Segmented Pedal Shaft Assembly for Accurate Brake-by-Wire Sensing
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Solution Overview
Problem
Existing control-by-wire vehicle pedals lack accurate and reliable methods for determining the position of the pedal, particularly in brake-by-wire systems, which affects the precision and efficiency of vehicle braking control.
Innovation Solution
A vehicular pedal assembly with a pedal shaft formed by two shaft portions coupled by a ratchet joint and supported by a position sensor assembly that determines the rotational position of the pedal shaft, generating signals for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece pedal shaft is used, then the structure is simple, but the assembly precision and reliability of pedal position detection are insufficient
Solution Approach 1:
The pedal shaft is divided into multiple segments (first shaft portion, second shaft portion, third shaft portion) connected by joints. This segmentation allows each segment to be independently manufactured and assembled, improving overall assembly precision and detection reliability while managing structural complexity through modular design.
2Ease of manufacture
If a one-way ratchet joint is used to couple shaft portions, then the assembly ease is improved, but the rotational precision may be compromised
Solution Approach 1:
A set screw acts as an intermediary element within the ratchet joint, engaging with a hexagonal recess to lock the shaft portions together. This intermediary mechanism provides precise rotational positioning while maintaining ease of assembly through the ratchet's one-way engagement feature.
Data Source
AI summary
A vehicular pedal assembly includes a pedal including a first support and a second support, a pedal shaft supported by the pedal housing for rotation about a pedal axis, a pedal arm drivably engaged with the pedal shaft to rotate the pedal shaft about the pedal axis, and a position sensor assembly coupled to the pedal shaft and operable to determine a rotational position of the pedal shaft and generate a signal based on the rotational position. The pedal shaft includes a first shaft portion coupled to the first support, a second shaft portion coupled to the second support, and a joint coupling the first shaft portion and the second shaft portion. The joint is positioned between the first support and the second support.