TECHNICAL FIELD
The present disclosure relates to an assembly or installation of a pedal of a vehicle. In particular, the present disclosure relates to a device and a method for initial zero setting of shunt plate of a non-contact type position sensor of a foot operated pedal of a vehicle, such as a brake pedal, an accelerator pedal or a clutch pedal.
BACKGROUND
Vehicles generally utilize a foot-operated device, such as a pedal assembly, to control the movement of the vehicle. For example, vehicles include a brake pedal assembly for transmitting a braking input signal from the vehicle operator to the wheels of the vehicle. A pedal assembly may include an electronic device to generate an electronic signal indicating operation of pedal. The signal may be used by the vehicle control system for various purposes such as detecting, monitoring or displaying operation of the pedal. For example, a pedal position sensor is used for generating and delivering the electrical signal which is responsive to the position of the pedal. Use of a non-contact type position sensor for this purpose is known in the art. The non-contact type sensor may be a Hall Effect sensor used in combination with magnets and a shunt plate. The shunt plate is used to activate or deactivate the sensor by moving of the shunt plate in between or away from the magnet and hall sensor.
During the installation of a pedal assembly a sensor, magnets and shunt plate are required to be aligned and set at a predetermined position corresponding to the initial or zero position of the pedal to ensure proper working of the assembly. Zero position corresponds to a predetermined position of a pedal in its rest state or at a starting point of the stroke of the pedal. Conventionally, for facilitating easy installation in an assembly line, an alignment tool such as a gauge is first mounted or placed on one of the components, and then using the gauge a correct

position is determined for the component. After ensuring the components are aligned as desired, the component may be fastened in the predetermined positions. After fastening, the gauge is unmounted for use in a subsequent pedal installation. Accordingly, repeated mounting and unmounting of the gauge is required in this type of installation. Therefore, such assembly may require high assembly time and fatigue for the assembly men. Also, the gauge may wear out or deteriorate or get damaged under repeated usage over time, which may lead to improper installation. In view of the above there is a need to devise a better approach for pedal installation.
Present disclosure is directed to address the problems as discussed above and other problems associated with the art.
SUMMARY
A device for installation and alignment of a shunt plate and a sensor assembly for a pedal of a vehicle is disclosed. The device has a first clamp configured for mounting of the device on the sensor assembly and a second clamp configured for holding a shunt plate on the device, wherein when the device is mounted on the sensor assembly, the shunt plate is held at a position of desired alignment of the shunt plate relative to the sensor assembly.
In an aspect, the device has a back stopper configured to obstruct movement of the shunt plate when the shunt plate is mounted on the pedal and moved along with the pedal.
In an aspect, the first clamp has two arms extending forwardly from a base of the device. The arms are adapted to hold at least a portion of a housing of the sensor assembly when the device is mounted on the sensor assembly.

In an aspect, the second clamp has a top plate extending rearwardly from the base and a bottom plate extending rearwardly from the base parallel to the top plate, wherein the shunt plate is held in the second clamp by clamping the shunt plate between the top plate and the bottom plate.
In an aspect, the device has a side stopper protruding from the bottom plate. The side stopper is configured to keep the shunt plate in alignment when the shunt plate is held in the second clamp.
In an aspect, the base is configured for receiving between an extension extending from the housing and holding a magnet and the housing that houses a sensor.
A method of installation and alignment of a sensor assembly and a shunt plate for a pedal assembly is disclosed. The method comprises mounting the shunt plate on the device as disclosed herein. Mounting the device on the sensor assembly. Mounting the sensor assembly on a bracket of the pedal assembly. Securing the shunt plate on a pedal lever of the pedal assembly.
In an aspect, the method further includes actuating the pedal lever to release the device from the sensor assembly.
Further, a sensor installation kit for a pedal assembly of a vehicle is disclosed. The sensor installation kit has a shunt plate, a sensor assembly and a device. The sensor assembly has a housing and a non-contact type sensor disposed in the housing. An extension extends from the housing and a magnet is disposed in the extension. The magnet is juxtaposed to the sensor with a predetermined distance therebetween. The device has a base adapted to be received in the space between the sensor and the magnet, a first clamp extending forwardly of the base, the first clamp configured to clamp the extension for mounting the device on the sensor assembly, and a second clamp configured for holding a shunt plate on the device.

When the device is mounted on the sensor assembly, the shunt plate is held at a position of desired alignment of the shunt plate relative to the sensor assembly.
In an aspect, the sensor installation kit further has a bracket configured for mounting of the sensor assembly, the bracket configured for mounting on the vehicle structure proximate to a pedal lever of the pedal assembly.
BRIEF DESCRIPTION OF FIGURES
Figure 1 illustrates a perspective view of a shunt plate as an example.
Figure 2 illustrates a perspective view of device in accordance with an
embodiment of the present disclosure.
Figure 3 illustrates a perspective view of a shunt plate mounted on the device of
Figure 2.
Figure 4 illustrates a perspective view of the device along with the shunt plate as
shown in Figure 3, mounted on a sensor assembly according to an embodiment of
the present disclosure.
Figure 5 illustrates a side view of a bracket mounted with the sensor assembly of
Figure 4.
Figure 6 illustrates a perspective view of a pedal assembly installed in
accordance with an embodiment of the present disclosure.
Figures 7(a) to 7(c) illustrate removal of the device after installation of the pedal
assembly in accordance with an embodiment of the present disclosure.
DESCRIPTION OF PRESENT DISCLOSURE
A method and a device (38) for zero-setting of a pedal is disclosed. The method and the device (38) as disclosed herein may be used during installation of a pedal assembly (12) for a vehicle. The method and the device (38) as disclosed herein provides for a simplified and less time consuming assembly of a pedal in a vehicle.

Figure 1 illustrates a shunt plate (10) as an example of a shut plate used for a pedal assembly (12) shown in Figure 6. The shunt plate (10) has a substantially Z shaped profile having two horizontal sections at the two ends, namely a first end (14) and a second end (16), and a vertical section (18) connecting the first end (14) with the second end (16). The first end (14) of the shunt plate (10) defines a plurality of elongated slots (20) to facilitate mounting of the shunt plate (10) on a pedal lever (22) as shown in Figure 6. Whereas the second end (16) is configured to work with a non-contact type position sensor as discussed later herein. The second end (16) is configured to conform with the design and orientation of the non-contact type sensor to be used with the pedal assembly (12). In the embodiment as shown, a Hall Effect sensor assembly, hereafter referred to as sensor assembly (24) is used. In the shunt plate (10) as shown, the second end (16) of the shunt plate (10) has a forward section (26) configured to actuate the sensor (30) and a rear section (28) connected to each other with the vertical section (18) as shown in Figure 1. The sensor assembly (24) may include a sensor (30), a magnet (32) and a housing (34). The forward section (26) is configured to enter a space between the magnet (32) and the sensor (30), to actuate the sensor (30) by altering the magnetic field of the magnet (32).
Referring to Figure 4, the sensor (30) and the magnet (32) may be placed in a housing (34) as shown, such that the sensor (30) and the magnet (32) are held at a distance with respect to each other. In the embodiment as shown, the sensor (30) is placed inside the housing (34) juxtaposed to the magnet (32). The magnet (32) is housed in an extension (36) extending from the housing (34) such that the magnet (32) is placed at distance from the sensor (30) and such that there is enough space for insertion of the second end (16) in the space between the housing (34) and the extension (36). The shunt plate (10) can be made of any material that is capable to interfere with a magnetic flux or magnetic field of the magnet (32). The sensor assembly (24) is configured such that when the second end (16) of the shunt plate (10) is positioned between the magnet (32) and the sensor (30), change in magnetic field is sensed by the sensor (30). Thus, the

sensor (30) detects proximity of the shunt plate (10) by sensing/detecting change in magnetic field of the magnet at the point of location of the sensor (30) due to movement of the shunt plate (10).
Figure 2 illustrates a zero setting device, hereinafter referred to as a device (38), that is used to align the shunt plate (10) with the sensor assembly (24) and the pedal lever (22) during the installation or assembly of the pedal assembly (12). As shown in Figure 2, the device (38) has a base (40) and two arms (42) extending from the base (40). The two arms (42) are flexible and provided with snap locks (44) at the end of the arms (42). The two arms (42) are placed at a distance with each other such that a portion of the extension (36) of the housing (34) can be received in between the arms and the snap locks (44) can engage the extension (36) to retain the device (38) on the extension (36) or the housing (34) as shown in Figure 4. Thus, the two arms of the device (38) form a first clamp for mounting the device (38) on the sensor assembly (24).
The device (38) further has a bottom plate (46) and a top plate (48), both extending from the base (40). In the embodiment as shown, the top plate (48) and the bottom plate (46) extend parallel to each other in a direction opposite to the direction of the extension (36) of the two arms (42) from the base (40). The top plate (48) and the bottom plate (46) are provided with a slight distance therebetween such that second end (16) of the shunt plate (10) can be held between the top plate (48) and the bottom plate (46) as shown in Figure 3. To insert the second end (16) of the shunt plate (10) in between the top plate (48) and the bottom plate (46), the second end (16) of the shunt plate (10) is positioned on the bottom plate (46), and slid towards the base (40) such that the second end (16) of the shunt plate (10) is clamped between the top plate (48) and the bottom plate (46) as shown in Figure 3 and Figure 4. Once the shunt plate (10) is mounted on the device (38), the shunt plate (10) is held in position by the top plate (48) and the bottom plate (46). Accordingly, the top plate (48) and

bottom plate (46) form a second clamp for mounting the shunt plate (10) on the device (38).
Further, the device (38) has one or more side stoppers (50) and a back stopper (52), both projecting upwards from the flat bottom plate (46). The side stoppers (50) are configured to prevent rotation or movement of the shunt plate (10) relative to the device (38) and secure the shunt plate (10) in correct position with respect to the device (38) during assembly. Accordingly, the side stoppers (50) ensure that the second end (16) is placed in correct position and retained in correct position on the device (38) for the purpose of assembly. Further, the back stopper (52) extends from the top plate (48) upwards at a distal point away from the base (40) as shown in Figure 2. The back stopper (52) is configured such that when the shunt plate (10) mounted on the device (38) is moved towards the back stopper (52), the back stopper (52) abuts the vertical section (18) of the shunt plate (10) and tends to move the device (38) along with the shunt plate (10) when the vertical section (18) is pushed against the back stopper (52), as discussed later herein. The device (38) may be made of any suitable material such as plastic, fiber, or any other polymeric material.
The use of the device (38) and the method of installation of the pedal assembly (12) using the device (38) is explained now. For installation of the pedal assembly (12), first the shunt plate (10) may be mounted on the device (38) by inserting the second end (16) of the shunt plate (10) between the top plate (48) and the bottom plate (46) as shown in Figure 3. After mounting the shunt plate (10) on the device (38), the device (38) along with the shunt plate (10) may be mounted on the housing (34) by pushing the arms (42) of the device (38) against the extension (36) of the housing (34) to receive the extension (36) between the arms (42) and engage the snap locks (44) with the arms (42) to mount the device (38) along with the shunt plate (10) on the housing (34) as shown in Figure 4. The dimensions or design configuration of the device (38) is made such that in the mounted position of the device (38) on the housing (34) as shown in Figure 4,

the shunt plate (10) is positioned at the desired zero position or the initial setting position. The device (38) ensures that the shunt plate (10) is held firmly in a predetermined position relative to the sensor (30) and the magnet (32), i.e. in a predetermined initial or zero setting of the shunt plate (10) and the sensor assembly. The predetermined position may be a position where the second end (16) of the shunt plate (10) is placed between the sensor (30) and the magnet (32).
After mounting the device (38) along with the shunt plate (10) on the housing (34), the sensor assembly (24) along with the housing (34) may then be mounted on a bracket (54) as shown in Figures 5 and 6 by using mounting screws. The bracket (54) may be mounted to vehicle body structure (56), such that the bracket (54) along with the sensor assembly (24) is disposed in a predetermined position relative to the pedal lever (22). The pedal lever (22) is pivotally mounted to the vehicle body structure (56) as known in the art. On mounting of the bracket (54), the elongated slots (20) on the first end (14) of the shunt plate (10) get aligned, with the corresponding screw holes (not shown) provided on the pedal lever (22). The elongated shape of the elongated slots (20) on the shunt plate (10) ensure that there is enough tolerance accommodated for preventing any misalignment between the elongated slots (20) and the screw holes. Once the screw holes match, the shunt plate (10) may be fastened to the pedal using suitable means such as screws (58).
Figures 7(a)-7(c) illustrate removal of the device (38). For removal of the device (38), the pedal lever (22) may simply be actuated once. Figure 7(a) illustrates the pedal assembly (12) in the initial state after mounting of the shunt plate (10) on the pedal lever (22). On pushing of the pedal lever (22), the pedal lever (22) pivots about the pivot point (60) and the shunt plate (10) tends to move away from the housing (34). Further, as the shunt plate (10) moves away from the housing (34), the device (38) is held back on the housing (34) by the arms (42), and the second end (16) of the shunt plate (10) gets released from the hold of the

top plate (48) and the bottom plate (46) of the device (38). After complete disengagement of shunt plate (10) from the hold of the top plate (48) and the bottom plate (46), as the shunt plate (10) moves further away from the housing (34), the vertical section (18) of the shunt plate (10) abuts the back stopper (52) of the device (38), and tends to move the device (38) along with the shunt plate (10), i.e. away from the housing (34). Figure 7(b) illustrates the pedal lever (22) pushed away from the sensor assembly (24) until the vertical section (18) of the shunt plate (10) abuts the back stopper (52). As the housing (34) is securely mounted on the bracket (54), on further pushing of the device (38) further away from the housing (34), the snap locks (44) or the arms (42) deform or break and the device (38) gets dragged away and disengaged from the housing (34) of the sensor assembly (24). Figure 7(c) illustrates the device (38) at point of disengagement from the housing (34). Once the device (38) is detached from the housing (34), the device (38) may fall on the floor of the vehicle under force of gravity and may be removed manually from the vehicle floor.
Accordingly, the steps in the method of installation of the sensor assembly (24) on the pedal lever (22) may be summarized as follows. The shunt plate (10) is mounted on the device (38) as shown in Figure 3. The device (38) is then mounted on the housing (34) using the snap locks (44). The housing (34) which includes sensor (30) is then mounted on the bracket (54). Subsequently, the bracket (54) is mounted on the vehicle body structure (60) and the shunt plate (10) is mounted on the pedal lever (22) by using mounting screws (58) with sufficient tightening torque as per standard. Lastly, the pedal is actuated once to detach and remove the device (38) after installation of the pedal assembly (12).
In case the arms are deformable, the device (38) may be reused for installation of other pedal assemblies. Alternatively, the device (38) may be configured for a single use.

It may be understood that the method and device (38) as disclosed herein may be used for installation of any pedal assembly (12) such as brake pedal, clutch pedal, accelerator pedal etc. Necessary modifications may be made in the device (38) and the method as disclosed herein as needed.
Accordingly, the method and the device (38) as disclosed herein provide for an improved installation procedure for installing pedal assemblies and sensor assemblies in a vehicle. By using the method and the device (38) as disclosed herein, considerable time saving can be achieved during installation of the pedal assembly (12). Further, the method and device (38) as disclosed herein is easy to use and practice.

CLAIM:
1. A device (38) for installation and alignment of a shunt plate (10) and a
sensor assembly (24) for a pedal of a vehicle, the device (38) comprising:
a first clamp configured for mounting of the device (38) on the sensor assembly (24); and
a second clamp configured for holding a shunt plate (10) on the device (38);
wherein when the device (38) is mounted on the sensor assembly (24), the shunt plate (10) is held at a position of desired alignment of the shunt plate (10) relative to the sensor assembly (24).
2. The device (38) as claimed in claim 1, further comprising:
a back stopper configured to obstruct movement of the shunt plate (10) when the shunt plate (10) is mounted on the pedal and moved along with the pedal.
3. The device (38) as claimed in claim 1, wherein the first clamp comprises two arms (42) extending forwardly from a base (40) of the device (38), the arms (42) adapted to hold at least a portion of a housing (34) of the sensor assembly (24) when the device (38) is mounted on the sensor assembly (24).
4. The device (38) as claimed in claim 1, wherein the second clamp comprises:
a top plate (48) extending rearwardly from the base (40);
a bottom plate (46) extending rearwardly from the base (40) parallel to the top plate (48);
wherein the shunt plate (10) is held in the second clamp by clamping the shunt plate (10) between the top plate (48) and the bottom plate (46).

5. The device (38) as claimed in claim 4, further comprising:
a side stopper protruding from the bottom plate (46), the side stopper configured to keep the shunt plate (10) in alignment when the shunt plate (10) is held in the second clamp.
6. A device (38) as claimed in claim 3, wherein the base (40) is configured for receiving between an extension (36) extending from the housing (34) and holding a magnet (32) and the housing (34) that houses a sensor.
7. A method of installation and alignment of a sensor assembly (24) and a shunt plate (10) for a pedal assembly (12) comprising:
mounting the shunt plate (10) on the device (38) as claimed in claim 1;
mounting the device (38) on the sensor assembly (24);
mounting the sensor assembly (24) on a bracket (54) of the pedal assembly (12);
securing the shunt plate (10) on a pedal lever of the pedal assembly (12);
8. The method as claimed in claim 7, further comprising:
actuating the pedal lever to release the device (38) from the sensor assembly (24).
9. A sensor installation kit a pedal assembly (12) for a vehicle, the sensor
installation kit comprising:
a shunt plate (10);
a sensor assembly (24) comprising:
a housing (34);
a non-contact type sensor disposed in the housing (34);
an extension (36) extending from the housing (34); and

a magnet (32) disposed in the extension (36), the magnet (32) juxtaposed to the sensor with a predetermined distance therebetween; a device (38) comprising:
a base (40) adapted to be received in the space between the sensor and the magnet (32);
a first clamp extending forwardly of the base (40), the first clamp configured to clamp the extension (36) for mounting the device (38) on the sensor assembly (24);
a second clamp configured for holding a shunt plate on the device;
wherein when the device is mounted on the sensor assembly (24), the shunt plate is held at a position of desired alignment of the shunt plate relative to the sensor assembly (24).
The sensor installation kit as claimed in claim 9, further comprising:
a bracket (54) configured for mounting of the sensor assembly (24), the bracket (54) configured for mounting on the vehicle structure proximate to a pedal lever of the pedal assembly (12).