Accelerator Pedal Unit Mechanical Surge Force Switch

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Solution Overview

Problem

Existing accelerator pedal units for vehicles have complex designs requiring additional spring elements and long actuating paths for generating a surge in force, which increases complexity and necessitates position detection along the axis of movement, making them difficult to manage and produce.

Innovation Solution

A sprung unit with a stop element and a movable counter-stop element is introduced, allowing the counter-stop element to switch between a stop position and a release position, enabling the additional return force to be mechanically switched on and off independently of the surge force, using a purely mechanical interpretation without the need for electrical switching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a lifting magnet and magnetic plunger are used to generate surge in force, then additional force can be applied to the accelerator pedal, but the structure becomes complex and requires additional spring elements and position detection

Engineering Contradiction:

Improveadditional return forceVSAvoidstructure complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent replaces the lifting magnet and magnetic plunger system with a purely mechanical stop element and counter-stop element arrangement. The spring element mechanically actuates the stop element to engage with the counter-stop element, eliminating the need for electromagnetic components and their associated control systems, thereby reducing structural complexity while maintaining the ability to generate additional return force

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the lifting magnet and position detection components from the system. By using a mechanical stop element that directly engages with the counter-stop element on the accelerator pedal, the system removes unnecessary components while preserving the core function of generating surge force through spring prestress

Inventive Principle:

Principle #2Taking out (Extraction)

2Force

If a lifting magnet system is used for surge in force, then force information can be provided to the driver, but long actuating paths are required and position detection along the axis of movement is necessary

Engineering Contradiction:

Improvesurge in forceVSAvoidactuating path

Core Design Contradiction:

ForceVSLength of moving object

Solution Approach 1:

The patent changes the dimension of engagement from linear axial movement to radial or lateral engagement. The stop element engages with the counter-stop element in a direction perpendicular to the main actuating path of the accelerator pedal, allowing surge force generation without requiring long axial actuating paths or complex position detection along the movement axis

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If additional spring elements are added to maintain contact between plunger and contact surface, then permanent contact is achieved, but device complexity increases

Engineering Contradiction:

Improvecontact maintenanceVSAvoidnumber of spring elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the function of maintaining contact with the primary spring element already present in the system. The spring element serves dual purposes: providing the prestress force for surge generation and maintaining engagement between the stop element and counter-stop element, thereby eliminating the need for separate additional spring elements and reducing overall complexity

Inventive Principle:

Principle #5Merging (Combining)

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 solution simplifies the structure of the accelerator pedal unit by allowing the additional return force to be easily switched on and off, providing independent feed force for different haptic signals and actuator embodiments, reducing complexity and enhancing mechanical reliability.

Implementation Method 1

a spring element (27) is received in the sprung unit (17), with which the stop element (18) is prestressed in a longitudinal direction (25)

Methodology Applied

Scientific EffectSpring prestress: Spring

Implementation Method 2

The actuator (21) comprises a lifting magnet arrangement (22)

Methodology Applied

Scientific EffectElectromagnetic force: Electromagnet

Data Source

PatentUS10220703B2Accelerator pedal unit for a vehicle

Publication Date: 2019.03.05 HELLA GMBH & CO KGAA

AI summary

An accelerator pedal unit for a motor vehicle, having a base body on which an accelerator pedal is accommodated rotatably mounted in a rotary joint and which, starting from a resting position, can be moved by actuation in an actuating direction. A sensor unit is accommodated in the base body, which senses the position of the accelerator pedal via a feeler element. A return spring is provided, with which the accelerator pedal is prestressed into the initial position. A moveable counter-stop element can be moved into a stop position in which, when the accelerator pedal is actuated, the stop element comes into contact with the counter-stop element and runs into the sprung unit when an additional force is applied to the accelerator pedal and can be moved into a release position in which, when the accelerator pedal is actuated, the stop element can move freely in a movement region.