Riassunto analitico
This project starts from the need of reducing the time spent to design the pedal box for a race car application. For “pedal box” are considered all the pedals needed to control a race car like throttle, brake and clutch pedal and all the ancillaries connected to these components. This dissertation contains all the phases needed from a conceptual to a prototyping phase of this assembly. The main characteristic of this new assembly is the possibility of using it in all the future projects without the need of adapting it, so it must have a “plug and play” nature. This goal is not that easy considering that Dallara race cars are used by different drivers during their life and thus they must be adjustable in every sensible part. The starting point was the benchmarking of all the pedal assemblies built by Dallara during its history, gathering information about all the problems and how they were solved. This was carried on defining some parameters thanks to which it was possible to compare very different concepts and designs. Inside this comparison different competitor products were also considered and analysed. From this comparison a functional analysis was done to rediscuss the main functions of these apparently simple components. The output of this analysis was a list of demands and wishes for each component. All this information was gathered using Excel sheets and internal Dallara data and software like PTC Creo. The design phase was driven by all the information and goals retrieved from the previous phases and this gave way to change completely some point of views on some major components used by Dallara in the pedal assemblies. For example a rotational damper was studied to replace the actual linear one and a modular concept was embedded in the design of all the assembly. The design phase was also composed by: • Packaging evaluation on the recent models produced by Dallara. • Drivers feedback and expectations. • Kinematic analysis of the pedal movement using PTC Creo. • FEM analysis on the main components of the brake and throttle assemblies and therefor a load case evaluation using PTC Creo. • Definition of all the carry over, commercial and bespoke components. The final result is a complete study, also composed of a cost analysis, ready to be produced at a prototype stage and tested to validate the main concepts used and developed in this dissertation especially for the driver feedback. As future developments a testing phase could be carried on. The new components like the brake pedal and master cylinders support or the rotary damper could be tested to validate their fatigue life and maximum load capability simulated in the FEM.
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Abstract
This project starts from the need of reducing the time spent to design the pedal box for a race car application. For “pedal box” are considered all the pedals needed to control a race car like throttle, brake and clutch pedal and all the ancillaries connected to these components.
This dissertation contains all the phases needed from a conceptual to a prototyping phase of this assembly.
The main characteristic of this new assembly is the possibility of using it in all the future projects without the need of adapting it, so it must have a “plug and play” nature. This goal is not that easy considering that Dallara race cars are used by different drivers during their life and thus they must be adjustable in every sensible part.
The starting point was the benchmarking of all the pedal assemblies built by Dallara during its history, gathering information about all the problems and how they were solved. This was carried on defining some parameters thanks to which it was possible to compare very different concepts and designs. Inside this comparison different competitor products were also considered and analysed.
From this comparison a functional analysis was done to rediscuss the main functions of these apparently simple components. The output of this analysis was a list of demands and wishes for each component.
All this information was gathered using Excel sheets and internal Dallara data and software like PTC Creo.
The design phase was driven by all the information and goals retrieved from the previous phases and this gave way to change completely some point of views on some major components used by Dallara in the pedal assemblies. For example a rotational damper was studied to replace the actual linear one and a modular concept was embedded in the design of all the assembly.
The design phase was also composed by:
• Packaging evaluation on the recent models produced by Dallara.
• Drivers feedback and expectations.
• Kinematic analysis of the pedal movement using PTC Creo.
• FEM analysis on the main components of the brake and throttle assemblies and therefor a load case evaluation using PTC Creo.
• Definition of all the carry over, commercial and bespoke components.
The final result is a complete study, also composed of a cost analysis, ready to be produced at a prototype stage and tested to validate the main concepts used and developed in this dissertation especially for the driver feedback. As future developments a testing phase could be carried on. The new components like the brake pedal and master cylinders support or the rotary damper could be tested to validate their fatigue life and maximum load capability simulated in the FEM.
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