Design and Analysis of a Pedal Box System for FSAE 2010

The main purpose of this project is to design and analyze an effective and practical
pedal box for the 2010 UTP Formula SAE car by improving the parameters such as
pedal box size, pedal travel, pedal ratio, input force and ergonomic concept. The
pedal box that used for braking and accelerating is a vital part of the vehicle because
the driver directly interacts with it and this makes ergonomics considerations
essential to the success of the design. The scope of study includes the material
selection, fabrication and stress-strain analysis without violating Formula SAE
design specification outlines rules. The calculations of the pedal ratio and pedal
travel angle were done using Microsoft Excel. Once the geometry was finalized, the
design was drawn using CATIA. FEA on certain key components was conducted
using the functions of the same software. The dynamics and kinematics of the design
was analyzed using ADAMS. In ADAMS, the design was simulated to obtain the
force or load distribution of the pedals. The results verified the improvement in the
final design compared to the previous design such as pedal box size reduction,
optimum pedal ratio and pedal travel values, and the ideal range of input force.