Electric Utility Vehicle

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Formula Lightning Racing Team
Electric Utility Vehicle
Indiana University-Purdue University Indianapolis
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DESCRIPTION OF PROJECT

• Customer Description
• Background

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Formula Lightning Race Team

• Sponsored by IUPUI
• Started in 1994
• Involves design, construction, and racing of a
  high-speed electric racecar
• Short-track ovals and road courses around U.S.
• Competes against teams from other engineering
  schools
• Notre Dame, Arizona State, Florida/Florida A M,
  Ohio State, and Rensselaer Polytechnic
• Ken Rennels, IUPUI Mechanical Engineering
  Technology Department chair, is team manager

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EUV Project Description

• Electric track support vehicle
• Tow the electric racecar without batteries
  (1200) around the outer pit areas and in-track
  pits of a typical racetrack.
• Capable of towing or transporting the batteries
  (1600) used in the electric racecar.

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PLANNING

• Project Team
• Project Planning

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Project Team 
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Customer Requirements

• Electric powered
• Pulls the electric racecar w/o batteries (1200)
• Pulls on itself or a trailer 1 set of batteries
  (1600)
• Hauled with racecar in the transporter
• Uses same batteries as the race car

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CONCEPT DEVELOPMENT

• Engineering Specifications
• Concept Alternatives and Selection

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Engineering Specifications

• General Description
• Regulatory Standards
• Chassis
• Vehicle Characteristics
• Drive System
• Vehicle Performance
• Battery Systems
• Electrical
• Charger System

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Concept Alternatives Selection

• ATV (All-Terrain Vehicle)
• Golf Cart
• Industrial Cart
• Redesign NEV

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PROJECT DEVELOPMENT
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Chassis Design

• Design Constraints
• Size
• Loads
• ProE Modeling
• Chassis Modifications

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Suspension System

• Design Constraints
• Suspension Analyses
• Ride Quality (Natural Suspension Frequency
• Ratio of Sprung to Unsprung Weight
• Rollover Threshold
• Polar Moment of Inertia
• Suspension Modifications

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Braking System

• Design Constraints
• Braking System Analyses
• Braking Modifications

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Drive System

• Design Constraints
• Customer Requirements
• Engineering Specifications
• Product Constraints
• SIMPLEV Modeling
• Proposed Drive System
• 72V DC Motor and Controller
• Existing Dana Transaxle
• Outboard Charger

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Batteries

• Design Constraints
• Battery Hold-Down System Design

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Trailer Hitch

• Design Constraints

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Trailer Hitch (cont)

• ANSYS Modeling
• Proposed Trailer Design

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Final Product Status

• Completed
• Frame Tack-Welded
• Most body panels riveted
• Suspension Brakes No Modifications
• Designed
• Motor, Controller
• Hitch
• Battery Supports