Last week (Week 4), the group dove into the modelling of the pedal box, in addition to working on the Finite Element Analysis (FEA) which resulted from the design. Specifically, the FEA of the brake pedal was tested to see the strength of the material, and the pedal box slide was incorporated into the overall design.
For this week (Week 5), more analysis was done on the pedal box as the group gets ready for its manufacturing. The final design of the pedal box is as such:
To start off, the group focused on making the pedal box as light as possible. In order to achieve this goal this week, much of the group's attention was directed towards the throttle pedal. Last week (Week 4), David and Lauren both worked to find the appropriate thickness of the throttle pedal. While this is great for the overall design, it then makes the system marginally heavier. In order to counteract this, David put holes in the design and thinned the width of the throttle. This makes the overall system lighter but just as reliable as the previous design. A pad was also created on the throttle so it is easier to access for the driver. Finally, a pin was placed at the base of the throttle to control how far it can be pressed (bottom of right image). All of these changes can be seen below.
The work for this week did not stop there, as much work done on the brake pedal as well. First, David found given CAD designs of the master cylinders from our chosen manufacturers. He then worked to incorporate these into the final design of the pedal box. One problem that occurred when David did this was that the overall design did not match the dimensions of the new master cylinders. In order to overcome this issue, David had to change the dimensions of the pedal box drawing to make sure they fit.
David also worked with the FEA of the brake pedal, as last week (Week 4), the FEA stated that the brake pedal was stationary. He assumed that assumed that the displacement is negligible of the pedal and the balance bar assembly (seen behind the pedal) is fixed. This then created a more realistic version of the pedal's FEA, having it not bend. The new FEA can be seen below.
While David's hard work was unmatched this week, other group members worked to better the design as well.
Thomas and Lauren continued to work on the overall design of the sliders for the pedal box. Lauren integrated them along with the base, and in a meeting with some senior members of Formula SAE, she found that a design similar to the previous year would work best with the base.
This task of changing the overall design of the sliders was passed to Thomas, the final design of this can be seen below. As can be seen, the original design was made longer and the cut for the hex bolt was put all the way through the design.
Lauren also added pins and hex bolts to the worked with integrating the sliders with the base, which can also be seen below.
Finally, the group met with a few senior members of Formula SAE to go over the basis for the pedal box design. The overall design was met with support.
For next week (Week 6), our focus will turn to the more physical application of our analysis, as pedal box will begin to be constructed.
For this week (Week 5), more analysis was done on the pedal box as the group gets ready for its manufacturing. The final design of the pedal box is as such:
To start off, the group focused on making the pedal box as light as possible. In order to achieve this goal this week, much of the group's attention was directed towards the throttle pedal. Last week (Week 4), David and Lauren both worked to find the appropriate thickness of the throttle pedal. While this is great for the overall design, it then makes the system marginally heavier. In order to counteract this, David put holes in the design and thinned the width of the throttle. This makes the overall system lighter but just as reliable as the previous design. A pad was also created on the throttle so it is easier to access for the driver. Finally, a pin was placed at the base of the throttle to control how far it can be pressed (bottom of right image). All of these changes can be seen below.
The work for this week did not stop there, as much work done on the brake pedal as well. First, David found given CAD designs of the master cylinders from our chosen manufacturers. He then worked to incorporate these into the final design of the pedal box. One problem that occurred when David did this was that the overall design did not match the dimensions of the new master cylinders. In order to overcome this issue, David had to change the dimensions of the pedal box drawing to make sure they fit.
| The design of the master cylinders. |
David also worked with the FEA of the brake pedal, as last week (Week 4), the FEA stated that the brake pedal was stationary. He assumed that assumed that the displacement is negligible of the pedal and the balance bar assembly (seen behind the pedal) is fixed. This then created a more realistic version of the pedal's FEA, having it not bend. The new FEA can be seen below.
It is to be noted that the force applied to the brake pedal is much less than the threshold of the material it is made out of. This means that the material the pedal is made out of will not warp or brake under the pressure given.
While David's hard work was unmatched this week, other group members worked to better the design as well.
Thomas and Lauren continued to work on the overall design of the sliders for the pedal box. Lauren integrated them along with the base, and in a meeting with some senior members of Formula SAE, she found that a design similar to the previous year would work best with the base.
| Last year's design |
Lauren also added pins and hex bolts to the worked with integrating the sliders with the base, which can also be seen below.
| The hex bolt and the pin (seen on the left and right, respectively) |
Finally, the group met with a few senior members of Formula SAE to go over the basis for the pedal box design. The overall design was met with support.
For next week (Week 6), our focus will turn to the more physical application of our analysis, as pedal box will begin to be constructed.
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