What you are about to read is a foundational document created by me, Noah Hickman, the Longhorn Racing Solar Fergo System Lead for the 2024-2025 competition season. I have chosen to create this document to make a referenceable database for any new and future ergonomics subsystem members. Though I made this documentation purely off my knowledge and research of solar car ergonomics construction, this is a universal document that includes useful information for ergonomics design in general, which means any and every team, LHR Combustion, Electric, Solar, or even teams beyond UT Austin can hopefully utilize this document. I hope for this document to aid in the design, procurement, and manufacture of any and every piece of a competition car's ergonomics design.
This document or rather my experiences and knowledge gained from my time in LHR is not accurately portrayed or represented without acknowledging those who helped me along the way. From Solar’s team captain, to chief engineer and mechanical lead, as well as members and leads of both the Combustion and Electric team, I cannot thank those enough for the impact they have had on my development as an engineer, and therefore the creation of this document and information therein.
Goals of the Ergonomics Subsystem (subject to change):
- Consider all and every component that the driver touches and uses during normal driving operations:
- This includes and is not limited to:
- Driver model
- Pedal box
- Driver Communications system
- Driver harness/seatbelt configuration
- Belly pan
- Driver seat
- Driver cooling
- Steering wheel
- Brakes (brake lines, proportioning valve, etc.)
- Parking/Handbrake
- This includes and is not limited to:
- Additionally consider items that shield the driver and that are specific to each driver (I say this as ASC requires multiple drivers)
- This includes and is not limited to:
- Ballast Box
- Frame cushioning/padding
- Driver shielding
- This includes and is not limited to:
- Take in any design considerations or concerns from systems such as Controls (Dashboard), Electromechanical (Cooling), and Dynamics (Brakes, Steering Wheel) to ensure smooth integration and that all design cases are met
- To meet ASC guidelines (which directly affect the ballast box, steering wheel, braking system, seatbelt setup, etc.), design each component to meet standards
- Utilize topology optimization and prototyping to refine each design, maximizing the weight to stiffness ratio, and upholding high DFM (design for manufacturing) standards
- Perform FEA simulation via SolidWorks or ANSYS (preferably ANSYS) in order to once validate FOS of at least 1.1+ and ensure parts are optimal for their average use/load cases
- Manufacture each necessary part via manual milling, lathing, CNC, TIG/MIG welding, etc. etc.
- Integrate with the frame and other systems
TLDR: One big subsystem, many smaller (but highly significant) projects
Foundational Documentation/Good Reads (in a good reading order):
- Fergo ASC and VR3 Documentation Break Down → This is an non-negotiable must read for all members, as it specifically lays out the guidelines and regulations we must follow to ensure we meet ASC and FSGP standards.
- Cockpit Design of a Formula Student Race Car: An Ergonomics Study → Though based on FSAE, this provides a good overview onto the design methodology of the cockpit of a car, regarding what considerations to take in, what you are designing for, and how those can be affected by the design.
- The entire “To Win” series by Carroll Smith is a great series written on motorsport racing and race car development as a whole. These are great reads as a whole if you like cars, motorsport, and automotive engineering in general.
Ergo Idea dump 
:
- Wet layup carbon fiber molded seat, starts from foam CNCed mold that is then overlayed with carbon fiber, resin, etc.
- Composite, fully 3d printed steering wheel???? ( with 3d printed grips )
- Top-opped pedal box with lightweight materials
Related articles