Pedal Stroke Sensor Link Mechanism for Backlash Reduction
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Solution Overview
Problem
Existing pedal stroke sensor installations face challenges in accurately detecting pedal deflection angles when the sensor is placed far away from the pedal, due to potential backlash and position gaps caused by uneven contact and increased distance between the sensor arm and the pedal.
Innovation Solution
A link mechanism is employed to connect the pedal and the pedal stroke sensor, allowing for the transmission of pedal deflection without backlash, even when the sensor is placed far away, by using a rotatable link bar with ball joints to maintain contact and amplify the deflection angle for precise detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pedal stroke sensor is placed far away from the pedal to avoid interference with dashboard devices, then the sensor can be installed in an unobtrusive location, but the detection accuracy of pedal deflection angle deteriorates due to increased distance and potential backlash
Solution Approach 1:
A link mechanism serves as an intermediary component between the pedal and the sensor arm. This link mechanism includes a link bar that rotatably connects the pedal to the sensor arm, enabling the sensor to be positioned away from the pedal while still accurately transmitting deflection information through the intermediate link structure.
Solution Approach 2:
The solution moves the sensor away from the direct linear path between the pedal pivot and the detection point, positioning it in a different spatial dimension on the pedal bracket. The link mechanism transmits motion across this spatial separation, allowing the sensor to detect deflection angles from an offset position without compromising accuracy.
2Ease of operation
If the sensor arm and the pedal are located far away from each other to accommodate dashboard device layout, then the sensor can be positioned in an unobtrusive place, but accurate detection of pedal deflection angle becomes difficult
Solution Approach 1:
The link mechanism acts as a mediator that bridges the spatial gap between the pedal and the sensor arm. By introducing this intermediate mechanical connection, the system maintains accurate motion transmission despite the increased distance, allowing the sensor to be positioned conveniently while preserving measurement precision.
3Ease of operation
If the sensor arm and engaging member are slidably engaged to transmit pedal deflection, then the sensor can be located away from the pedal, but uneven contact during pedal stroke creates gaps and backlash between components
Solution Approach 1:
Instead of having the sensor arm slide along the engaging member (which causes uneven contact), the design inverts the connection approach by using a link bar that rotatably connects to both the pedal and the sensor arm. This rotational connection eliminates the sliding action and associated gaps, providing consistent contact throughout the pedal stroke.
Solution Approach 2:
The link bar serves as an intermediary that replaces the direct sliding engagement between the sensor arm and pedal. This intermediate rotational connection maintains consistent contact and eliminates backlash while still enabling the sensor to be positioned away from the pedal.
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 link mechanism enables accurate detection of pedal deflection angles with ease, preventing position gaps and enhancing sensitivity, ensuring precise control of regenerative braking in electric vehicles.
Implementation Method 1
The link mechanism is capable of transmitting displacement without causing backlash. Even if the pedal stroke sensor is placed away from the pedal, there occurs no position gap of the pedal, which triggers an error.
Implementation Method 2
uneven contact between the sensor arm and the engaging member during a pedal stroke makes a gap between these two components
Data Source
AI summary
A pedal stroke sensor is placed at a point of a pedal bracket, which is located away from a pedal, and where the pivot of the pedal stroke sensor is not aligned with the pivot of the pedal; the pedal and the pedal stroke sensor, which are thus separated away from each other, are connected together by a link mechanism; and a pedal deflection is transmitted through the link mechanism to the pedal stroke sensor.