Formula Student Spec Pedal box

27/12/2023

This project was born from the need of every Formula Student team to incorporate the vehicle control pedals in their car. The pedal box is a key element as it directly influences the design of surrounding components such as chassis and suspension. In addition, there are no commercial options that are well suited to the needs of this type of vehicle, so each team ends up designing and manufacturing its own model.

The main characteristics that define the design are the small size of these cars and the limited space for the driver inside the cockpit. In addition, up to 4 drivers are used in the competition, so the cockpit must be adjustable in its position and the ergonomics must be adjusted to suit drivers of different heights.

On the other hand, a brake pedal must be able to withstand a 2 kN force without breaking, so it must be sufficiently strong and rigid to minimise deflection.

The materials of construction of the pedal box are mainly aluminium and carbon fibre. These are very light materials with high mechanical properties, ideal for a racing car. The selected aluminium is 7075-T6. It is a slightly denser material than other aluminiums but offers the best mechanical properties for this application.

It also incorporates a carbon fibre throttle pedal and carbon fibre shoe surfaces.

The design was done using Solidworks CAD software. Stress simulations were carried out to define the geometry and section thicknesses of the parts. 


Features:

The pedalbox is constructed mostly of aluminium, but incorporates a carbon fibre accelerator pedal, side shoe mounts.

Dimensions:

  • 162 mm x 270 mm x 270 mm (L x W x H).

General:

  • Formula Student rules compliant.
  • Adjustable base in 4 positions for different drivers. 100 mm of travel.
  • Ball lock pins fasteners and rails for quick adjustment.
  • Heel and toe side supports.

Throttle pedal

  • Made of carbon fibre.
  • Incorporates double position sensor and double return spring.
  • Start and end of movement position and adjustable throttle travel.

Brake pedal:

  • Two master cylinders for front and rear axle.
  • Master cylinders with pivoting spherical bearings.
  • Balance bar.
  • Adjustable emergency brake overtravel switch.
  • Reserve reservoirs mounted to the pedal.

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