Ergonomics & Driver ControlsDavid Anlian, Justin Greenidge & Alan Radojcic

Problem BackgroundFormula 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.

Project ScopeThe 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. Pedal box2. Seat3. Shifting System4. Steering System5. Dashboard6. Fuel Tank

Shifting SystemThe 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.

Pedal BoxThe 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

Final Assembly

Steering SystemThe 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

DashboardKey Design Aspects • Carbon Fiber construction• Tachometer in direct view while driving• Aim MXLPista Data Acquisition System

SeatKey Design Aspects• Seatback angle of 50° from horizontal• Durable and lightweight carbon fiber construction

Fuel TankThe 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 2013Acknowledgements

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