Powertrain
Purpose
The powertrain is the heart of the car, the intermediary connection between the electrical and mechanical systems. The main purpose is to deal with converting electrical power from the electrical components to mechanical force in the wheels and everything in between, so the car can be propelled. The subsystem can be split into the motor, driveline, and differential.
Goals
| Primary Goals |
|---|
| Optimise and manufacture a twin motor drivetrain |
| Improve mounting accessibility and ease of assembly |
| Design and manufacture chain tensioning system |
| Secondary Goals |
|---|
| Weight optimisation |
| Research and development into torque vectoring |
| Research and development into in-hub motors |
Key Components
Motors
To start the process off, at the heart of the powertrain systems, the motor delivers motion from electrical energy that can be transferred to the entire car. Different motor configurations can be used, each with its own unique perks and features, and the goal is to find the most suitable configuration. The motor will also need to be controlled for different scenarios and precautionary safety reasons, requiring collaboration with the software team. The motor selection process will require communication with the software, electrical, vehicle dynamics, chassis and aerodynamics subteams.
Driveline
The driveline is a symphony of mechanical components consisting of a chain or a belt, gears and driveshafts to orchestrate the flow of energy. For each component, specific calculations are conducted to ensure a balance in torque and power throughout all stages of motion. Parameters of different drivelines and motors are often inserted into lap simulators to validate the ideal setup for the car itself. Efficiency is also a key part of the driveline, which is improved through the design of a custom chain tensioning method and the lubricating of all the components. Collaboration between chassis and vehicle dynamics sub teams is required to build a successful driveline.
Differential
The differential delivers the final force from the rest of the powertrain and spins the wheels of the car. Drivability is heavily influenced by the differential through spinning the wheels at different speeds to aid in turning. This system includes the differential or spool, CV joints and axle half shafts.
Mounting
To put everything together, a powertrain package will need to be created. This package encapsulates all the other powertrain systems, where custom mounts, housing and protective shields are designed in CAD, then undergoing finite element analysis simulations (FEA) to predict stresses and points of failure. The goal is to create a lightweight and easy to assemble package.
Chain Guard and Motor Scatter Shield
The chain guard acts as a protective measure for other components in the car and people around the car upon the chain detaching or other catastrophic failures of the driveline.
Like the chain guard, the motor scatter shield acts as a protective shield for personnel operating near the motor when running. Skills for design include sheet metal CAD and FEA. Manufacturing skills include power tools and sheet metal manufacturing.
Future Research Projects
Future research projects for the Powertrain subsystem in MUR Motorsports focus on improving performance and innovation. Key areas include improving torque vectoring performance and exploring in-hub motors to reduce weight and optimise packaging. There’s also a focus on powertrain weight optimisation, using lightweight materials to improve efficiency, and advanced cooling solutions to maintain performance under extreme conditions. Additionally, research into battery and energy management aims to optimise battery use and enhance energy recovery systems. These projects could lead to significant advancements in electric vehicle technology.
Industry and Work Opportunities
Working in the powertrain subsystem of MUR Motorsports provides valuable opportunities for the growing electric vehicle (EV) industry. Engineers with experience in motor design, energy management, and drivetrain optimisation are highly sought after for roles in EV development, focusing on improving motor efficiency, battery systems, and overall vehicle performance. In addition to the EV sector, opportunities also exist in motorsports, particularly in electric racing and in the energy and aerospace industries, where electric propulsion and energy storage are becoming increasingly important. These skills also open doors to manufacturing and systems integration roles within the EV field.
Materials and Manufacturing Exposure
| Materials |
|---|
| Mild Steel |
| Aluminium |
| Manufacturing |
|---|
| Milling and Lathing |
| CNC Machining |
| Laser Cutting |
| Welding |