Pedal Box

The final SolidWorks design of the pedal box features upright master cylinders, optimizing space for significant weight savings and improving ergonomics by avoiding driver obstruction. This design, informed by anthropometric research and driver measurements, ensures a perfect fit of pedal heights and positions. It is constructed from flat aluminum pieces, designed for efficient 2D plasma cutting, assembly, and welding, contrasting with the previous heavier design that relied on long screws for structural integrity. This approach streamlined manufacturing while maintaining the system's functionality and strength.

In our design process, we chose to weld the pieces of the pedal box together to reduce weight, despite potential drawbacks such as reduced strength and warping from welding. The pedal box, made from 6061 aluminum and designed to withstand significant driver load, underwent FEA simulations in SolidWorks for validation. To mitigate warping due to high heat during welding, we also decided to integrate welding in the frame's construction.

The photo displays the completed pedal box, crafted from 6061 aluminum for optimal strength and weight efficiency. Featuring upright master cylinders for ergonomic design and space-saving, this final product is the result of detailed anthropometric research and collaborative effort. It demonstrates successful engineering validated by FEA simulations.

The project's success was enabled by the crucial support of my Ergonomics team, highlighted in the accompanying photo, culminating in a successful year for which I am grateful.