0 to 60 in 2.15 sec - max 80 mph student EV using AMK

[BigOutrunner]

Some pictures from their FB page

Not too long anymore until the casing of VDL and the motor of AMK will be joined with the upright of NLR and the gears of Hankamp. Heading towards 20.000 RPM!

Doc

Can someone please attempt to comment on DUT's gearing on the aluminum NLR knuckle joint in Doc's pics?
Is this the only way to achieve 20,000 rpm? What are the tradeoffs too, if any?
Hub motors can't go that fast supposedly, especially on big outrunners.
I like the 20K speed figure. Seems I need to go back to the drawing board re my big outrunner project.
Thanks all!

 

[bearing]

You can see more pics of the geared hub here:
http://dutracing.tudelft.nl/wp-content/gallery/dut13-production-assembly/935166_10151391209581104_70748609_n.jpg
http://dutracing.tudelft.nl/wp-content/gallery/dut13-production-assembly/mg_3634.jpg
http://dutracing.tudelft.nl/cars/dut13/

It's a two stage reduction, involving both simple gears, and a planetary gear in the second stage.

They must have updated their power train design, because it no longer looks like they have the rear motors mounted at the wheel.

No, it's the other way around. The old design (2012) had drive shafts to the wheels. The 2013 model has one motor in each wheel hub.
http://dutracing.tudelft.nl/wp-content/gallery/dut12-design/dut12_design1.png

 

[BigOutrunner]

You can see more pics of the geared hub here:
http://dutracing.tudelft.nl/wp-content/gallery/dut13-production-assembly/935166_10151391209581104_70748609_n.jpg
http://dutracing.tudelft.nl/wp-content/gallery/dut13-production-assembly/mg_3634.jpg
http://dutracing.tudelft.nl/cars/dut13/

It's a two stage reduction, involving both simple gears, and a planetary gear in the second stage.

They must have updated their power train design, because it no longer looks like they have the rear motors mounted at the wheel.

No, it's the other way around. The old design (2012) had drive shafts to the wheels. The 2013 model has one motor in each wheel hub.
http://dutracing.tudelft.nl/wp-content/gallery/dut12-design/dut12_design1.png

Thanks man! Taking a good hard look at the stuff they've got and all I can say is, 'My, what deep pockets your sponsors have !'.
Machining that stuff cost an arm and a leg.

 

[Timmey]

Thanks man! Taking a good hard look at the stuff they've got and all I can say is, 'My, what deep pockets your sponsors have !'.
Machining that stuff cost an arm and a leg.

Knowing the guy at AMK who did the sponsorship for DUTracing for the DUT11/12 and being involved in Formula Electric myself, I know the pockets will have to be very deep for normal FSAE cars and extremely deep for Electric racing. Way outside the "non-professional weekend autocross racer" the car should be designed for....

 

[bearing]

I know the pockets will have to be very deep for normal FSAE cars and extremely deep for Electric racing. Way outside the "non-professional weekend autocross racer" the car should be designed for....

Was that the original intent?
I once saw a for sale ad of one of the Swedish FSAE cars. But other than that, I've never seen anything that indicates that FSAE cars are being used outside of the FSAE contests.

 

[Timmey]

No, it's designed for the FSAE competition.

The intent of the competition is to simulate a company which designs a "weekend-racer" car for a group of investors, being the judges.
This is done to educate future (motorsport/automotive) engineers into 'real world' engineering.

The car is judged on cost, design and marketing/business in static presentations.
The longitudinal/lateral/efficiency of the car is tested on 4 different 'tracks':
1) 75m acceleration
2) figure-eight skid pad
3) single timed lap
4) 22 km race (timed)

The current electric FSAE-cars are very high tech machines featuring all wheel drive, torque vectoring, ABS, ESP, etc. All mounted to a fully carbon monocoque chassis using the latest motor/battery technologies and active aerodynamics wings. We even have teams developing their own tires just to only last 25km to attain that extra 2% grip. For the companies/sponsors involved this means highly motivated free (future) employees and a free test team/setup to test new technologies.

http://www.youtube.com/watch?v=mgmk8rlVJO0

 

[Punx0r]

It's a bit strange, because I thought the FSAE rules control total build cost (including parts, materials, jigs, and assembly labour). Unless some team are happy to score a zero in the costing part of judgement and blow a shit-ton of cash on a very sophisticated car?

 

[liveforphysics]

I'm not saying those hubs aren't bling'n, because they are, however, I bet it's less than $1000 materials (aluminum blocks and bearings and ring gears) cost to make them (when you already have the right machining tools at your disposal), along with having some machining student pulling a few late chip-spewing nights.

I imagine the battery is the most pricey part of the car, followed by the controllers.

Awesome acceleration! Wow! Does this thing just obliterate all the gas powered FSAE cars?

 

[Timmey]

Wow! Does this thing just obliterate all the gas powered FSAE cars?

It does. Mainly on acceleration and autocross the difference is noticeable.

This year for the first time an electric car won the overall competition.

http://www.racecar-engineering.com/news/eth-zurich-males-history-at-formula-student/

 

[Punx0r]

Any EV FSAE car is guaranteed to walk the fuel efficiency part of the challenge, too

 

[bearing]

I found the specs:
AMK DT5-14-10 4x
Weight 3.7 kg
Maximum power 27 KW
Maximum torque 25 Nm

[pre]AMK DT5-14-10 4x
D - DYNASYN three-phase motor
T - "High-torque motor" family of motors
5 - Size (3-10)
14 - Approx. continuous standstill torque in Nm
10 - Number of poles[/pre]

More info on the motor:
"higher induction than classic electrical steel; for example, at 2.3 T their saturation magnetisation is 13% higher than that of electrical steel."

http://www.automotive-eetimes.com/en/the-sportier-side-of-electric-vehicles.html?cmp_id=71&news_id=222902525
http://www.edn.com/design/automotive/4416249/2/The-sportier-side-of-electric-vehicles-
http://www.vacuumschmelze.com/fileadmin/Medienbiliothek_2010/Downloads/HT/FachartikelSPORTIERSIDEELECTRICVEHICLES-engl-Druck_01.pdf