Vehicle Pedal Spring Housing Assembly Without Bending Jigs
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Solution Overview
Problem
Existing pedal devices for vehicles face challenges in assembly due to the need for jigs to bend and hold coil springs, particularly in brake pedal devices with higher elastic force, which complicates the manufacturing process.
Innovation Solution
The pedal device incorporates a configuration where the elastic member of the reaction force generation mechanism is assembled in a non-bending state through a largest opening in the first housing, which is then closed by the second housing, eliminating the need for a bending jig during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the elastic member is assembled in a bent state to fit the compact housing space, then the device can be miniaturized, but the assembly process requires complex bending jigs and procedures
Solution Approach 1:
The elastic member is pre-formed in its final bent configuration during manufacturing, eliminating the need for on-site bending operations. This preliminary action allows the component to be directly installed in its functional position without requiring complex bending jigs or procedures during assembly
Solution Approach 2:
Instead of bending the elastic member to fit the housing space constraints, the housing is designed with an opening that accommodates the elastic member in its natural state, and the member is inserted in reverse assembly sequence, avoiding the need for bending operations entirely
2Ease of manufacture
If the housing is designed with a large opening for easy assembly, then the assembly process is simplified, but the housing structure becomes more complex
Solution Approach 1:
The housing is divided into two separate parts: a first housing that provides the opening for elastic member insertion, and a second housing that closes the opening. This segmentation allows each housing part to have a simpler, more functional design rather than requiring one complex housing with both large opening and closing mechanisms
Solution Approach 2:
The first and second housings are designed to fit together like nested dolls, where the first housing with the opening is positioned to allow elastic member insertion, and the second housing is positioned to close the opening from the outside, creating a layered assembly structure that simplifies both housing individual components
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
This configuration simplifies the assembly process by eliminating the requirement for a bending jig, thereby improving the assemblability of the pedal device and reducing manufacturing complexity.
Implementation Method 1
The reaction force generation mechanism has an elastic member that generates a reaction force against the driver's pedaling force applied to the pedal pad
Data Source
AI summary
A pedal pad in an organ-type pedal device swings about a predetermined axis when stepped on by a driver's foot. A sensor unit outputs a signal corresponding to a swing angle of the pedal pad. A reaction force generation mechanism has an elastic member that generates a reaction force against a driver's pedaling force applied to the pedal pad. A first housing covers the reaction force generation mechanism, and an opening at least on one side. A second housing is provided on one side of the first housing in a swing direction of the pedal pad. Further, the first housing has a largest opening on a second housing side, which is closed by the second housing and into which the elastic member of the reaction force generation mechanism in a non-bending state is insertable.