FSAE Pedal Box

This year I was tasked with designing the pedal box for the UC Berkeley Formula Electric Racing team (FEB). The angles, pedal effort, and adjustability of the pedal box were determined by taking ergonomic data from the FSAE rule book and our custom built ergo jig.

I designed a split baseplate, dovetail rail system to contrain translational and rotational movement in xyz, while still ensuring quick and easy adjustability. Since these rails are >2ft long (due to the constraints of our chassis) I ran extensive calculations to ensure they maintain a deflection of under 1mm. Through a combined method of hand calcs and writing my own MATLAB script I determined the optimized dimensions for my dovetail shape.

I went on to manufacture the rails from 7075 Al on a manual mill, adhering to tight tolerances (accounting for anodizing the parts), and as of now they will be done later this week...