Edwin Odom, Steven Beyerlein, and Joe Law (University of Idaho)

CHALLENGE - The goal of this multi-year project is to create a fully functional University of Idaho entry in the hybrid FSAE competition with a research project developed to design, optimize and build the race car. Within the project, a critical aspect was the design of the braking system considering brakes, pedals and the kinematic system. Brakes and pedals design goals include: capability of locking up all four wheels simultaneously at 20 mph, rising rate braking, ergonomic pedal design, and minimization of deflection with maximum braking force.

SOLUTION - modeFRONTIER has been used to perform a multi-objective optimization using the genetic algorithm MOGA II automating the simulation process. Solidworks, for the force analysis, Genesis, for structural analysis and SAM 6.1, for the kinematic layout, have been integrated using modeFRONTIER’s workflow.

BENEFITS - Performing a multi-objective optimization using modeFRONTIER enabled to obtain the optimal configuration of the braking system maximizing structural rigidity, minimizing weight considering different ergonomic parameters. With the use of genetic algorithms in modeFRONTIER, the pedal and brake design were optimized based on a female or male driver. In the case of a male driver, for the driver to have his feet in a position to maximize force, a foot rest needs to be added to the floor of the car. For this driver to have his feet in an optimum position, the upper roll-cage bars should be raised to allow for clearance between the roll-cage and his feet. Optimal solutions have been successfully tested by the drives.