ADJUSTABLE PEDAL APPARATUS WITH DEFINED ADJUSTMENT PATH

Abstract: An adjustable pedal apparatus includes a vehicle support and a pedal subassembly. The pedal subassembly includes an upper portion pivoted to the support, a lower pedal lever, and an adjustment device comprising an elongated track on the upper portion and a mating follower on the lower portion. The track is arcuate, which causes the pedal to adjust a virtual pivot such that the pedal pad is lowered upon adjustment toward a vehicle driver, but that causes the pedal to move farther than the follower. A row of teeth on the track are engaged by a cable-driven reversible worm gear for powered adjustment of the pedal location.

Description: ADJUSTABLE PEDAL APPARATUS WITH DEFINED ADJUSTMENT PATH BACKGROUND OF INVENTION The present invention relates to under-dash pedal systems for vehicle control, and more particularly relates to adjustable foot pedals that are adjustable relative to a seated person in a vehicle for optimal positioning and function. Adjustable foot pedal systems for control of vehicles are known. For example, see U.S. Patent 3,828,625. However, improvements are desired to allow linear adjustment of the pedals so that a location of the pedals to the vehicle floor and to the driver can be more appropriately controlled. For example, it is desirable to adjust the pedals in a manner that is most similar to adjusting a vehicle seat, since linearly adjusting a vehicle seat relative to foot pedals is widely accepted by the public and government regulators. However, a problem may result if the pedals are linearly adjusted because, with conventional thinking, this requires that the actuators (e.g. push rods, cables, and mechanical linkages) connecting the pedals to the associated vehicle components (e.g. a master brake cylinder, an engine throttle, or a clutch) be lengthened or shortened as the pedals are adjusted. Some designers are hesitant to make a length of actuators adjustable, because this can introduce play, wear, and reduced reliability into the actuator. Nonetheless, there are potential cost savings if foot pedals are made adjustable instead of a vehicle seat being adjustable on a floor pan of the vehicle. Also, there are potential safety improvements related to airbag deployment that will occur by keeping a seat relatively stationary and pedals adjustable. Even if the above challenges are overcome, the adjustable pedal system must be able to meet certain functional criteria. For example, the braking pedal must be able to withstand significant torsional stress that occurs during hard braking of the vehicle. Further, the accelerator and brake pedal systems should preferably position the accelerator pedal and the brake pedal at the same relative positions after an adjustment, so that the driver does not mis-hit or have other problems when quickly switching from one pedal to the other. At the same time, the accelerator and brake pedal systems must be relatively simple, reliable, and very durable for long use. Another problem is caused by horizontally /rearwardly extending and protruding objects. It is undesirable to incorporate such protruding objects under an instrument panel or dash where they can cause leg and knee injury during a vehicle crash. Also, there is not much room under an instrument panel, such that any pedal system must take up a minimum of space. Accordingly, an apparatus solving the aforementioned problems and having the aforementioned advantages is desired. SUMMARY OF THE INVENTION In one aspect of the present invention, an adjustable pedal apparatus includes an upper portion adapted for attachment to a vehicle support, a lower lever portion supporting a pedal pad, and an adjustment mechanism connecting the upper and lower portions. The adjustment mechanism includes a curved track, and a follower slidably engaging the track to define a virtual pivot spaced away from the track so that the pedal pad follows a predetermined path as the follower is slidably adjusted along the curved track. By this arrangement, the follower travels a shorter distance than the pedal pad during adjustment of the adjustment mechanism. In another aspect of the present invention, an adjustable pedal apparatus includes a support configured for attachment to a vehicle and a pedal-supporting subassembly. The pedal-supporting subassembly includes an upper portion pivotally engaging the support, a lower portion supporting a pedal construction, and an adjustment mechanism connecting the upper and lower portions. The adjustment mechanism includes a curved track, and a follower slidably engaging the track. An adjuster for adjusting the pedal construction includes a rack extending along the track and attached to one of the track and the pedal construction, and further includes a driven gear operably supported on the other of the track and the pedal construction for operably engaging the rack to adjust the pedal construction along the track. The adjustment mechanism further includes a drive cable attached to the driven gear for rotating the driven gear. By this arrangement, the follower travels a shorter distance than movement of the pedal during adjustment of the adjustment mechanism. In another aspect of the present invention, a method comprises steps of providing an adjustable pedal construction that includes structure defining a virtual pivot and a pedal construction supported for movement about the virtual pivot, and pivoting the pedal construction about the virtual pivot. In still another aspect of the present invention, a method comprises steps of providing a passenger compartment of a vehicle, the passenger compartment including an instrument panel defining an obstructed location where pedal-supporting structure cannot be located, and also providing a foot-operated pedal pad adapted for connection to a vehicle system for controlling the vehicle system, where the pedal pad has a series of preferred locations of adjustment in the passenger compartment for seated vehicle drivers having different length legs, differently shaped bodies, and different user preferences, the series of preferred locations defining a path of adjustment. The method includes designing a pedal adjustment mechanism for adjustably supporting the pedal pad for adjustable movement about a virtual pivot, where the adjustment mechanism includes a track and follower designed to position the pedal pad selectively along the path of adjustment with the virtual pivot being in an obstructed location in the passenger compartment. These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an exploded perspective of an adjustable pedal apparatus embodying the present invention; Figs. 2 and 3 are perspective views of the brake pedal subassembly shown in Fig. l; Figs. 4 and 5 are exploded perspective views of the pedal subassembly shown in Figs. 2 and 3, respectively; Figs. 6 and 7 are side views of the accelerator pedal subassembly shown in Fig. 2; and Fig. 8 is a perspective view of the brake pedal subassembly shown in Fig. 2, but showing a path of the pedal during adjustment about a first virtual pivot point. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT A pedal-supporting apparatus 20 (Fig. 1) includes a bracket support 21 configured for attachment to a vehicle firewall under the vehicle's instrument panel, and a brake pedal subassembly 22 (Fig. 2) pivoted to the support 21. Though a brake pedal subassembly is illustrated, it is contemplated that the present invention could be used on any vehicle pedal system. The brake pedal subassembly 22 includes an upper portion 24 pivotally engaging the support 21 (Fig. 1), and a lever portion 25 coupled to the upper portion 24 by an adjustment device 26. The adjustment device 26 includes a longitudinally curved track or channel 27 attached to the upper portion 24, and a hat- shaped follower 28 on the lever portion 25. The follower 28 includes blade-shaped curved edges operably engaging the track 27. The curved track 27 defines an arcuate path particularly shaped to cause the lever portion 25 to pivot about a virtual pivot strategically located well above the adjustment device 26, such that the brake pedal pad 29 moves along a predetermined path that optimally positions the pedal pad 29 for large- bodied vehicle drivers (when in a far-from-the-driver, forwardly-adjusted position) and for small bodied vehicle drivers (when in a close-to-the-driver, rearwardly-adjusted position). The arcuate track 27 results in a shorter track, since the movement of the pedal pad is magnified over the movement of the follower 28. By this arrangement, the total volumetric package size of the adjustment device 26 and also of the upper portion 24 is considerably smaller than adjustable pedal systems where the track is linear, since less travel of the adjustment device itself is needed. This also results in substantial advantages in terms of a more compact assembly, smaller parts, reduced weight, and a safety improvement in terms of less elongated protruding components under a vehicle dash. At the same time, the curved track defines a virtual pivot instead of an actual pivot, which has advantages since the curved track can be located at a lower position without requiring structure at the location of the virtual pivot. Nonetheless, it is contemplated that a curved track can be made into a straight track by making the radius of curvature into infinity. The bracket support 21 (Fig. 1) includes apertured flanges 30 for attachment to a vehicle firewall. The support 21 further includes sidewalls 31 optimally designed for strength and light weight. Holes 32 are provided in sidewalls 31 for receiving a pivot pin 33. The sidewalls 31 are constructed with bends, apertures, and reinforcement ribs to provide optimal strength and low weight. It is noted that support 21 can be a stamped metal part, a die-cast part, or a molded plastic component. The upper portion 24 (Fig. 4) of the subassembly 22 includes a body 34 with L- shaped arcuate flanges 35 and 36 on one side defining the track 27 between them. A top section 37 of the body 34 extends above the top flange 35 and supports a transverse cylindrical section or pivot mount 38 for receiving pivot pin 33. The cylindrical section 38 has a length chosen to fill the space between the sidewalls 31 (Fig. 1), and has a diameter to closely but rotatably receive the pivot pin 33. A flange 38 (Fig. 4) extends downwardly from the body 34 and includes a connector 39 for connection to a push rod such as for operating a master brake cylinder of a vehicle braking system. Such push rods are well known in the art, and need not be described in detail herein for an understanding by a person skilled in this art. An opening 40 is cut through body 34 at a location generally in the longitudinal center of the track 27. A housing 41 is screw-attached to a side of the body 34 opposite the flanges 35 and 36. A gear member 42 is positioned in the housing 41 and rotatably supported by an axle 43. The gear member 42 includes a first drive gear 44 that extends through the opening 40 and operably engaged with a rack 45 in the follower 28 as described below, and includes a second gear 46 positioned beside the first gear 44 and also supported on the axle 43. A worm gear 47 is rotatably supported in the housing 41 by cylindrical section 48 at a 90-degree orientation from the axis of the second gear 46 and operably engages the second gear 46. A motor-driven cable 49 (Fig. 1) is attached to the worm gear 47 and is attached to a rotatable shaft of a DC reversible electric motor, such as are sometimes used in vehicles. When the motor is rotated, the worm gear 47 engages the second gear 46, causing the first gear 44 to rotate, engage the rack 45, and move the follower 28 along the track 27. The worm gear 47 includes an exposed tail end configured to be engaged by a second cable 50, such that the second cable 50 is rotated at the same time and in the same direction as the first cable 49 when the motor is operated. It is contemplated that the second cable 50 can be extended to a second adjustable pedal apparatus similar to apparatus 20. By this means, multiple adjustable pedal apparatus can be simultaneously adjusted. The lever portion 25 includes a lever 51 attached to the hat-shaped follower 28 by rivets 52' (or by welding, or other means). The pedal pad 29 is attached to a lower end of the lever 51. The follower 28 is "hat" shaped, and includes a center wall 52, arcuate edge flanges 53 that mateably slidably engage the recesses formed under the L- shaped flanges 35 and 36, and transverse walls 54 that connect the edge flanges 53 to the center wall 52. Plastic bearing caps (see Fig. 4) and lubricant can be used on flanges 35 and 36 to reduce friction and provide uniform sliding movement, but it is noted that some frictional resistance is desired to help prevent undesired adjustment movement. To adjust the pedal subassembly, the motor is operated to rotate cable 49 and in turn rotate gears 47 and 44 of gear member 42, thus moving follower 28 and lever portion 25 along the arcuate track 27. To use the brake pedal, the vehicle driver presses on the pedal pad 29, causing the lever portion 25 and the upper portion 23 to pivot as a unit about pivot pin 33, thus pushing the push rod toward the master brake cylinder. Notably, the curved adjustment device 26 (Fig. 8) (i.e. track 27 and follower 28) defines a virtual pivot 56 that is substantially above the track 27. As illustrated, the radius 57 that extends between the virtual pivot 56 and the pedal pad 29 is about 326 mm, and the radius 58 to a centerline on the track 27 is about half that distance. Also, the virtual pivot 56 is located rearward (i.e. toward the vehicle driver) from the adjustment device 26. As a result, when the follower 28 moves 40 mm in an arcuate forward direction (toward a vehicle driver), the pedal pad 29 moves along a predetermined arcuate path that is 76 mm toward the vehicle driver and 10 mm lower. This results in an optimal position of the pedal pad 29 relative to the vehicle floor pan, both when the pedal pad 29 is adjusted to its forward position 59 (optimal for large bodied persons) and when adjusted to its rearward position 60 (optimal for small bodied persons). It is to be understood that different virtual pivot points can be designed into the present device. For example, the virtual pivot 56A illustrates a second location directly above the track 27, which results in the pedal pad 29 moving through an arcuate path segment of about 76 mm where the front and rear positions of the pedal pad 29 are about equal in height. Thus, different vehicle manufacturer specifications can be easily met. Importantly, the chordal longitudinal length of edge flanges 53 of the follower 28 and their engagement with the L-shaped flanges 35 and 36 results in a mechanically advantageous arrangement capable of withstanding substantial torques. This is important because at least one manufacturer specifies that the pedal construction must withstand 300 pounds of force at the brake pad 29. Translating this force through the long torque arm of lever portion 25 to pivot pin 33 and back to the track 27 results in over 2000 pounds of force on the flanges 35 and 36. Thus, length of engagement by the edge flanges 53 on the L-shaped flanges 35 and 36 is important for sufficient torsional strength. In the present arrangement, a chordal length of track 27 that is about 110 mm and a follower length that is about 55 mm provides the necessary strength while still meeting the small volumetric size requirements of most vehicle manufacturers for this device. This compares to a linear track that would have to be about 160 mm or longer in order to provide similar pedal travel and torsional resistance. As shown in Figs. 11-14, the body 34 is a one-piece body with flanges 35 and 36 integrally formed from the contiguous and continuous material of a main portion of the body 34. Consistent with this, it is contemplated that the body 34 can be made by casting or molding into a near-final net shape, or by machining the body 34, and can be made of metal, polymeric, a composite or a combination of materials. In the foregoing description, those skilled in the art will readily appreciate that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.

Claims: The invention claimed includes: 1. An adjustable pedal apparatus comprising: an upper portion adapted for attachment to a vehicle support; a lower lever portion supporting a pedal pad; and an adjustment mechanism connecting the upper and lower portions, the adjustment mechanism including a curved track and a follower slidably engaging the track to define a virtual pivot spaced away from the track so that the pedal pad follows a predetermined path as the follower is slidably adjusted along the curved track, whereby the follower travels a shorter distance than the pedal pad during adjustment of the adjustment mechanism. 2. The pedal apparatus defined in claim 1, wherein one of the upper portion and the adjustment mechanism includes a pivot for pivotally supporting the lower portion and pedal pad. 3. The pedal apparatus defined in claim 2, wherein the upper portion includes the pivot and wherein the pivot is adapted to pivotally support an assembly of the upper portion, the lower portion, and the adjustment mechanism. 4. The pedal apparatus defined in claim 1, wherein the curved track is attached to the upper portion and the follower is attached to the lower portion. 5. The pedal apparatus defined in claim 1, wherein the curved track includes a body with at least one curved flange defining an arcuate section of the track. 6. The pedal apparatus defined in claim 5, wherein the at least one curved flange includes opposing curved flanges. 7. The pedal apparatus defined in claim 1, wherein the curved track is elongated and comprises a curved channel. 8. The pedal apparatus defined in claim 7, wherein the follower is "hat" shaped and is also elongated to define a curve complementary to the curved track. 9. The pedal apparatus defined in claim 8, wherein the follower includes teeth, and the adjustment mechanism includes a drive mechanism operably engaging the teeth to selectively motivate the follower along the track. 10. The pedal apparatus defined in claim 9, wherein the "hat" shape of the follower defines a longitudinally extending recess, and a rack including that teeth are positioned in the recess. 11. The pedal apparatus defined in claim 1 , wherein the adjustment mechanism includes a row of teeth on the follower and further includes a drive mechanism with gearing operably supported on the track and adapted to be driven by an actuator cable, the gearing operably engaging the row of teeth for motivating the follower selectively along the track. 12. The pedal apparatus defined in claim 1, wherein the curved track includes a one- piece body with integrally formed opposing flanges defining the track on the body. 13. The pedal apparatus defined in claim 1, wherein the curved track defines a radius that is longer than a total vertical height of an assembly of the upper and lower portions. 14. The pedal apparatus defined in claim 1, including a second upper portion adapted for attachment to the vehicle support; a second lower lever portion supporting a second pedal pad; and a second adjustment mechanism connecting the second upper and lower portions, the second adjustment mechanism including a second track and a second follower slidably engaging the second track. 15. The pedal apparatus defined in claim 14, wherein the second track defines a second virtual pivot spaced away from the second track so that the second pedal pad follows a second predetermined path as the second follower is slidably adjusted along the second track. 16. The pedal apparatus defined in claim 14, wherein the second track includes second opposing flanges defining the second track, and wherein the second follower is hat-shaped and includes opposing flanges with bearing material thereon that is shaped to slidably engage the opposing flanges. 17. The pedal apparatus defined in claim 16, including a drive cable operably connecting the first and second drive mechanisms. 18. The pedal apparatus defined in claim 1, wherein a ratio of movement of the pedal pad to the follower is 2:1. 19. The pedal apparatus defined in claim 1, wherein the follower includes a row of teeth, and wherein the adjustment mechanism includes a three-dimensional one-piece body defining a first side of the track and integrally-formed flanges forming another side of the track, the adjustment mechanism including gearing and the body further including a window for receiving and operably supporting the gearing adjacent the track so that the gearing operably engages the row of teeth for motivating the follower along the track. 20. The pedal apparatus defined in claim 19, wherein the integrally formed flanges are made of continuous and contiguous material of the body and form a C-shaped transverse cross section with the body, with the track being a longitudinally-extending cavity formed within the C-shaped cross section. 21. The pedal apparatus defined in claim 20, wherein the one-piece body comprises a solid mass of material capable of being heated and flowed into a near-final net shape. 22. The pedal apparatus defined in claim 20, wherein the one-piece body comprises a solid mass of material capable of being molded or cast, and thereafter cooled into a final shape. 23. The pedal apparatus defined in claim 20, wherein the track defines a known radius at least as great as a length of the lower portion. 24. The pedal apparatus defined in claim 20, wherein the track defines a known radius greater than a total length of the lower portion and the upper portion and that positions the virtual pivot above the upper portion. 25. An adjustable pedal apparatus comprising: a support configured for attachment to a vehicle; a pedal-supporting subassembly with an upper portion pivotally engaging the support, a lower portion supporting a pedal construction, and an adjustment mechanism connecting the upper and lower portions, the adjustment mechanism including a curved track and a follower slidably engaging the track; and an adjuster for adjusting the pedal construction including a rack extending along the track and attached to one of the track and the pedal construction, and further including a driven gear operably supported on the other of the track and the pedal construction for operably engaging the rack to adjust the pedal construction along the track, and still further including a drive cable attached to the driven gear for rotating the driven gear, whereby the follower travels a shorter distance than movement of the pedal during adjustment of the adjustment mechanism. 26. The pedal apparatus defined in claim 25, wherein the curved track has a cross section with an elongated vertical dimension and has upper and lower flanges that stiffen the curved track. 27. The pedal apparatus defined in claim 25, further including a second pedal- supporting subassembly including an upper portion with a second curved track having a cross section with an elongated vertical dimension and having upper and lower second flanges that stiffen the second track; the subassembly further including a second pedal construction including a downwardly hanging pedal portion and a second follower slidably engaging the second curved track; and a second adjuster for adjusting the second pedal construction including a second rack oriented along the second track and attached to one of the second track and the pedal construction, and further including a second drive gear operably supported on the other of the second track and the second pedal construction for operably engaging the second rack to adjust the second pedal construction along the second track, and further including a second drive cable operably connected to the first-mentioned driven gear and to the second driven gear for rotating the second driven gear. 28. The pedal apparatus defined in claim 25, wherein the curved track includes a one-piece body with integrally formed flanges defining the track on the body. 29. The pedal apparatus defined in claim 25, wherein the curved track defines a radius that approaches infinity. 30. A method comprising steps of: providing an adjustable pedal construction that includes structure defining a virtual pivot and a pedal construction supported for movement about the virtual pivot; and pivoting the pedal construction about the virtual pivot. 31. The method defined in claim 30, wherein the structure includes a track and the pedal construction includes a follower operably engaging the track and also includes a pedal pad, and wherein a ratio of movement of the pedal pad to the follower is 2: 1 when the pedal construction is pivoted about the virtual pivot. 32. The method defined in claim 30, including a second pedal construction including a second structure defining a second virtual pivot and a second pedal construction including a second pedal pad supported for movement about the second virtual pivot, and including a drive mechanism connected to both of the first-mentioned and second pedal constructions for moving both of the first-mentioned and second pedal pads about the respective first-mentioned and second virtual pivots. 33. A method comprising steps of: providing a passenger compartment of a vehicle, the passenger compartment including an instrument panel defining an obstructed location where pedal-supporting structure cannot be located; providing a foot-operated pedal pad adapted for connection to a vehicle system for controlling the vehicle system, the pedal pad having a series of preferred locations of adjustment in the passenger compartment for seated vehicle drivers having different length legs, differently shaped bodies, and different user preferences, the series of preferred locations defining a path of adjustment; and designing a pedal adjustment mechanism for adjustably supporting the pedal pad for adjustable movement about a virtual pivot, where the adjustment mechanism includes a track and follower designed to position the pedal pad selectively along the path of adjustment with the virtual pivot being in an obstructed location in the passenger compartment. 34. The method defined in claim 33, wherein the adjustment mechanism includes a curved track and pedal-pad-supporting follower slidably engaging the curved track, the curved track defining point of rotation of the pedal pad that is located at the virtual pivot.

Inventors: FISHER DANIEL J, FISHER, DANIEL, J.
Applicants: FISHER DANIEL J, GRAND HAVEN STAMPED PRODUCTS, FISHER, DANIEL, J.
Application year: 2001
Main classification: B60R
IPC codes: B60T7, G05G1