FSAE (EV) Design Spec Sheet 2015
Competitors: Please read the Instructions-Tips (tab below) prior to the completion and submission of this sheet.
Car No. E17
School Swinburne University of Technology
Dimensions Units
Overall Dimensions mm Length: 3054 Width: 1100 Height: 1109
Wheelbase & Track mm Wheelbase: 1530 Front Track: 1100 Rear Track: 1050
Center of Gravity Design Height mm CG Height: 287 Confirmed Via: Tilt Test
Mass without driver kg Front: 78 Rear: 113 Total: 191
Weight Distribution with 68kg driver % Front: 42 % Left: 50
Suspension Parameters Units Front Rear
Tire Size, Compound and Make m Hoosier 18x7.5-10 R25B Hoosier 18x7.5-10 R25B
Wheels (width, construction) m 10x8-2; 3 Piece 7075-T6 Aluminium 10x8-2; 3 Piece 7075-T6 Aluminium
Suspension Type Twin Tube, 4 way adjustable TTX25 MkII Ohlins Shocks; Direct Acting; Double A-arm Twin Tube, 4 way adjustable TTX25 MkII Ohlins Shocks; Direct Acting; Double A-arm
Suspension design travel mm Jounce (col D): Rebound (col E): 25 25 Jounce (col G): Rebound (col H): 25 25
Wheel rate (chassis to wheel center) N/mm 36 70
Roll rate (chassis to wheel center) NM/deg 382 674
Sprung mass natural frequency Hz 3.8 4.5
Jounce Damping % critical 75 at __ mm/sec: 75 70 at __ mm/sec: 75
Rebound Damping % critical 90 at __ mm/sec: 75 98 at __ mm/sec: 75
Motion ratio _.__:1 0.82 Type: Rising rate progressive 0.74 Type: Rising rate progressive
Ride Camber (Rate of Camber Change) deg/m -59 -89
Roll Camber deg/deg 0.47 0.22
Static Toe (- out, + in) deg -1 +1
Static camber deg -1 -0.5
Static camber adjustment method Shims on the top of the upright Shims on the top of the upright
Anti dive / Anti Squat % 0 0
Roll center height above ground, static mm 10 20
Roll center position at 1g lateral acc mm Height (col D): Lateral (col E): 10.06 - 0.88 Height (col G): Lateral (col H): 20.16 - 0.10
Front Caster, Trail, and Scrub Radius Caster (deg): 5 Kin Trail (mm): 13 Scrub Rad (mm) 21
Front Kingpin Axis Inclination (deg): 4 Offset (mm): 37
Static Ackermann % 98.5 Adjustable? No
Suspension Adjustment Methods Camber (shims), Static toe (threaded rod), Anti-dive/squat (interchangable ferrules)
Steer Ratio, C-Factor, Steer Arm Length Steer Ratio (x:1) 1 c-factor (mm) 106.4 Steer Arm Length 70
Brake System / Hub & Axle Units Front Rear
Rotors Dia: 135mm; Thickness: 5mm; Material: Bisplate 80; Venting: 90x4.7mm Holes Dia: 135mm; Thickness: 5mm; Material: Bisplate 80; Venting: 90x4.7mm Holes
Master Cylinder Tilton Racing 77-625; Push-type; 5/8" Bore Tilton Racing 77-1000; Push-type; 1" Bore
Calipers Brembo P234; Material: Cast Aluminium; Piston diameter: 34mm; Type: 2 Piston - Opposed Brembo P234; Material: Cast Aluminium; Piston diameter: 34mm; Type: 2 Piston - Opposed
Brake Pad/Lining Material Bendix custom proprientry compound Bendix custom proprientry compound
Force and Pressures @ 1g Deceleration Front Pres. (bar): 41.3 Rear Pres. (bar): 17.7 Pedal Force (kN) 0.49
Upright Assembly 3+1 Axis CNC 7075-T6 Aluminium 3 Axis CNC 7075-T6 Aluminium
Hub Bearings Timken Angular Contact Ball Bearing; Size: 62x40x12 Timken Angular Contact Ball Bearing; Size: 62x40x12
Axle type, size, and material 7075-T6 Aluminium, Hard Anodised 7075-T6 Aluminium, Hard Anodised
Ergonomics Units
Driver Size Adjustments Sliding track, adjustable pedal box
Seat (materials, padding/damping) Composite construction molded
Steering Wheel (dia, construction) Diamter (mm) 240 Construction MOMO
Shift Actuator (type, location) N/A
Clutch Actuator (type, location) N/A
Instrumentation LV status, Insulation fault, AMS fault, Safety loop fault, Tractive system on, car in drive, Tractive battery status, LV
"Optional:
(e.g., Driver Safety Systems, etc.?)"
Electrical (non-drive systems) Units
Power Management / Control Induvidually fused custom fuseblock with regulated supplies, variable cooling and battery management system
Wiring / Loom / ECM mounting PPE braided sleeve skeleton topology with keyed connectors, dual pair shielded DeviceNET cabling and interlock
Battery / Charging System Fully independent auxiliary 4s3p 15Ah ELV battery
Grounding Permanently grounded single piece aluminium honeycomb core backed with star ground wire in looming
Driver Assist Systems Custom developed drive-by-wire, traction control and electronic differential/torque vectoring systems
Logging / Telemetry Custom developed telemetry and logging system with live systems configuration dashboard
Special Sensing Technology Quad unsprung 9-axis corner modules expandable for travel and tire temps with sprung module for gyro and GPS
Frame Units
Frame Construction Full Monocoque
Material Carbon fibre skins and Aluminium honecomb core
Joining method and material Bonded Carbon Fibre Composite
Bare frame mass with brackets & paint kg Target: 17 Physical Test: 17
Torsional stiffness N-m/deg Target: 3000 Simulated: Physical Test:
Torsional stiffness validation method
Impact Attenuator configuration Impaxx 700 Foam impact attenuator
Impact Attenuator dimensions mm Width: 305 Height: 350 Depth: 255
Impact Attenuator energy capacity kJ Energy: Method:
Tractive Drive Power System Units Front Rear
Motor Manufacturer / Model / Type Enstroj Emrax 228 HV Combined Cooled
Motor Technology utilized 3-phase permanent magnet synchronous
Motor Count and Location(s) 2x independently controlled inbound motors
Driven Wheel Count & Location(s) 2x independently controlled rear wheels
Nominal Motor Voltage (phase and volts) P, V Phase (col D): Voltage (col E): Phase (col G): Voltage (col H): 3 250VRMS
Maximum Design Motor RPM (1/min) rpm 5500
Base Speed (max torque until xx RPM) rpm 5500
Maximum Motor Torque (peak) Nm for Xsec 240Nm
Maximum Motor Torque (continuous) Nm 125Nm
Maximum Motor Power (peak) kW at RPM 100kW @ 5000rpm
Maximum Motor Power (continuous) kW @ RPM 40kW @ 1600rpm
Motor Speed Sensor(s)? If so, what type LTN RE-15-1-A14 resolver mounted to motor plate
Significant Motor Modifications PT100 high accuracy temperature sensors
Motor Controller(s) Type / Model Tritium WaveSculpter 200
Motor Controller Discharge Power (peak) kW for x sec 165kVA instantaneous
Controller Continuous Discharge Power kW 107kVA
Accumulator Cell Manufacturer / Type EiG C020
Accumulator Cell Voltage / Capacity Volts, mAh 4.15V, 20Ah
Accumulator Voltage (fully charged) V 448.2V
Accumulator Cell Technology/Chemistry LiNiCoMnO2 (NMC)
Accumulator Cell Configuration 108s
Accumulator Discharge Power (peak) kW for x sec 90kW for 3s (soft limited 80kW)
Accumulator Discharge Pwr (continuous) kW 60kW
Accumulator Full Charge Time hrs:min 4:00
Accumulator Charging Efficiency % 92% nominal
Accumulator Charging Power kW 3kW
Torque Control Modes (vectoring, etc.) Torque vectoring, traction control
Other Special Components Bimetallic temperature cutoff
Drivetrain Units
Drive Type Spur gear, single stage reduction
Differential Type (if used) Electronic
Final Drive Reduction Ratio _:1 2.22:1
Vehicle Speed @ max power (design) rpm kph 1st gear: 155km/h 2nd gear: N/A 3rd gear: N/A
Vehicle Speed @ max power (design) rpm kph 4th gear: N/A 5th gear: N/A 6th gear: N/A
Half shaft size and material 20.50mm, S150 case-hardened steel
Axle Joint type Dual plunging tripod
Aerodynamics (if applicable) Units
Type / Configuration Undertray only (Forces described below consider the car as a whole)
Forces (at 80 kph, ρ= 1.162 kg/m^3) Downforce (N): 74 % Front: 40 Drag (N): 110
Coefficients & Reference Area Cl: 0.366 Ref. Area (m^2): 0.705 Cd: 0.544
Noteable Features (active, etc) Transparent rear diffuser cover
Other Information Units
Body Work (material, process) Infused kevlar nose cone, side pods and under tray
Optional Information