Patent Description:
A pedal simulator is a part mounted on an electro-mechanical brake (EMB), and provides a driver with the braking feeling generated from an existing mechanical brake.

In the prior art, a hydraulic system is applied to the EMB. However, as technologies related to an electro-mechanical brake system, i.e., a Brake-By-Wire System, and an autonomous vehicle have recently emerged, the development of a non-hydraulic brake system is required.

A pedal may be divided into an organ-type pedal and a pendant-type pedal. In the prior art, a pedal simulator had to be newly developed according to types and layouts of a pedal. Since a separate pedal simulator is required depending on the types of a pedal, production cost increases, and repair is difficult. Therefore, there is a need to solve the problems.

The background technology of the present invention is disclosed in <CIT>) entitled "PEDAL SIMULATOR.

<CIT> describes a brake pedal emulator system comprising: an emulator housing; a damper positioned within and operably attached to the emulator housing; a shaft that is slidably received within the emulator housing; and a sequential spring system positioned within the emulator housing and in operable contact with the shaft wherein the shaft compresses said sequential spring system while the damper exerts a dynamic dampening force against a movement of the shaft.

Various embodiments are directed to a pedal simulator capable of improving valid and invalid strokes and a braking feeling.

In an embodiment, a pedal simulator includes: a housing having an inner space; a piston part slidably disposed at the inner space of the housing and including a plurality of piston rod units; and a plurality of damper parts disposed at the housing and facing the plurality of piston rod units, respectively, wherein each of the damper parts is configured to be compressed by a pressure from a respective one among the piston rod units.

Each damper part is configured to be compressed by the respective piston rod unit at a different time.

The plurality of damper parts includes first and second damper parts, the piston part further includes: a piston body unit having first and second sides; and a piston pressing unit disposed at the first side of the piston body unit, and the plurality of piston rod units includes: a first piston rod unit disposed at the second side of the piston body unit and configured to press the first damper part; and a second piston rod unit disposed at the second side of the piston body unit, spaced apart from the first piston rod unit and configured to press the second damper part.

The first and second piston rod units have respectively different lengths.

The first damper part is disposed to face the first piston rod unit and compressed by the pressure from the first piston rod unit, and the second damper part is disposed to face the second piston rod unit, spaced apart from the first damper part, and compressed by the pressure from the second piston rod unit.

The first damper part includes: a first damper body unit disposed at the housing; a first damper contact unit spaced apart from the first damper body unit and configured to move by the first piston rod unit in contact with the first damper contact unit; a connection unit having a first side movably disposed on the first damper body unit and a second side disposed on the first damper contact unit; a sensor unit disposed on the first damper body unit and configured to detect a position of the first piston rod unit; and a spring unit having a first side in contact with the first damper body unit and a second side in contact with the first damper contact unit, and configured to provide an elastic force to the first damper contact unit.

The connection unit includes: a connection block unit movably disposed at the first damper body unit; and a connection rod unit having a first side disposed on the connection block unit and a second side disposed on the first damper contact unit.

The second damper part comprises an elastically deformable material and couped to the housing.

The piston pressing unit is rotatably coupled to the piston body unit.

In an embodiment, a pedal simulator includes: a housing detachably disposed on a pedal part and having an inner space; a piston part slidably disposed at the inner space of the housing and including a plurality of piston rod units; and a plurality of damper parts disposed at the housing and facing the plurality of piston rod units, respectively, wherein each of the damper parts is compressed by a pressure from a respective one of the piston rod units.

The housing includes: a housing body part configured to movably accommodate the piston part, wherein the plurality of damper parts is disposed at the housing body part; and a hook part disposed on an outer side of the housing body part and detachably coupled to the pedal part.

The hook part comprises a plurality of hook parts disposed at an edge of the housing body part.

The pedal simulator according to the present invention enables common use of products through modularization applicable to all pedal parts regardless of types and shapes of a pedal part.

Since various types of pedal parts due to modularization according to the present disclosure come into common use, repair and replacement of products can be reduced, and productivity can be improved.

In addition, according to the present invention, as a first piston rod unit and a second piston rod unit are formed to have different lengths, the first and second piston rod units are tunable so that a user can have appropriate initial and medium period braking feelings and an appropriate later period braking feeling.

Moreover, according to the present invention, it is possible to reduce the volume of a housing through parallel structures of first and second piston rod units and first and second damper parts.

Effects of the present invention are not limited to the aforementioned effects, and may include various effects within a range evident to those skilled in the art from the following description.

Hereinafter, a pedal simulator will be described in detail with reference to the accompanying drawings through various exemplary embodiments. In such a process, the thicknesses of lines or the sizes of elements illustrated in the drawings may have been exaggerated for the clarity of a description and for convenience' sake.

Terms to be described below have been defined by taking into consideration their functions in the present disclosure, and may be changed depending on a user or operator's intention or practice. Accordingly, such terms should be defined based on the overall contents of this specification.

<FIG> is a perspective view schematically illustrating that a pedal simulator according to the present invention is mounted (or disposed) on an organ-type pedal part, <FIG> is a perspective view schematically illustrating that the pedal simulator according to the present invention is mounted on a pendant-type pedal part, <FIG> is a perspective view schematically illustrating the pedal simulator according to the present invention, <FIG> is an assembled perspective view schematically illustrating the pedal simulator according to the present invention, <FIG> is a cross-sectional view schematically illustrating the pedal simulator according to an embodiment of the present invention, <FIG> is a perspective view schematically illustrating a piston part according to the present invention, <FIG> is a cross-sectional view schematically illustrating the piston part according to the present invention, <FIG> is a cross-sectional view schematically illustrating that a piston pressing unit is coupled to a piston body unit by caulking in the piston part according to the present invention, <FIG> is a perspective view schematically illustrating a first damper part according to the present invention, <FIG> is a cross-sectional view schematically illustrating initial and intermediate braking in the pedal simulator according to the present invention, and <FIG> is a cross-sectional view schematically illustrating later braking in the pedal simulator according to the present invention.

Referring to <FIG> and <FIG>, a pedal simulator <NUM> according to the present invention may be detachably mounted on pedal parts 10a and 10b regardless of types and shapes of the pedal parts 10a and 10b, such as an organ-type pedal part 10a and a pendant-type pedal part 10b.

Therefore, the pedal simulator <NUM> according to the present invention is modularized and easily assembled into the pedal parts 10a and 10b such as the organ-type pedal part 10a and the pendant-type pedal part 10b. Since the pedal simulator <NUM> according to the present invention is applicable to all the pedal parts 10a and 10b, common use of the pedal simulator <NUM> may be achieved.

A hook part <NUM> of a housing <NUM> is hook-coupled to an insertion hole part 11a of the organ-type pedal part 10a so that the pedal simulator <NUM> may be easily assembled into the organ-type pedal part 10a.

In addition, the hook part <NUM> of the housing <NUM> is hook-coupled to an insertion hole part 11b of the pendant-type pedal part 10b so that the pedal simulator <NUM> may be easily assembled into the pendant-type pedal part 10b.

Referring to <FIG>, the pedal simulator <NUM> according to an embodiment of the present invention includes the housing <NUM>, a piston part <NUM> and damper parts <NUM>.

In the present embodiment, the housing <NUM> is mounted on the pedal parts 10a and 10b, such as the organ-type pedal part 10a and the pendant-type pedal part 10b. The damper parts <NUM> are mounted in an inner space of the housing <NUM>, and the housing <NUM> movably accommodates the piston part <NUM>.

The housing <NUM> may be detachably mounted on the pedal parts 10a and 10b, such as the organ-type pedal part 10a and the pendant-type pedal part 10b.

The housing <NUM> includes a housing body part <NUM> and the hook part <NUM>. The damper parts <NUM> are mounted on one side of the housing body part <NUM>, i.e., an inner left surface of the housing body part <NUM> in <FIG>.

The piston part <NUM> is movably accommodated in the housing body part <NUM>. The housing body part <NUM> includes a first guide unit <NUM> and a second guide unit <NUM> into which the piston part <NUM> can slide. The first guide unit <NUM> and the second guide unit <NUM> are formed as cylindrical grooves.

A first damper part <NUM> of the damper parts <NUM> is mounted in the first guide unit <NUM>. A first piston rod unit <NUM> of the piston part <NUM> is slidably disposed in an inner space of the first guide unit <NUM>. An inner diameter of the first guide unit <NUM> is formed to be larger than an outer diameter of the first piston rod unit <NUM>.

A second damper part <NUM> of the damper parts <NUM> is mounted in the second guide unit <NUM>. A second piston rod unit <NUM> of the piston part <NUM> is slidably disposed in an inner space of the second guide unit <NUM>. An inner diameter of the second guide unit <NUM> is formed to be larger than an outer diameter of the second piston rod unit <NUM>.

The hook part <NUM> is formed in a ring shape on an outer side of the housing body part <NUM>, and is detachably coupled to the insertion hole parts 11a and 11b of the organ-type and pendant-type pedal parts 10a and 10b. The hook part <NUM> may be conveniently assembled and mounted onto the pedal parts 10a and 10b, such as the organ-type pedal part 10a and the pendant-type pedal part 10b.

The hook part <NUM> may be provided as a plurality of hook parts <NUM> which are formed at predetermined intervals on an edge of the housing body part <NUM>. The plurality of hook parts <NUM> may be formed on the housing body part <NUM>, and accordingly, insertion hole parts 11a and 11b of the pedal parts 10a and 10b may also be provided as a plurliaty of insertion hole parts 11a and 11b. Therefore, since the hook parts <NUM> and the insertion hole parts 11a and 11b of the pedal parts 10a and 10b are coupled at a plurality of points, the pedal simulator <NUM> and the pedal parts 10a and 10b may be stably coupled, and the rotation or movement of the pedal simulator <NUM> may be prevented.

Referring to <FIG>, the piston part <NUM> is slidably mounted in the inner space of the housing <NUM>. The piston part <NUM> includes a piston body unit <NUM>, a piston pressing unit <NUM>, the first piston rod unit <NUM> and the second piston rod unit <NUM>.

The piston body unit <NUM> is disposed on the outer side of the housing body part <NUM> of the housing <NUM>. The piston body unit <NUM> includes a plate and a rod protruding from the plate to the opposite side of the housing body part <NUM>.

The rod of the piston body unit <NUM> is formed with a hollow groove so that the piston pressing unit <NUM> can be mounted. That is, as illustrated in <FIG>, the piston pressing unit <NUM> is mounted in the rod of the piston body unit <NUM>, specifically, the hollow groove of the rod. The piston pressing unit <NUM> is moved to the left (refer to <FIG>) by an external force.

Referring to <FIG> and <FIG>, the piston pressing unit <NUM> is coupled to the piston body unit <NUM> by caulking. That is, as the rim of the rod of the piston body unit <NUM> is pressed and caulked toward the piston pressing unit <NUM>, the piston pressing unit <NUM> moved by the external force may be kept rotatably coupled to the rod of the piston body unit <NUM>.

Since the piston pressing unit <NUM> is caulked to the piston body unit <NUM>, assembly time and cost may be reduced.

The first piston rod unit <NUM> is mounted on the other side of the piston body unit <NUM>, i.e., a left side of the piston body unit <NUM> in <FIG>. The piston pressing unit <NUM> is mounted on one side of the piston body unit <NUM>, and the first piston rod unit <NUM> and the second piston rod unit <NUM> are mounted on the other side of the piston body unit <NUM>, which is opposite to one side of the piston body unit <NUM>.

The first piston rod unit <NUM> presses any one of a pair of damper parts <NUM>. That is, the first piston rod unit <NUM> presses the first damper part <NUM> of the damper parts <NUM>.

The second piston rod unit <NUM> is mounted on the other side of the piston body unit <NUM>, i.e., the left side of the piston body unit <NUM> in <FIG>, so as to be spaced apart from the first piston rod unit <NUM>, and presses the other one of the pair of damper parts <NUM>. That is, the second piston rod unit <NUM> presses the second damper part <NUM> of the damper parts <NUM>.

The first piston rod unit <NUM> and the second piston rod unit <NUM> are formed in a cylindrical shape and to have different lengths. The first piston rod unit <NUM> and the second piston rod unit <NUM> are spaced apart from each other and disposed in parallel on the piston body unit <NUM>.

The first piston rod unit <NUM> presses the first damper part <NUM>, and the second piston rod unit <NUM> presses the second damper part <NUM>. Since the first piston rod unit <NUM> and the second piston rod unit <NUM> are formed to have different lengths, the timing at which the first piston rod unit <NUM> comes into contact with the first damper part <NUM> and the timing at which the second piston rod unit <NUM> comes into contact with the second damper part <NUM> may be different from each other.

Accordingly, since the contact time and length of the first piston rod unit <NUM> and the first damper part <NUM> are different from the contact time and length of the second piston rod unit <NUM> and the second damper part <NUM>, a braking feeling felt by a user may be different, which makes it possible to provide initial and medium period braking feelings and a later period braking feeling.

A length L1 of the first piston rod unit <NUM> is formed to be shorter than a length L2 of the second piston rod unit <NUM>. The first damper part <NUM> protrudes more toward the piston part <NUM> than the second damper part <NUM>.

The first piston rod unit <NUM> is disposed in the housing body part <NUM> so as to face the first damper part <NUM>, and is moved toward the first damper part <NUM> and presses the first damper part <NUM> when the external force is applied thereto.

The second piston rod unit <NUM> is disposed in the housing body part <NUM> so as to face the second damper part <NUM>, and is moved toward the second damper part <NUM> and presses the second damper part <NUM> when the external force is applied thereto.

Referring to <FIG>, before the external force is applied to the piston part <NUM>, the second piston rod unit <NUM> and the second damper part <NUM> are spaced apart from each other, and similarly, the first piston rod unit <NUM> and the first damper part <NUM> are spaced apart from each other. A separation distance between the first piston rod unit <NUM> and the first damper part <NUM> is shorter than a separation distance between the second piston rod unit <NUM> and the second damper part <NUM>.

Therefore, when the first piston rod unit <NUM> and the second piston rod unit <NUM> are moved by the movement of the piston part <NUM>, the first piston rod unit <NUM> comes into contact with the first damper part <NUM> first. In this case, the second piston rod unit <NUM> is not yet in contact with the second damper part <NUM> (refer to <FIG>).

Accordingly, the first piston rod unit <NUM> is moved to come into contact with the first damper part <NUM>, and provides a braking operation starting force while the first piston rod unit <NUM> is further moved to press the first damper part <NUM>. In this case, the first piston rod unit <NUM> may be provided the user with an initial period braking feeling and a medium period braking feeling.

When the movement of the piston part <NUM> further increases, the second piston rod unit <NUM> also comes into contact with the second damper part <NUM> (refer to <FIG>). While the first piston rod unit <NUM> is already in contact with the first damper part <NUM>, the second piston rod unit <NUM> comes into contact with the second damper part <NUM>, thereby providing the user with a later period braking feeling.

The length L1 of the first piston rod unit <NUM> and the length L2 of the second piston rod unit <NUM> are tunable to provide the user with an appropriate braking feeling.

Referring to <FIG> and <FIG>, the damper part <NUM> is provided as a plurality of damper parts <NUM> that are mounted in the housing <NUM>, and are compressed by being pressed by the piston part <NUM>. In the present disclosure, the plurality of damper parts <NUM> include the first damper part <NUM> and the second damper part <NUM>, and are mounted in the housing <NUM>.

The first damper part <NUM> is disposed to face the first piston rod unit <NUM>, and is mounted in the first guide unit <NUM> of the housing <NUM>. In the present disclosure, the first damper part <NUM> is formed to protrude more toward the piston part <NUM> than the second damper part <NUM>.

The first damper part <NUM> includes a first damper body unit <NUM>, a first damper contact unit <NUM>, a connection unit <NUM>, a sensor unit <NUM> and a spring unit <NUM>. The first damper body unit <NUM> is mounted in the first guide unit <NUM> of the housing body part <NUM>. The first damper body unit <NUM> may be fixed to the first guide unit <NUM> of the housing body part <NUM> by bolting, bonding, press-fitting or the like.

The first damper contact unit <NUM> is disposed to be spaced apart from the first damper body unit <NUM>, and comes in contact with the first piston rod unit <NUM> which moves. Even though the first piston rod unit <NUM> moves, the braking operation is not performed until the first piston rod unit <NUM> comes into contact with the first damper contact unit <NUM>. Therefore, such a period that the braking operation is not performed is referred to as an invalid period of braking. A period in which the first piston rod unit <NUM> is moved further and comes into contact with the first damper contact unit <NUM> is referred to as a valid period of braking.

One side of the connection unit <NUM>, i.e., a left side of the connection unit <NUM> in <FIG>, is movably mounted in the first damper body unit <NUM>, and the other side of the connection unit <NUM>, i.e., a right side of the connection unit <NUM> in <FIG>, is mounted on the first damper contact unit <NUM>. The connection unit <NUM> includes a connection block unit 315a and a connection rod unit 315b.

The connection block unit 315a is movably mounted in the first damper body unit <NUM>. The connection block unit 315a may be moved in an inner space of the first damper body unit <NUM> by the pressure from the first piston rod unit <NUM> transmitted through the connection rod unit 315b. The connection block unit 315a may be formed of rubber, plastic or the like.

The connection rod unit 315b is formed in a rod shape in which one side thereof, i.e., a left side thereof in <FIG> is mounted on the connection block unit 315a, and the other side thereof, i.e., a right side thereof <FIG> is mounted on the first damper contact unit <NUM>.

The sensor unit <NUM> is mounted on an outer surface of the first damper contact unit <NUM>, and measuresinformation on a position of the first piston rod unit <NUM>. The sensor unit <NUM> includes a magnet having a magnetic force. The sensor unit <NUM> measures information on magnitude of a stepping force applied by the first piston rod unit <NUM> or a position of the first piston rod unit <NUM> through a change in a magnetic field that is changed according to the movement of the first piston rod unit <NUM>, and provides a control unit (not illustrated) with the measured information.

One side of the spring unit <NUM>, i.e., a left side of the spring unit <NUM> in <FIG>, is connected to the first damper body unit <NUM>, the other side of the spring unit <NUM>, i.e., a right side of the spring unit <NUM> in <FIG>, is connected to the first damper contact unit <NUM>, and the spring unit <NUM> provides an elastic force to the first damper contact unit <NUM> moved by the first piston rod unit <NUM>.

The spring unit <NUM> is interposed between the first damper body unit <NUM> and the first damper contact unit <NUM>, and is compressed by the first damper contact unit <NUM> pressed by the first piston rod unit <NUM>.

When the pressing force of the first piston rod unit <NUM> is released, the compressed spring unit <NUM> provides the first damper contact unit <NUM> with an elastic force, i.e., an elastic restoring force, and returns the first damper contact unit <NUM> to its original position. The spring unit <NUM> may be formed of a coil spring that surrounds an outer side of the connection rod unit 315b.

The second damper part <NUM> is disposed to face the second piston rod unit <NUM>, and is mounted in parallel so as to be spaced apart from the first damper part <NUM> in the housing <NUM>. The second damper part <NUM> is mounted in the second guide unit <NUM> of the housing body part <NUM>.

The second damper part <NUM> is formed of an elastically deformable material, and is coupled to the second guide unit <NUM> of the housing body part <NUM> of the housing <NUM> by press-fitting. The second damper part <NUM> may be coupled to the housing <NUM> in the press-fitting way and may be easily assembled thereto.

An operation of the pedal simulator <NUM> according to an embodiment of the present disclosure is described with reference to <FIG> and <FIG>.

Referring to <FIG>, when the piston pressing unit <NUM> is pressed, the piston body unit <NUM> is moved, and accordingly, the first piston rod unit <NUM> and the second piston rod unit <NUM> are moved toward the first damper part <NUM> and the second damper part <NUM>, respectively. In this case, the first piston rod unit <NUM> is moved along the first guide unit <NUM>, and the second piston rod unit <NUM> is moved along the second guide unit <NUM>.

The first piston rod unit <NUM> having a shorter separation distance from the damper parts <NUM> than the second piston rod unit <NUM> presses the first damper contact unit <NUM> of the first damper part <NUM> first. In this case, the user may have an initial period braking feeling when the first piston rod unit <NUM> presses the first damper contact unit <NUM>.

When the first piston rod unit <NUM> continuously presses the first damper contact unit <NUM>, the spring unit <NUM> is compressed and deformed so that the user may have a medium period braking feeling. While being moved by the first piston rod unit <NUM>, the sensor unit <NUM> transmits information on a position or stepping force of the first piston rod unit <NUM> according to a change in a magnetic field to the control unit (not illustrated).

Referring to <FIG>, when the second piston rod unit <NUM> disposed in parallel with the first piston rod unit <NUM> comes into contact with the second damper part <NUM>, the user may have a later period braking feeling.

The second damper part <NUM> may be formed of an elastically deformable material including rubber, silicone or plastic, or a combination thereof. Therefore, when the second piston rod unit <NUM> comes into contact with the second damper part <NUM>, the user feels harder. Accordingly, the user may recognize that the braking is completed when the second piston rod unit <NUM> comes into contact with the second damper part <NUM>.

The compressed spring unit <NUM> provides the first damper contact unit <NUM> with an elastic force, i.e., an elastic restoring force, and returns the first damper contact unit <NUM> to its original position.

The pedal simulator <NUM> according to the present disclosure enables common use of products through modularization applicable to all pedal parts regardless of types and shapes of the pedal parts 10a and 10b.

Since various types of the pedal parts 10a and 10b due to modularization according to the present disclosure come into common use, repair and replacement of products can be reduced, and productivity can be improved.

In addition, according to the present disclosure, as the first piston rod unit <NUM> and the second piston rod unit <NUM> are formed to have different lengths, the first and second piston rod units are tunable so that a user can have appropriate initial and medium period braking feelings and an appropriate later period braking feeling.

Moreover, according to the present disclosure, it is possible to reduce the volume of the housing <NUM> through parallel structures of the first and second piston rod units <NUM> and <NUM> and the first and second damper parts <NUM> and <NUM>.

Claim 1:
A pedal simulator (<NUM>) comprising:
a housing (<NUM>) having an inner space;
a piston part (<NUM>) slidably disposed at the inner space of the housing (<NUM>) and including a plurality of piston rod units (<NUM>, <NUM>); and
a plurality of damper parts (<NUM>) disposed at the housing (<NUM>) and facing the plurality of piston rod units (<NUM>, <NUM>), respectively,
characterized in that each of the damper parts (<NUM>) is configured to be compressed by a pressure from a respective one among the piston rod units (<NUM>, <NUM>).