Objective
Redesign the powertrain to consume less current, allowing the electrical division to develop a more efficient motor controller.
Determining Motor Specifications
Used track data and current car specifications to determine the minimum power required to complete a lap on time.
Demonstrated that the previous motor was 4x more powerful than what was required.
The 1 KW Koford motor that we now use is 10% more efficient than the previous motor and draws 3x less current.
Mount Design
Reduced the powertrain weight by 800g (1.7lb) by designing a gear-motor adapter that functions as a mount for the motor and gearbox.
Increased powertrain efficiency by using the gear-motor mount as an adapter plate allowing us to directly fix the gearbox shaft onto the motor shaft.
Learned how to use topology optimization to design 3 reliable, lightweight mounts.
Manufacturing
Used the milling machine to accurately position the holes, ensuring optimum shaft alignment.
Used the waterjet where possible to finish all 3 parts in under 1 month.
Final Product
Designed a new powertrain in 7 months, or half the time previously used.
Decreased the number of components required from 7 to 4.
Reduced the powertrain weight by 1.5Kg (3.3 lb).
Increased efficiency by 30%.