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Erik van den Berg – Chief PowertrainDaan van der Wiel – Chief Engineer
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Table of contents
The team
Top level concept
Powertrain
Electronics
Suspension
Chassis
Do’s and Don’ts
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Founded in 2000
10 combustion cars
Known for lightweight concept
The team
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The team
Large team of ±60 people
Full-time management
Part-time engineers
Old team members
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Top Level Concept
First electric car
Young, inexperienced team
1 electrical engineering, 2nd year student
Set realistic targets!
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Top Level Concept
Custom motors?
Torque vectoring?
4WD?
RWD car with torque vectoring possibilities
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Top Level Concept
Power?
Pack capacity?
Target weight?
Simulations!
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Top Level Concept
What defines our concept on a basic level?
Total power output of the motor(s)
Size of the battery pack (=Energy)
Weight of the car
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Track Simulator:
Only straights simulated
Newton: F = m· a
Cornering performance based on competition experience
Track Simulator in Matlab/Simulink
Top Level Concept
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Competition Simulator: Simulations of whole competition in Matlab/Simulink
Dynamic events only
All kinds of cars simulated, lightweight low power to heavy
high powered cars
Sensitivity analysis performed for uncertain parameters
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DUT11
DUT11DUT11
DUT11
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Conclusion from simulations:
Power: 40-50 kW
Accumulator capacity: 6.0 kWh
Resulting car weight about 180 kg
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Packaging
Determine layout and design spaces
Large effect on final balance and handling
Trade-off between CoG location and yaw inertia
Dependent on choice of motors
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Powertrain
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Powertrain: System Description
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The Accumulator
Overview Accumulator:
5.7 kWh for 100% DOD
355V nominal, 400V peak
288 LiPo cells, wired in 96S3P
43 kg
Exchangeable in 10 minutes
Rechargeable to 90% in 1 hour
Elithion BMS
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Sizing of the Accumulator:
Needed energy content derived from Motec data
5,7 kWh enough for Endurance at 100% power in theory
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The Cells:
Radio Control grade Lithium Polymer cells
Suitable ratio of power density vs energy density
Power Density: 4.3 kW/kg
Energy Density: 176 Wh/kg
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The Modules:
Ensuring safety: module voltage 29.6V
Serviceable: pack can be assembled in 45 min.
Transparent polycarbonate for inspection and protection
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The Motors:
• Ideal motor power derived from simulation
• AMK Antriebe motors used with 56 kW combined
• Industrial material: simple & reliable
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The Motors & Motor Controllers:
Motor Type: AMK DT5-30 (PM synchronous)
Power: 14 kW nominal/ 28 kW peak
RPM: 10,500 max
Weight: 12 kg (per motor)
MC Type: AMK KW-40 Motor Controllers
Input voltage: 350 VDC
Cooling type: Water cooling (motors & MC’s)
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The Motors: Power curves
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45 km/h 120 km/h
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The Transmission
Overview:
• Ratio of 1:7.2
• Very slim design needed
• Single step
• Spur gears
• Oil bath lubrication
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ECU
HV Battery management
system
Steering wheel
DashboardSensors Switches
IMD
MC’s AIR’s
LV Battery
CAN-Bus
Analogue & Digital
Power
Analogue & Digital
Control System Overview:
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Electronic Control Unit In house developed
Lightweight (450 gr.)
Relatively cheap
Safety functionality
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• Dashboard with LCD display for information• Warnings• Lap times• Energy Consumption
• Buttons on the steering wheel• Motor torque• Motor braking• Menu controls• Power boost
Dashboard & Steering Wheel
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Suspension
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Load path analysis
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Chassis
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Monocoque
Carbon fibre monocoque
Vacuum infusion
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Motor cover
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Length/Width/Height 2628/1407/1064 mm
Weight 175 kg
Weight distribution 41/59
Power (nom./peak) 28/55 kW
Tractive system voltage 400 V
Battery pack capacity 5.7 kWh
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Do
Recruit electrical engineering students when designing an
electric car!
Make clear agreements with suppliers
Use big safety margin on delivery time
Perform quality control (checklists)
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Do
Use test time efficiently (good test plan, clear tasks, rested,
exchangeable battery pack)
Train your drivers
Practice entire endurance before competition
Execute important tests before the competition
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Don’t
Execute the rain test the night before you leave to FSUK…
Expect something is simple to design (design everything!)
Neglect high voltage safety (≥2 people, clear signs,
responsible person, gear)
Underestimate the battery pack
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Looking back...
Goals and expectations were chosen such that they were a
challenge to meet but feasible with the resources we had.
The car was designed to score the most points overall, not
on individual events. The concept and parameters chosen
at the start of the year gave us exactly that!
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Questions?
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Length/Width/Height 2628/1407/1064 mm
Weight 175 kg
Weight distribution 41/59
Power (nom./peak) 28/55 kW
Tractive system voltage 400 V
Battery pack capacity 5.7 kWh
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Steer by wire
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Powertrain Weight Distribution
43
24
8.5
9
2.54.5 3.5
Weight per Part of Powertrain [kg]
AccumulatorMotorsMotor ControllersGearboxesHalfshaftsCoolingHV Wiring
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Regenerative braking recovers 20% of used energy (1.2 kWh)
Actual Power Usage during Endurance:
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Controller
Radiator
Pressure valve
Catch can
Pump
Gearbox
Motor
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Accumulator Tips & Tricks
Always a lot more work than you anticipate
When working with HV always have two people present!
Modular construction makes assembly easier and safer
Ensure you have plenty of fuses
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The Cooling System: Schematic Overview
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The Cooling System: Testing
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Spindles
Al 7075-T6
Integrated tripod-housing
Integrated brake disk carrier
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Rims
CFRP – Aluminium hybrid
Relatively easy to produce
No special tools required