Patent Publication Number: US-2023159008-A1

Title: Passive force emulator pedal assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This utility patent application claims priority benefit from U.S. provisional patent application Ser. No. 63/281,379, filed Nov. 19, 2021 and entitled “Passive Pedal Force Emulator Assembly”, the entire contents of which is incorporated herein in its entirety. 
    
    
     TECHNICAL FIELD 
     The present specification generally relates to pedal assemblies for vehicles and, more specifically, to pedal assemblies providing a pedal effort hepatic feel to a user. 
     BACKGROUND 
     Many pedal systems are passive driven. For example, a brake-by-wire for a braking system may be passive driven. However, newer braking pedal systems are now an e-boost braking system where a boost of the braking system is provided by an electric motor to provide the braking system with an active force. As such, the need for mechanical braking by the operator is reducing and the need for system components to perform the braking on behalf of the operator is increasing. As such, there is a need for passive force emulator to provide a pedal effort haptic feel to the operator when a pedal is depressed. 
     SUMMARY 
     In one embodiment, a pedal assembly is provided. The pedal assembly includes a housing, a spring arm member, a pedal arm, a spring carrier, and a spring guide member. The spring arm member is coupled to the housing. The pedal arm has a hub portion and an opposite pedal pad. The hub portion is pivotally retained in the housing by the spring arm member at the hub portion. The spring carrier is coupled to the pedal arm and to the spring arm member. The spring carrier has at least one spring positioned to provide a first pedal effort force to the pedal arm at a first amount of predetermined travel of the pedal arm. The spring guide member has a contact surface and an opposite rear surface that contacts a second at least one spring positioned between the rear surface and the housing. The contact surface receives contact from the pedal arm when the pedal arm exceeds a second amount of predetermined travel of the pedal pad. The at least one spring provides a second pedal effort force. When the pedal pad is depressed to the first amount of predetermined travel of the pedal arm, the at least one spring of the spring carrier applies the first pedal effort force onto the pedal arm and when the pedal pad is further depressed to the second amount of predetermined travel of the pedal pad, the contact surface and the second at least one spring applies the second pedal effort force onto the pedal arm. The second pedal effort force is a greater pedal effort than the first pedal effort force. 
     In another embodiment, a pedal assembly for a vehicle is provided. The pedal assembly includes a housing, a spring arm member, a pedal arm, a spring carrier, and a spring guide assembly. The spring arm member is coupled to the housing. The pedal arm has a hub portion and an opposite pedal pad. The hub portion is pivotally retained in the housing by the spring arm member at the hub portion. The spring carrier is coupled to the pedal arm and to the spring arm member. The spring carrier has at least one spring positioned to provide a first pedal effort force to the pedal arm at a first amount of predetermined travel of the pedal arm. The spring guide assembly has a spring guide member and a second at least one spring extending in perpendicular direction with respect to the spring carrier. The spring guide member has a cam surface and an opposite rear surface. The second at least one spring is positioned between the rear surface and the housing. The cam surface is positioned to be in contact with the pedal arm. The second at least one spring provides a second pedal effort force at a second amount of predetermined travel of the pedal pad. When the pedal pad is depressed to the first amount of predetermined travel of the pedal arm, the at least one spring of the spring carrier applies the first pedal effort force onto the pedal arm and when the pedal pad is further depressed to the second amount of predetermined travel of the pedal pad, the cam surface and the second at least one spring applies the second pedal effort force onto the pedal arm. The second pedal effort force is a greater pedal effort than the first pedal effort force. 
     In yet another embodiment, a pedal assembly is provided. The pedal assembly includes a housing, a spring arm member, a pedal arm, a spring carrier, a spring guide member, and a contact member. The spring arm member is coupled to the housing. The pedal arm has a hub portion and an opposite pedal pad. The hub portion is pivotally retained in the housing by the spring arm member at the hub portion. The spring carrier is coupled to the pedal arm and to the spring arm member. The spring carrier has at least one spring positioned to provide a first pedal effort force to the pedal arm at a first amount of predetermined travel of the pedal arm. The spring guide member has a contact surface and an opposite rear surface that contacts a second at least one spring positioned between the rear surface and the housing. The spring guide member and the second at least one spring extends in a direction perpendicular to the spring carrier. The contact surface receives contact from the pedal arm when the pedal arm is at a second amount of predetermined travel of the pedal pad. The at least one spring provides a second pedal effort force. The contact member is coupled to the housing. The contact member makes contact with the pedal arm to provide a third pedal effort force when the pedal arm is at a third amount of predetermined travel of the pedal pad. When the pedal pad is depressed to the first amount of predetermined travel of the pedal arm, the at least one spring of the spring carrier applies the first pedal effort force onto the pedal arm and when the pedal pad is further depressed to the second amount of predetermined travel of the pedal pad. The contact surface of the spring guide member and the second at least one spring applies the second pedal effort force onto the pedal arm. The second pedal effort force is a greater pedal effort than the first pedal effort force, and the contact member applies the third pedal effort force onto the pedal arm. The third pedal effort force is a greater pedal effort than the second pedal effort force. 
     These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
         FIG.  1    schematically depicts a left side perspective view of a pedal assembly according to one or more embodiments shown and described herein; 
         FIG.  2    schematically depicts a cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  with a pedal arm in an undepressed state according to one or more embodiments shown and described herein; 
         FIG.  3    schematically depicts a cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  with the pedal arm in a partially depressed state according to one or more embodiments shown and described herein; 
         FIG.  4    schematically depicts a cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  with the pedal arm in a fully depressed state according to one or more embodiments shown and described herein; 
         FIG.  5    schematically depicts an exploded perspective view of the electronic throttle pedal assembly of  FIG.  1    according to one or more embodiments shown and described herein; 
         FIG.  6    schematically depicts a partial perspective and cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  without a housing and in a undepressed state according to one or more embodiments shown and described herein; 
         FIG.  7    schematically depicts a side cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  with a pedal arm in an undepressed state according to one or more embodiments shown and described herein; 
         FIG.  8    schematically depicts a side cross-sectional view of the pedal assembly of  FIG.  1    taken from line  1 - 1  with the pedal arm in a fully depressed state according to one or more embodiments shown and described herein; 
         FIG.  9    graphically depicts a desired force response curve for a pedal assembly according to one or more embodiments shown and described herein; 
         FIG.  10    graphically depicts an output force response curve for the pedal assembly of  FIG.  1    according to one or more embodiments shown and described herein; and 
         FIG.  11    graphically depicts independent output force response curves for pedal effect force generating components of the pedal assembly of  FIG.  1    according to one or more embodiments shown and described herein. 
     
    
    
     DETAILED DESCRIPTION 
     A brake pedal emulator (BPE) is a device that takes the place of a brake pedal and other hardware and is be used on an electromechanical braking system where there is no direct mechanical or hydraulic connection between the brake pedal and the calipers. The BPE inputs are force and travel distance from the driver&#39;s foot. Further inputs may include reference voltage for all sensors, ground for all sensors, and reaction loads at all fastening points. The BPE outputs are force feedback/resistance to driver&#39;s foot as a function of travel and speed. Multiple pedal position sensor outputs are a function of travel, and error codes relating to the sensor outputs. Optional function is the conditioning of the output signals to provide the driver&#39;s intended braking input signal. The intention is that the BPE behaves to the driver as closely as possible as a conventional braking system in terms of pedal feel and deceleration performance. 
     The BPE may be located in the passenger compartment in a driver&#39;s footwell area. The BPE needs to meet the same mechanical loads as conventional pedal assemblies and must behave in a similar way as the conventional pedal. For example, the BPE needs to behave similar to conventional pedals when respect to applying loads, lateral loads, reverse loads vs. deflections and plastic deformation. 
     Conventional brake pedal assemblies include a pedal mounting bracket with a pivotally attached pedal arm/lever that has certain pedal force characteristics that need to be met during the apply stroke of the pedal. As such, the BPE needs to be configured to meet these same certain pedal force characteristics. Further, in some embodiments, the BPE may also include a downstop for the brake pedal stroke. Additionally, the BPE needs to be configured to withstand panic braking loads. 
     The BPE assembly disclosed herein meets the following criteria: the BPE fails functional such that upon any failure, the driver is permitted to operate the braking system by applying the pedal and provide an appropriate sensor signal output; the BPE is configured to withstand foreseeable conditions and abuse a pedal will take; and the BPE is scalable to automotive volume series production and be cost effective to manufacture and assemble. 
     An example pedal assembly described herein includes three different components each configured to provide a different pedal effort force to a pedal arm as a function of travel of the pedal arm. For example, the example pedal assembly includes a housing that receives a spring arm member positioned within and coupled to the housing, a spring carrier coupled to the pedal arm, a spring guide member, and a contact member. A hub portion of the pedal arm pivotally engages with a portion of the spring arm member. The spring carrier is coupled to the pedal arm and to the spring arm member. At least one spring is positioned within the spring carrier to provide a first pedal effort force to the pedal arm at a first amount of predetermined travel of the pedal arm. The spring guide member has a cam surface and a second at least one spring. The cam surface is positioned to be in contact with the pedal arm along with the second at least one spring to provide a second pedal effort force at a second amount of predetermined travel of the pedal arm. The contact member is coupled to the housing and makes contact with the pedal arm to provide a third pedal effort force at a third amount of predetermined travel of the pedal arm. 
     As used herein, the term “communicatively coupled” means that coupled components are capable of exchanging data signals with one another such as, for example, electrical signals via conductive medium or a non-conductive medium, though networks such as via Wi-Fi, Bluetooth, and the like, electromagnetic signals via air, optical signals via optical waveguides, and the like. 
     As used herein, the term “longitudinal direction” refers to the forward-rearward direction of the assembly (i.e., in the +/−X-direction depicted in  FIG.  1   ). The term “lateral direction” refers to the cross-assembly direction (i.e., in the +/−Y-direction depicted in  FIG.  1   ), and is transverse to the longitudinal direction. The term “vertical direction” or “up” or “above” refer to the upward-downward direction of the assembly (i.e., in the +/−Z-direction depicted in  FIG.  1   ). 
     Referring initially to  FIG.  9   , there is shown a desired force response curve for a pedal assembly, such as an example pedal assembly  10  schematically depicted in  FIGS.  1 - 8   . As can be seen, as the pedal travels the greater the apply force that is required. The force is non-linear and increases significantly near the end of the travel of the pedal. This type of force response is typically found in a mechanical pedal design where there is a linkage either mechanically or hydraulically coupled with the brake calipers. As a pedal effort (PE) is applied to the pedal, the pedal arm pivots to allow the pedal to travel. The emulator applies an opposite emulator force (EF) to provide the driver with a resistive force that changes according to the speed in which the PE is applied. 
     Referring now to  FIGS.  1 - 8   , a pedal assembly  10  is schematically depicted. The pedal assembly  10  includes a housing  12 , a pedal arm assembly  14 , a spring arm member  56 , a spring carrier  58 , a spring guide assembly  60 , a sensor assembly  62 , and a bearing guide member  64 . The housing  12  includes a pair of sidewalls  26   a ,  26   b , a front wall portion  26   c , a rear wall portion  26   d , a lower wall portion  26   e , an upper wall portion  26   f  and a top wall portion  26   g . The front wall portion  26   c  is positioned above the rear wall portion  26   d  in the vertical direction (i.e., in the +/−Z direction). The pair of sidewalls  26   a ,  26   b , the upper wall portion  26   f , and the front wall portion  26   c  define an upper recess  27 . The pair of sidewalls  26   a ,  26   b , the rear wall portion  26   d , the lower wall portion  26   e , and a top wall portion  26   g  define a lower recess  28 . A receiving slot  30  extends between the pair of sidewalls  26   a ,  26   b  below the front wall portion and above the lower wall portion  26   e  in the vertical direction (i.e., in the +/−Z direction). 
     The lower wall portion  26   e  includes an indention  39  or void. The indention  39  is positioned below the receiving slot  30  in the vertical direction (i.e., in the +/−Z direction). The indention  39  receives a contact member  42  to position the contact member  42  to make contact with the pedal arm  16  at a predetermined distance of travel of the pedal arm  16 , as discussed in greater detail herein. 
     A protrusion  31  extends within the upper recess  27 . The protrusion  31  has a radius portion  32  and a rotation surface portion  34 . The radius portion  32  extends from an interior surface  36  of the upper wall portion  26   f  and an interior surface  38  of the front wall portion  26   c  in a semi-circular shape within the upper recess  27 . That is, the radius portion  32  may extend from interior surface  36  of the upper wall portion  26   f  in the vertical direction (i.e., in the +/−Z direction) and from the interior surface  38  of the front wall portion  26   c  in the longitudinal direction (i.e., in the +/−X direction). The rotation surface portion  34  may extend from the interior surface  38  of the front wall portion  26   c  in the longitudinal direction (i.e., in the +/−X direction) a distance greater than the radius portion  32 . The rotation surface portion  34  may be arcuate or curvilinear in shape to correspond to and/or compliment an outer surface  43  of a hub portion  18  of a pedal arm  16 , as discussed in greater detail herein. 
     The bearing guide member  64  may be arcuate to correspond to the shape of the hub portion  18 . The bearing guide member  64  includes an inner surface  66   a  and an opposite outer surface  66   b . A recess  68  extends along the arcuate shape of the outer surface  66   b  to receive the radius portion  32  of the protrusion  31 . As such, the bearing guide member  64  may be positioned to abut the interior surface  36  of the upper wall portion  26   f  and the interior surface  38  of the front wall portion  26   c  while receiving the radius portion  32  of the protrusion  31  such that the inner surface  66   a  of the bearing guide member  64  makes contact with the hub portion  18  of the pedal arm  16 . That is, the bearing guide member  64  is positioned between the hub portion  18  of the pedal arm  16  and the interior surface  36  of the upper wall portion  26   f  and the interior surface  38  of the front wall portion  26   c  of the upper recess  27  of the housing  12 . 
     The pedal arm assembly  14  includes the pedal arm  16 , which includes the hub portion  18  at a proximal end  20  and a pedal pad  22  at a distal end  24 . The hub portion  18  may include a groove surface  41  extending circumferentially around the hub portion  18 . In some embodiments, the proximal end  20  may include a slot  21  extending in the general vertical direction (i.e., in the +/−Z direction) below the groove surface  41  of the hub portion  18  in the vertical direction (i.e., in the +/−Z direction). The slot  21  may receive a portion of the bearing guide member  64  to retain or couple the bearing guide member  64 . Further, the slot  21  may receive a portion of the spring arm member  56 , as discussed in greater detail herein. 
     The proximal end  20  may include a bore  19  extending through the pedal arm  16  in the lateral direction (i.e., in the +/−Y direction) and receives a fastener such as a screw, rivet, bolt and nut, and/or the like. The hub portion  18  may be pivotally coupled to the rotation surface portion  34  of the housing  12 , as discussed in greater detail herein. As such, the pedal arm  16  pivots, moves, and/or rotates within the housing  12  based on a pressure applied to the pedal pad  22  at the distal end  24  the pedal arm  16 . 
     The pedal arm  16  further includes an extension portion  44  and a contact surface  46 . In some embodiments, the extension portion  44 , the contact surface  46 , and the rear surface  48  may be monolithically formed with the pedal arm  16 . In other embodiments, the extension portion  44  may be coupled or attached to the pedal arm  16  via a fastener such as bolt and nuts, screws, rivets, weld, epoxy, adhesive, hook and loop, and the like. The extension portion  44  extends from a rear surface  48  of the pedal arm  16  in in the longitudinal direction (i.e., in the +/−X direction). In some embodiments, the extension portion  44  is formed with two legs  50   a ,  50   b  extending from the rear surface  48  to an apex  52 . As such, in this embodiment, the extension portion  44  in cross-section may generally be triangular shaped. This is non-limiting and, in other embodiments, the extension portion  44  may be square in shape, rectangular in shape, spherical in shape, octagonal in shape, and/or any other shape, including regular and irregular shapes. The apex  52  may be radiused or arcuate to provide a contact surface  54 , as discussed in greater detail herein. 
     The contact surface  46  of the pedal arm  16  may be a portion of the rear surface  48  of the pedal arm  16  that extends in the longitudinal direction (i.e., in the +/−X direction). As such, the contact surface  46  may be a planar surface. This is non-limiting and the contact surface  46  and/or the rear surface  48  may be curvilinear, arcuate, angled, and/or any other shape. The contact surface  46  of the pedal arm  16  may be positioned below the extension portion  44  in the vertical direction (i.e., in the +/−Z direction). The contact surface  46  and/or the rear surface  48  of the pedal arm  16  makes contact with the contact member  42  at the predetermined distance of travel of the pedal arm  16 , as discussed in greater detail herein. 
     In some embodiments, the rear surface  48  of the pedal arm  16  may further include a downstop  132 . The downstop  132  may be positioned below the contact surface  46  in the vertical direction (i.e., in the +/−Z direction). At a predetermined amount of travel of movement of the pedal arm  16 , the downstop  132  may make contact with the lower wall portion  26   e  of the housing  12 . In some embodiments, the downstop  132  may make contact and be partially received within the recess  134  of the lower wall portion  26   e  of the housing  12 . As such, the downstop  132  and the lower wall portion  126   e  of the housing  12  may prevent movement of the pedal arm  16  beyond a predetermined position during a force applied to the pedal pad  22 . 
     The pedal arm  16  is positioned within the receiving slot  30  and pivots, moves, and/or rotates within the receiving slot  30  of the housing  12 , as discussed in greater detail herein. The hub portion  18  of the pedal arm  16  is positioned within the upper recess  27  and pivots, moves, and/or rotates against the rotation surface portion  34  within the upper recess  27  of the housing  12 , as discussed in greater detail herein. 
     Still referring to  FIGS.  1 - 8   , the spring arm member  56  is coupled to the pair of sidewalls  26   a ,  26   b  of the housing  12 . The spring arm member  56  includes a pair of walls  70   a ,  70   b , a top wall  70   c , and a front wall  70   d , defining a cavity portion  72 . A hub contact portion  74  may extend from an outer surface  76  of the front wall  70   d  in the longitudinal direction (i.e., in the +/−X direction). The hub contact portion  74  may be arcuate or curvilinear in shape to correspond to and/or compliment the groove surface  41  of the hub portion  18  of the pedal arm  16  and to be positioned within the slot  21  of the pedal arm  16 , as discussed in greater detail herein. As such, in some embodiments, the hub contact portion  74  may extend further in the longitudinal direction (i.e., in the +/−X direction) from the outer surface  76  of the front wall  70   d  at a lower position than the hub contact portion  74  extends from the outer surface  76  at an upper positon near the top wall  70   c  in the vertical direction (i.e., in the +/−Z direction). The hub contact portion  74  of the spring arm member  56  is positioned to retain the hub portion  18  of the pedal arm in the housing  12  and to allow the hub portion  18  to rotate, pivot, or otherwise move within the housing about the hub portion  18 . 
     The spring carrier  58  is coupled to the spring arm member  56  at one end and to the extension portion  44  of the pedal arm  16  at the other end. A portion of the spring carrier  58  may be received within the cavity portion  72  and may be coupled to an inner surface  78  of the top wall  70   c . In some embodiments, the spring carrier  58  may be coupled to the inner surface  78  of the top wall  70   c  via a fastener such as a nut and bolt, screw, rivet, hook and loop, adhesive, weld, and/or the like. In other embodiments, the spring carrier  58  may be coupled to the inner surface  78  of the top wall  70   c  via a press fit configuration with the inner surface  78  of the top wall  70   c , which includes a pair of spaced apart ribs or projections that receive a portion of the spring carrier  58  between them in a press fit configuration. 
     The spring carrier  58  includes a female spring guide  80 , an outer spring  82 , an inner spring  84 , and a male spring guide  86 . The inner spring  84  is received within an inner diameter of the outer spring  82 , depicted by arrow A 1  on  FIG.  5   . Further, the female spring guide  80  and the male spring guide  86  are coupled to one another within an inner diameter of the inner spring  84 , depicted by the arrow A 2  in  FIG.  5   . The outer and inner springs  82 ,  84 , in the assembled state, are coaxially aligned. Each of the outer and inner springs  82 ,  84  extend between a spring receiving surface  81  of the female spring guide  80  and a spring receiving surface  83  of the male spring guide  86 . As such, the outer and inner springs  84 ,  86  extend between the female spring guide  80  and the male spring guide  86  such that are each are in contact with the spring receiving surface  81  of the female spring guide  80  and a spring receiving surface  83  of the male spring guide  86 . 
     Such an arrangement retains the inner spring  84  and the outer spring  82  while permitting for the inner spring  84  and the outer spring  82  to expand and collapse as a function of the amount of travel of the pedal arm  16 , as discussed in greater detail herein. As such, the inner spring  84  and the outer spring  82  may be compression springs with the same or different potential and kinetic energies. 
     In some embodiments, each of the outer spring  82  and the inner spring  84  may be formed of a steel material. In other embodiments, each of the outer spring  82  and the inner spring  84  may be formed of stainless steel, wire, carbon steel, alloy steel, elgiloy, Monel®, copper, nickel, and/or the like. 
     A protrusion  88  extends from the female spring guide  80  to act as a coupling point to couple the female spring guide  80  to the top wall  70   c  of the spring arm member  56 , as discussed in greater detail herein. For example, the protrusion  88  may be coupled to the top wall  70   c  of the spring arm member  56  via a fastener or via a press fit configuration, as discussed in greater detail herein. 
     A protrusion  90  extends from the male spring guide  86  to act as a coupling point to couple the male spring guide  86  to the extension portion  44  of the pedal arm  16 . The protrusion  90  of the male spring guide  86  may be coupled to the extension portion  44  of the pedal arm  16  via a fastener such as a nut and bolt, screw, rivet, hook and loop, adhesive, weld, and/or the like. In other embodiments, the protrusion  90  may be coupled to the extension portion  44  of the pedal arm  16  via a press fit configuration where the leg  50   a  may include a pair of spaced apart ribs or projections that receive a portion of the protrusion  90  between them in a press fit configuration. In this embodiment, the leg  50   a  may include a recess portion that the protrusion  90  is recessed within. 
     In other embodiments, the tension caused by the male spring guide  86  and the female spring guide  80  compressing the inner spring  84  and the outer spring  82  may cause the protrusion  88  to remain in contact with the inner surface  78  of the top wall  72   c  and to the leg  50   a  of the extension portion  44  of the pedal arm  16 . As such, regardless of the amount of travel of the pedal arm  16 , there is a tension caused by the male spring guide  86  and the female spring guide  80  maintaining a position of contact of the spring carrier  58  extending between the extension portion  44  of the pedal arm  16  and the top wall  72   c  of the spring arm member  56 . 
     When the pedal arm  16  is moved from the home or without force applied position, an elongated member  87  of the male spring guide  86  slidably engages with a receiving bore  89  of the female spring guide  80  to collapse the outer spring  82  and the inner spring  84  and apply the load of the outer spring  82  and inner spring  84  against the leg  50   a  of the extension portion  44  of the pedal arm  16 . As the outer spring  82  and the inner spring  84  compress due to the movement of the pedal arm  16 , the spring carrier  58  continues to transfer the load into the pedal arm  16  such that a pedal effort is increased as a function of the amount of travel of the pedal arm  16 . 
     The spring guide assembly  60  includes a spring guide member  92  and a coil spring  94 . The coil spring  94  is positioned within the lower recess  28  and portions of the spring guide member  92  are pressed in the longitudinal direction (i.e., in the +/−X direction) into and out of the lower recess  28  based on the amount of travel of the pedal arm  16 , as discussed in greater detail herein. As such, the spring guide assembly  60  extends in a longitudinal direction (i.e., in the +/−X direction) and the spring carrier  58  generally extends in the vertical direction (i.e., in the +/−Z direction). As such, the spring guide assembly  60  extends and moves in a perpendicular direction compared to the spring carrier  58  that extends and moves in the vertical direction (i.e., in the +/−Z direction). 
     The spring guide member includes a cam surface  96   a  and an opposite rear surface  96   b . The coil spring  94  is positioned between, and makes contact with, the rear surface  96   b  of the spring guide member  92  and an inner surface  98  of the rear wall portion  26   d  of the lower recess  28 . The coil spring  94  may have a smaller overall length than the inner spring  84  and the outer spring  82 . 
     In some embodiments, the coil spring  94  may be formed of a steel material. In other embodiments, the coil spring  94  may be formed of stainless steel, wire, carbon steel, alloy steel, elgiloy, Monel®, copper, nickel, and/or the like. 
     The spring guide member  92  may include a pair of arms  100   a ,  100   b  that each include an angled surface  102   a ,  102   b . The pair of arms  100   a ,  100   b  may be resilient members to permit for a snap fit or cantilever fit into a respective slot  104   a ,  104   b  of the top wall portion  26   g  and lower wall  28   g  of the housing  12  that define the lower recess  28 . 
     The cam surface  96   a  may be planar or may be recessed within the spring guide member  92 . Moreover, the cam surface  96   a  may include different segments with different shapes or angles. As such, one segment may be arcuate with a constant radius while other segments may be curvilinear with or without uniform radii. It should be appreciated that the shape of the cam surface  96   a  changes a force characteristic when the contact surface  54  of the apex  52  slidably engages with different portions of the cam surface  96   a  as a function of the amount of travel of the pedal arm  16 . 
     That is, the cam surface  96   a  and the coil spring  94  together apply more or less force onto the extension portion  44  of the pedal arm  16  so that depending on the amount of pressure of the pedal pad  22 , the force output pedal effort felt by the user changes, as discussed in greater detail herein. That is, the contact surface  54  of the apex  52  of the extension portion  44  may move along the cam surface  96   a  in response to the amount of pressure applied to the pedal pad  22 , which also compresses the coil spring  94  against the inner surface  98  of the rear wall portion  26   d  within the lower recess  28 . 
     The housing  12 , the pedal arm  16 , the spring arm member  56 , the spring guide assembly  60 , the bearing guide member  64 , the female spring guide  80 , and/or the male spring guide  86  may be a molded plastic. For example, the housing  12 , the pedal arm  16 , the spring arm member  56 , the spring guide assembly  60 , the bearing guide member  64 , the female spring guide  80 , and/or the male spring guide  86  may be may be formed with various materials such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate/acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high density polyethylene, low density polyethylene, polystyrene, PEEK, POM (Acetal/Delrin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, and/or the like. Additionally, additives may be added such as UV absorbers, flame-retardants, colorants, glass fibers, plasticizers and/or the like. 
     In some embodiments, the housing  12 , the pedal arm  16 , the spring arm member  56 , the spring guide assembly  60 , the bearing guide member  64 , the female spring guide  80 , and/or the male spring guide  86  may be formed from injection molding. In other embodiments, the housing  12 , the pedal arm  16 , the spring arm member  56 , the spring guide assembly  60 , the bearing guide member  64 , the female spring guide  80 , and/or the male spring guide  86  may be may be formed from additive manufacturing techniques. Additive manufacturing techniques refer generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components. Although additive manufacturing technology is described herein as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction, other methods of fabrication are possible and within the scope of the present subject matter. For example, although the discussion herein refers to the addition of material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use layer-additive processes, layer-subtractive processes, or hybrid processes. 
     The contact member  42  may have an engagement surface  106  that makes contact or slidably engages with the contact surface  46  and/or the rear surface  48  of the pedal arm  16 . The engagement surface  106  may have a plurality of spaced apart recesses  108  extending through the engagement surface  106  in the vertical direction (i.e., on the +/−Z direction). The contact member  42  may be configured to slidably engage and/or compresses upon contact with the contact surface  46  and/or the rear surface  48  such that an additional pedal effort force is generated and felt by the user, as discussed in greater detail herein. 
     The contact member  42  may be an elastomer material such as a cured silicone rubber that may be applied as a liquid via a one-shot injection molding or other known methods to form any shape desired. In other embodiments, the contact member  42  may be a silicone rubber, natural rubber, or other elastomeric material that is formed using compression and other techniques and that is suitable for repetitive compression over millions of cycles and has temperature performance desired in pedal assembly applications. The plurality of spaced apart recesses  108  may affect the compression characteristic of the contact member  42  when contact is made with the contact surface  46  and/or the rear surface  48  of the pedal arm  16 . 
     In some embodiments, the elastomer material of the contact member  42  may have a stiffness characteristic of at least 100 newton-millimeters (N/mm) spring rate in an uncompressed state, or starting state. In some embodiments illustrated herein, the contact member  42  may have a stiffness characteristic of at least 150 newton-millimeters (N/mm) spring rate in an uncompressed state, or starting state. As the contact member  42  is compressed and/or slidably engaged from the pressure applied by the contact surface  46  and/or the rear surface  48  of the pedal arm  16 , the stiffness characteristic of the contact member  42  sharply increases until a fully compressed state, as best illustrated in  FIG.  11   , and disclosed in greater detail herein. 
     The housing  12  may be a hanging assembly that is mounted to a dash of a vehicle such as to an instrument panel, a firewall and/or the like. As such, portions of the rear wall portion  26   d  and/or the top wall portion  26   g  may be coupled, mounted or otherwise attached to a component of the vehicle to hold the pedal pad  22  and the distal end  24  of the pedal arm  16  off a vehicle floor in a vertical direction (i.e., in the +/−Z direction). 
     The sensor assembly  62  detects movement of the hub portion  18  of the pedal arm  16  via an inductive sensing assembly  110  and a Hall Effect sensing assembly  112 . In the inductive sensing assembly  110 , a coupler  114  is positioned in a coupler carrier  116  that may extend within and between a pair of openings  118  of the housing  12  and through the bore  19  of the hub portion  18 . As such, the coupler carrier  116  may include an elongated member  120  with a distal end  122  that also includes a magnet  124 , for use with the Hall Effect sensing assembly  112 , as discussed in greater detail herein. 
     In some embodiments, the inductive sensing assembly  110  includes a printed wiring assembly  123  and a connector housing  126 . The printed wiring assembly  123  may include a circuit board (or a printed circuit board), which may include at least one receiver coil, a transmitter coil, and a plurality of terminal pins extending therefrom. The coupler  114  may be mounted or attached to the coupler carrier  116  in the vicinity of and perpendicular to the pivot axis at the hub portion  18 . The coupler  114  may be positioned adjacent to the at least one receiver coil. In some embodiments, the coupler  114  may include distinct lobes, such as three lobes as illustrated in  FIG.  5   . This is non-limiting and the coupler  114  may have more or less lobes, be circular, or other shapes, such as a half-moon, square, rectangular, and/or the like. The coupler  114  may rotate or pivot upon movement of the pedal pad  22  of the pedal arm  16 . 
     The at least one receiver coil and the transmitter coil detect the movements of the coupler  114  and that data is transmitted to an electronic control unit and/or powertrain controller communicatively coupled to the inductive sensing assembly  110  via the plurality of terminal pins extending within the connector housing  126 . Portions of the inductive sensing assembly  110  may include overmold to encapsulate the electronic components, and it may include solderless connections between the printed wiring assembly and plurality of terminal pins, such as compliant through-hole pins. 
     The Hall Effect sensing assembly  112  detects movement of the magnet  124  using Hall Effect technology. In some embodiments, the Hall Effect sensing assembly  112  includes a printed wiring assembly  125  and a connector housing  128 . The printed wiring assembly  125  may include a circuit board, which may include at least one Hall Effect chip and a plurality of terminal pins  130  extending therefrom. The at least one Hall effect chip is sensitive to a Hall effect detection of magnetic change, and to convert a displacement or angular measurement of a coupler, such as the magnet  124 , to an electronic or electromagnetic signal. This information is transmitted through the plurality of terminal pins positioned within the connector housing  128  and to the electronic control unit and/or the powertrain controller for processing. The connector housing  128  may be a dual connector housing, as illustrated in  FIG.  5   , a single connector housing, or have more than two connector housings. 
     The magnet  124  may be mounted or attached to the sidewall  26   b , opposite to the side of the inductive sensing assembly  110 , at the pivot point of the hub portion  18  in the vicinity of and perpendicular to the pivot axis. As such, the magnet  124  may be positioned adjacent to the at least one Hall Effect chip. In some embodiments, the magnet  124  may be generally circular. In other embodiments, the magnet  124  may be a plurality of other shapes, such as rectangular, square, hexagonal, octagonal, and/or the like. The magnet  124  may rotate or pivot upon movement of the pedal pad  22  of the pedal arm  16 . 
     The at least one Hall effect chip detects the movements of the magnet  124  and that data is transmitted to the electronic control unit and/or powertrain controller communicatively coupled to the Hall effect sensing assembly  112  via the plurality of terminal pins extending within the connector housing  128 . Portions of the Hall Effect sensing assembly  112  may include overmold to encapsulate the electronic components, and it may include solderless connections between the printed wiring assembly  125  and the plurality of terminal pins  130 , such as compliant through-hole pins. 
     It should be understood that the inductive sensing assembly  110  and the Hall Effect sensing assembly  112  simultaneously measure the movement of the hub portion  18  of the pedal arm  16  such that redundant sensing may occur. Further, the redundant sensing described herein uses different sensing techniques, which provide for a more robust redundant sensing compared to conventional systems. 
     In operation, when the pedal arm  16  is moved between a plurality of depressed positions, the hub portion  18  rotates or pivots within the housing  12  and against or slidably engages with the bearing guide member  64  and the spring arm member  56  such that the pedal arm  16  pivots or rotates, which in turn compresses the inner spring  84  and the outer spring  82  of the spring carrier  58  during a first predetermined travel amount of the pedal arm  16 . Such rotation within or against the bearing guide member  64  and the spring arm member  56  and the compression of the inner spring  84  and the outer spring  82  causes or generates a first pedal effort force onto the pedal arm  16 . 
     When the pedal arm  16  pivots or rotates to the second predetermined amount of travel, the contact surface  54  of the apex  52  of the extension portion  44  of the pedal arm engages with the cam surface  96   a  of the spring guide member  92  and the rear surface  96   b  compresses the coil spring  94  into the rear wall portion  26   d  of the lower recess  28 . Such movement causes or generates a second pedal effort force onto the pedal arm  16 . The second pedal effort force is a greater pedal effort force felt by the user than the first pedal effort force, as discussed in greater detail herein. 
     When the pedal arm  16  pivots or rotates to the third predetermined amount of travel, the contact surface  46  and/or the rear surface  48  of the pedal arm  16  makes contact and slidably engages with the contact member  42 , which in turn causes slideable engagement with and/or compression of the contact member  42 . The contact member  42  causes or generates a third pedal effort force onto the pedal arm  16 . The third pedal effort force is a greater pedal effort force felt by the user than that of the first pedal effort force and the second pedal effort force, as discussed in greater detail herein. 
     Now referring to  FIGS.  10  and  11   , an example graphical illustration of the various pedal effort force generated onto the pedal arm  16  as a function of an amount of travel of the pedal arm  16  is schematically depicted. It should be understood that the forces and travel amounts for of the pedal arm  16  is for illustrative purposes only and is not limiting to the amount of forces or travel distances depicted in  FIG.  10   . As illustrated from the 0-millimeter (mm) position until the fully depressed position (illustrated as 66 mm), the inner spring  84  and/or the outer spring  82  of the spring carrier  58  are always applying a force to the pedal arm  16 . 
     As the pedal arm  16  moves or travels, the force increases due to the tension in the spring carrier  58  acting on the spring arm member  56  as well as the friction caused from the hub portion  18  rotating against the hub contact portion  74  of the spring arm member  56  and the bearing guide member  64 . As such, the pedal effort generated by the tension in the spring carrier  58  acting on the spring arm member  56  as well as the friction caused from the hub portion  18  rotating against the hub contact portion  74  of the spring arm member  56  and the bearing guide member  64  is generally linear as a function of the amount of travel distance of the pedal arm  16 . 
     When the pedal arm  16  travels approximately 34 mm, the contact surface  54  of the extension member  40  of the pedal arm  16  makes contact with the cam surface  96   a  of the spring guide member  92  of the spring guide assembly  60 . Upon contact, the coil spring  94  begins to compresses and the various segments of the cam surface  96   a  provide or generate the second pedal effort. As illustrated, the second pedal effort is in addition to the first pedal effort such that the user feels an increased pedal effort on the pedal pad  22  that is a combination or total of the first pedal effort in addition to the second pedal effort. 
     As illustrated, the spring guide assembly  60  applies the second pedal effort as a function of the amount of travel of the pedal arm  16  from the 34 mm position through the fully depressed position (illustrated as 66 mm). The pedal effort generated by the tension in the coil spring  94  and the cam surface  96   a  is generally linear as a function of the amount of travel distance of the pedal arm  16  with a steeper angle of increase than that of the pedal effort generated by the tension in the spring carrier  58  acting on the spring arm member  56  as well as the friction caused from the hub portion  18  rotating against the hub contact portion  74  of the spring arm member  56  and the bearing guide member  64 . 
     When the pedal arm  16  travels approximately 50 mm, the contact surface  46  of the pedal arm  16  makes contact with the contact member  42 . Upon contact, the contact member  42  slidably engages with the contact surface  46  and/or compresses to provide or generate the third pedal effort. As illustrated, the third pedal effort is in addition to the first pedal effort and the second pedal effort such that the user feels an increased pedal effort on the pedal pad  22  that is a summation or total of the first pedal effort, the second pedal effort and now the third pedal effort. The force characteristic curve generated by contact of the contact surface  46  against the contact member  42  is a sharply increasing curve extending in a nearly vertical direction as a function of the amount of travel distance of the pedal arm  16 . 
     It should now be understood that the pedal assembly described herein includes three different components, each configured to provide a different pedal effort force to a pedal arm as a function of travel of the pedal arm. For example, the pedal assembly includes a spring carrier coupled to the pedal arm, a spring guide assembly, and a contact member. Each provide a different pedal effort onto the pedal arm depending on the amount of travel of the pedal arm and the summation of the pedal effort forces apply at the fully travel position of the pedal arm. 
     It is noted that the terms “substantially” and “about” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. 
     While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.