Parameter	Specification
Project Type	Formula Student Electric Vehicle
Vehicle Category	Formula Student Electric (FSAE EV)
Drive Configuration	Rear-wheel single motor drive
Chassis Type	Steel tubular spaceframe chassis
Powertrain Type	Electric powertrain
Motor Type	PMSM (Permanent Magnet Synchronous Motor)
Motor Rated Power	4 kW
Motor Peak Power	13.5 kW
Motor Rated Voltage	72 V
Motor Maximum Torque	72 Nm
Motor Rated Torque	15 Nm
Motor Rated Speed	4000 RPM
Motor Maximum Speed	6500 RPM
Motor Cooling	Air cooled
Motor Efficiency	>92%
Motor Protection	IP67
Battery Type	Lithium-ion NMC cells
Battery System Voltage	72 V
Battery Maximum Voltage	84 V
Battery Minimum Voltage	50 V
Battery Capacity	73 Ah
Total Battery Cells	300 cells
Cell Configuration	5S15P
Estimated Battery Energy	6.7 kWh
Estimated Vehicle Range	67 km
Maximum Output Current	116.4 A
Motor Controller Type	Field Oriented Control (FOC)
Controller Peak Power	20 kW
Communication System	CAN Bus
Vehicle Control Unit	Integrated VCU
Differential Type	Open chain differential
Differential Ratio	1:4
Chain Drive Ratio	1:3.14
Transmission Type	Chain drive
Shaft Diameter	1 inch
Tire Diameter	21 inch
Rim Diameter	13 inch
Tire Width	155 mm
Tire Aspect Ratio	65
Suspension Type	Independent suspension
Simulation Software	ANSYS, SolidWorks Simulation, MATLAB/Simulink
CAD Software	SolidWorks
Analysis Methods	Vehicle dynamics, FEA, torque-speed analysis
Testing Methods	Dyno testing, performance validation
Manufacturing Methods	CNC plasma cutting, welding, machining, assembly
Data Processing	Python-based signal filtering and analysis
Safety Systems	AMS, BSPD, shutdown circuit, inertia switch
Documentation	Technical calculations, CAD drawings, simulation reports

The Formula Student Electric Vehicle project was a multidisciplinary engineering project focused on the design, development, analysis, and validation of a complete electric race car powertrain system for Formula Student competition applications. The project aimed to develop a lightweight, high-performance, and energy-efficient electric vehicle capable of operating under dynamic racing conditions while complying with Formula Student Electric (FSAE EV) regulations and safety requirements.

The vehicle architecture was developed around a rear-wheel single motor drive configuration due to its simplicity, lower weight, reduced system complexity, and cost effectiveness while still maintaining competitive performance and energy efficiency. The complete drivetrain system consisted of a Permanent Magnet Synchronous Motor (PMSM), custom accumulator battery pack, motor controller, chain drive transmission, open differential, axle assembly, Vehicle Control Unit (VCU), and associated control and safety systems.

The electric powertrain was powered using a custom-designed 72V accumulator system composed of 300 NMC lithium-ion cells arranged in segmented configurations with integrated Accumulator Management System (AMS) and Battery Management System (BMS). Battery sizing calculations were performed based on vehicle dynamics, motor power requirements, acceleration characteristics, and estimated race conditions. The battery system was designed to provide high current output, stable voltage delivery, thermal reliability, and operational safety during endurance and autocross events.

A Permanent Magnet Synchronous Motor (PMSM) was selected because of its high torque density, high efficiency, low-speed torque characteristics, and rapid acceleration response required for Formula Student racing applications. The selected motor delivered a peak power output of 13.5 kW and a maximum torque of 72 Nm while operating at a nominal voltage of 72V. Detailed powertrain calculations were performed to determine traction force, torque requirements, wheel speed, gear ratios, shaft sizing, and transmission efficiency using vehicle dynamic equations and analytical modeling techniques.

The drivetrain incorporated a chain drive transmission system combined with an open chain differential to transfer power from the motor to the rear axle assembly. The chain drive ratio and differential ratio were optimized to maximize wheel torque while maintaining suitable acceleration and top-speed characteristics for race track conditions. Shaft sizing and drivetrain component selection were performed considering torsional loading, shear stress, safety factors, and manufacturability.

A Vehicle Control Unit (VCU) was integrated as the central control system responsible for startup sequencing, signal management, safety interlocks, traction system monitoring, and communication between major subsystems. The VCU processed signals from the accelerator pedal position sensor (APPS), brake system plausibility device (BSPD), accumulator management system, traction system, inertia switch, and shutdown circuits. CAN bus communication was implemented for reliable communication between the motor controller, battery systems, and control electronics.

Extensive simulation and analytical studies were conducted throughout the project. Vehicle dynamic modeling and traction force analysis were carried out using MATLAB/Simulink-based approaches to estimate vehicle performance under various drive cycles and racing conditions. Parameters including rolling resistance, aerodynamic drag, acceleration forces, and gear transmission characteristics were incorporated into the mathematical models to optimize motor selection and drivetrain configuration.

Finite Element Analysis (FEA) was performed using ANSYS and SolidWorks Simulation to validate the structural integrity of motor mounts, differential mounts, sprockets, and other drivetrain support components subjected to operational loading and torque conditions. Edge mesh refinement and static structural analysis techniques were used to evaluate stress concentration regions and determine factors of safety for critical components.

The project also involved dynamometer (dyno) testing of the electric motor to experimentally validate torque-speed characteristics, efficiency curves, power delivery, and motor performance under controlled loading conditions. The dyno setup incorporated torque sensors, voltage sensors, current sensors, dual-motor testing configurations, and data acquisition systems to evaluate real-world motor behavior. Python-based data analysis techniques including moving average filtering and Savitzky-Golay filtering were applied to smooth noisy experimental data and generate usable performance curves.

Manufacturing and fabrication activities included CAD modeling, CNC plasma cutting, machining, lathe operations, mounting fabrication, welding, drivetrain assembly, and system integration. Motor and differential mounting structures were fabricated using CNC-cut mild steel plates followed by machining and finishing operations to ensure proper alignment and structural rigidity. The project emphasized lightweight construction, manufacturability, reliability, and serviceability suitable for high-performance racing environments.

Overall, the project provided comprehensive experience in electric vehicle powertrain engineering, vehicle dynamics, battery systems, drivetrain design, control systems, simulation, testing, manufacturing, and multidisciplinary engineering integration within a real Formula Student racing environment.

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