Shell Eco-Marathon Car

A Student Proposal By:

Mohamed Kombor [21-0535] Hadab Al Hadabi [20-0535]
Mohamed Al Kindi [20-0090] Khalid Al Naabi [20-0027]
Said Al Muhaijri [20-0083] Ammar Al Reesi [20-0064]

Year 3 Project Supervised By:

Dr. Akrum abdullatif & MR. ALI AL HUMAIRI
 Abstract
The Shell Eco-marathon is an annual competition to design and build energy-
efficient racing cars around the world. The goal is to achieve optimal fuel
efficiency that exceeds the limits of sustainable transport innovations (“Everything
You Need to Know About Shell Eco-Marathon | Shell Eco-Marathon,” 2023.). The
main goals of the Eco marathon are to achieve exceptional fuel efficiency and
minimize energy consumption. To achieve these goals, participating student teams
focus on maximizing miles per gallon (MPG) or kilometers per liter of fuel by
designing and implementing highly efficient engines and motors. Teams strive for
records when driving the longest distances with the least fuel consumption, for
example in 2023 the first-place winners of the Shell Eco-Marathon Asia and the
Middle East were able to drive with an internal fuel of 1868 km/l of petrol in
internal combustion engine and prototype design categories (S, SURLA,2023). The
Eco marathon thus acts as a testing platform for sustainable transport solutions,
forcing students to innovate in design, weight reduction and aerodynamics to
create the most energy efficient vehicles. This Proposal will dictate our plan, aim
and objectives to design, modify and reconstruct certain parts of an existing Eco-
Marathon car while simultaneously testing multiple weak points and stability
factors to determine weak points in its structure, drive train and most importantly
turn it into an electrical system which will be the main source of power for the car.

I. Project Overview (PW 3)

Aim and Objective
The eco-marathon competition is divided into two categories, the urban concept which focuses
more on practical designs, and the prototype concept which focuses more on overall efficiency
(Shell Eco-Marathon – Institute of Competition Sciences, n.d.). The vehicles are also separated
by energy source from internal combustion engines including gasoline, diesel, ethanol, and liquid
natural gas and vehicles in the electric mobility category run on hydrogen fuel cells and lithium-
ion batteries.

The project aims to upgrade the current GUtech

prototype concept vehicle (See Figure 1) to a more
mechanically stable structure, more aerodynamic
with the overall objective being converting the
current vehicle to be electrically powered from the
previous internal combustion engine. Thus, this
term the current design will undergo further testing
in the workshop, looking for mechanical adjustment
to be made and by the end of the term a
mechanically stable vehicle that can be pushed and
starred manually without falling. Figure 1 // Current Eco-Marathon Car

Problem statement
The current state of the automotive industry has been undergoing drastic changes toward the
electrical engines sectors instead of the internal combustion ones, due the continuing serge of
greenhouse gasses leading to climate change. According to Europe's leading NGO campaigning
for cleaner transport (Transport and Environment, 2021) ‘’toxic emissions from tailpipes of
diesel and petrol cars have caused air pollution problems in European towns and cities for
decades and cause tens of thousands of unnecessary, premature deaths each year. Now, as sales
of zero emission electric cars surge across Europe and the end of the internal combustion engine
is in sight, the industry is clutching at straws to keep the polluting engine alive’’. Thus, for this
project will be focusing to change the prototype design concept to be suitable for the electrical
motor as the undergoing trend towards electrically powered car is on the serge, with this term
main and secondary focuses on the mechanical aspects of the vehicle are as follows:
Main Objectives:
1. Reverse Engineer the Car: The team analyzed the concurrent car located in GU1 Building and
have decided to take apart the car to study the structure and mechanisms that were built by
previous students to furthermore understand how the car operates and handles.

* More in detail analyses will allow us to shift our focuses to certain aspects of the car and
objectives might be exposed to certain changes throughout the time being.

2.Planning & Design

3. Install an Electric Engine (Planning): The current car ran on two sources of energy one being
hydrogen and the other being Petrol, which is good in theory, but many issues arise in
applications as syncing two sources of energy in a limited amount of space is an inefficient task.
We aim to increase efficacy by changing the current car to a better alternative which is an
electric engine with a battery.

4. Upgrade steering system: After a brief inspection of the car, we found out that the steering
system is not aligned correctly and needed to be replaced by a more efficient one which will
smoother transfer of energy when the driver needs to turn.

5.Upgrade suspension: No suspension system has been found on the current vehicle which leads
to energy being tossed around the car uncontrollably while driving it. A redesigned Suspension
system will allow the car to comfortably dissipate sudden shock which will put less effort onto
the Electrical Engine

*Suspect to change depending on limitations and time.

Secondary Objectives:

1-Saving weight: Power consumption is directly related to the weight of a vehicle, thus reducing
the weight will help us gain more efficient mileage.

2-Checking for Weak Points: Welding might be required to reinsure the structure of the vehicle
while also checking the body for any air gaps that could cause an extra amount of drag on the
vehicle which would reduce efficiency.

(NOTE: All objectives could be subject to change depending on the progress and needs of the
current car, we are still not sure until we are done with the first 2 phases of the main objective.)
II. Methodology

As the aim is to change the eco-marathon car from gas and hydrogen powered to electric
powered, we should consider a well-planned approach supported and optimized from the rules
and regulations related to eco-marathon races. The approach and methodology of implementing
this project should meet and satisfy the criteria and specification included earlier in this report.
To transfer from gas power to electrical power system we should consider the following
approach in terms of the structure of the eco-marathon car that will make such modification
valid, possible, safe with respect to rules and function.
 To start with, each of the new electrical components such as battery, electrical motor, and
other parts must be well seated in the back of the structure or body of the car. A proper
set of handles and straps must be designed and produced with a lightweight material such
as aluminum and manufactured with bolt holes for further assembly.
 An aluminum 2mm shield to be created that will be fixed in between of the driver seat
and all the electrical and motional parts in the back. This shield should act like a safety
separator that separates the driver from any possible unexpected events like the motor
over-heating for instance.
 The driver seat must be repaired to a new one which is more stable with more features
concerning safety of the driver.
 The current frame of the car is assembled and joined using bolts and nuts, which can
result in worse cases if the car experiences a real collision with a body or object.
Therefore, the new design of the frame must be joined using welding to provide more
stability and safety.
 Current steering system is basic and not good enough for a racing car. A modified system
to be considered that will include suspensions with components including a more reliable
steering link, shock absorber, coil spring, control arms, and a braking system.
 Add modifications related to the car cover sheet of aluminum, considering both weight
reducing and aesthetics.

Machines used for implementation:

 CNC Machine: To be used for precision making of a part.
 Centre lathe machine: To be used for working with circular cross-sectional parts.
 Milling machine: To be used to remove unwanted sections in any piece of material.
 Laser cutter: To be used for cutting unwanted sections of a sheet of material.
 Gas Welding: To be used for joining the frame of the car.
 III. List of Requirements

Item Item Item Item Item Item Quantity

No. Name Size Material Link
1 Aluminium Sheet 2x2x0.1 m Carbon Fiber - 2
Composites
3 Engine materials - Magnesium Alloys -
5 Gears and Gear - Titanium Alloys -
Clusters
6 Suspension - Carbon fiber -
components composites
7 Steering Overall diameter: Aluminum Link 1
mechanisms 300mm Composites
8 Brake discs - Ceramic Matrix -
Composites
9 Door panels and Closed-Cell Foam -
interior trim
-
10 Load Bearing - Steel Alloys -
Gears (Lightweight)
11 Lightweight - 7075-T651 high -
Sprocket grade aluminium
12 Timing Chain 12 mm Dyneme fibre Link -

//List made from materials used in top competitors of Eco-Marathon Competition

(Note: A more comprehensive List of Materials will be listed once the first two steps of the
Major Objective is done and we have a more detailed understanding of what we need)
IV. Fusion 360 Model

Figure 2 // Current Car Model with Electric Motor

As seen in Figure 2, The car has been made in

Fusion 360 and an estimate position of the
battery and electric motor has been set in the
rear compart of the vehicle. More efforts will
be accomplished to make sure the parts sync
correctly with the wheel and stable acceleration
will be plausible.

Figure 3 // Close View

V. Project Overview (PW 4)

Shell Eco-Marathon Battery Electric Category

Big oil and gas multinational corporations are investing in research and development in
renewable energy, and some are challenging engineering students to design and race energy-
efficient vehicles. The well-established Shell Eco marathon competition is now held annually in
the Americas, Europe, and Asia, and is drawing participation from university student teams.
Interest in electric, solar, and hybrid electric vehicles, as well as motorbikes, has been steadily
growing in recent years (Howlader et al., 2014). The vehicles that are powered by battery are
only powered by an electric motor and a battery according to the Shell Eco-Marathon regulation
(SEM).

Aim and Objective

Ensuring the mechanical stability and structural integrity of the prototype design vehicle during
this semester 6 (2023-2024) the team will continue to work on the next semester (2024-2025) on
the electrical aspects of the construction, from motor connections, battery placement, brake, and
emergency systems and more. The team’s aim is to use high efficiency motors and batteries as
the goal is to design a car that can travel the longest distance with the least amount of energy.
Thus, the main objective is to connect the battery electric motor with the necessary connection to
make sure the overall project workability.

Problem statement
1. Install the electric motor: We need to figure out the electrical wiring from the battery to the
motor as well get the positioning right while having good support to not waste energy to
vibrations.
2. Install the battery: We need to make sure the battery is connected well, and the battery should
be easy to access for recharging or replacing. Also, the battery should be in a safe place away
from any component that might overheat.
3. Wiring: We need to ensure that wiring is correctly insulated and grounded while sticking to
safety requirements
4. Install the electrical system: Make sure all sensors and control systems are in place and fully
functional and the wiring is neat and tidy.
VI. Methodology

After finishing the first part of the car structure (mechanical part), the electrical part of the Eco
Marathon electric car involves a systematic approach to motor placement and wheel connection.
 Motor Placement:
We need to figure out where the electric motor should be placed inside the automobile body,
taking efficiency and weight distribution into account. Make sure the location you select
balances performance and efficiency while adhering to the overall design objectives. So we need
to make in mind while we are making the car that there must be a seat for the electrical motor.
 Wheel Connection:
We have to design a wheel connection mechanism, ensuring a reliable link between the wheels
and the electric motor. Integrate the chosen transmission mechanism to efficiently transfer power
from the electric motor to the wheels.
With a chain-based connection between the electric motor and the wheel in our three wheeled
Eco Marathon electric car. We have to select a high-quality chain that is appropriate for the load
and power requirements of the electric car. Create a regular lubrication regimen to lower friction
and increase the chain's long lifespan. Also, we will use a dependable chain tensioning system to
keep the chain in the right tension and lower the chance of slippage. We must check and adjust
the tension on a regular basis to make sure the chain stays in the right tension with the sprockets.

 Electrical System: Sensors, Controllers and Safety Mechanisms to be installed.

Electrical systems and their controllers have to be properly designed and installed to complete a
fully functional car; multiple wiring paths will be created to route each individual wire to its
appropriate destination. Insulation will also be a big focus as exposed wiring can be dangerous
when the car is operating. Depending on our needs, an Arduino or PCB controller will then be
installed to become the “brain” of the car and could calculate basic variables such as speed,
battery consumption and basic operations.
 VII. List of Requirements

Item Item Item Item Item Item

No. Name Size Material Link Quantity
1 Electric 60V - Link 1
Motor Kit
2 Wiring - - -
3 Battery - - -
4 Battery Meter 5.71x4.53 Plastic Link -
x0.63 inch
5 Fuse - - -
6 Arduino Board - - -
7 Bread Board - - -
8 Arduino - -
Battery
-
9 Voltmeter - - -
10 Arduino - - -
Components
11 Screen - - -
12

(Note: Very rough list, a more comprehensive list will be made and sent after some more
planning is accomplished.)
References:
Everything you need to know about Shell Eco-Marathon | Shell Eco-Marathon. (2023). Retrieved from
https://www.shellecomarathon.com/stories/everything-you-need-to-know-about-shell-eco-marathon.html

S ,SURLA . (2023). Here are the results of the 2023 Shell Eco-Marathon Asia-Pacific and Middle East.
VISOR. Retrieved from https://visor.ph/industry/here-are-the-results-of-the-2023-shell-eco-marathon-
asia-pacific-and-middle-east/
Shell Eco-Marathon – Institute of Competition Sciences. (n.d.).
https://www.competitionsciences.org/competitions/shell-eco-marathon/

Electric vehicles are far better than combustion engine cars when it comes to air pollution. Here’s why -
Transport & Environment. (2023, January 25). Transport & Environment.
https://www.transportenvironment.org/discover/electric-vehicles-are-far-better-than-combustion-engine-
cars-when-it-comes-to-air-pollution-heres-why/#:~:text=Switching%20from%20an%20ICE%20 to,being
%20a%20 polluting%20 combustion%20process.

Howlader, A. H., Chowdhury, N. A., Faiter, M. M. K., Touati, F., & Benammar, M. (2014).
Development of energy efficient battery electric car for Shell Eco-Marathon competition - Qatar
University experience. 2014 Ninth International Conference on Ecological Vehicles and
Renewable Energies. https://doi.org/10.1109/ever.2014.6844148