between the pressing portion and load sensor through its elastic properties. The elastic material self-regulates the clearance without requiring manual intervention, allowing the device to service itself during assembly.
Solution Approach 2:
The invention changes the physical state of the pedal pad from rigid to elastically deformable. This parameter change allows the pedal pad to adapt its shape and maintain consistent contact pressure with the load sensor, eliminating the need for precise manual clearance adjustment while ensuring reliable force transmission.
2Manufacturing precision
If manual clearance adjustment is performed for each component, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The elastic pedal pad automatically compensates for dimensional variations in components through its deformability. During assembly, the pedal pad self-adjusts to achieve optimal contact conditions, eliminating the need for time-consuming manual clearance adjustment operations and significantly improving production efficiency.
Solution Approach 2:
The invention uses elastic material for the pedal pad, creating a composite structure that combines the rigidity needed for force transmission with the flexibility required for automatic clearance compensation. This material selection enables both manufacturing precision and high productivity.
3Reliability
If dimensional variations of components are accommodated through adjustment, then reliability is improved, but device complexity increases
Solution Approach 1:
The elastic pedal pad serves as a self-adjusting element that automatically compensates for dimensional variations in the pedal plate and load sensor. This eliminates the need for complex external adjustment mechanisms, maintaining device simplicity while ensuring reliable and consistent contact between components.
Solution Approach 2:
By changing the physical parameter of the pedal pad from rigid to elastic, the invention enables the component itself to absorb dimensional variations. This simple parameter change provides reliability improvement without adding any additional adjustment mechanisms or increasing device complexity.
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
Eliminates the need for manual clearance adjustment, simplifies manufacturing, and maintains consistent contact with the load sensor, reducing variability and enhancing production efficiency.
Implementation Method 1
Incorporating an elastically deformable pedal pad that absorbs dimensional variations, ensuring the pressing portion consistently contacts the load sensor without manual adjustment through elastic deformation.
Data Source
AI summary
A pedal pad includes a tread portion depressed by a driver, is fixed to a pad holder, and is displaced together with the pad holder with respect to a support when depressed. A load sensor is fixed to the pad holder and detects a pedal effort of the driver acting on the pedal pad. A pedal effort transmission member includes a pressing portion that presses the load sensor to transmit the pedal effort to the load sensor, and is placed between the tread portion and both the load sensor and the pad holder, and pressed by the tread portion. The pedal pad holds the pedal effort transmission member against the pad holder so that the pressing portion is pressed against the load sensor by the elastic deformation of the pedal pad when the depression operation is not performed.