Simulation-driven experiments resolve throttle pedal vibration issues

This study investigates the resolution of accelerator pedal vibration issues during horn activation in vehicle tuning through finite element analysis combined with real-world test data. For certain facelift models experiencing NVH challenges with pedal vibrations upon horn usage, simulation identified a pedal bracket modal frequency of 355.9 Hz, while experimental vibration transfer function (VTF) measurements from horn to pedal mounting points revealed a resonant peak in acceleration response-suggesting coupling between the horn excitation frequency and pedal bracket modal characteristics. Given the prohibitive cost of modifying production-specification horns or retooling existing pedal bracket molds, this research developed an innovative approach: comparative analysis between experimentally measured and simulated VTF curves was conducted to identify structural stiffness deficiencies along the transmission path from front longitudinal beam horn mounting points to firewall accelerator pedal attachments. Simulation-driven optimization pinpointed design improvements which were subsequently validated through physical testing. Most existing studies focus on the structural optimization of the pedal itself, with little discussion on the influence of accessory mounting points (e.g., horn) on pedal vibration. This study fills this gap and introduces how to select appropriate accessory mounting positions to break the vibration transmission path and reduce pedal-induced vibration at the target frequency. The implemented solution achieved an 88.4% vibration reduction (from 544.8 mm/s² to 63.3 mm/s²), with significant subjective improvement in pedal vibration perception during horn operation. This simulation-testing integrated methodology demonstrates substantial cost savings and development cycle acceleration for in-production vehicle NVH refinement.