Design and Analysis of a Pedal Box System for a small Race-car

The objective ofthis project is to study, analysis, enhanced and further optimize a pedal
box system for a small race-car which is Formula SAE Third Race Car. For this new
car, UTP FSAE team has decided to use CBR600 engine as it vital part. The proposed
design will be based around a hybrid-composite space-frame chassis and the design will
be optimized for the best ergonomics, performance and strength-mass ratio. Therefore a
further study and analysis on the pedal box system needs to be done. The scope of study
includes the usage of computer aided engineering software such as CA TIA and ADAMs
for modelling and analysis. First, the pedal box system design needs to be performed by
using CATIA. Then, stress analysis for throttle, brake and clutch pedal being conducted
by using the same software. In order to compare the new pedal box design with
previous pedal box design (UTP FSAE Second Car), ADAMs software has been used to
conduct dynamics and kinematics analysis. The results explained that the new pedal box
design can minimize driver's foot load to depress the pedal for about half of previous
pedal box design load. For stress analysis results, the brake pedal which is the crucial
part in pedal box system can endure a 1 OOkg of load. Therefore the results show that the
new pedal design is safe to be proposed as a pedal box system for UTP FSAE Third
Car.