warwick racing evgp · 2013 sustainable motor expo in september. this will feature up to 10 uk and...
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7.1 Electronics Mount The redesigning the control box was focused on waterproofing rather than light
weighting. This allows easy access to the power electronics without having to
completely remove the top panel.
Original Design Alternative Design Improved Design
Weight (kg) 1.40 2.70 1.70
Material Al / Perspex Al / EOS PrimePart Al / Perspex
Manufacture In-house EOS ALM In-house
Warwick Racing evGP Improving the Warwick Racing Electric Grand Prix Vehicle
Through Light Weighting and Powertrain Optimisation
7.0 Design Improvement Objectives Chassis: To reduce the mass of the kart by using advanced, sustainable materials and optimising components through design.
Powertrain: To optimise and improve our kart’s battery, motor and power electronics performance.
7.3 Battery Cycling Battery Cycling data was analysed to rearrange our cells
according to their maturity, allowing us to produce the
most reliable and efficient set of cells.
This improvement will allow an increase of 1.5% in
energy available for the race.
7.5 Steering The stub axle transfers the steering motion
to the wheels. FEA was used to optimize
design through removal of unnecessary
material.
The stub axles will be made using selective
laser sintering by our sponsor, EOS. This
technology offers a new freedom in
design by removing traditional
manufacturing limitations.
Old
Design
New
Design
Weight (kg) 0.716 0.466
Material Steel Maraging steel
Manufacturer Tony Kart EOS
1.0 Introduction The Warwick Racing evGP (Electric Vehicle Grand Prix) Project involves developing
an electric go-kart to compete in the annual worldwide evGP event in the United
States. The ultimate aim of evGP Project is to promote a green future for
motorsports through the use of electric vehicle technology.
Warwick Racing has competed in the last two years, coming an impressive first
place in 2012. This year we are looking to securing this title whilst increasing our
outreach in the U.K., through the development of a local evGP event.
4.0 UK Event In collaboration with
Coventry University and
Cheltenham motorsports,
we are organizing an
inaugural event at the
2013 Sustainable Motor
Expo in September.
This will feature up to 10
UK and US teams
competing in a Wheel-to
-wheel race, eco-
challenge and design
competition.
Right
Left
New Old New Old
Old Design New Design
Weight (kg) 60.40 55.65
Material Aluminum
6061 T6
Aluminum/
Magnesium
Manufacturer In-house In-house/
Elektron
Newly designed battery cases redistribute
weight to improve the balance and handling of
the kart. The combination of improved cell
orientation and material selection means a
reduction in strapping, reducing weight from
12.6kg to 4.75kg.
Nerf bars have been redesigned in magnesium to
support this, saving a further 3.5kg.
7.4 Battery Cases
All protection components will be manufactured in-house using a polypropylene composite,
Tritek, formed on polyurethane foam. Parts will be lightweight and impact resistant.
Original Design Alternative Design Improved Design
Weight (kg) 1.77 1.30 0.73
Material Steel ABS Foam and Tritek
Manufacture Tony Kart Tony Kart In-house
Last year, the kart endured many impacts resulting in damaged parts, e.g. chassis, axle, steering.
Therefore, lightweight bumpers and side pods will be added to provide additional protection.
FEA was used to compare design alternatives and ensure designs could withstand impacts.
7.2 Protection
Meet the Team
Name: Evangelos
Contoleon
Role: Project Leader &
Sponsorship
Name: Sean Oliver
Role: Chief Engineer &
Powertrain Team Leader
Name: Matthew
Duckhouse
Role: Public Relations &
Chassis Team Leader
Name: Luke Lynch
Role: Test Engineer &
Outreach
Name: Jenny Chan
Role: Project Manager &
Chassis Team
Name: Alex Kullmann
Role: Finance & Chassis
Team
Name: Sam Tracy
Role: CAD Manager &
Powertrain Team
Name: Mauricio Cavalieri
Carreiro
Role: Health & Safety
Officer & Powertrain Team
3.0 Finance & Sponsorship
8.0 Overall Weight Improvements
Total Weight Saved: 9.71kg
Total Percentage Weight Saving: 14.14%
1.68 seconds saved per LAP!
Part Weight (kg) Improved Weight (kg) Weight Saved (kg)
Battery Packs 60.40 55.65 4.75
Nerf Bar Bars 3.90 0.65 3.25
Rear Bumper 1.77 0.96 0.81
Floor Tray 1.20 0.88 0.32
Stub Axle 0.72 0.47 0.25
Footrest 0.33 0.17 0.16
Sponsorship Panel 0.32 0.07 0.26
Chain Guard 0.03 0.01 0.02
Our Aim:
To defend our championship title in the 2013 evGP and pave
the way for a future U.K. evGP event.
2.0 Our Schedule The main phases of our project can be seen in the Gantt chart below.
These are scheduled to ensure the deadline for shipping (8th March) is
met.
Currently, designs have been finalised, and are just about to begin
the manufacturing stage of the project.
2.1 Project Gantt Chart
6.0 Outreach We aim to raise awareness,
through outreach events
promoting engineering and
eco-friendliness in the
wider community.
We have participated in the
Imagineering Fair,
Nissan Formula Student
Event and the MIA
International Low
Carbon Racing
Conference.
5.0 Testing & Track Analysis
Track tests will consist of altering
variables in kart setup to obtain
optimum lap times.
Dynamometer Testing is currently
being carried out (see right) to
optimise the performance of the
powertrain system for racing
conditions.
The kart’s performance will be optimised through track
testing and virtual simulations of the official track (see
below).
Material change from Aluminium to Titanium
0.32kg saved
7.6.2 Sponsorship Panel
Removal of
unnecessary
brackets and
weight
Made from light
Tritek composite
79% Weight
Saving
7.6.3 Footrest
Part number reduced from 6 to 1
0.16kg saved
7.6 Other Improvements
7.6.1 Floor Tray
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