Optimizing the mechanicalpackaging of drivetraincomponents in Formula Studentbattery electric vehicles : Development of electric drivetrains for student engineering competition

Abstract: The world has seen a rapid increase in the development of electric vehicles. This development is made possible by competent engineers. Formula Student competitions offer engineering students the opportunity to not just get a head start in knowledge on how to develop electric vehicles but also get the opportunity to try out new concepts and technologies that may not yet be widely adopted. In a highly competitive environment, such as motorsports, the motivation to optimize and innovate is great. By reducing weight and inertia teams can greatly increase the performance of their vehicles. A lot of effort is made to optimize existing parts and concepts, but the best strategy for reducing mass and inertia is to eliminate the need for a part or a system all-together. By rethinking how the drivetrain of a Formula Student vehicle is packaged and interconnected, significant mass and inertia savings can be made. This is, however, often a difficult process that requires a lot of problem solving in many different engineering disciplines such as: electromechanics, electromagnetics, thermodynamics, mechanical design, material science and electronics. This thesis concludes that the most performant vehicle configuration is to utilize four-wheel drive as this allows for far better utilization of the available traction. Several ideas and concepts on how the packaging of drivetrain can be optimized are detailed and discussed. One concept calls for the design of a custom electrical machine, a rough estimation of which is done using analytical methods. These concepts are then compared to an existing drivetrain concept. It is concluded that the concept that is presented needs more work if it is to ever become a viable solution.