Last week (Week 5), the group focused on preparing for the manufacturing of the pedal box. In order to do this, the design was made lighter and the group used the Finite Element Analysis (FEA) tool on Solidworks to see how well the material would hold up under force.
This week (Week 6), the group finalized the preparations for manufacturing and sent parts to be created.
In order to prepare for manufacturing, the group finalized the computer aided design of the pedal box, which can be seen below.
In order to finalize this design, David added the real model of the balance bar to the assembly and added ball bearings to the pedals. These make the overall design more realistic when it comes to how the pedal box is actually going to function.
Additionally, one problem that the group ran into was the forces on the brake pedal. It was determined that the screws holding the balance bar and master cylinder systems were under too much pressure. In order to fix this, Lauren put a slit in brake pedal to make the bracket flush with the rest of the pedal. This helps the forces to be distributed better, and can be seen below.
This week (Week 6), the group finalized the preparations for manufacturing and sent parts to be created.
In order to prepare for manufacturing, the group finalized the computer aided design of the pedal box, which can be seen below.
| Balance Bar (Left) || Ball Bearing (Bottom Right) |
Additionally, one problem that the group ran into was the forces on the brake pedal. It was determined that the screws holding the balance bar and master cylinder systems were under too much pressure. In order to fix this, Lauren put a slit in brake pedal to make the bracket flush with the rest of the pedal. This helps the forces to be distributed better, and can be seen below.
Another problem that came to the group was how the pedal box would be attached to the chassis (supporting frame) of the cart. Thomas and Lauren overcame this problem through FEA analysis and the design below was created.
The three small holes towards the bottom will be used for attaching the slide to the chassis, for bolts to be placed through them.
Lauren also made adjustments to all of the dimensions so that they were the appropriate size to be drilled; David checked to make sure all parts could be assembled. They both also worked to make drawings and dxf files of parts, so that certain parts can be manufactured. The base should be made this week.
Finally, Lauren put all the material the group needs (ex. master cylinders, balance bar, bearings) on an order sheet. They will be ordered as soon as possible by the senior members of Formula SAE.
For this upcoming week (Week 7), the group will continue with the manufacturing of the pedal box. As new pieces are constructed, their compatibility will be tested with the frame. Additionally, the group will begin to work on their final report and presentation.
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