FSAE Electric Powertrain Design
Drivetrain Assembly
Drivetrain Failure Analysis
FSAE Electric
Powertrain Design
Tony Hamre, Mason Evans, Greg Kerchmar, Michael
Sciortino
●
3:1 gear ratio (15 and 45 tooth sprocket with 520
chain)
●
Uses same differential as FSAE formula car.
●
Braces made of ¾” 2014 Aluminum to save weight
●
Emrax 228 motor physically spins around, so all motor
mount bolts are on the back side, allowing the shaft on
the front side to spin freely
●
Chain tensioner is free spinning and can be adjusted
and set with a lead screw and nut.
●
This side of the brace is directly connected to the
motor and will experience the highest stress
●
Tests on 2014 Aluminum at the peak torque of 250
N-m shows a safety factor of ~4.6 in the areas of
highest stress concentration
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s
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Batteries tested at in STAR-CCM with scale sections to best represent running
conditions
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Air velocity is 2 m/s
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Each battery produces nominal 2 W of heat
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Maximum allowable temperature is 60C
●
Batteries do not exceed 31C during normal operation
●
Samsung 18650 Batteries in 72 series, 10 parallel
arrangement
●
Premade Energus Battery Packs
○
Built in fuse and temperature sensor
○
UL rated insulating plastic
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Nominal Voltage: 252 V
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Max Continuous Discharge: 200 A
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Modular design
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All aluminum components can be anodized
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r
C
o
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l
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g
F
a
n
s
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A pair of 1000 CFM fans will provide the required
air flow to successfully air cool the accumulator.
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r
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Mechanical connectors for easy disconnect
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High voltage rating
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Mechanical locking
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Allows for modular battery segments
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IP67 and UL94V
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FSAE compliant
Battery Cooling
Battery Arrangement
Battery System Connectors
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o
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Easy quick disconnect
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Easy troubleshooting
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MIL-DTL-26482 rating
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FSAE compliant
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R
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(
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)
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DCNEV250
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Current- 250A
continuous
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Voltage-900V
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Sealed IP67
rating
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Aluminum Radiator (dyed water for cooling)
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AN fittings and hoses to be used
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Hose clamps
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Radiator mounted on the side like old chassis design
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Slight tilt angle to increase time of heat dissipation
Accumulator
●
Samsung 18650 Batteries in 72 series, 10 parallel arrangement
●
Premade Energus Battery Packs
○
Built in fuse and temperature sensor
○
UL rated insulating plastic
●
Nominal Voltage: 252 V
●
Max Continuous Discharge: 200 A
●
Modular design
●
All aluminum components can be anodized
High and Low Voltage Connectors
•
All Connectors are UL and IP rated to insure reliability
•
Continue the Modular approach
Accumulator Cooling
C
F
D
A
n
a
l
y
s
i
s
●
Batteries tested at in STAR-CCM with scale
sections to best represent running conditions
●
Air velocity is 2 m/s
●
Each battery produces nominal 2 W of heat
●
Maximum allowable temperature is 60C
●
Batteries do not exceed 31C during normal
operation
A
i
r
C
o
o
l
i
n
g
F
a
n
s
●
A pair of 1000 CFM fans will provide the
required air flow to successfully air cool
the accumulator.
Drivetrain
●
3:1 gear ratio for
●
FSAE Formula differential
●
¾” 2014 Aluminum braces
●
Emrax 228 motor
●
Adjustable chain tensioner
●
4.6 safety factor at max
torque
M
o
t
o
r
C
o
o
l
i
n
g
●
Aluminum Radiator (dyed
water for cooling)
dissipates heat from motor
and battery management
system
●
AN fittings to be used
●
(⅝ inch rubber hose)
●
Hose clamps
●
Radiator mounted on the
side with a slightly tilted
angle to increase time of
heat dissipation
In-depth overview of the FSAE electric powertrain design featuring battery cooling, arrangement, connectors, accumulator setup, and cooling system. The design includes Samsung 18650 batteries, premade Energus Battery Packs, aluminum radiator, air cooling fans, and high voltage main power braces. Detailed technical specifications for optimal performance and efficiency are highlighted.
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Presentation Transcript
FSAE Electric Powertrain Design Tony Hamre, Mason Evans, Greg Kerchmar, Michael Sciortino Battery Cooling Battery Arrangement Samsung 18650 Batteries in 72 series, 10 parallel arrangement Premade Energus Battery Packs Built in fuse and temperature sensor UL rated insulating plastic Nominal Voltage: 252 V Max Continuous Discharge: 200 A Modular design All aluminum components can be anodized Aluminum Radiator (dyed water for cooling) AN fittings and hoses to be used Hose clamps Radiator mounted on the side like old chassis design Slight tilt angle to increase time of heat dissipation CFD Analysis Batteries tested at in STAR-CCM with scale sections to best represent running conditions Drivetrain Assembly Drivetrain Failure Analysis Air velocity is 2 m/s Each battery produces nominal 2 W of heat Maximum allowable temperature is 60C Batteries do not exceed 31C during normal operation Battery System Connectors This side of the brace is directly connected to the motor and will experience the highest stress Air Cooling Fans Tests on 2014 Aluminum at the peak torque of 250 N-m shows a safety factor of ~4.6 in the areas of highest stress concentration A pair of 1000 CFM fans will provide the required air flow to successfully air cool the accumulator. 3:1 gear ratio (15 and 45 tooth sprocket with 520 chain) Uses same differential as FSAE formula car. High Voltage Main Power Braces made of 2014 Aluminum to save weight Mechanical connectors for easy disconnect High voltage rating Mechanical locking Allows for modular battery segments IP67 and UL94V FSAE compliant Emrax 228 motor physically spins around, so all motor mount bolts are on the back side, allowing the shaft on the front side to spin freely Accumulator Isolation Relay (AIR) Chain tensioner is free spinning and can be adjusted and set with a lead screw and nut. DCNEV250 Current- 250A continuous Voltage-900V Sealed IP67 rating Low Voltage Communications Easy quick disconnect Easy troubleshooting MIL-DTL-26482 rating FSAE compliant
Accumulator Samsung 18650 Batteries in 72 series, 10 parallel arrangement Premade Energus Battery Packs Built in fuse and temperature sensor UL rated insulating plastic Nominal Voltage: 252 V Max Continuous Discharge: 200 A Modular design All aluminum components can be anodized High and Low Voltage Connectors All Connectors are UL and IP rated to insure reliability Continue the Modular approach
Accumulator Cooling CFD Analysis Batteries tested at in STAR-CCM with scale sections to best represent running conditions Air velocity is 2 m/s Each battery produces nominal 2 W of heat Maximum allowable temperature is 60C Batteries do not exceed 31C during normal operation Air Cooling Fans A pair of 1000 CFM fans will provide the required air flow to successfully air cool the accumulator.
Drivetrain 3:1 gear ratio for FSAE Formula differential 2014 Aluminum braces Emrax 228 motor Adjustable chain tensioner 4.6 safety factor at max torque
Motor Cooling Aluminum Radiator (dyed water for cooling) dissipates heat from motor and battery management system AN fittings to be used ( inch rubber hose) Hose clamps Radiator mounted on the side with a slightly tilted angle to increase time of heat dissipation
