1. Ergonomics & Driver Controls
David Anlian, Justin Greenidge & Alan Radojcic
Problem Background
Formula 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.
Final Assembly
Shifting System
The 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.
Project Scope
The 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:
Pedal box
Seat
Shifting System
Steering System
Dashboard
Fuel Tank
Dashboard
Key Design Aspects
Carbon Fiber construction
Tachometer in direct view while driving
Aim MXLPista Data Acquisition System
Steering System
The 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
Pedal Box
The 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
Fuel Tank
The 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 2013
Seat
Key Design Aspects
Seatback angle of 50° from horizontal
Durable and lightweight carbon fiber construction
Acknowledgements
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