• Adjustability - Account for drivers with different heights by designing the pedal tray to be adjustable

• Mounting - Design mounting holes for all required sensors and components

• Weight reduction - Optimize for weight while maintaining structural strength.

• Streamlined manufacturing - Implement design and manufacturing techniques to decrease production time and lower associated costs.

• Cost reduction - Utilize cost-effective materials that retain the required strength and stiffness without sacrificing performance (FOS, Deflection)

Materials 

• Dummy Master Cylinders: Carbon Steel

• Pedal Tray: 6061 T6

• Brake Pedal: 7075 T6

Forces

• 450 lbf applied to the top of pedal, 15 deg displacement

Fixtures

• The bottom of pedal tray is fixed

• Dummy Master cylinder and brake Pedal are rigidly pinned

Contacts

• Brake and dummy MC are “contact” (no penetration)

Other settings

• The pedal tray is set as rigid to speed up the simulation

Material:

• 7075 T6

Forces

• 450lbf on the top of the pedal

Fixtures

• Fixed hinge at pivot

• Frictionless constraint at the balance bar interface

B22: The B22 brake pedal was constructed from a 7075 T6 aluminum billet. A waterjet cutting was used to cut the two-dimensional geometry. Subsequently, the pivot and balance bar mounting holes post-processed to their required tolerance.

B23: The B23 brake pedal was constructed from a 7075 T6 aluminum billet.A CNC mill was used to create the webbing. The pivot and balance bar mounting holes post-processed to their required tolerance.