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 355.9Hz, while experimental vibration transfer function (VTF) measurements from horn to pedal mounting points revealed a Hz peak - suggesting coupling between 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.The implemented solution achieved an 88.4% vibration reduction (from 544.8mm/s² to 63.3mm/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.