Modular Pedal Simulator With Segmented Damper Plates
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Solution Overview
Problem
Conventional pedal simulators require complex damper designs to replicate the smooth pressure rise curve of hydraulic boosters, necessitating new designs for various braking scenarios, and are limited by the type and shape of the pedal.
Innovation Solution
A modular pedal simulator design featuring a housing, piston part, damper parts, and elastic support, allowing for adjustable damper diameters, thicknesses, and hardnesses, enabling universal application across different pedal types and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastically deformable dampers are used to provide braking feel, then braking feel similar to hydraulic booster can be achieved, but the damper shape becomes complicated and new dampers must be developed for various braking requirements
Solution Approach 1:
The damper is divided into a stack of multiple thin plate members (first plate member, second plate member, etc.) connected by dampers. This segmentation allows each plate member to be simple in shape while collectively providing the required braking feel characteristics through their stacked configuration.
Solution Approach 2:
The plate members are designed to be elastically deformable, allowing them to dynamically respond to braking forces. The elastic deformation of each plate member contributes to the overall braking feel, enabling adjustment of braking characteristics by changing material properties or geometry of individual plates rather than redesigning the entire damper shape.
2Reliability
If conventional pedal simulators are designed for specific pedal types, then braking feel can be optimized for that pedal type, but the design cannot be applied to other pedal types and shapes
Solution Approach 1:
The pedal simulator is designed with a universal structure where the piston part can be detached and replaced. The housing and damper assembly remain constant while different piston parts can be installed to accommodate different pedal types and shapes, allowing one base design to serve multiple pedal configurations.
Solution Approach 2:
The detachable piston part allows the system to dynamically adapt to different pedal configurations. By replacing the piston part rather than redesigning the entire simulator, the system can be quickly reconfigured for different pedal types while maintaining the core braking feel generation mechanism.
3Reliability
If complex damper designs are used to replicate smooth pressure rise curves, then braking feel accuracy is improved, but assembly and repair costs increase and productivity decreases
Solution Approach 1:
The damper is segmented into multiple simple plate members stacked together, each with straightforward geometry. This segmentation simplifies manufacturing of individual components while the collective arrangement of stacked plates achieves the smooth pressure rise curve characteristic, reducing both manufacturing complexity and assembly difficulty.
Solution Approach 2:
Instead of changing the complex shape of the damper to adjust pressure rise characteristics, the invention changes parameters such as the number of plate members, their thickness, material properties, or spacing. These parameter adjustments allow tuning of the pressure rise curve while keeping the basic structure simple and easy to manufacture.
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 provides a customizable braking feel, reduces assembly and repair costs, and enhances productivity by allowing commonization across various pedal configurations.
Implementation Method 1
an elastic part elastically supporting the piston part inside the housing
Implementation Method 2
a first damper member which is mounted on the first plate and elastically-deformable, and a second damper member which is mounted on the second plate, is in contact with the support plate, and is elastically-deformable
Data Source
AI summary
A pedal simulator of a vehicle includes a housing, a piston part movably disposed in the housing, a plurality of damper parts mounted on the piston part, stacked in an axial direction of the piston part, and supported and compressed by the housing and the piston part in response to a movement of the piston part, and an elastic part elastically supporting the piston part inside the housing.