Vehicle Pedal Unit Layout for Small-Stroke Carpet Integration
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Solution Overview
Problem
Existing drive-by-wire systems with small pedal strokes face challenges in integrating pedal units into vehicles without negatively affecting the mobility of the housing or requiring larger carpet cuts, and sealing measures are difficult due to low carpet elasticity.
Innovation Solution
A pedal unit design with a fixable outer housing, a movable housing, and a sensor assembly that allows for small strokes, enabling integration under a carpet with minimal cut-outs and effective sealing, using thin-walled housings and redundant sensor modules for precise actuation detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a movable housing with small stroke is used in drive-by-wire systems, then the pedal travel is reduced and vehicle control precision is improved, but the integration into vehicles with carpet becomes difficult and sealing measures are compromised
Solution Approach 1:
The pedal unit is divided into distinct modular components: a fixed outer housing that interfaces with the vehicle structure and carpet, and a movable inner housing containing the sensor assembly. This segmentation allows the outer housing to provide structural stability and carpet compatibility, while the inner housing enables precise sensor detection with minimal travel distance.
2Shape
If the pedal unit is integrated under carpet with minimal cut-outs, then the vehicle interior aesthetics are improved, but sealing measures become difficult to implement
Solution Approach 1:
A sealing element is introduced as an intermediary component between the outer housing and the carpet. This sealing element creates an effective seal without requiring extensive carpet modifications, thus maintaining both aesthetic appearance and sealing reliability. The sealing element can be integrated into the outer housing structure or applied as a separate sealing layer.
3Device complexity
If thin-walled housings are used for the pedal unit, then the device complexity and weight are reduced, but the structural strength and noise resistance may be compromised
Solution Approach 1:
The housing structure is segmented into the fixed outer housing and the movable inner housing, each optimized for its specific function. The outer housing can be thinner since it provides structural mounting, while the inner housing contains the sensor assembly and requires controlled movement. This segmentation allows reduction of overall complexity and weight while maintaining necessary strength through strategic material distribution.
Solution Approach 2:
The outer housing and inner housing are designed to work together as an integrated assembly. The outer housing provides structural support and mounting interfaces, while the inner housing contains the sensor mechanism. By merging these components into a coordinated assembly, the overall structural strength is maintained even with thinner individual walls, and noise resistance is improved through the combined structure.
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 facilitates seamless integration of pedal units into vehicle interiors with minimal carpet disruption and enhanced sealing, ensuring reliable actuation detection and reduced noise, while allowing for modular and tool-free assembly.
Implementation Method 1
a movable housing (24) which is closed in the direction of the pedal head (12), which is arranged between the outer housing (19) and the inner housing (25) and is mounted on the inner housing (25) so as to be displaced in the longitudinal extension of the inner housing (25) with a small stroke against the force of a return spring (28)
Implementation Method 2
at least one sensor module (36) arranged inside a sensor housing (31) open in the direction of the pedal head (12) and arranged inside the inner housing (25) and designed to detect a stroke movement of the movable housing (24) caused by the actuating force (FB) of the driver's foot
Data Source
AI summary
A pedal unit for controlling a vehicle function includes a pedal head, which receives an actuating force of a driver's foot, an outer housing which is open in the direction of the pedal head, an inner housing connected to the outer housing and which is open in the direction of the pedal head, a movable housing, and a sensor assembly. The movable housing is closed in the direction of the pedal head, arranged between the outer housing and the inner housing, mounted on the inner housing displaceably in the longitudinal extension of the inner housing with a small stroke against the force of a return spring, and is connected to the pedal head. The sensor assembly includes at least one measuring circuit having at least one sensor module arranged inside a sensor housing to detect a stroke movement of the movable housing caused by the actuating force.