Design and analysis of a high-performance, integrated drive, in-hub electrical machine for the drivetrain for the FSAE UoM racing team

Abstract

Power-dense and torque-dense electrical machines are becoming more and more prevalent in the automotive industry as a result of the growing demand for greener transportation. This is crucial for everyday vehicles, but especially for race cars, which are renowned for their rapid response capabilities, high power output, and lightweight construction. The goal of the proposed research is to develop a state-of-the-art electrical drive unit with superior characteristics such that the Formula SAE University of Malta Racing Team could utilize it as its next generation drivetrain. Integrated drive machines have demonstrated their value by reducing weight, lowering manufacturing costs and enhancing overall efficiency. The scope of this research is therefore to design an electrical machine such that it would be incorporated into the hub of the wheel of the race car. A partially integrated power electronic drive is then combined with the motor to result in a high-performance machine which will be manufactured and used for the Formula SAE UoM race car. This would then be utilized as a next generation drivetrain for future racing competitions. To develop this machine, advanced engineering methodologies, tools and software will be used together with a multidisciplinary approach as means for the electrical machine to achieve the best performance, in terms of power density and power-to-weight ratio as well as efficiency. Direct drive is also seen as advantageous as gears are proven to be heavy, require maintenance and are an extra point of failure. Hence, combining all the outlined points would allow the machine to maximize its performance such that it is suitable for racing applications.