Formula SAE Pedal Box
Objectives
Redesign and manufacture a rules compliant pedal box that increases driver comfort and reliability.
Outcomes and Contributions
The 2024 WPI Formula SAE car needed some improvements to increase its reliability and competitiveness. My responsibility was to redesign and manufacture the pedal box of the car to increase driver comfort and reliability. On the driver comfort side, I modified the driver’s foot placement to allow the drivers to actuate the pedals more naturally, while 3D printed heel cups ensured their feet remained secured and stable on the pedals, even when driving around a corner. To increase reliability, I thickened the baseplate to prevent the pedal box from twisting under high loads and implemented three accelerator pedal sensors to add robustness to the accelerator pedal position detection. During the first test session, drivers immediately reported the ergonomic feel of the pedals was greatly improved from the previous design. Additionally, the sensors increased the reliability, allowing the car to complete a 40-lap endurance stint without having to reset or retire it due to a pedal fault. Our team competed in the New Hampshire Formula Hybrid/Electric competition and finished 3rd overall.
Technical Details
The baseplate, pedals, and sensor mounts were machined using 6061 aluminum. Both the accelerator and brake pedals were lengthened to allow the driver’s feet to rest directly on the pedal, providing the driver with additional grip. 3D printed heel cups also allowed the driver’s feet to remain planted. The accelerator pedal featured two COTS hall effect potentiometers, which replaced two sensors made in-house, to increase the reliability of detecting the position of the accelerator pedal. Additionally, a limit switch, which activated when the pedal was at its rest position, added another level of safety. The brake pedal also featured brake pressure sensors, which enabled regen braking detection and brake light activation.
Fig. 1 - CAD Model of Pedal Box
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Fig. 2 - Assembled Pedal Box Installed in Car