Pedal Simulator Damper Mechanism for EV Braking Force
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Solution Overview
Problem
Electric vehicles experience a significant difference in pedal stepping force during regenerative braking, which is not effectively addressed by existing systems, leading to a suboptimal braking experience.
Innovation Solution
A pedal simulator comprising a damper housing unit, damper holder unit, damper piston unit, damper pressing unit, and elastic units to enhance the sense of pedal feel and improve regenerative braking performance by minimizing part addition and layout changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate independent chamber such as a valve is provided to prevent pedal force transmission in regenerative braking, then structural separation is achieved, but device complexity increases
Solution Approach 1:
The patent merges the regenerative braking force transmission path with the conventional brake pedal mechanism by removing the separate valve chamber. The pedal simulator directly transmits regenerative braking forces through the pedal arm and linkage mechanisms, eliminating the need for structural separation while maintaining functional independence through controlled force transmission paths.
Solution Approach 2:
The pedal simulator is designed to serve multiple functions: it handles both regenerative braking force transmission and conventional friction braking operations through a single integrated mechanism. The pedal arm and linkage system can accommodate different braking modes without requiring separate dedicated structures for each function.
2Loss of energy
If regenerative braking force is generated when accelerator pedal is released, then energy recovery is achieved, but a large sense of difference is felt in pedal stepping force
Solution Approach 1:
The patent employs spring elements with varying stiffness coefficients and damper components with adjustable damping coefficients to dynamically modify the pedal stepping force characteristics. By changing the mechanical parameters of these compliant elements, the system smooths out the force perception differences during regenerative braking while maintaining effective energy recovery.
Solution Approach 2:
Spring and damper elements are introduced as intermediary components between the pedal and the regenerative braking force transmission path. These intermediaries act as buffers that soften the abrupt force changes and reduce the sense of difference in pedal stepping force, providing a more comfortable operating experience.
3Productivity
If pedal simulator is designed to improve regenerative braking performance, then braking efficiency increases, but system complexity may increase
Solution Approach 1:
The pedal simulator is segmented into distinct functional modules: the pedal assembly, pedal arm, linkage mechanisms, spring elements, and damper components. Each segment performs a specific function and can be independently optimized or adjusted, allowing improved braking efficiency through modular design without proportionally increasing overall system 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
The pedal simulator improves regenerative braking performance, enhances pedal feel, and reduces the difference in pedal stepping force during regenerative braking without increasing the overall system complexity.
Implementation Method 1
a first elastic unit disposed between the damper pressing unit and the damper housing unit to elastically support the damper pressing unit
Implementation Method 2
a damper unit coupled to the damper piston unit, accommodated inside the damper housing unit, and compressed by a movement of the damper piston unit
Data Source
AI summary
A pedal simulator includes a damper housing unit, a damper holder unit coupled to the damper housing unit, a first bearing unit rotatably disposed on the damper holder unit, a damper piston unit slidably accommodated inside the damper housing unit, a damper unit coupled to the damper piston unit, accommodated inside the damper housing unit, and compressed by a movement of the damper piston unit, a damper pressing unit coupled to the damper piston unit to press the damper piston unit, and a first elastic unit disposed between the damper pressing unit and the damper housing unit to elastically support the damper pressing unit.