Pedal Simulator Using Orifice Flow Resistance for Realistic Braking

Solution Overview

Problem

Conventional pedal simulators fail to accurately replicate the difference between pedal pressure and reaction force during braking, leading to an unfamiliar braking sensation for drivers and a complex, costly configuration.

Innovation Solution

A pedal simulator with a closed circuit configuration between the simulation chamber and accumulator, utilizing a sliding check valve, orifice, and return spring to adjust pedal pressure and provide a realistic braking sensation through flow path resistance, eliminating the need for multiple springs and rubber dampers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple springs and rubber dampers are used to provide pedal sensation, then the pedal sensation can be provided, but the configuration becomes complicated and costs increase

Engineering Contradiction:

Improvepedal sensationVSAvoidconfiguration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple springs and rubber dampers into a single integrated damper assembly. The damper includes a piston, spring, and damping element integrated within one housing, eliminating the need for separate components while maintaining the pedal sensation function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The damper assembly serves multiple functions simultaneously: it provides spring force for pedal return, damping force for vibration reduction, and friction control for pedal feel. This multi-functional design replaces what previously required multiple separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple springs and rubber dampers are used to provide pedal sensation, then the pedal sensation can be provided, but costs increase

Engineering Contradiction:

Improvepedal sensationVSAvoidcosts

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple springs and rubber dampers into a single integrated damper assembly. The damper includes a piston, spring, and damping element integrated within one housing, eliminating the need for separate components while maintaining the pedal sensation function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The damper assembly serves multiple functions simultaneously: it provides spring force for pedal return, damping force for vibration reduction, and friction control for pedal feel. This multi-functional design replaces what previously required multiple separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Force

If conventional pedal simulator components are used, then basic pedal pressure can be provided, but the difference between pedal pressure and reaction force during pedal release is not generated

Engineering Contradiction:

Improvepedal pressureVSAvoidpedal sensation realism

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent introduces a friction element that creates dynamic friction force during pedal release, making the reaction force different from the applied pedal pressure. This dynamic friction mechanism replicates the realistic sensation of pedal release that conventional static spring-damper systems cannot achieve.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The friction element changes the force parameters during pedal operation. During pedal application, the friction element creates resistance; during pedal release, it creates a different resistance pattern, thereby changing the force characteristics to match real brake pedal behavior.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a more realistic and familiar braking sensation by adjusting pedal pressure and repulsive force, simplifying the configuration and reducing costs by eliminating the need for additional components.

Implementation Method 1

providing a sense of the pedal through the flow path resistance of the orifice

Methodology Applied

Scientific EffectFlow path resistance: Drag

Implementation Method 2

a check valve which is pressurized by a piston, provided in the simulation chamber to be slideable, and is slid

Methodology Applied

Scientific EffectPressure-driven sliding: Pressure Gradient

Implementation Method 3

a return spring provided between the check valve and the damping housing and returning the check valve to its original position

Methodology Applied

Scientific EffectElastic force: Spring

Implementation Method 4

an accumulator configured to store oil discharged through the orifice

Methodology Applied

Scientific EffectHydraulic pressure storage: Hydraulic Accumulator

Data Source

PatentUS9718448B2Pedal simulator

Publication Date: 2017.08.01 HL MANDO CORP

AI summary

A pedal simulator of the present invention is disclosed. According to an aspect of the present invention, the pedal simulator, which is connected with a master cylinder and receives pedal pressure of the driver and configured to provide a sense of a pedal for a driver, includes: a simulation chamber having one end connected with the master cylinder and the other end provided in the simulator block closed by a damping housing, and configured to store oil; a check valve pressurized by the piston, provided in the simulation chamber to be slideable, and slid; an orifice formed in the simulator block and allowing a flow of oil in the simulation chamber by the sliding check valve; and an accumulator configured to store the oil discharged through the orifice.