Passive force emulator pedal assembly

1. A pedal assembly comprising:

a housing;

a spring arm member coupled to the housing;

a pedal arm having 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, an extension portion extending from a rear surface of the pedal arm, the extension portion having a radiussed portion;

a spring carrier coupled to the pedal arm and to the spring arm member, the spring carrier having 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; and

a spring guide member having 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 arm, the second at least one spring provides a second pedal effort force,

wherein the radiussed portion of the extension portion is spaced apart from the contact surface of the spring guide member when the pedal pad is in the first amount of predetermined travel of the pedal arm and contacts the contact surface of the spring guide member when the pedal pad is moved to the second amount of predetermined travel of the pedal arm, and

wherein 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 arm, 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.

2. The pedal assembly of claim 1 , wherein the first pedal effort force increases as the pedal pad travels through the first amount of predetermined travel of the pedal arm.

3. The pedal assembly of claim 1 , wherein the second pedal effort force increases as the pedal pad travels through the second amount of predetermined travel of the pedal arm.

4. The pedal assembly of claim 1 , wherein the spring guide member extends in a direction that is angled with respect to the spring carrier.

5. The pedal assembly of claim 1 , wherein the contact surface of the spring guide member is a cam surface positioned to be in contact with the pedal arm.

6. The pedal assembly of claim 1 , further comprising:

a contact member coupled to the housing, the contact member makes contact with the pedal arm to provide a third pedal effort force at a third amount of predetermined travel of the pedal arm .

7. The pedal assembly of claim 6 , wherein when the pedal pad is depressed to the third amount of predetermined travel of the pedal arm, 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.

8. The pedal assembly of claim 6 , wherein the contact member is positioned in the housing below the spring carrier and the spring guide member in a vertical direction.

9. The pedal assembly of claim 8 , wherein the contact member makes contact with the rear surface of the pedal arm below the extension portion extending from the rear surface of the pedal arm in the vertical direction.

10. The pedal assembly of claim 1 , further comprising:

a sensor assembly having:

a coupler rotatably mounted to one side of the hub portion, and

an inductive sensor assembly configured to detect movement of the coupler.

11. The pedal assembly of claim 10 , wherein the sensor assembly further comprising:

a magnet mounted to the other one side of the hub portion,

a Hall Effect sensor assembly configured to detect movement of the magnet .

12. A pedal assembly for a vehicle, the pedal assembly comprising:

a housing;

a spring arm member coupled to the housing;

a pedal arm having a hub portion and an opposite pedal pad, the hub portion is movably coupled to the housing by the spring arm member at the hub portion;

a spring carrier coupled to the pedal arm and to the spring arm member, the spring carrier having 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; and

a spring guide assembly having a spring guide member and a second at least one spring extending in an angled direction with respect to the spring carrier, the spring guide member having a cam surface and an opposite rear surface, the second at least one spring positioned between the rear surface and the housing, the second at least one spring provides a second pedal effort force at a second amount of predetermined travel of the pedal arm, the cam surface is spaced apart from the pedal arm when the pedal arm is at the first amount of predetermined travel of the pedal arm and when the pedal arm is at the second amount of predetermined travel of the pedal arm, the cam surface is in contact with the pedal arm,

wherein 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 arm, 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.

13. The pedal assembly of claim 12 , wherein the first pedal effort force increases as the pedal pad travels through the first amount of predetermined travel of the pedal arm.

14. The pedal assembly of claim 13 , wherein the second pedal effort force increases as the pedal pad travels through the second amount of predetermined travel of the pedal arm.

15. The pedal assembly of claim 12 , further comprising:

a contact member coupled to a void of the housing, the contact member makes contact with the pedal arm to provide a third pedal effort force at a third amount of predetermined travel of the pedal arm.

16. The pedal assembly of claim 15 , wherein when the pedal pad is depressed to the third amount of predetermined travel of the pedal arm, 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.

17. The pedal assembly of claim 16 , wherein the contact member is positioned in the housing below the spring carrier and the spring guide member in a vertical direction.

18. The pedal assembly of claim 12 , further comprising:

a sensor assembly having:

a coupler rotatably mounted to one side of the hub portion,

an inductive sensor assembly configured to detect movement of the coupler,

a magnet mounted to the other one side of the hub portion, and

a Hall Effect sensor assembly configured to detect movement of the magnet.

19. A pedal assembly comprising:

a housing;

a spring arm member coupled to the housing;

a pedal arm having 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;

a spring carrier coupled to the pedal arm and to the spring arm member, the spring carrier having 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; and

a spring guide member having 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 an angled direction with respect to the spring carrier, the contact surface is spaced apart from the pedal arm when the pedal arm is at the first amount of predetermined travel of the pedal arm and the contact surface receives contact from the pedal arm when the pedal arm is at a second amount of predetermined travel of the pedal arm, the at least one spring provides a second pedal effort force,

a contact member 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 arm,

wherein 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 arm, 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.

20. The pedal assembly of claim 19 , further comprising:

a sensor assembly having:

a coupler rotatably mounted to one side of the hub portion,

an inductive sensor assembly configured to detect movement of the coupler,

a magnet mounted to the other one side of the hub portion, and

a Hall Effect sensor assembly configured to detect movement of the magnet.