Modular pedal assembly for vehicles

• US 10,296,036 B2
• Filed: 10/13/2010
• Issued: 05/21/2019
• Est. Priority Date: 01/24/2003
• Status: Active Grant

• Current Assignee: Club Car Incorporated
• Original Assignee: Club Car Incorporated
• Inventors: Cosby, Christopher D., Crow, Douglas T., Hardy, David R., Morgan, Paul E., Newman, Duane E., Stewart, Geoff D., Welsh, Michael L.
• Primary Examiner(s): Yabut, Daniel D
• Application Number:
  US12/903,289
• Publication Number:
  US 20110023652A1
• Time in Patent Office: 3,142 Days
• Field of Search: 74512-514, 74560, 74542, 188 7331, 477210, 303 20
• CPC Class Codes: B60K 26/00 Arrangements or mounting of propulsion unit control devices in vehicles
• CPC Class Codes: B60Q 1/441 Electric switches operable by the driver's pedals
• CPC Class Codes: G05G 1/30 Controlling members actuated by foot
• CPC Class Codes: G05G 1/36 Mounting units comprising an assembly of two or more pedals, e.g. for facilitating mounting
• CPC Class Codes: G05G 1/38 comprising means to continuously detect pedal position
• CPC Class Codes: G05G 1/46 Means, e.g. links, for connecting the pedal to the controlled unit
• CPC Class Codes: G05G 5/005 for preventing unintentional use of a control mechanism G05G5/28 takes precedence
• CPC Class Codes: G05G 5/12 for holding members in an indefinite number of positions, e.g. by a toothed quadrant G05G5/28 takes precedence
• CPC Class Codes: Y10T 74/20528 Foot operated
• CPC Class Codes: Y10T 74/20534 Accelerator

Abstract

A modular pedal assembly for use with a vehicle that includes a prime mover, a control circuit, and a brake assembly. The modular pedal assembly including a base that is removably connectable with the vehicle, a brake pedal, an accelerator pedal that is displaceable between a first position and a second position, and a control output regulator that includes a first sensor and a second sensor. In a vehicle having an electric motor prime mover, the first sensor is a limit switch electrically connected to the control circuit, and the second sensor is a variable resistor. In a vehicle having an internal combustion engine prime mover, the first sensor is a limit switch operable to control a starter motor, and the second sensor is a limit switch operable to control a spark plug ignition.

Claims

1. A modular pedal assembly for use with a vehicle, the vehicle including a prime mover, and a brake assembly, the pedal assembly comprising:

a base removably connected with the vehicle;

a brake pedal having a brake pedal pad and a brake pedal lever arm connected thereto, the brake pedal movably coupled with the base and operatively coupleable with the brake assembly;

a parking brake pedal having a parking brake pedal pad and a parking brake pedal lever arm connected thereto, the parking brake pedal movably coupled with the base and wherein the parking brake lever arm is slidingly engageable and nested within a slotted portion of the brake pedal lever arm substantially over the length of the brake pedal lever arm;

an accelerator pedal having an accelerator pedal pad and an accelerator pedal lever arm, the accelerator pedal movably coupled with the base so as to be displaceable between a first position and a second position;

a control output regulator coupled to the accelerator pedal and including a first sensor and a second sensor, and electrically connected with the prime mover when the base is connected with the vehicle;

wherein the first sensor enables operation of the prime mover and the second sensor generates a control signal for operation of the prime mover; and

wherein the base has a top side having a top side face and an opposing bottom side having an opposing bottom side face, the opposing bottom side face defining a mounting surface for connection to the vehicle and located opposite the top side face, wherein the brake pedal is pivotably coupled with the base, wherein the accelerator pedal arm is pivotably connected to the base, wherein the brake pedal pad and an accelerator pedal pad of the accelerator are located on the top side, wherein a pivot point of the brake pedal and a pivot point of the accelerator pedal are disposed on the opposing bottom side of the base and offset from the bottom side face in a direction away from the top side face, and wherein the accelerator pedal arm extends through the base past the top side and past the bottom side such that a portion of the accelerator pedal arm resides past the top side face and a portion of the accelerator pedal arm resides past the bottom side face; and

wherein the top side of the base includes a top side length and a top side width, wherein the top side length is greater than the top side width, wherein the top side length has a first end opposite a second end, and wherein the parking brake pedal and the accelerator pedal are located between the first end and the second end.

2. The modular pedal assembly as recited in claim 1, further comprising a plurality of fasteners;

wherein the entire modular pedal assembly is mounted to the vehicle by mounting the base to the vehicle with the fasteners, and wherein the entire modular pedal assembly is removed from the vehicle by removal of the fasteners from the base.

3. The modular pedal assembly as recited in claim 1 wherein:

the brake pedal is displaceable between a first position at which the brake assembly is inactivated and a second position at which the brake assembly is activated, the brake pedal being releasably lockable at the second position; and

the accelerator pedal is operatively coupled with the brake pedal such that when the brake pedal is locked at the second position, displacement of the accelerator pedal releases the brake pedal from the second position.

4. The modular pedal assembly as recited in claim 1 wherein the control output regulator is disposed within a housing removably connected with the base so as to position the control output regulator generally proximal to the accelerator pedal.

5. The modular pedal assembly of claim 1, wherein:

the prime mover is an electric motor;

the first sensor is a limit switch actuatable to turn on a control circuit of the motor; and

the second sensor is a variable resistor that generates a signal proportional to a displacement of the accelerator pedal between the first position and the second position.

6. The modular pedal assembly as recited in claim 5 wherein:

the vehicle includes a battery, and the control circuit is configured to regulate voltage or current between the battery and the motor; and

the control circuit adjusts the voltage or current to the electric motor in response to the signal generated by the variable resistor.

7. The modular pedal assembly of claim 1, wherein:

the prime mover is an internal combustion engine;

the first sensor is a limit switch operable to turn on a control circuit of the internal combustion engine; and

wherein the second sensor is a limit switch operable to control a spark plug ignition of the internal combustion engine.

8. The modular pedal assembly as recited in claim 7 wherein:

the control circuit includes a solenoid operatively coupled with a starter motor; and

the first sensor is electrically connected with the solenoid such that the solenoid is electrically connected with the starter motor when the accelerator pedal displaces from the first position and towards the second position.

9. The modular pedal assembly as recited in claim 7 wherein:

the control circuit includes a magneto electrically coupled with the spark plug ignition; and

the second sensor is electrically connected with the magneto such that the magneto is electrically coupled with the spark plug ignition when the accelerator pedal displaces from the first position and towards the second position.

10. The modular pedal assembly of claim 1, wherein the parking brake lever arm is movable with the brake lever arm when the brake pad is depressed and the parking brake lever arm is movable relative to the brake lever arm when the parking brake pad is depressed.

11. The modular pedal assembly of claim 1, wherein the slotted portion the brake pedal lever arm is a slotted channel having opposing sides between which nest the parking brake pedal lever arm;

and wherein opposing flanges are generally flat and have attachment points for connection to the vehicle, the opposing flanges located in a common plane with the top side of the base.

12. The modular pedal assembly of claim 11, wherein the brake pedal pad includes a bottom and top edge, and wherein at least one of the opposing sides of the brake pedal lever arm extends from a pivot mount point proximate a first end of the brake lever arm toward the bottom edge of the brake pedal pad, and wherein the opposing flanges are connected by a spanning portion of the base that extends between the opposing side ends, the spanning portion in the same plane as the opposing side ends.

13. The modular pedal assembly of claim 12, wherein the parking brake pedal lever arm is elongate in shape and received within the slotted channel of the brake pedal lever arm, and wherein the at least one of the opposing sides of the brake pedal lever arm extends past the bottom edge of the parking brake pedal pad toward a second end of the brake lever arm.

14. The modular pedal assembly of claim 1, wherein the base further includes a peripheral boundary defining outer edges of the top side and outer edges of the bottom side, the peripheral boundary including a base front, base back, and opposing side ends, the peripheral boundary having an interior into which the pedals are disposed.

15. The modular pedal assembly of claim 14, wherein the opposing side ends each have a side end top side characterized by a side end length and a side end width, the side ends each also including a side end thickness smaller than the respective side end length and side end width, each side end top side extending in a direction coincident with a direction of the base top side.

16. The modular pedal assembly of claim 15, wherein the opposing side ends include openings for the receipt of fasteners to secure the base to the vehicle.

17. A modular pedal assembly mountable as a module upon a vehicle having a brake assembly and adaptable for use on the vehicle having either a gas engine or an electric motor drive, the modular pedal assembly having a mounted state in which the modular pedal assembly is mounted in the vehicle and an unmounted state, the modular pedal assembly comprising:

a base adapted to be mounted in a vehicle in the mounted state;

a first pedal having a first pedal pad and a first pedal lever arm pivotally coupled to the base in the unmounted state of the modular pedal assembly and having a portion coupled to the brake assembly in the mounted state of the modular pedal assembly;

a second pedal having a second pedal pad and a second pedal lever arm, the second pedal pivotally coupled to the base in the unmounted state of the modular pedal assembly and having a portion coupled to the drive in the mounted state of the modular pedal assembly, the second pedal having an unactuated state and an actuated state, the actuated state defined by pivotal movement of the second pedal with respect to the base;

a third pedal having a third pedal pad and a third pedal lever arm nestingly received within the first pedal lever arm over a length of the first pedal lever arm between a pivot point and a bottom edge of the first pedal pad, the third pedal lever arm pivotally coupled to the base in the unmounted state of the modular pedal assembly and having a portion coupled to the brake assembly in the mounted state of the modular pedal assembly;

a control output regulator coupled to the second pedal in the unmounted state of the modular pedal assembly and also electrically coupled to the drive assembly in the mounted state of the modular pedal assembly, the control output regulator adaptable to be used with vehicles driven by gas engines and electrical motors, the control output regulator having a sensor configured to detect the pivotal position of the second pedal and to communicate the position to drive in the mounted state of the modular pedal assembly; and

an abutment connected to the first pedal configured to engage the third pedal after the third pedal pad is moved to a predetermined position causing the first pedal to move with the third pedal over a predetermined range of motion;

wherein the base is in the form of an elongate shape that extends past opposing lateral sides of the first pedal and the second pedal such that both the first pedal and the second pedal are located between ends of the elongate shape;

wherein the base further includes a peripheral boundary defining outer edges of a top side and outer edges of a bottom side, the peripheral boundary including a base front, base back, and opposing side ends, the peripheral boundary having an interior into which the pedals are disposed;

wherein the opposing side ends each have a side end top side characterized by a side end length and a side end width, the side ends each also including a side end thickness smaller than the respective side end length and side end width, each side end top side extending in a direction coincident with a direction of the base top side; and

wherein the top side of the base includes a top side face, the bottom side of the base includes a bottom side face, the bottom side face having a mounting surface for connection to the vehicle wherein the first pedal is pivotally coupled with the base a first distance away from the bottom side face in a direction away from the top side face, wherein the second pedal arm is pivotally connected at a pivot point with the base a second distance away from the bottom side face in a direction away from the top side face, and wherein the second pedal arm extends through the base past the top side and the past the bottom side such that a portion of the second pedal arm resides past the top side face and a portion of the accelerator pedal arm resides past the bottom side face.

18. The modular pedal assembly as recited in claim 17, wherein the sensor is a first sensor and the control output regulator further includes a second sensor positioned to detect the pivotal position of the second pedal and able to communicate the position to the drive in the mounted state of the modular pedal assembly.

19. The modular pedal assembly as recited in claim 18, wherein the first sensor is a limit switch and the second sensor is a potentiometer, the limit switch senses the state of the second pedal in the mounted state of the modular pedal assembly and communicates the state to the electrical motor drive, the potentiometer senses the state of the second pedal in the mounted state of the modular pedal assembly and communicates the state to the electrical motor drive by sending a voltage that varies with the position of the second pedal.

20. The modular pedal assembly as recited in claim 18, wherein the first sensor is a first limit switch and the second sensor is a second limit switch, the first and second limit switches having an open and closed state, the first limit switch senses the state of the second pedal in the mounted state of the modular pedal assembly and communicates the state to the gas engine drive via a first circuit, the second limit switch senses the state of the second pedal in the mounted state of the modular pedal assembly and communicates the state to the gas engine drive via a second circuit, the gas engine drive operable with the first limit switch closed and the second limit switch open and inoperable with the first limit switch open and the second limit switch closed.

21. The modular pedal assembly of claim 17, wherein the third pedal is movable relative to the first pedal between first and second positions corresponding to a parking brake being inactivated and activated, respectively.

22. The modular pedal assembly of claim 21, further comprising:

an engagement element connected to a lever at one end and a pivot pin at the opposing end;

a projection extending from the opposing end of the engagement element;

a toothed portion operably connected to the brake assembly and configured to lockingly engage with the projection when the parking brake is activated;

an arm movable between first and second positions, wherein the arm prevents the projection of the engagement element from engaging with the toothed portion in the first position and permits engagement of the projection and the toothed portion in the second position; and

wherein the lever operable to move the arm between the first and second positions and pivot the engagement element.

23. The modular pedal assembly of claim 22, wherein displacement of the second pedal releases the third pedal from the second position.