September 2012

Introduction

 

• Experienced team of motorsport engineering and EV drivetrain professionals (WRC, F1, Tier 1, OEM and Startup)
• Established credibility and thought leadership in green racing
• Objective to use the race track as a laboratory for road car technology development
• Full V cycle design philosophy
• Professional racing culture and knowhow
• Proven knowhow in the development and commercialisation of new science and technology
• Partnership oriented business model
• Corporate Social Responsibility and green agenda expertise

 

 

Project Objectives

 

• Design an electric drivetrain exceeding the performance of the original IC unit
• Adopt a whole vehicle approach to improving performance and efficiency
• Follow a Motorsport approach to timescales
• Follow an Automotive approach to QA, safety and testing
• Provide a platform for the integration and proof of concept of new and innovative technologies

 

Technical Summary

Key Technologies:

 

Chassis:

• Carbon fibre monocoque LMP1 with natural and recycled body panels

 

Drivetrain:

• Drayson Racing Technologies 4X2-640

 

Active aerodynamics: 35% drag reduction

Structural battery

Wireless battery charging

Energy recovery damping

 

Partners:

• Qualcomm Halo
• Cosworth
• Multimatics
• BAE Systems
• Lifeline
• Bender
• Cooper Bussmann
• Warwick Manufacturing Group
• Blackmore Precision Engineering
• Huber & Suhner
• Gigavac

 

4X2-640 Drivetrain

Power:

• 640kW, 850Bhp

 

Mechanical:

• 4 motor with integrated transmission
• Single speed, independent drive
• Stress bearing battery and gearbox housings

 

Battery:

• A123 high power

 

HV System:

• Integrated system control & monitoring
• Meets most automotive safety standards

 

Control:

• Cosworth ECU platform with DRT control algorithms

 

Active Dynamics:

• Brake energy regeneration, Torque Vectoring and Traction Control

 

Performance
Top speed		320kph
Acceleration	0-100kph	3.0s
	0-160kph	5.1s
Max Power in qualify mode		640kW
Running time in race mode		>15 minutes
Weight (inc. driver)		1180kg

 

 

Engineering

Simulation:

• Aerodynamics and vehicle performance
• Mechanical strength
• Drivetrain design and thermals
• Battery energy, power and thermals
• Electrical component selection and optimisation

 

Safety:

• Analysis techniques such as FMEA
• Multiple level failure management
• Passive and active safety systems

 

CAD:

• Packaging
• Mechanical design
• Serviceability

 

Quality Assurance:

• Disciplined work process
• Full project documentation and traceability
• Document management

 

Project Timing

2011:

• July: Project kicked off
• September: Simulation work complete
• November: Design documentation complete

 

2012:

• January: Initial car build complete
• April: Safety case complete
• May: Test rig and virtual testing complete
• June: Dyno testing complete
• July: Debut event.

 

Results:

• Worked ‘out of the box’
• No failures, bugs or mechanical problems to date
• Suppliers & Partners: “Most seamless delivery”
• Meets performance targets

 

Debut

Goodwood Festival of Speed

• Minimum pre-event track testing
• Extremely good drivability
• Fastest electric car
• 11th quickest car overall
• More to come…