See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/325844696

Cockpit Design of a Formula Student Race Car: An Ergonomics study for the
Cockpit

Conference Paper · December 2017

CITATIONS READS

0 5,945

2 authors, including:

Faisal Talib
Aligarh Muslim University
110 PUBLICATIONS   1,428 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

E-Service Consumption View project

A DEMATEL Approach for Prioritizing the TQM Enablers and IT Resources in the Indian ICT Industry View project

All content following this page was uploaded by Faisal Talib on 21 August 2018.

The user has requested enhancement of the downloaded file.

Cockpit Design of a Formula Student Race Car: An Ergonomics study for the
Cockpit
Arshil Ahmad, Syed Ali Zaheen, Israr Ahmad and Faisal Talib

Department of Mechanical Engineering, Zakir Husain College of Engineering & Technology, Aligarh Muslim University,
Aligarh, UP, India

Abstract. The aim of this paper is to present a set of parameters for ergonomic design of a Formula Student Racing Car
cockpit. Motor racing is one of the most renowned sports across the globe and therefore, its design is utmost important
for achieving highest safety and comfort. Design of cockpit is one of the important part of Formula student racing car
as it contains several essential components which a driver needs to operate during its operation like steering, lever,
accelerator pedal, brake pedal and seat. After design the race car is tested for different test and is completely finalized
before the final race. Certain issues are faced by the driver which can be easily prevented by proper design of the
cockpit. This paper gives quick review of these issues by removing fatigue, seat comfort mainly related to support
posture and the orientation of driver. Seat comfort is also related to driver’s anthropometry and the amount of time
spent during sitting that may affect the comfort level, providing most comfortable position to the driver. This paper
ensures safety of driver from accidents by suggesting the certain set of parameters of an ergonomically designed
Formula student racing car which can be more comfortable and safe during its operation. The analyses are performed
on seat based criteria like fit parameters related to anthropometric measurement and support parameters defined with
respect to seated posture. Data were compiled and used to design a cockpit suitable for people within the range of 95
percentile male and 5 percentile females. Proposing such a design of cockpit, the driving technique may be improved
drastically and less fatigue to the driver can be achieved. Finally, the paper concludes by highlighting the major
findings, discussion on results and scope for further studies

Keywords: Cockpit design, fatigue, anthropometry, comfort.

1 Introduction
SAE International organizes the Formula SAE (FSAE) series design competitions that provide an opportunity for
students to gain quality experiences through the design of prototype Formula racing cars. This type of competition is
growing and becoming more popular with current competitions that are taking place across the globe namely North
America, Australia, Brazil, Italy, UK, Austria, Germany and Japan. Each team is tested on different parameters such
as design, cost and business logics. The desired goal is not only to build a car that performs the best, but also to
ensure that the driver is comfortable inside the cockpit. The ergonomics of a cockpit is considered as a very crucial
component(Beal 437). Ergonomics or the study of human-machine interfacing is important to vehicle design
because the ultimate control of the vehicle belongs to the driver. When designing this “interface” between person
and machine, several aspects should be taken into account so that the best system of control is produced
(Fernandes). The vehicle control has to be placed strategically so that driver drives car easily and the car will
achieve it’s peak performance.(Beal 437). The design goal of seating position is to provide a position of comfortable
leverage for the drivers so that they do not become tired during the operation of control system from an inconvenient
position. Vehicle controls should be within a comfortable reach of the driver and also comfortable to operate.
Controls that are inconvenient to reach or difficult to operate will distract the driver and potentially results in more
driving mistakes. The vehicle cockpit should serve the driver, not the other way around. The more driver-friendly
the ergonomics are, the more comfortable the driver will be and the better he can focus on driving.
The purpose of this paper is to examine the issues faced by the driver during driving of the Formula student car by
proposing design of the cockpit. The study ensures safety of driver from accidents by suggesting the certain set of
parameters of an ergonomically designed Formula student car which can be more comfortable and safe during its
operation. Rest of the paper is organized as follows. Next section presents a brief literature review of past studies
undertaken on the subject followed by elaboration of methodology used. In the subsequent section design of the
apparatus and data collection was carried out followed by the discussion on results and findings. Finally,
conclusions and scope for future wok was presented at the end.

1
2 Literature Review
Formula student competition in UK such as FSAE gives an astounding opportunity for engineering students to
acquire experience in the field of designing, fabrication and testing of the vehicle. The objective of this type of
competition is to involve students in different operations in practical work by applying different theories into
practical work and to build up new talent of student in automotive field. Seat of any vehicle or formula student race
vehicle is one of the important component of a racing car and should be designed at the best comfort level so that the
driver feel less fatigue and vehicle attain maximum efficiency. They support most of the weight of the driver and
thigh support also given for easy operation of the vehicle such as pedal, brake, throttle to give maximum support to
the driver as they drive long time in dynamic condition.

2.1 Competition Rules

According to the rules that are evenly govern for the chassis is the constraint part of the research . If any single rule
is violate then car will be disqualified from the competition. Within the competition rules that are evenly for the
cockpit, so it is necessary that all rules regarding cockpit should meet. Some of the important aspect that should be
considered mandatory are MAIN HOOP,FRONT HOOP, BULKHEAD, MAIN HOOP BRACING,FRONT HOOP
BRACING ,BULKHEAD SUPPORT, OTHER BRACING AND SIDE IMPACT MEMBERS. Size of the angle of
back seat and thigh rest and knee height also varying with the height of the driver(FSAE international 2017-18 rule
T3.10.3). When seated normally and restrained by the driver's restrained system, the helmet of a 95th percentile
male (anthopomatrical data) all the team driver's must be:

• a minimum of 50.8mm (2inches)from the straight line drawn from the top of the main hop to the top of the
front hoop.

• a minimum of 50.8mm(2inches)from the straight line drawn from the top of the main hoop to the lower end
of the of the main hoop bracing extend rewards.

• T3.10.4 The 95th percentiles male template will be position as fellows

• the bottom 200mm circle will be placed on the seat bottom such that the distance between the center of the
circle and the rear most of the pedals is not less than 915mm(36 inches).

2.2 Overview of Past Research Study

Before commencing any design work it is useful to see what is already been done by others in the same field. As
mention" FORMULA SAE RACE CAR COCKPIT DESIGN AN ERGONOMICS STUDY FOR THE COCKPIT".
(Mariotti and Jawad,2000). In this paper they have taken back rest angle 50 then they adjusted other parameter, with
a number of sample used. While each dimension was determined with the consideration of how it influenced the
other dimension were selected . In this they have also taken the parameter of 95th percentiles of male and 5th
percentiles of female and for thigh angle in this paper is quite low range 35 and 30. Another text that was analyzed
for "An ergonomics study of UniKL MSI Perodua Eco-challenge Race Car cockpit"(Shamsuddin et al,.2014).In this
paper is concerned about the hierarchy of goal in ergonomics. First is concerned that do not posses any element that
causes dangers to human life or health than come to the accepted condition upon which the people involved can
voluntarily agree, and last one is to generate "optimal" condition which is well adapted to driver. In this paper they
find out the comfort level through software RULA(Rapid upper Limb Assessment) and CATIA V5R16. Through
this to find out human posture analysis and human activity analysis. 95 percentile By analyzing these papers ,the
data found is quiet remarkable like in first paper but there are here are some dimensions that has given specific
consideration like back seat angle ,which is taken as constant and thigh angle is of very low range. In second paper
all the dimensions are calculated through using design softwares (CATIA and RULA) and chart system..

The study in this paper is based on varying cockpit dimensions that is back seat angle is varied from 50-80 and thigh
angle is varied from 10-20 degrees. Some dimensions are made constant for achieving meaningful data ,the first one
is pedal height and second is distance between seat bottom and to the height of pedal 915mm( SAE RULE
T3.10.4),knee angle is varied according to the height of driver that is concerned with SAE rule 95 percentile male

2
and 5 percentile female. The knee angle is dependent on back seat angle and thigh angle ,driver having different
height have different knees angles.

3 Methodology
An ergonomic study was done to find out maximum comfortable posture of driving for the driver while ensuring all
the safety aspects for driving. The main resource for creating the posture was rule T3.10.4 from the 2015 FSAE
rulebook, seen in Figure 1. This template shows the positioning of the 95th percentile male within the vehicle. The
template is accompanied by the following text (SAE International 2014):
• The seat will be adjusted to the rearmost position.
• The pedals will be placed in the most forward position.
• The bottom 200 mm circle will be placed on the seat bottom such that the distance between the
• center of this circle and the rearmost face of the pedals is no less than 915 mm (36 inches).
• The middle 200 mm circle, representing the shoulders, will be positioned on the seat back.
• The upper 300 mm circle will be positioned no more than 25.4 mm (1 inch) away from the head
• restraint (i.e. where the driver's helmet would normally be located while driving).

Fig1. FSAE 95th percentile male template (SAE International 2014).

T3.10.4 aided in determining the location of certain body parts and the lengths between locations on the body for the
creation of the posture. It was determined that the line extending from the neck to the top of the head should be
parallel to the vertical .The shoulder should be against the seat back and the buttock should be against the seat
bottom. The distance from the hip joint to the toe should be 915 mm (the minimum value within the rules). Initially
ergonomics of previous FSAE race car were tested. Some basic dimensions of cockpit like back seat angle ,thigh
angle were listed and some dimensions were made constant namely pedal height and the distance from centre of
bottom circle of seat dia 200mm to the height of pedal as per the FSAE rules this length should not be less than
915mm by sitting and analyzing. Then an ergonomic design were made while considering all of these dimensions. In
order to achieve more accurate data some dimensions were made constant. Seat dimensions are the basic building
dimensions of cockpit that’s why they were included . Analyzing was done on two seat angle 55 and 70 to figure
out the most comfortable angle. Subjects of different heights and weights were used to identify the desired angle
according to their comfort and fatigue . Subjects gave their feedback according to their comfort by sitting in the
apparatus . Cockpit dimensions were calculated according to the established data. The goals established for cockpit
are as follows:
• The driver attains maximum comfortable position for driving.
• The other factor for improved driving is seat thigh angle which facilitates knees according to operation of
pedals.
• Steering location so that
• the drivers grip the steering wheel so that their
• upper arm and forearm are at approximately at 90degree angle for the best mechanical advantage
while steering.
• the drivers can turn the wheel without hitting their legs with the wheel or their hands. (See Figure 1.
The steering wheel is not a full circle. The bottom portion of the wheel is flat, but this "added"
clearance no longer exists as the wheel is turned.)

3
 • the drivers can move their legs while operating the pedals without bumping the steering wheel in the
process.
• Dash height so that• the steering wheel stays within the height of the dash according to the FSAE rules (see
Figure 2).
• the drivers can see at least 20 feet ahead to the ground for reasonable visibility as specified by the
drivers.

Fig. 2 Cockpit rule(2014 FSAE rule5)

• Clearance between the dash and the floor of the cockpit so that drivers do not hit their legs while exiting the
vehicle. (The steering wheel is removable so that it is not an issue during egress).
• Proper width of the cockpit to accommodate the seat and the drivers' legs and shoulders.
• Pedal assembly location so that
• drivers can reach the pedals.
• the height of the assembly feels comfortable to the drivers.
• Shifter location close to the steering wheel so that hand travel between the wheel and the shifter is a minimum
distance for quick shifting and faster lap times.
• Tachometer and warning lights for the oil and temperature gauges within the line of sight, and oil and water
temperature gauges within eye range.

3.1 Design of Apparatus

An ergonomic apparatus was made intended to adjust almost all heights of drivers .In this analysis drivers height
ranges from 95 percentile male to 5 percentile female as per the regulations of FSA(FSAE 2014). Seat back angle,
thigh angle, dash height and pedal assembly were easily adjustable according to the anthropometry of drivers. The
required measurement was easy measurable regarding the comfort of drivers.
The ergonomic apparatus is pictured in figure 3. Two boards consisting of mock seat are hinged on a two
by four and represent the seatback and thigh angle. To set the back seat angle a rod is placed through two adjacent
vertical two by fours. In order to adjust seat back thigh angle, apparatus incorporates block underneath seat which
can change the thigh angle.

Fig3. Ergonomic Apparatus Cockpit.

3.2 Data Obtained
Table 1 show the data collected after all the analysis ,the subject felt comfort according to their height as they may
have short or long legs and that affects in bending of their knees . The bending of knees also gives direction to thigh

4
angle as can be seen from Table 1 the most comfortable thigh angle experiences by most of the subjects was 20.
Height was measured from the subjects

Table 1. Cockpit Dimension data from subjects.

NAME HEIGHT BACK SEAT ANGLE THIGH ANGLE KNEE ANGLE AT 10 KNEE ANGLE AT 20 DISTANCE BETWEEN BOTTOM CENTRE TO PEDAL HEIGHT PEDAL HEIGHT
A 5'9" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
B 5'8" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
C 5'9" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
D 5'7" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
E 6'2" 55 20 MORE COMFORT LESS COMFORT 915mm 280mm
F 5'8" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
G 5'11" 55 20 MORE COMFORT LESS COMFORT 915mm 280mm
H 5'2" 55 20 MORE COMFORT LESS COMFORT 915mm 280mm
I 5'3" 55 20 MORE COMFORT LESS COMFORT 915mm 280mm
J 5'8" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
K 5'7" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm
L 5'5" 70 20 LESS COMFORT MORE COMFORT 915mm 280mm

4 Results and Discussion

As per the ergonomic study of cockpit following results were calculated
-Backseat angle
There are two variation in back seat angle for different heights of subjects i.e 55 degrees and 70 degrees . some
subject of longer heights find it more comfort in sitting and holding steering in 55 degrees angle this is due to
various factors as of their bending of knees and thigh angle. In case of short height subject they find it more
comfortable in 70 degrees angle this is due to vision they will get to see in front.
-Thigh angle 20 degrees.
This angle is suitable for most of the subjects . The analysis were done using to different thigh angles and they were
10 and 20 degrees. The final comfortable angle is taken 20 degrees.
Each dimension is determined with the consideration of how it affected other dimension above answer is based on
the feedback data survey. Since driver should grip the steering wheel in a way that can give best mechanical
advantage. As shown in Table 1 the distance between centre of hip bottom circle and pedal height is fixed that is
915mm. The steering wheel position was set fixed while keeping the design of cockpit unchanged. The advantages
of having lower thigh angle is the clearance between knees of the driver and dashboard in which steering wheel is
fitted. The thigh angle causes in increase and decrease of length of legs of driver. If thigh angle is not adjusted well
enough it affects visibility of driver too. The height of dashboard remains fixed. There is a disadvantage of
decreasing the height of dashboard that is reduce egress from the car and in increase in roll hoop height to
accommodate the head clearance required by the rules. Figure 2 illustrates head clearance .Head clearance is defined
as the clearance between driver’s head and an imaginary line drawn from the top of dash and from the top of roll
hoop. In order to meet this requirement if the distance between drivers head and dash is decreased then the roll hoop
height must increase.

Fig 4. Driving posture for the 95th percentile male

5
 A full synopsis of the angles and lengths used within the posture can be found in Tables 2 and 3 and an explanation
of how the angles and lengths were measured can be found in Figure 4. Within the tables and figures, “hip to toe”
refers to the distance between the bottom 200 mm circle to the pedal, “hip to shoulder” refers to the distance
between the 200 mm circles, and “shoulder to center of head” refers to the distance between the upper 200 mm
circle and the 300 mm circle. Note that there is a range for the knee angle. This is due to the different leg lengths
among people of the same height. In order to keep the distance from the hip to the toe constant , the knee angle had
to be adjusted accordingly.
Table 2. FSAE posture lengths.

Table 3. FSAE joint angles

5 Conclusions
The ergonomic apparatus provides accurate results as mentioned earlier. This ergonomic apparatus provide s a good
approximation of how a person of either of those statures would fit within a FSAE vehicle cockpit. This apparatus
will assist students in creating a cockpit that meets the guidelines for user accommodation. While this apparatus
provides the FSAE teams a helpful design tool, the teams cannot rely entirely on the apparatus to create a design
that accommodates drivers of different sizes. FSAE teams will have to consider many other aspects when creating
their cockpit designs. Equipment choices could potentially affect how the driver fits into cockpit. For instance, this
apparatus is shown without helmets.

REFERENCES
1 SAE International (2014) 2015 Formula SAE® Rules.
2 Beal, G.F “Making The Cockpit Practical for the Pilot” SAE journal (Transactions).August 1945,Vol 53,no.8:
437-440,496.
3 Fernandes, M.G.P “COCKPITS :Design and Development”. SAE Technical Papers Series. October 13-
14,1992;921445:1-8.
4 Mariotti, E and B. Jawad (2000) Formula SAE Race car Cockpit Design An Ergonomics Study for the Cockpit,
Tech. Rep. 2000-1-3091,SAE Technical Paper. SAE "CDS Event History : SAE College Design Series".
5 SAE International 2017-18 Formula SAE Rules.
6 Shamsuddin, H.K.,Ilyas, A.H.,Nurhidayat, M. and Shafee , K.H.(2015)."An Ergonomics Study of UniKL MSI
Perodua Eco-Challenge Race Car Cockpit" . August 2015,Vol 1 ,Issues3,PP 119-124.
7 Boyd, D.K.,Killen, C.D. and Parkinson, M.B. “Manikin Design : A Case Study of Formula SAE Design
Competition”.

View publication stats