Electric Drivetrain

We in the subteam Electric Drivetrain are responsible for providing the necessary propulsion needed for the electric racecar. During development, we are facing the same challenges as the automotive industry: from energy storage, the conversion of that energy, to finally powering the electric engines.

Engine, Gearbox and Test Stand

We drive an all-wheel concept with four central engines. The electric motors are self-developed, permanent-magnet, synchronous three-phase motors, which were developed in cooperation with the Electrotechnical Institute (ETI) at KIT as part of a graduation theses and then further optimized. 
 

In order to continuously improve our engines, we have an electric motor test bench with transient operation. This allows us to test the cooling and efficiency of our engines and to measure the engine maps. In addition, we can map the vehicle electronics here and thus ensure comparable test conditions.

 

Battery and Power Electronics

The battery is the energy storage and central element of our electric vehicle. With a self-developed Battery Management System (BMS), it takes up a large share of the total weight of the vehicle, which is why it must be installed as low to he ground as possible. We manufacture the battery from 280 individual LiPo cells ourselves, and reach an operating voltage of over 580 volts. The possibility of energy recovery during braking helps us increase the efficiency of the vehicle and save weight. 

The power electronics form the interface between the battery and the motors. It regulates the applied currents and voltages on the motors, and thus the output power, depending on the driver's request. These were developed and manufactured in the 2016 season by KA-RaceIng members through numerous theses.

 

Safety and Cooling System

 

In our racecar, we install a series of monitoring, maintenance, and diagnostic devices to detect potential errors. In addition, we prevent overheating by active cooling of the battery, the power electronics, and the motors.

Since the 2015 season our electric car is characterized by the so-called Dual-X-Drive. This is due to the arrangement of our engine-gear unit, and its rotation about two axes in the vehicle, to minimize losses in the drive train.