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  • 2020 EV Drivetrain End of Semester Update

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    Stewart Prince
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    The document summarizes the EV drivetrain subteam's work on designing and manufacturing the drivetrain for CSUN's Formula SAE electric vehicle. It discusses the objectives, research conducted, design iterations including calculations and analysis, manufacturing progress made, and plans to continue fabrication and assembly of remaining components like the motor output sprocket, rear sprocket, and halfshafts. The conclusion emphasizes lessons learned around sprocket design and reports the estimated weight of the drivetrain both with and without the EMRAX motor.

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    2020 EV Drivetrain Report

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    The document summarizes the EV drivetrain subteam's work on designing and manufacturing the drivetrain for CSUN's Formula SAE electric vehicle. It discusses the objectives, research conducted, design iterations including calculations and analysis, manufacturing progress made, and plans to continue fabrication and assembly of remaining components like the motor output sprocket, rear sprocket, and halfshafts. The conclusion emphasizes lessons learned around sprocket design and reports the estimated weight of the drivetrain both with and without the EMRAX motor.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    47 views31 pages

    2020 EV Drivetrain End of Semester Update

    Uploaded by

    Stewart Prince
    The document summarizes the EV drivetrain subteam's work on designing and manufacturing the drivetrain for CSUN's Formula SAE electric vehicle. It discusses the objectives, research conducted, design iterations including calculations and analysis, manufacturing progress made, and plans to continue fabrication and assembly of remaining components like the motor output sprocket, rear sprocket, and halfshafts. The conclusion emphasizes lessons learned around sprocket design and reports the estimated weight of the drivetrain both with and without the EMRAX motor.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 31

    CSUN FSAE 2019-2020

    EV Drivetrain
    Subteam update
    Gaston Olvera
    Anibal Olvera
    CSUN FSAE 2019-2020

    Agenda

    • Objective
    • Research
    • PDR/CDR
    • Calculations/Analysis
    • Design iterations
    • Manufacturing
    • Moving forward/Conclusion
    CSUN FSAE 2019-2020

    Objective

    • Transfer mechanical energy from the


    electric motor to the wheels
    • Design and Analyze for worst case
    scenario
    • Meet Design Criteria/ Regulations
    CSUN FSAE 2019-2020

    Research

    • Drivetrain Components
    • 2018-2019 EV Formula team
    • Other schools
    • Changes/Improvements
    CSUN FSAE 2019-2020

    Post PDR

    • Drivetrain summary
    • Differential
    • Drive Choice
    • CV joints
    • Placement of components
    CSUN FSAE 2019-2020

    Calculations - Maximum tractive limit


    CSUN FSAE 2019-2020

    Calculations
    CSUN FSAE 2019-2020

    Design Iterations
    CSUN FSAE 2019-2020

    Design Iterations
    CSUN FSAE 2019-2020

    Chain

    • 420 Tensile strength: 5,400 lbs


    • Calculated chain tension: 1,160 lbs

    • Weight difference information


    420 - chain weight 1.336 Lbs 53T Sprocket (8.44 inch diameter)
    520 - chain weight 1.993 Lbs 53T Sprocket (10.55 inch diameter)
    Weight reduction of 33%

    • Gear Ratio 4.4


    CSUN FSAE 2019-2020

    Post CDR

    • New Drivetrain redesign


    • Topology
    • Gear ratio reduced to 3.92
    • Manufacture motor output
    shaft and sprocket as one part
    CSUN FSAE 2019-2020

    Motor Output shaft and sprocket


    CSUN FSAE 2019-2020

    Designing a Sprocket on Solidworks


    • 2019 IC Drivetrain left a document about how to design a sprocket
    on Solidworks
    • This process was used to model motor output shaft and rear
    sprocket
    CSUN FSAE 2019-2020

    Motor Output Shaft Analysis

    Since the output shaft is such a critical component


    several analysis was completed to validate the
    reliability of the part.

    • Shear & Moment Diagrams


    • Torsional Analysis
    • Fatigue Analysis
    CSUN FSAE 2019-2020

    Rear Sprocket
    CSUN FSAE 2019-2020

    Car Model
    CSUN FSAE 2019-2020

    Motor/Differential Mounting plate (DRIVE)

    2.8 lbs 2.19 lbs


    CSUN FSAE 2019-2020

    Motor/Differential mounting Plate

    1.71 lbs 1.57 lbs


    CSUN FSAE 2019-2020
    CSUN FSAE 2019-2020
    CSUN FSAE 2019-2020
    CSUN FSAE 2019-2020
    CSUN FSAE 2019-2020
    CSUN FSAE 2019-2020

    Manufacturing Progress
    CSUN FSAE 2019-2020

    Manufacturing

    • Motor output sprocket/shaft


    CSUN FSAE 2019-2020

    Assembly progress
    CSUN FSAE 2019-2020

    Manufacturing
    CSUN FSAE 2019-2020

    Assembly Progress
    CSUN FSAE 2019-2020

    Moving Forward

    • Motor output sprocket


    • Rear sprocket
    • Saw tooth washers
    • Motor scatter shield and chain guard
    • Mounting tabs
    • halfshafts
    • Encoder housing
    CSUN FSAE 2019-2020

    Encoder Housing
    CSUN FSAE 2019-2020

    Conclusion

    • Learned how to design a sprocket


    • Topology
    • Weight w/o EMRAX: 27.255 lbs
    • Weight w/ EMRAX: 54.255 lbs

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