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Hand control for newer vehicles with electronic throttles

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  • Hand control for newer vehicles with electronic throttles

    I had tried to post this for someone in vB5 but the pictures failed, so I'll put it back up here.
    This is a hand control I fabricated for my 2006 VW Golf GTI w/DSG sequential automatic gearbox.
    Because the FBW (FlyByWire) throttle units use a pretty small sender in the accelerator pedal with only 6 wires to it, and because I had made a similar setup on a race car using Bowden cables, it was a no-brainer that I could greatly improve on the 90* hand controls I'd had in my pervious street cars. I plan on miniaturizing the throttle sensor and started to machine a delrin housing, but got lazy! I built what yoiu see in 06 and have used it ever since. Some day, I hope to complete making the tiny box with the throttle sensor in it as well as RJ32(?) connectors, and tagging it on the backside of the brake arm, out of sight and out of the way. The temporary setup with the long cable works fine, so WTF.
    Click image for larger version

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    69yo male T12 complete since 1995
    NW NJ

  • #2
    I see the photos in the above post when I click on the links. Do you?? (vB5 would "post" pictures that only were seen on my machine but no one else saw.)
    I used the same procedure as in the below linked to post where the photo appears in the post.
    However, I posted another pic in the below linked ("#5" highlighted) post elsewhere and it appears a photo.
    Before posting the above, I tried attaching a photo to this post:#5
    That photo is beautiful and visible on my machine; how about yours?
    69yo male T12 complete since 1995
    NW NJ

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    • #3
      Yep. photos show up fine. GREAT SETUP!

      Comment


      • #4
        Thanks. Yes, it's very much improved over most commercial deals. The handle is well enough supported on the single vertical support tube for my worst abuse (and I do mean abuse!) but if it were for the general public, there should be a second support tube and a "bridge between them. That would be totally bulletproof. What's nice is how easily it is fitted. I only cut a 1" hole in the under-dash directly below one of the 4 M8/1.5 mounting screws for the cast aluminum upper steering column mounting plate; that screw was replaced with a section of M8 threaded rod which carries the complete control. The brake handle (coated with tool-dip and painted) and trottle handle are far enough from the wheel to pass your hand through the gap, but close enough to rest your palm on the (see worn off paint) top with elbow on armrest; and steer with thumb and forefinger while throttling with the others. Very restful after holding my arm up to use normal 90* controls! Of course, you can hold it like a pistol and squeeze the trigger/throttle as intended.
        I don't know why the pictures didn't post, but links posted 4 times! I don't know what happened to the edit function or I'd fix it. And I don't know why I'm a guest, or where my original fall 2013 posts about these controls went. Patience!
        69yo male T12 complete since 1995
        NW NJ

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        • #5
          revisiting a botched post

          Hopefully with pictures!
          Attached Files
          69yo male T12 complete since 1995
          NW NJ

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          • #6
            they're awfully big, but at least they're there!!

            Here are pics of left/right details.
            Hanging from the brake push-rod, is the electronic throttle position sender module, hanging from a loop in it's connecting harness. Click image for larger version

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            It is controlled by a bicycle brake lever that has the cable going through the steel tubing of the control, then branching out of the tubing to go to the throttle module.
            The module is simply the guts of a VW electronic throttle pedal with the bulk of it discarded/cut off, and a provision made to operate it with a bicycle brake cable.
            You can see a chrome toggle switch in the dashboard, on the left just below the hand control; this selects hand control (up) or foot control (down). I think it also is a good theft deterrent! Whenever an AB takes my car and leaves it in AB mode, I'll start it up and put it in R; it pulls pout of it's space with no throttle and all seems fine until I put it in D and give it throttle. It takes me a while to remember what the problem is; I expect a their would bail out before making any sense of it!
            Attached Files
            Last edited by pfcs49; 04-23-2014, 12:26 PM.
            69yo male T12 complete since 1995
            NW NJ

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            • #7
              I never completed the panned control....

              but here is a photo of the partially completed throttle position sensor that would be very tiny and would be attached to the back-side of the main part of the control, where it would be inconspicuous and well protected.Click image for larger version

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              The area that is outlined in black is the swept area of the sensor. There is a little square of steel sheet metal on a plastic sled below the circuit-board, pulled by the throttle cable. There is ~1mm/.040" of air between the circuit-board and the little metal square; you can see how little the sender moves from idle to wide open throttle. Pretty neat stuff!
              Attached Files
              Last edited by pfcs49; 04-23-2014, 12:32 PM.
              69yo male T12 complete since 1995
              NW NJ

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              • #8
                Just revisited these posts. Although ALL pictures are now shown, I wanted to edit it down so it only had the required ones and maybe made better sense, but I don't see an "Edit Post" option, like I was looking at someone else's post!!?

                Moderators??

                EDIT: but this recent post has that edit post function showing-which I am using to add this with now!
                69yo male T12 complete since 1995
                NW NJ

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                • #9
                  There is probably a time limit on how old of a post you can edit. I think I have run into that, or heard of that on other forums.

                  Originally posted by pfcs49 View Post
                  Just revisited these posts. Although ALL pictures are now shown, I wanted to edit it down so it only had the required ones and maybe made better sense, but I don't see an "Edit Post" option, like I was looking at someone else's post!!?

                  Moderators??

                  EDIT: but this recent post has that edit post function showing-which I am using to add this with now!
                  Better to remain silent and be thought a fool, than to speak and remove all doubt.

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                  • #10
                    This is a very interesting concept - I don't completely understand whether the idea is to physically push the pedal sor to send an electronic signal further upstream. In either case I really like the simplicity of mechanical hand controls. This looks more complex and I worry about failures which could be life threatening

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                    • #11
                      Originally posted by Icarus View Post
                      This is a very interesting concept - I don't completely understand whether the idea is to physically push the pedal sor to send an electronic signal further upstream. In either case I really like the simplicity of mechanical hand controls. This looks more complex and I worry about failures which could be life threatening
                      The braking function is wholly mechanical and a whole lot simpler than conventional controls; there's a lot less linkage, joints and bracketry to wear, fail or come loose.
                      The throttle function simply moves VW's electronic throttle pedal sensor up to the hand control and operates it mechanically via a bicycle brake lever and cable. The (unmodified) electronic throttle is fail-safe; the position sensors are redundant; if both signals aren't identical, the vehicle assumes something is wrong and goes into limp-mode making only a tiny amount of power available-enough to go very slowly to the dealer. OR-if there is a larger disparity, it provides no throttle function and the car will only idle, the same as all VWs built in the last decade, so, IMHO, this is simpler and more reliable than any of my former manufactured controls.
                      69yo male T12 complete since 1995
                      NW NJ

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                      • #12
                        Using a bicycle brake lever is a great idea. *If* one has finger tip control, then feathering a pedal should be fairly easy.
                        I have had periodic paralysis all my life. I lost my ability to walk in 2011 beginning with a spinal block, which was used for a hip fracture caused by periodic paralysis.

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                        • #13
                          Originally posted by nonoise View Post
                          Using a bicycle brake lever is a great idea. *If* one has finger tip control, then feathering a pedal should be fairly easy.
                          I had an ongoing conversation with a hi-function quad friend who got an Audi A3 about how or what to implement for a similar control without the squeezing throttle. Maybe a contoured knob deal that fits into the pocket of the palm and is rotated ~90*, idle >WOT? Let the cruise area of the sweep be in the relaxed/neutral area of forearm/wrist rotation.
                          The nice thing about these little transducers is the ability to easily link them to many architectures, all using low force.
                          69yo male T12 complete since 1995
                          NW NJ

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                          • #14
                            Do you have any spare American pedals to examine and compare? I totally forgot how my Chrysler one was laid out, so if you have one to dissect... Or a Ford, I'm still playing around with one of those turds...probably be a better 'practice' chassis, lol.

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                            • #15
                              Originally posted by Andy View Post
                              Do you have any spare American pedals to examine and compare? I totally forgot how my Chrysler one was laid out, so if you have one to dissect... Or a Ford, I'm still playing around with one of those turds...probably be a better 'practice' chassis, lol.
                              Junkyard!
                              When I was doing this I got a couple Volvo assys used; the VW was $79 list @VW, cost me $53 with my discount.
                              I hunch that yours is very much like the VW which AFAIK is Bosch. I wouldn't be surprised if the circuit boards are the same.
                              When I did the GTI, I cut the pedal harness near the pedal and ran a pair of 6 conductor cables back up to a terminal strip that I hid behind the access panel to the left of the steering column.
                              I thought I would have to switch 4 poles or the ECM would see a fault (both power and both signal legs), but discovered later that I could leave power and ground connected to both sensors (foot and hand control) and only needed a DPDT switch on the two signal legs. Nevertheless, having all six conductors in an exposed row on the strip made it easy to pense out the circuitry which was stupid because it was not ordered; instead of two identical groups of 3, they were intermingled in no sensible order!
                              Next one I do, I'll only run 8 wires back from the splice (instead of 12) to the terminal strip. I wonder if you left both controls fully connected, what you'd have? It might work if you only opened one at a time, but I like leaving my foot down where the gas pedal sits PLUS with the switch set to hand control, I don't mind leaving the key in the car in some places. If a thief started it and put it in gear, I don't think they would wait to find out why it doesn't go!
                              69yo male T12 complete since 1995
                              NW NJ

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