Pedal Sensor Carrier Groove for Secure Damping Element Retention
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Solution Overview
Problem
Existing pedal sensors face the issue of the damping element gradually slipping out of its groove due to the open front side, which cannot be closed for manufacturing purposes, leading to instability and potential functional impairment.
Innovation Solution
A bar is strategically placed on the front side of the groove to secure the damping element externally, preventing lateral slipping without compromising the manufacturing process or adding significant weight, and in another design, the bar is molded as a single piece with the carrier for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the groove front side is closed to secure the damping element, then the damping element is held securely, but the molded part cannot be pulled out of the injection mold
Solution Approach 1:
The groove is divided into two functional zones: a closed rear portion that secures the damping element and an open front portion that allows demolding. The bar element creates a segmented structure where the damping element is retained in the closed zone while the open zone facilitates manufacturing.
Solution Approach 2:
The bar element extends in a direction perpendicular to the groove's opening, creating a three-dimensional securing structure. This lateral extension prevents the damping element from slipping out while maintaining the groove's open front side for demolding purposes.
2Ease of manufacture
If the groove front side is opened to allow demolding, then the molded part can be pulled out, but the damping element slips out gradually
Solution Approach 1:
The bar element acts as an intermediary structure that provides securing function without closing the groove front side. It mediates between the need for open demolding and the need for damping element retention, allowing both requirements to be satisfied simultaneously.
3Reliability
If a securing structure is added to the groove, then the damping element is held securely, but the device complexity increases
Solution Approach 1:
The bar element is integrated directly into the carrier body as a single molded structure, merging the securing function with the existing carrier geometry. This integration avoids adding separate components and minimizes structural complexity while achieving reliable damping element retention.
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 damping element is securely held in place, ensuring consistent performance and preventing slipping without impacting the manufacturing process or increasing weight, thus maintaining pedal sensor functionality and haptic quality.
Implementation Method 1
The elastic damping element is pressed into the open long side of the groove
Implementation Method 2
a damping element that is fixed to the carrier in a groove in such a way that any contact between the pedal arm and the carrier is dampened
Data Source
AI summary
A pedal sensor is provided with a carrier that can be mounted to a motor vehicle. A housing is formed at the carrier, and a pedal arm is mounted on the carrier so as to be pivotable. A mechanism to transmit movements of the pedal arm relative to the carrier is arranged in the housing, and a sensor for measuring the movements is provided. A damping element is fixed to the carrier in a groove in such a way that any contact between the pedal arm and the carrier is dampened. The damping element is securely held on the carrier. This is achieved by the damping element being secured on both sides against slipping out of the groove.