Pedal Tray

High-level Design Goals

· 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)

Single Wall Prototype

To evaluate the feasibility of a single-wall throttle pivot concept, a 3D printed prototype was created. This design offered potential benefits in both assembly simplification and weight reduction. However, stability concerns emerged during testing.

Full Assembly

Pedal Tray key components:

Brake Pedal
Throttle Pedal
Throttle Return Mechanisim
Linear Potentiometers
Master cylinders
Brake Bias Bar
Brake Over Travel Switch
Quick Release Pin

Structural Analysis

FEA Setup:

Material:

6061 T6

Forces

Per the values in the last slide. Force direction was opposite the directions calculated from the FBD

Contacts

No penetration between tray and floor

Fixtures

Fixed hinge at pivot
Fixed top face of floor

Connections

1850 lbf rigid bolts at tray tabs

Manufacturing

The pedal tray was constructed from a 6061 T6 aluminum billet. A waterjet cutting process precisely defined the two-dimensional geometry of the tray. Subsequently, the pivot and mounting holes were machined using a milling machine for optimal precision and alignment.

Full Assembly

Skills Used: Solidworks, Solidworks Simulation, Engineering Drawings with GD&T. Waterjet, Mill, 3D Printing