Project Article - Drayson Racing Technologies
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Case Study: Engineering the Drayson B12/69 EV

  • Introduction
  • Project Objectives
  • Technical Summary
  • 4X2-640 Drivetrain
  • Engineering
  • Project Timing
  • Debut

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

 

Drayson Racing Technologies, B12 testing

 

Drayson Racing Technologies, B12 testing

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

 

DRT Dash & Wheel Photo

 

DRT Dash & Wheel Photo

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
  • Michelin
  • Yokogawa
  • Blackmore Precision Engineering
  • Huber & Suhner
  • Carter
  • Lifeline
  • Gigavac
  • Cooper Bussmann
  • Bender
  • Aston University
  • PWR Performance Products
  • Millers Oils
  • MRTC Motorsport Communications
  • WMG Innovative Solutions
  • Mission Motorsport
  • Hans Seat
  • TRS Motorsport Equipment
  • SFS Perfomance

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

 

Drayson Racing Technologies, B12 testing

 

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

 

Dracyson Racing Technologies V Cycle Process Diagram

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…

 


 

 

Media and Press contact details

 

For all Media and Press enquiries please email:
media@draysonracingtechnologies.com

Quick contacts

 

T: +44 (0) 1865 841044

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