Date of Graduation

Spring 2016

Document Type

Honors Research Project

Degree Name

Bachelor of Science

Major

Mechanical Engineering

Research Sponsor

Dr. Shao Wang

Abstract

The purpose of this project was to design and produce the pedal box assembly for the electric formula SAE racecar team’s 2016 racecar. To complete this project, a working 3D model and corresponding blueprints were created. Materials were selected, machined, and assembled. FEA software was used to verify the design. The final step was manufacturing and assembling all the components together and placing them in the racecar. The precision machining was completed on campus at the University of Akron, and was considered a vital measurable of the project.

This assembly allows for the actuation of two aluminum 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 breaking system. The amount of force applied relative between the front wheels and rear wheels will be calibrated during the testing of the racecar. The other pedal actuates linear potentiometers that are used to gage the acceleration of the racecar. The linear potentiometers will be integrated into the electrical system of the car. The assembly is robust and adaptable.

This report explores several different conceptual pedal design solutions. Different basic sketches were created to help visualize the varied ideas and gain input from other potential drivers of the car. The integrating subsystem engineers were consulted with throughout design and manufacturing to insure successful incorporation into the car. This report documents the design process, describes the manufacturing process, and records lessons learned throughout the project.

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