• Computational render of design proposal
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Design and integration of a scalable all wheel drive electric powertrain
Group Members
Alvaro Sanchez Vela, Joe Coakley, Owen Burnell, Alexander Sheers, Tobias Cameron, Tesvin John, Matthew Mustard
Professor Andrew Cruden, Dr Dmitry Bavykin
EPRSC, Sevcon - BorgWagner, EMRAX
The rapidly growing EV market promises higher vehicle efficiencies and no emissions at point of use, including particulate emissions in towns and cities. Increasing the current charging rates of Electric Vehicles (EV) is a crucial hurdle for their widespread use. The development of a platform for the University to showcase its research into EV technology, such as Combined Charging Systems (CCS), is therefore relevant and necessary in the current social and environmental climate.

This project aimed to provide the required CCS platform by improving all of the major EV Demonstrator (EVD) subsystems, including the vehicle drivetrain, high voltage electronics and power source. This project will also lead the way for the development of
a Formula Student Electric Vehicle.

Techniques such as Laser Scanning and Finite Element Analysis were utilised by the group to support reverse engineering, ensure geometric accuracy and analysis, the performance of part design and the materials used.

To increase the possible range of the EVD, a Nissan Leaf high voltage battery was recycled and repackaged to fit the space available. The updated EVD was designed to utilise torque vectoring algorithms to control its rear motors, acting as a virtual differential. The group was supported throughout the project by our industrial partner, BorgWarner, who also generously provided two state of the art motor controllers, a DC-DC converter and essential integration advice.