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