University Technology of Sydney: Motorsports Electric Team


UTS: Motorsports Electric represents the University of Technology, Sydney, in the Formula SAE Australasia Competition. Our team currently consists of 26 students with diverse interests and skills from the faculties Engineering and Information Technology, Business, Science and Arts. Formed in 1999 as UTS Motorsports, our team has made ten appearances at the competition with an internal combustion car.

In 2014, our team decided to make the switch to the Electric Vehicle category with the intention to enter our first electric car in the 2015 Formula SAE Competition. Designed for lightness We are currently in the design stage of our project. The design concept for our electric car (UTSME15) includes an aluminium honeycomb monocoque for a lighter and stiffer chassis, solid rear axle with a single motor chain drive, double wishbone direct acting suspension and lithium iron phosphate (LiFePO4) battery cells; we are expecting a torque output of 600 Nm.

As long-term development goals, we are aiming for torque vectoring, hub-mounted motors, regenerative braking and wireless telemetry systems. Our team is grateful to have RS Components on board as a sponsor, as we face the exciting challenge of building our first electric car.

 

October Update 2014

Our team has spent the past few months on product research and generating design concepts for UTSM15. Our concepts are based around our two main design goals of a lightweight car and reliability. Having doubled the size of our team since the beginning of the year, we have many new team members who have shown great enthusiasm in research and development of various components and systems of the car.

We recently held a Concept Review Night where each member of the team presented their design concepts and justifications to the rest of the team and our faculty advisors. The Review Night was a good opportunity for our new team members to experience what is involved in the FSAE Design Event, and for everyone to receive feedback on their design concepts. In the next few months our team will be further developing and refining our design concepts, focusing on our Powertrain Development. We will also commence testing and manufacture of our aluminium monocoque.

February Update 2015

Over the semester break, our team has made great progress in the design of our first electric car. We have finalized our base line (or alpha) electronics and safety systems focusing on creating a system that will work and be rule compliant in relation to the competition. The main components of this system include a custom designed solid-state Power Distribution Module, limited sensor data being captured by a MOTEC CDL3, a failsafe shutdown circuit, custom analog comparator circuits for activation of a Tractive System Active Light, and an implausibility device measuring the difference between two individual torque encoder signals. We have also outlined our beta system which will include upgrades like a fully functioning CAN network, electronic Pre-charge and Discharge circuits, and upgraded safety circuitry.

We have selected an Emrax 228 permanent magnet axial flux motor, a Unitek Bamocar D3 controller and will be using 108 lithium iron phosphate cells wired in series for our battery. The product support from RS Components has allowed us to work towards our running powertrain goal in building our cooling system, accumulator and Grounded Low Voltage safety systems. We expect to have our motor running on the dyno within the next few months. Our team has also started manufacture of our suspension components and will soon begin the manufacturing of our aluminium monocoque.

We plan to have our whole car design completed by the end of March, and our whole car built by the end of June. Having doubled the size of our team since the beginning of the year, we have many new team members who have shown great enthusiasm in research and development of various components and systems of the car.

We recently held a Concept Review night where each member of the team presented their design concepts and justifications to the rest of the team and our faculty advisors. The Review night was a good opportunity for our new members to experience what is involved in the FSAE Design Event, and for everyone to receive feedback on their design progress. In the next few months, our team will be further developing and refining our design concepts, focusing on our Powertrain Development and will also commence testing and manufacture of our aluminium monocoque.

FSAE 2015 Results

Juliet is the very first fully electric Formula SAE car for the 30 students who make up the team. The car features a single electric motor alongside a 7.2kWh LiFePO4 accumulator with the aim of having a electric power train that produces high torque.

Products supplied by RS Components helped UTS Motorsports Electric in creating cooling systems, the accumulator and grounded low voltage safety systems. Fantastic first time result! Electrical challenges held the team back from passing the inspections and receiving the required stickers to head out onto the track until the final day, just in time for the endurance events. A strong start for the first endurance run although coming half a lap short of completing the entire run due to battery management systems issues which ended up preventing the team from starting the second and final endurance run of the day. Placing third out of the six electrical teams that competed this year is a fantastic first time result. UTS after the event said "thank you to our sponsors and the UTS Machine Shop for helping with our EV build, we'd also like to thank everyone who has supported us through the year including Monash Motorsport for letting us use their workshop over the weekend".

 

Meet the team   

Photo gallery   

Electrical safety checklist - tick — at Australian Technology Park

Motor presentation at the Concept Review Night

Second version of our mock chassis

Cooling system set up

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