Cross-Reference to Related Applications

This application claims priority to U.S. provisional application No. 63/254,378 filed October 11 , 2021 and titled “Vehicle Pedal Spring Resistance Emulator Assembly with Position Sensor,” which is hereby incorporated by reference in its entirety.

Field

This arrangement relates to a vehicle pedal spring resistance emulator assembly with a position sensor and, more specifically, a vehicle brake pedal spring resistance emulator assembly with a position sensor.

Background

Brake-by-wire vehicle brake pedals do not utilize a conventional vacuum or hydraulic system for braking.

There is a desire to replicate or emulate the feel of a conventional vacuum or hydraulic braking system in brake-by-wire vehicle brake pedals.

The present arrangement is directed to a brake-by-wire vehicle brake pedal and, more specifically, a vehicle brake pedal spring resistance emulator assembly that replicates or emulates the resistance feel of a conventional vacuum or hydraulic braking system.

The present arrangement is also directed to a brake-by-wire vehicle brake pedal and, more specifically, a vehicle brake pedal spring resistance emulator assembly with a position sensor for sensing the position of the vehicle brake pedal.

Summary

The present arrangements are directed generally to a vehicle pedal emulator assembly comprising a housing defining an interior cavity, a sleeve extending and adapted for sliding movement in the interior cavity of the housing, first and second springs in one end of the interior cavity of the housing, the first and second springs being compressible in response to the sliding movement of the sleeve in the interior cavity of the housing, and third and fourth springs in an opposed end of the interior cavity of the housing, the third and fourth springs being compressible in response to the sliding movement of the sleeve in the interior cavity of the housing.

In one aspect, the sleeve defines an interior cavity, the third and fourth springs being located in the interior cavity of the sleeve.

In one aspect, the sleeve defines an interior cavity, the first spring extending into the interior cavity of the sleeve.

In one aspect, a shaft extends in the interior cavity of the housing and into the interior cavity of the sleeve, the first and second springs surrounding the shaft.

In one aspect, a shaft extends in the interior cavity of the housing and into the interior cavity of the sleeve, the third spring extending between an end of the sleeve and an end of the shaft.

In one aspect, the vehicle pedal emulator further comprises an inductive sensor for sensing the position of the sleeve relative to the housing, and a Hall Effect sensor for sensing the position of the sleeve relative to the housing.

In one aspect, the vehicle pedal emulator further comprises a printed circuit board with an inductive coil and a Hall Effect integrated circuit, the printed circuit board being located on the housing, an inductive target on the sleeve and moveable relative to the inductive coil in response to the sliding movement of the sleeve relative to the housing, and a Hall Effect magnet on the sleeve and moveable relative to the Hall Effect integrated circuit in response to the sliding movement of the sleeve relative to the housing.

In one aspect, the vehicle pedal emulator further comprises a wake-up switch which is actuable in response to the sliding movement of the sleeve relative to the housing.

In one aspect, the vehicle pedal emulator further comprises a lever on the wake-up switch which is actuable in response to contact with a tab on the sleeve in response to the sliding movement of the sleeve relative to the housing.

In one aspect, the vehicle pedal emulator further comprises a printed circuit board located on the housing, the wake-up switch being located on the printed circuit board.

In one aspect, the first and second springs are disposed in a telescoping relationship relative to each other.

In one aspect, the third and fourth springs are disposed in a telescoping relationship relative to each other.

In one aspect, the first, second, third, and fourth springs are arranged and compressible in a parallel relationship.

The present arrangements are also directed to a vehicle pedal emulator assembly comprising a housing defining an interior cavity, a sleeve extending and adapted for sliding movement in the interior cavity of the housing, the sleeve defining an interior cavity, a shaft extending in the interior cavity of the housing and into the interior cavity of the sleeve, first and second springs in one end of the interior cavity of the housing, the first and second springs being compressible in response to the sliding movement of the sleeve in the interior cavity of the housing, the first spring extending into the interior cavity of the sleeve, and third and fourth springs in an opposed end of the interior cavity of the housing, the third and fourth springs being compressible in response to the sliding movement of the sleeve in the interior cavity of the housing, the third spring extending into the interior cavity of the sleeve.

In one aspect, the first spring surrounds the shaft and the second spring surrounds the first spring.

In one aspect, the third spring extends between an end of the sleeve and an end of the shaft, the fourth spring surrounding the third spring.

In one example, the first, second, third, and fourth springs are arranged and compressible in a parallel relationship.

In one example, the first and second springs surround the shaft and extend between one end of the housing and one end of the sleeve, the third and fourth springs extending between one end of the sleeve and the other end of the shaft.

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

Brief Description of the Drawings

These and other features can best be understood by the description of the accompanying Figs, as follows:

Fig. 1 is a perspective view of a vehicle brake pedal spring resistance emulator assembly;

Fig. 2 is an exploded view of the vehicle brake pedal spring resistance emulator assembly shown in Fig. 1 ;

Fig. 2A is vertical cross-sectional view of the vehicle brake pedal spring resistance emulator assembly shown in Fig. 1 ;

Fig. 3 is a vertical cross-sectional view of the vehicle brake pedal spring resistance emulator assembly shown in Fig. 1 extending and coupled between a vehicle pedal arm and a vehicle floor bracket with both the vehicle brake pedal spring resistance emulator assembly and vehicle pedal arm in a disengaged and fully extended position;

Fig. 4 is a vertical cross-sectional view of the vehicle brake pedal spring resistance emulator shown in Fig. 1 extending and coupled between a vehicle pedal arm and the vehicle floor bracket with both the vehicle brake pedal spring resistance emulator assembly nd vehicle pedal arm in a first engaged and compressed position;

Fig. 5 is a vertical cross-sectional view of the vehicle brake pedal spring resistance emulator assembly shown in Fig. 1 extending and coupled between a vehicle pedal arm and the vehicle floor bracket with both the vehicle brake pedal spring resistance emulator assembly and vehicle pedal arm in a fully engaged and compressed position; Fig. 6 is a simplified exploded perspective view of the position sensor assembly of the vehicle brake pedal spring resistance emulator assembly;

Fig. 7 is an enlarged broken perspective view of the assembly for activation of the wake-up switch of the vehicle brake pedal spring resistance emulator assembly; and

Fig. 8 is an enlarged broken top plan view of the assembly for activation of the wake-up switch of the vehicle brake pedal spring resistance emulator assembly.

Detailed Description

Figs. 1 and 2 depict the vehicle brake pedal spring resistance emulator assembly or module or member 100 in accordance with the arrangements.

Figs. 3, 4, and 5 depict the vehicle brake pedal spring resistance emulator assembly 100 coupled to a vehicle brake pedal assembly 10 which, in the embodiment shown, includes a base/bracket 12 and an elongate brake pedal arm 14 adapted or configured for counterclockwise/engaging/braking and clockwise/disengaging/non-braking rotation and movement.

The vehicle brake pedal spring resistance emulator assembly 100 is operably coupled to the vehicle brake pedal assembly 10 in a relationship extending between the base/bracket 12 and the underside of the brake pedal arm 14 and further in a relationship with a first end bracket or ball stud 122 thereof is operatively coupled to the underside of the brake pedal arm 14 and a second opposed end bracket or adjustable eyelet 123 coupled to the pedal base/bracket 12.

The vehicle brake pedal emulator assembly 100 is generally in the form and shape of an elongate elastomeric hollow cylinder or housing or tube comprising a first generally cylindrical elongate hollow interior cylinder or tubular housing or sleeve 130 including an exterior circumferential wall 132 defining and forming an interior hollow elongate cylindrically or tubular shaped receptacle or cavity or hollow interior chamber 134 as shown in Figs. 1 , 2 and 2A.

The housing or sleeve 130 defines a first open end 131 in communication with the hollow interior chamber 134 and an opposed closed end 133 that includes and is closed by the first end bracket or ball stud 122 as shown in Figs.

1 , 2, and 2A.

An elongate shaft 136 extends through the interior of the cavity or chamber 134 defined by the housing or sleeve 130 and includes a first end 138 extending into the first end bracket 122 and an opposed second end defining a spring receptable 149 as shown in Figs. 2, 2A and 3. The shaft 136 extends in a relationship co-linear with the longitudinal axis of the housing or sleeve 130.

A first pair of helical elongate compression springs 140 and 142 are located in the interior cavity 134 of the housing 130 and surround the shaft 136 in a telescoping relationship with the helical elongate compression spring 140 surrounding the shaft 136 and the helical elongate compression spring 142 surrounding and spaced from the spring 140.

The vehicle brake pedal emulator assembly 100 further comprises a second generally cylindrical elongate elastomeric hollow interior cylinder or tubular housing or sleeve 150 including an exterior circumferential wall 152 defining and forming an interior hollow elongate cylindrically or tubular shaped receptacle or cavity or chamber 154 as shown in Figs. 1 , 2, and 2A.

The sleeve 150 defines a first open end 153 extending into the cavity or chamber 134 of the first housing or sleeve 130 and an opposed closed end 155. The second opposed end bracket 123 is threadingly secured and extends outwardly from the closed end 155 as shown in Figs. 2 and 2A.

A metal shaft 156 extends inwardly from the closed end 155 and into the interior of the cavity or chamber 154 defined by the sleeve 150 as shown in Fig. 2A.

A second pair of helical elongate compression springs 160 and 162 are located in the interior cavity 154 of the sleeve 150 and surround the shaft 156 in a telescoping relationship with the helical elongate compression spring 160 surrounding the shaft 156 and the helical elongate compression spring 162 surrounding and spaced from the spring 160 as shown in Fig. 2A, and Figs. 3-5.

The sleeve 150 extends in a relationship generally co-linear with the longitudinal axis of the housing 130 and is adapted or configured for sliding back and forth movement within the interior of the cavity 134 of the housing 130 as described in more detail below.

The vehicle brake pedal emulator assembly 100 further comprises a third generally cylindrical elongate metal hollow interior cylinder or tubular housing or sleeve 170 including an exterior circumferential wall 172 defining and forming an interior hollow elongate cylindrically or tubular shaped receptacle or cavity or chamber 174.

The sleeve 170 includes opposed open ends 176 and 178 with the open end 176 defining a spring receptacle. The sleeve 170 also includes an interior shoulder 180 defining a through-hole or opening 182 as shown in Fig. 2A. The sleeve 170 is located and secured in the cavity or chamber 154 of the sleeve 150 via a pin 171 shown in Figs. 4 and 5.

The sleeve 150 is located and mounted in the interior cavity or chamber 134 of the housing 130 in a relationship wherein the shaft 136 extends through the open end 153 of the sleeve 150 and the open end 176 of the sleeve 170 located in the interior of the sleeve 150 and through the through-hole or opening 182 defined in the interior shoulder 180 of the sleeve 170 as shown in Fig. 2A.

A bearing 183 is located between the shaft 136 and the interior shoulder 180 and supports the shaft 136 for linear back and forth sliding movement through the sleeve 150 as shown in Figs. 2 and 2A.

The helical elongate compression spring 140 includes a first end 140a in abutting relationship with the closed end 133 of the housing 130 and an opposed second end 140b extending through the open end 153 of the sleeve 150 and the open end 176 of the sleeve 170 and into an abutting relationship with the interior shoulder 180 of the sleeve 170 as shown in Fig. 2A.

The helical elongate compression spring 142 includes a first end 142a in abutting relationship with the interior face of the closed end 133 of the housing 130 and an opposed free second end 142b which is spaced from the interior shoulder 180 of the sleeve 170 in the disengaged and fully extended relationship of the vehicle brake pedal emulator assembly 100 as shown in Figs. 2A and 3. The helical elongate compression spring 160 includes a first end 160a in abutting relationship with the closed end 155 of the sleeve 150 and an opposed second end 160b in abutting relationship with the spring receptacle end of the shaft 136.

The helical elongate compression spring 162 includes a first end 162a in abutting relationship with the interior face of the closed end 155 of the sleeve 150 and an opposed second end 162b which is spaced from the spring receptacle end of the shaft 136 in the disengaged and fully extended relationship of the vehicle brake pedal emulator assembly 100 as shown in Figs. 2A and 3.

In the embodiment shown, the helical elongate compression springs 140 and 160 comprise the stage 1 pedal force resistance emulator springs of the vehicle brake pedal emulator assembly 100, the helical elongate compression spring 142 comprises the stage 2 pedal force emulator spring, and the spring 162 comprises the stage 3 pedal force emulator spring.

Thus, in the embodiment shown, the vehicle brake pedal emulator assembly 100 includes a total of four pedal force resistance springs with two such helical elongate compression springs 140 and 142 located at one end of the assembly 100 and the other two such helical elongate compression springs 160 and 162 located at the opposed end of the assembly 100 with the sleeve 150 positioned and located between and separating the helical elongate compression springs 140 and 142 from the helical elongate compression springs 160 and 162.

Moreover, in the embodiment shown, the helical elongate compression springs 140 and 160 are positioned opposite and spaced from each other in a colinear relationship and the helical elongate compression springs 142 and 162 are positioned opposite and spaced from each other in a co-linear relationship.

The vehicle brake pedal emulator assembly 100 is adapted to create and generate linear resistance forces on the brake pedal arm 14 in response to the travel or movement or stroke of the brake pedal arm 14 during operation of a vehicle with a brake-by-wire system and which emulates the resistance feel of a vehicle with a conventional vacuum or hydraulic braking system. Specifically, and referring to Figs. 3 and 4, it is understood that an initial depression of the brake pedal arm 14 by the foot of a vehicle operator causes inward sliding movement of the sleeve 150 into the interior cavity 134 of the housing or sleeve 130 which results in the compression of both of the stage 1 helical elongate compression springs 140 and 160, which results in the generation of a stage 1 resistive force against the brake pedal arm 14.

Moreover, and referring to Figs. 4 and 5, it is further understood that the further depression of the brake pedal arm 14 by the foot of the vehicle operator causes further inward sliding movement of the sleeve 150 into the interior cavity 134 of the housing or sleeve 130 which results in the further compression of the stage 1 helical elongate compression springs 140 and 160 and also the compression of the spring 142 as a result of the opposed second end 142b of the spring 142 coming into abutting relationship with the interior shoulder 180 of the sleeve 170 so as to generate a stage 2 pedal resistance force against the brake pedal arm 14 that is greater in magnitude than the stage 1 pedal resistance force.

Still further with reference to Fig. 5, it is still further understood that the still further depression of the pedal arm 14 by the foot of the vehicle operator causes still further inward sliding movement of the sleeve 150 into the interior cavity 134 of the housing or sleeve 130, which results in the still further compression of the stage 1 helical elongate compression springs 140 and 160, the further compression of the spring 142, and the compression of the spring 162 as a result of the first end 162a of the spring 162 coming into abutting relationship with the end of the shaft 136 so as to generate a stage 3 pedal resistance force against the brake pedal arm 14 that is greater in magnitude that the combination of the stage 1 and pedal resistance forces.

It is thus understood that in the embodiment shown, the helical elongate compression springs 140, 142, 160, and 162 function and compress in a parallel relationship relative or with respect to each other in which all of the helical elongate compression springs 140, 142, 160, and 162 are compressed together and simultaneously during at least a portion of the operation of the vehicle brake pedal emulator assembly 100.

The vehicle brake pedal emulator assembly 100 still further comprises a position sensor assembly 200 for sensing the position of the sleeve 150 relative or with respect to the housing 130 and thus for sensing the position of the brake pedal arm 14.

Referring to Figs. 1 , 2, 3, and 6, the position sensor assembly 200 includes redundant position sensor assemblies 200a and 200b as shown in Figs. 1 and 2, each including an inductive position sensor assembly 210 and a Hall Effect position sensor assembly 220.

Specifically, and with reference to the position sensor assembly 200a depicted in Figs. 1 , 2, 3, and 6, the position sensor assembly 200a includes a printed circuit board 230 and a connector assembly 240. The printed circuit board 230 includes an inductive coil 242 defined and formed on the lower surface 230a thereof and further includes a Hall Effect integrated circuit 244 mounted to the lower surface 230a thereof. The board 230 also includes a wake-up micro switch 300 mounted to the top surface 230b of the board 230.

The board 230 is mounted to the exterior face of exterior wall 132 of the housing 130. The connector assembly 240 is mounted over and operably electrically connected to the printed circuit board 230 as shown in Figs. 2 and 6.

In the embodiment as shown in Figs 1 and 2, the redundant position sensor assemblies 200a and 200b are positioned and mounted on the exterior face of the exterior wall 132 of the housing 130 in a side-by-side and diametrically opposed relationship relative to each other.

The position sensor assembly 200 and, more specifically each of the redundant position sensor assemblies 200a and 200b thereof, also includes an inductive target 250 and a Hall effect magnet 254. Fig. 6 depicts the pair of inductive targets 250 for the respective position sensor assemblies 200a and 200b coupled to a common or shared bracket 252. Figs. 2 and 6 depict only one of the Hall Effect magnets 254 but it is understood that the other Hall Effect magnet 254 is located and molded in the exterior face of the exterior wall 152 of the sleeve 150 in a relationship and position diametrically opposed to the Hall Effect magnet 254 shown in Fig. 2.

Referring to Figs. 2 and 3, the inductive target 250 is coupled or molded into the material of the exterior wall 152 of the sleeve 150 so as to be moveable longitudinally relative to or with respect to the housing 130 in response to the sliding movement of the sleeve 150 relative to the housing 130.

In a similar manner as shown in Fig. 2, the Hall Effect magnet 254 is coupled or molded into the material of the exterior wall 152 of the sleeve 150 so as to moveable longitudinally relative to the housing 130 in response to the sliding movement of the sleeve 150 relative to the housing 130.

In the embodiment shown, the inductive target 250 and the Hall Effect magnet 254 are positioned in a relationship opposed and spaced from the inductive coil 242 and the Hall Effect integrated circuit 244 on the printed circuit board 230. Still more specifically, in the embodiment shown, it is understood that the exterior wall 132 of the housing 130 separates the printed circuit board 230, and more specifically, the inductive coil 242 and Hall Effect integrated circuit 244 thereon, from the associated inductive target 250 and the Hall Effect magnet 254.

Stated another way, the exterior wall 132 of the housing 130 separates the printed circuit board 230, and more specifically the inductive coil 242 and Hall Effect integrated circuit 244, from the inductive target 250 and Hall Effect magnet 254.

It is understood that the longitudinal movement of the inductive target 250 relative to the housing 130 and thus relative to the inductive coil 242 formed on the board 230 results in a change in the inductance of the inductive coil 242 which is sensed and measured so as to allow the position of the sleeve 150 and thus the position of the brake pedal arm 14 to be determined and measured by an electronic control unit (ECU) associated with the vehicle for applying or releasing the vehicle brakes.

It is also understood that the longitudinal movement of the Hall Effect magnet 254 relative to the housing 130 and thus relative to the Hall Effect integrated circuit 244 on the printed circuit board 230 results in a change in the magnitude and/or direction of the magnetic field sensed by the Hall Effect integrated circuit 244 which is sensed and measured so as to allow the position of the sleeve 150 and thus the position of the brake pedal arm 14 to be determined and measured by an ECU associated with the vehicle for applying or releasing the brakes.

The incorporation of both an inductive sensor and a Hall Effect sensor on the circuit board 230 allows for a higher functional safety and the redundant measurement of the position of the brake pedal arm 14 in the event of a malfunction in either of the inductive sensor or the Hall Effect sensor. The incorporation of a second circuit board 230 with a second set of inductive and Hall Effect sensors allows for the redundant measurement of the position of the brake pedal arm 14 in the event of a malfunction with the other circuit board 230 or the sensors thereon.

The vehicle brake pedal emulator assembly 100 still further comprises the wake-up switch 300 that provides a wake-up function by opening a circuit when the vehicle brake pedal emulator assembly 100 is in its extended and disengaged position and closes the circuit when the vehicle brake pedal emulator assembly 100 is in its engaged and compressed position.

Referring to Figs. 6, 7, and 8, the wake-up switch 300 includes a lever 302 on the side of the wake-up switch 300 which is adapted or configured for movement and engagement in response to contact thereof with a tab 310 extending upwardly from the exterior wall 152 of the sleeve 150 during the sliding movement of the sleeve 150 relative to the housing 130 to activate the wake-up switch 300.

Numerous variations and modifications of the embodiment of the vehicle brake pedal spring resistance emulator assembly 100 of the present arrangements as described above may be effected without departing from the spirit and scope of the novel features. It is to be understood that no limitations with respect to the arrangements illustrated herein are intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.