DESIGN AND FABRICATION OF PEDAL BOX FOR FORMULA STUDENT VEHICLE

The main objective of this project is to Design and Fabricate the Pedal box for formula student vehicle. The purpose of making pedal setup as a box assembly is to reduce space consumption by mounting pedals in a box. The main advantage of pedal box is, it can be adjusted according to ergonomics of the vehicle as well as driver’s comfort. To complete this project, several designs were made considering various parameters from given rules in formula student rule book. Best suitable design was selected based on required ergonomics among all designs. Materials were selected, machined, and assembled. ANSYS software was used to verify the design. The final step was manufacturing and assembling all the components together and placing them in the race car. This assembly allows for the actuation of three pedals. One pedal applies force to the master cylinders used in the hydraulic braking system. A balance bar is used to allow for the calibration of the hydraulic braking system. The final assembly improves upon the previous year’s design as well as alleviating several concerns from the previous year. It has successfully integrated with the hydraulic braking systems as well as other subsystems, particularly the frame. This report documents the design process and describes the manufacturing process. The final design is tested and proved to be reliable in all possible working conditions.