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A modular, adjustable jig for optimizing driver ergonomics in Formula SAE electric vehicles.

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Race Car Ergonomics Jig (Phase II)

Proto6_1

A modular, adjustable, and collapsible jig designed to optimize driver ergonomics for Formula SAE Electric Vehicles. Developed to enhance Aztec Electric Racing’s testing capabilities at San Diego State University.

Project Status License: SDSU Tech stack: SolidWorks FEA Tools: Ansys | SolidWorks

Table of Contents

  1. Project Goals
  2. Features
  3. Design Highlights
  4. Technical Documentation
  5. Lessons Learned
  6. How to Use
  7. References
  8. License

Project Goals

  • Ergonomic Range: Accommodate 5th percentile female to 95th percentile male drivers.
  • Compliance: Ensure alignment with FSAE EV rulebook and safety standards.
  • Collapsibility: Support quick disassembly and storage in a 57-gallon bin.
  • Modularity: Enable interchangeable components (pedal box, steering column, seat) for future AER car iterations.

Why It Matters
- This jig empowers electric racing teams to streamline driver testing, enhance on-track safety, and reduce lead time in optimizing cockpit ergonomics.


Features

  • Tool-Free Adjustments
    Quick-release mechanisms allow seat and pedal positioning without specialized tools.

  • Multi-Degree Seat Assembly
    Pivoting seat mount plus telescoping punched tubing for seamless angle changes.

  • Integrated Harness & Headrest
    Built-in harness bar and adjustable headrest simulating real FSAE roll hoop geometry.

  • Storage Efficiency
    Collapsible to fit compact bins, maximizing limited shop space and portability.


Design Highlights

  1. T-slot Aluminum Extrusions

    • High strength-to-weight ratio and straightforward assembly via standard 80/20 components.
  2. Prototyping with 3D Printing

    • 1:6 scale PLA models to test basic geometry and module mobility.
  3. Advanced Ergonomics

    • Incorporates FSAE egress rules, seat recline angles, and adjustable pedal positions for thorough driver coverage.
  4. Validated via FEA

    • Multiple load scenarios (up to 450 lbs braking force) verified for frame and mounting plates.

Technical Documentation

Trade Studies

  • Base Frame Layout: Compared rectangular, single-beam, and two-level sliding bases for structural integrity vs. weight.
  • Collapsibility Methods: Sliding vs. hinge vs. disassembly, selecting the disassembly approach to maintain measurement repeatability.

Engineering Analysis

  • Seat Exo-Skeleton: Free body diagrams, shear, and moment analyses combined with SolidWorks/Ansys FEA.
  • Pedal Box Mount: Verified under a 450 lb braking load. Achieved a factor of safety > 14 with minimal deflection.
  • Frame Structure: Replaced hinges with internal butt fasteners and dowel pins for improved load distribution.
  • Refer to the Engineering Analysis file for technical context and analysis.

Prototyping and Testing

  • Scaled 3D Prints: Simple geometry prototypes used to test steering, pedal, and seat movement.
  • Iterative Refinements: Widened back pillars, reduced complexity of pivot joints, and integrated sponsor feedback on adjustability.

Lessons Learned

  • Team Coordination: Importance of transparent communication channels (weekly meetings, group chats) to manage overlapping assignments.
  • Iterative Design Process: Leveraged sponsor feedback to refine pedal box angles, steering mounts, and seat brackets.
  • Documentation & Version Control: Maintaining consistent CAD models avoided confusion in final design presentations.
  • Time Management: Balanced academic workloads, part lead times, and sponsor expectations effectively.

How to Use

Installation

Use SolidWorks 2022 or later (or a compatible viewer) to open the .SLDASM and .SLDPRT files located in the CAD/ directory.

Usage

  1. Customize CAD Components

    • Adjust seat angles, pedal box positions, or steering column length directly in SolidWorks.
    • All major subassemblies can be found in the CAD/ folder, and you can refer to the final assembly file to see the complete jig.
  2. Review FEA Studies

    • Open Ansys/Simulation files located in ./analysis to validate load capacities and confirm factors of safety.
    • Check boundary conditions, applied loads, and mesh settings to ensure they align with your specific design scenario.
  3. Prototype or Manufacture

    • Refer to ./docs/BOM.md for a comprehensive Bill of Materials (BOM), including 80/20 part numbers and recommended fasteners.
    • Use SendCutSend or a similar service for custom laser-cut parts, following your design’s required tolerances and materials.

References

  • *Formula SAE Rules 2024 (Version 1.0)
  • *Dr. Shaffar ME490W Lecture Slides
  • *80/20 Inc. T-slot Extrusion Catalog
  • *SendCutSend - Laser-cut custom brackets and plates
  • *Boskovich et al.: Ergonomic Jig Phase I Documentation (2023)

License

Disclaimer
This project is licensed through San Diego State University (SDSU).
Usage, distribution, and modifications should adhere to the licensing terms set by SDSU and the Aztec Electric Racing Team (AER).

If you plan to use or adapt this project outside the SDSU/AER context, please reach out to us at
shedgecock5567@sdsu.edu for additional guidance and permissions.

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A modular, adjustable jig for optimizing driver ergonomics in Formula SAE electric vehicles.

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