Single-Plate Brake Pedal with Crash Rotation Mechanism
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Solution Overview
Problem
Conventional brake pedal apparatuses for vehicles have low productivity and high manufacturing costs due to the use of multiple steel plates requiring different thicknesses and complex assembly processes, which also pose a risk to driver leg injury in crashes by not effectively separating from the car body.
Innovation Solution
A brake pedal apparatus formed from a single steel plate, where the pedal member is manufactured by bending to create a unified structure with a dash panel coupling part, side parts, and an extended part, including a pedal arm contact part to forcibly rotate the pedal arm away from the driver in accidents, reducing assembly complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple steel plates with different thicknesses are used to manufacture the pedal member, then high strength is achieved in critical areas, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges multiple steel plates into a single steel plate structure. The pedal member is formed from one steel plate through bending operations, eliminating the need to assemble multiple plates with different thicknesses. This reduces manufacturing complexity while maintaining structural integrity through strategic bending and forming of the single plate.
Solution Approach 2:
The patent applies local quality by creating different thickness regions within the single steel plate through bending and forming operations. The steel plate is bent to form various sections (dash panel coupling part, side parts, extended part) where local geometry changes provide varying effective thickness and strength characteristics without requiring multiple plates of different thicknesses.
2Strength
If multiple steel plates are assembled using welding or nuts and bolts, then the pedal member achieves required strength, but assembly time increases and productivity decreases
Solution Approach 1:
The patent combines multiple separate steel plates into a single integrated steel plate component. Instead of assembling multiple plates through welding or fastening operations, the entire pedal member is formed from one steel plate through bending and shaping processes, eliminating assembly steps and significantly improving productivity.
3Manufacturing precision
If a separate jig is used for assembly of multiple steel plates, then accurate positioning is achieved, but investment costs increase
Solution Approach 1:
The patent eliminates the need for separate assembly jigs by merging multiple steel plates into a single steel plate that is formed directly into the final pedal member shape through bending operations. The single plate approach removes the positioning and alignment requirements that would necessitate complex jig systems, reducing equipment investment costs.
4Strength
If thick steel plates are used to satisfy high strength requirements, then strength is improved, but forming difficulty and manufacturing costs increase
Solution Approach 1:
The patent applies local quality by creating varying effective thickness and strength characteristics within different regions of the single steel plate through bending and forming operations. Instead of using uniformly thick steel plates, the plate is shaped to provide local geometric variations that deliver required strength in critical areas while maintaining ease of manufacture overall.
Data Source
AI summary
A brake pedal apparatus for a vehicle has a pedal member manufactured by bending one steel plate. A pedal arm is forcibly rotated forwards by the pedal member being deformed in the event of crash or rear-end collision.