Ergonomics & Driver Controls
David Anlian, Justin Greenidge & Alan Radojcic
Problem Background
Formula SAE is an international collegiate engineering
design competition which challenges universities to design,
manufacture, and race formula cars. The premise of the
competition is to create a marketable race car for the
average weekend racer.
Final Assembly
Shifting System
The main focus for the design of the mechanical shifting linkage
are reliability, weight, and comfort. Some key design aspects
include:
• Designed weight is 3.5 lbs. versus a 6 lbs. linkage in the 2013
racecar
• Can withstand a force of 250 lbs.
Project Scope
The FSAE Ergonomics and Driver Controls team is
responsible for the complete design and manufacturing of
all subsystems of which the driver is in direct contact. This
includes:
1.
2.
3.
4.
5.
6.
Pedal box
Seat
Shifting System
Steering System
Dashboard
Fuel Tank
Pedal Box
The 2014 FSAE Pedal Box is designed to be lightweight,
durable, ergonomic, aesthetically pleasing, and easy to
assemble and disassemble.
• Extremely stiff with a high factor of safety (3.0 and up)
• 4 lbs. lighter than 2013 design
Steering System
The 2014 FSAE Steering Assembly is designed to be stiff, aesthetically
pleasing, and lightweight. Through careful material selection and
geometric design, this year’s steering assembly outperforms any
previous year’s design.
• Low deformation and flex with in components (0.01 cm < )
• New single U-Joint connection design (25% more precise)
• Minimal slop design (< 0.01 cm within system)
• 1 lb. lighter than 2013 design
Dashboard
Key Design Aspects
• Carbon Fiber construction
• Tachometer in direct view while driving
• Aim MXLPista Data Acquisition System
Fuel Tank
Seat
Key Design Aspects
• Seatback angle of 50° from horizontal
• Durable and lightweight carbon fiber construction
Acknowledgements
We would like to thank the following individuals for their immense efforts in advisement
and resource assistance for the engineering and manufacturing tasks undertaken this
semester:
• Dr. Steven Timmins
• Frank Sneeringer
• Steve Beard
• Jeff Ricketts
• Dave Fogarty
• Rob Buchler
• Adrian Sawyer
The main focus for the fuel tank were weight and volume. Some
key design aspects include:
• Use of .05” thick 5052 Aluminum Alloy for corrosion protection
and minimal weight
• A designed weight of 5 lbs. when compared to the 10.5 lbs.
tank built in 2013