Pedal Stroke Sensor Installation Structure for Brake Systems
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Solution Overview
Problem
Existing pedal stroke sensors for brake systems face challenges with complex structures, friction noise, low detection reliability, and calibration issues due to their installation location and method of detecting rotation angles, which complicates their integration into vehicles.
Innovation Solution
An installation structure for a pedal stroke sensor featuring a first shaft with a rack gear and a second shaft with a pinion gear, where a torsion spring maintains engagement between the gears, and a mounting member with a rubber fixing member to reduce space and improve mechanical precision, along with a pressing portion to restrict movements and reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pedal stroke sensor is installed in the brake pedal or master cylinder, then the sensor can detect pedal displacement, but the brake pedal assembly size increases and installation becomes difficult
Solution Approach 1:
The sensor assembly is segmented into modular components: the pedal stroke sensor, mounting member, and support structure are separate from the main brake pedal assembly. This allows the sensor to be installed independently without increasing the overall brake pedal assembly size, resolving the contradiction between detection capability and compact installation.
2Measurement precision
If the angle type pedal stroke sensor is installed spaced from the brake module, then the sensor can measure brake pedal movement, but offset calibration deteriorates quality
Solution Approach 1:
A support member acts as an intermediary between the sensor and the brake module, providing a stable mounting reference point. This intermediary structure ensures precise angular measurement while maintaining consistent spatial relationships, eliminating offset calibration issues that arise from direct mounting on moving components.
3Measurement precision
If the pedal stroke sensor detects rotation angle by contact method, then the sensor can measure rotation, but the structure becomes complicated and friction noise is generated
Solution Approach 1:
The patent replaces contact-based mechanical rotation detection with a non-contact optical sensing method. The pedal stroke sensor uses optical components to detect rotational angle without physical contact, eliminating friction noise and simplifying the overall structure while maintaining measurement precision.
4Measurement precision
If the pedal stroke sensor detects rotation angle by contact method, then the sensor can measure rotation, but detection reliability decreases due to durability changes
Solution Approach 1:
The patent substitutes mechanical contact-based rotation detection with non-contact optical sensing. This eliminates wear and friction associated with contact methods, significantly improving detection reliability and durability while maintaining accurate rotation angle measurement capability.
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 structure simplifies the installation process, enhances mechanical precision, reduces space between gears, and minimizes friction, leading to improved reliability and easier assembly of the brake pedal assembly within vehicles.
Implementation Method 1
The engagement maintenance portion may include a torsion spring whose one end is fixed and whose the other end is coupled with the pinion gear to maintain an engaged state of the pinion gear and the rack gear.
Implementation Method 2
The mounting member may be connected to the first shaft using a fixing member, and the fixing member may be made of a rubber material.
Implementation Method 3
The mounting member may be connected to the first shaft using a fixing member, and the fixing member may be made of a rubber material.
Data Source
AI summary
Disclosed herein is an installation structure for a pedal stroke sensor, including: a piston configured to move forward and backward by an operation of a pedal; a mounting member disposed on the piston; a first shaft coupled with the mounting member; a second shaft including a second gear engaged with a first gear of the first shaft; and a measuring portion disposed on the second shaft.