Pedal Simulator Nonlinear Feel via Sequential Spring and Damper Deformation
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Solution Overview
Problem
Conventional pedal simulators for brake-by-wire systems fail to provide a nonlinear pedal feeling effectively, leading to complexity and increased manufacturing costs, and often result in a different sense due to member contact during operation.
Innovation Solution
A pedal simulator design featuring a main housing with a reciprocally movable piston, an elastic support portion comprising a first and second coil spring, and a damper with sequential deformation portions, which generates a nonlinear pedal effort characteristic without member contact-induced sensations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single buffer member (one coil spring) is used in the pedal simulator, then the structure is simple, but the pedal feeling is limited to one-stage linear form only
Solution Approach 1:
The single buffer member is segmented into multiple buffer members (first buffer member and second buffer member) with different characteristics. The first buffer member provides initial buffering while the second buffer member engages after a predetermined displacement, creating multi-stage nonlinear pedal feeling without requiring a completely complex structure
Solution Approach 2:
The buffer members are designed with different stiffness characteristics and engagement sequences. The second buffer member is positioned to engage only after the first buffer member reaches its limit, creating a dynamic, multi-stage response that adapts to the braking process stages
2Adaptability or versatility
If multiple springs and dampers are applied to realize nonlinear pedal feeling, then the pedal feeling characteristic is improved, but the structure becomes complex and manufacturing costs increase
Solution Approach 1:
Multiple buffering functions are merged into a compact arrangement where the first and second buffer members work in sequence within the same structural space. This combines the functionality of multiple components while maintaining relative structural simplicity
Solution Approach 2:
The buffer members are arranged in a nested configuration where the second buffer member is positioned to engage only after the first buffer member is fully compressed. This nesting approach allows multiple buffering stages within a compact structure
3Adaptability or versatility
If multiple springs and dampers are applied to realize nonlinear pedal feeling, then the pedal feeling characteristic is improved, but manufacturing costs increase
Solution Approach 1:
The buffering function is segmented into discrete stages with the first and second buffer members having different characteristics. This segmentation allows for optimized manufacturing of each component based on its specific function, potentially reducing overall costs compared to a single complex component
Solution Approach 2:
The buffer members are designed with different physical parameters (stiffness, displacement limits) to create nonlinear pedal feeling. By varying parameters rather than adding complex mechanisms, the solution achieves sophisticated pedal characteristics at lower manufacturing cost
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 design achieves a nonlinear pedal feeling similar to conventional brake systems with reduced complexity and manufacturing costs, minimizing the generation of unwanted sensations during operation.
Implementation Method 1
a first coil spring which is supported, at an upper end thereof, by one side of the piston and generates elastic force by being compressed according to downward movement of the piston
Implementation Method 2
a second coil spring which is disposed beneath the support member and supported by a lower surface of the support member, the second coil spring generating elastic force by being compressed according to downward movement of the support member
Implementation Method 3
a damper including a first deformation portion and a second deformation portion having a volume greater than the first deformation portion which are vertically disposed within the main housing, the damper being made of an elastic material such that the first and second deformation portions are sequentially compressed and deformed while being pressed by the piston according to downward movement of the piston
Data Source
AI summary
Disclosed herein is a pedal simulator. The pedal simulator includes a main housing, a piston provided within the main housing so as to be reciprocally movable in upward and downward directions, an elastic support portion disposed within the main housing to provide elastic force in the upward direction against one piston, and a damper including a first deformation portion and a second deformation portion having a volume greater than the first deformation portion which are vertically disposed within the main housing, the damper being made of an elastic material such that the first and second deformation portions are sequentially compressed and deformed while being pressed by the piston according to downward movement of the piston.