Cross Reference to Related and Co-Pendsng Application

This application claims the benefit of the filing date and disclosure of U. S. Provisional Patent Application Serial No. 61/789, 111 filed on March 15, 2013, the contents of which are entirely incorporated herein by reference as well as all references cited therein.

Field of the Invention

The present invention relates to vehicle pedals in general and, in particular, to a vehicle pedal assembly incorporating an active force pedal.

Background of the invention

Vehicle accelerator/throttle pedals allow a vehicle operator to control the acceleration of a vehicle through either the application or removal of a foot force on the pedal. Pedals hav also been developed that provide haptic feedback to the operator by applying an active push back force to the pedal and the foot of the operator in response to the sensing of a variety of vehicle conditions or events including, for example, the vehicle exceeding a recommended speed, or the vehicle not keeping a safe distance behind another vehicle, or the vehicle sensing the presence of an object behind the vehicle when operating in reverse.

The present invention is directed to a new active force pedal.

Summary of the invention

The present Invention is directed to an active force pedal assembly comprising a housing, a pedal including an end mounted in the housing for pivotal movement relative to the housing, a torque motor adapted to generate a rotational force, and a shaft having a first end coupled to the pedal and an opposed end adapted for coupling with the torque motor. The rotational force generated by the torque motor is transferred to the shaft and results in the application of an active force on the pedal, In one embodiment, the torque motor is located in the housing.

In one embodiment, a housing wall separates the torque motor and the pedal and the housing waft defines an aperture and the shaft extends through the aperture.

In one embodiment, the torque motor is a six pole torque motor connected to the pedal in a direct drive arrangement.

In one embodiment, electronics are integrated in the housing for controlling the torque motor.

In on embodiment, the active force pedal assembly is a non-contacting sensor peda! assembly.

in one embodiment, the end of the pedal mounted in the housing includes a drum, the drum of the pedal and the torque motor being disposed in

horizontal side-by-side relationship and defining respective co-!ineariy aligned longitudinal axes.

The present invention is also directed to an activ force pedal assembly comprising a housing defining an interior cavity, a pedal including a drum

extending into the interior cavity of the housing, the drum defining a longitudinal and rotational axis and adapted for pivotal movement in the interior cavity of the housing about the longitudina! and rotational axis relative to the housing, a torque motor adapted to generate a rotational force, the torque motor being located in the interior cavity of the housing and defining a longitudinal axis disposed in a co-linea reialionship with the longitudinal and rotational axis of the drum of the pedal, and an elongate shaft in the housing having a first end extending info and coupled to the drum of the pedal and an opposed end extending into and adapted for coupling to the torque motor, the rotational force generated by the torque motor being transferred to the shaft and the drum of the pedai and resulting in the application of an active force on the pedal

In one embodiment, the housing includes first and second housing portions defining respective first and second interior housing cavities separated by a housing wait, the drum of the peda! extends into the first interior cavity and the torqu motor is located in the second interior cavity and is separated from the drum of the pedal by the housing wall, the housing wall defining a through-hole, the shaft extending through the through-hole in the housing wall.

In one embodiment, the pedal includes a pedal arm extending from the drum of the pedal in a direction and orientation generally normal to the longitudinal and rotational axes of the drum of the pedal, the longitudinal axis of the torque motor, and the shaft.

Other advantages and features of the present invention will be more readily apparent from the following detailed description of the preferred embodiment of the invention, the accompanying drawings, and the appended claims.

Brief Description of the Drawings

These and other features of the invention can best foe understood by the following description of the accompanying FIGURES in which:

FIGURE 1 is a front elevatbnal view of an active force pedal assembly in accordance with the present invention;

FIGURE 2 is a perspective view, partly in cross-section, of the active force pedal assembl shown in FIGURE 1 ; and

FiGURE 3 is an exploded perspective view, partly in cross-section, of the active force pedal assembly shown in FIGURES 1 and 2,

Detailed Description of the Embodiment

FIGURES 1 , 2, and 3 depict one embodiment of an active force vehicle accelerator pedal assembly 10 in accordance with the present invention.

The pedal assembly 10, which may be made of a suitable thermoplastic material, comprises an elongate pedal 12 and a housing 11 comprising a first pedal housing or housing portion 14 that houses the pedal 12 and a second motor housing or housing portion 16 that is unitar with the first pedal housing portion 14 and houses an active pedaf force generating device 19 which, in the embodiment shown, is in the form of an electric torque motor 19.

The housing 11 includes a generally flat base plate 17 which, in the embodiment shown, has three brackets 18 defining respective apertures 20 for screws, bolts, or the like (not shown) that aliow for securement of the pedal assembly 10 to the floor of a vehicle (not shown),

The housing 1 1 , and more specifically the first pedai housing portion 14 thereof, includes a pair of side walls 22 and 24 extending unitanly generally normally outwardl from the top exterior surface of the base 17 in a generally spaced-apart and parallel relationship. The housing 1 1, and more specifically the first pedal housing portion 14 thereof, still further includes a top arcuate cover wall 26 extending between the top peripheral edge of the respective side walls 22 and 24 in a relationship spaced from the base 17 and together with the base 17 and the side waifs 22 and 24 defining the first pedai housing portion 14; a front housing opening 28 in the housing 1 1, and mor specif ically in the first pedai housing portion 14, through which the drum 48 of the pedai 12 extends; a back or rear housing opening 32 in the first housing portion 14 for a connector assembly (not shown); and a first interior cavity 30 def ined in the housing 1 1 , and more specifically defined in the first pedal housing portion 4, for the drum 48 of the pedal 12 (FIGURES 2 and 3).

The housing portion 6 is, in the embodiment shown* generally

cyiindricaily-shaped and defined by a circumferentially-extending wail 33 protruding unitarify and generally normally outwardiy from the exterior surface of the side wall 24 of the housing 14 which, in combination with the side wall 24, defines a second inferior cavity 34 in the housing portion 16 and thus the housing 1 1 for the torque motor 19 (FiGURE 3).

In the embodiment shown, the first and second housing portions 14 and 16 and the respective first and second housing cavities 30 and 34 are separated by the side wall 24 with the exception that the side wall 24 defines a central through aperture 36 (FIGURE 3) adapted to receive an elongate and generally cylindrically shaped combination pedal/motor shaft 40 (FIGURE 3) as described in more detail below.

The pedal 12 includes a proximal first end 42 with a foot plate 44, an elongate pedal arm 43, and an opposed distal second end 46 with a generally cylmdricaliy shaped drum 48 (FIGURES 2 and 3} that extends through the front housing opening 28 and into the first interior housing cavity 30 of the housing portion 14 of the housing 11.

The drum 48 defines a central through-hole 50 (FIGURE 3) terminating in respective openings in the opposed side faces of the drum 48 and adapted to receive a first elongate half end segment of the shaft 40 for mounting the drum 48, and thus the pedai 12, for pivotal movement in the cavity 30 relative to the side walls 22 and 24 and the base 17 and thus for pivotal movement relative to the first housing portion 14 and the housing 11♦

in the embodiment shown, the pedal assembly 10 is a non-contacting sensor vehicle pedal assembly, of the type disclosed in for example U.S. Patent No, 7,926,384 to Wurn, the disclosure and description of which is incorporated herein by reference, that includes a magnet assembly 60 with a magnet 62 that protrudes outwardly from a front face of the drum 48 into the housing cavity 30 and extends in the direction of the rear opening 32 of the housing portion 14 (FIGURES 2 and 3).

Although not shown in any of the FIGURES but also disclosed in U.S. Patent No. 7,926,384, the disclosure and description of which is again

incorporated herein by reference, it is understood that the pedai assembly 10 also comprises a combination electrical connector/sensor assembly that is adapted to extend through the rear opening 32 of the housing 14 and into the housing cavity 30 in a relationship opposed and spaced f om the magnet 62 of the magnet assembly 60,

The combination connector/sensor assembly includes a printed circuit board including a plurality of electrical components mounted thereon including one or more sensors such as, for example, Hall effect sensors designed to sense a change in the magnetic field generated by the magnet 82 in response to the pivofai movement of the magnet 62 and th pedal 12 for the purpose of sensing the pivotal position of the pedai 12 and controlling the vehicle's acceleration and deceleration.

It is understood however that the present invention is also adapted for use in any other type of pedal assembly in which the generation of an active force may be desirable including for example a contacting sensor vehicle pedal assembly of the type disclosed in US Patent No, 8,042,430 to Campbell, the disclosure and description of which is incorporated herein by reference.

The active pedal force generating device 19 _» which in the embodiment shown is in the form of a generally cylindricaiiy-shaped electric torque motor 19, is located and mounted in the interior cavity 34 of the housing portion 16 of the housing 1 i a relationship wherein the side wall 24 of the housing 14 separates the torque motor 9 in the cavity 34 of the housing portion 16 from the pedal 1 in the cavity 30 of the housing portion 14 of the housing 1 1,

Although not shown or described herein In any detail, ft is understood that, as shown in FIGURES 2 and 3, the torque motor 19 may be of a construction that includes a stationary generally cylindrical^ shaped stator 23 and a generally cyJindricaily shaped rotor 25 that is rotaiabfe relative to the stator 23 and to which the second elongate half segment of the shaft 40 is adapted to be coupled. The rotor 25 includes a ring-shaped magnet 27 coupled thereto that is adapted for interaction with the electrical field generated by the stator 23 during operation of the torque motor 19 for causing the rotation of the rotor 25 and thus the rotation of the shaft 34 adapted to be coupled thereto.

In the embodiment and orientatio of the pedal assembly 0 as shown in the FIGURES, the pedal 12 and the torque motor 19 are positioned and oriented relativ to each other in a relationship wherein the drum 48 of the pedal 1 and the torqu motor 19 are disposed in a stde-by-side, adjacent, and parallel horizontal relationship on opposit sides of the housing wall 24; the drum 48 defines a horizontally extending longitudinal and rotational axis D that extends through the through-hole 50 defined therein and is disposed in a relationship generally co-linear with the horizontally extending longitudinal axis M of the torque motor 19 and extending through th through-hole 21 defined therein; and the longitudinal axis P of the pedal 1 extends in an orientation and direction generally normal to the longitudinal axes D and of the drum 48 and the torque motor 9 respectively. In the embodiment and orientation of the pedal assembly 10 as shown in the FIGURES and more particularly as shown in FIGURE 3, the elongate and generally cylindrical ly shaped metal combination pedal torque motor shaft 40 includes first and second opposed and unlary end or half shaft segments 41 and 46, The segment 41 includes an exterior eircu ferentially extending knurled or serrated surface 47.

Although FIGURE 3 depicts the shaft 40 and the torque motor 19 in exploded view, it is understood that, in the assembled and operational configuration of the pedal assembly 10, the shaft 40 is located and extends in the interior of the housing 11 in a generally horizontal relationship wherein the first end or half segment 41 extends into and is coupled to the drum 48 of the pedal 12 and the second end or half segment 45 extends into and is adapted to be coupled to the rotor 25 of the torque motor 19 and still more specifically in a relationship in which the shaft 40 extends through the aperture 36 defined in the side wall 24 of the housing 1; the first end or half shaft segment 41 of the shaft 40 extends into and through the Interior cavity 30 of the housing portion 14, and more specifically, into and through the through-hole SO defined in the drum 48 of the pedal 12 and is secured and coupled to the drum 48 as by for example pressing and meshing of the metal knurled surface 47 on the shaft segment 41 into the plastic material of the drum 48 of the pedal 12; and the second end or half shaft segment 45 of the shaft 40 extending Into and through the interior cavity 34 of the housing portion 16, and more specifically, into and through the through-hole 21 defined in the torque motor 1 ,

Thus, in the embodiment shown, the torque motor 19 is coupled to the drum 48 of the peda! 12 in a direct drive or coupling relationship via the shaft 40 which is coupled to both the torque motor 19 and the drum 48 of the pedal 2 and in which the shaft 40, in the embodiment shown, defines a longitudinal axis S which Is disposed and oriented in a relationship generally co-linear with the longitudinal axes M and D of the torque motor 19 and the drum 48 of the pedal 12 respectively. Moreover, in the embodiment shown, the pedai 2 and the pedal arm 43 define a longitudinal axis P that is oriented and extends in a direction and relationship generally normal to the longitudinal and rotational axes D of the drum 48 of the pedal 12, the longitudinal axis M of the torque motor 19, and the longitudinal axis S of the shaft 40,

The torque motor 19 is adapted for operation or activation in response to specific commands from the vehicle EC or by supplied power behavior as a result of a variety of vehicle conditions or events including, for example, a vehicle exceeding a recommended speed or speed limit or a vehicle not keeping a safe distance behind another vehicle, or a vehicle sensing the presence of an object behind the vehicle when operating the vehicle in reverse, or a vehicle losing traction, or a vehicle not being operated in a fuel efficient manner.

Operation or activation of the torque motor 19 causes the clockwise and/or counter-clockwise rotation of the rotor 25 of the torque motor 19 which, in turn, generates and applies a clockwise and or counter-clockwise rotational torque force or movement to the combination pedal/torgue motor shaft 40 coupled directly to the rotor 25 of the torque motor 19 which rotational force and torque, in turn, is transferred to the opposed end segment 41 of the shaft 40 which is coupled directly to the drum 48 of the pedal 12 which rotational force and torque, in turn, is transferred to the drum 48 of the pedal 12 which, in turn, results in the transfer and application of an active feedback or push back force on the pedal 12 and the foot of the operator via the foot plate 44, thus providing the operator with a sensory indication or signal to remove his/her foot from the pedal 12 and respond to the vehicula condition or event.

For example, the pedai assembly 10 can be configured for operation in a relationshi and manner wherein the torque motor 1 causes the clockwise rotation of the rotor 25 which, in turn, causes the clockwise rotation of the shaft 40 which, in turn, causes the clockwise rotation of the drum 48 of the pedal 12 which, in turn, causes the transfer and appitcation of an active feedback or push back force on the pedai 1 and the foot of the operator via the foot plate 44 that arrests the downward, inward, counter-clockwise acceleration movement of the pedai 12 and causes the reverse upward, outward, and clockwise movement of the pedai 1 to decelerate the vehicle and return the pedal 12 to its idle neutral position.

The torque motor 19 can be coupled and connected to the shaft 40 and the pedal 12 in a direct drive arrangement either mechanically or magnetically. The torque motor 19 could also be connected to the shaft 40 and the pedal 12 via an intermediate gear train or other type of intermediate mechanism including a mechanism that allows decoupling of the shaft 40 from the torque motor 19 if necessary or as desired.

Although not shown or described herein in any detail, it is understood that the second end of ha!f segment 45 of the shaft 40 that is coupled to the rotor 25 of the torque motor 19 can likewise include a knurled exterior surface similar to the knurled exterior surface 47 on the first end or half segment 41 of the shaft 40 that would be pressed into the material of the rotor 25 to Insure a secure coupling of the shaft 40 to the rotor 25 of the torque motor 19.

Moreover, and although also not shown or described in any detail, it is also understood that in such applications in which it may be desirable to allow the shaft 40 to be decoupled f rom the rotor 25 of the torque motor 19 during operation, the knurl on the exterior surface of the second end or half shaft segment 45 could be removed and substituted with a one way bearing or

Sprague that would be pressed into the rotor 25. This bearing would support the shaft 40 for rotation with the rotor 25 in one direction only, such as for example the clockwise direction shown in FIGURE 3, but would slip and become decoupled from the rotor 25 in the opposite direction such as for example the counter-clockwise direction in FIGURE 3.

The torque motor 19 can be of any suitable multiple pole stator design such as, for example, a two pole gear drive design or a six pole design as shown in the FIGURES and connected and coupled to the shaft 40 and the pedal 12 in a direct drive arrangement.

It is further understood that the concept of the present invention is likewise applicable to a brake or clutch pedai and that the torque motor 19 could be either a non-intelligent motor or a "smart" motor operabie and controllable via electronics integrated in the pedai assembly 10 including, for example, electronics mounted on a printed circuit board in the inierior housing of the pedal assembly 10 or directly mounted to the torque motor 19. It is still further understood that the electrical connector assembly for the torque motor 9 can be either integrated as part of the peda! assembly connector assembly or a separate connector assembly dedicated for the torque motor 19.

Numerous variations and modifications of the embodiment described above may be effected without departing from the spirit and scope of the novel features of the invention. It is to be understood that no limitations with respect to the specific active force pedal assembly illustrated herein are intended or should be inferred. It is, of course, intended to cover by the appended claims ail such modifications as fail within the scope of the claims.