Design of a wheel HUB motor for AWD electric race car

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Supervisor:
Dr. Balázs Gergely György
Department of Electric Power Engineering

Formula SAE is an international competition which challenges university students to construct and race Formula-style vehicles. The competition was started in 1981 for combustion cars. In response to growing interest in sustainable transport and electric vehicles, many universities began developing electric FSAE cars. The competition represent a valuable arena for electric vehicle research and evaluation.

At the Budapest University of Technology and Economics, I took part in the design, manufacturing, test and race process of three electric vehicles in the local Formula Student team, BME Formula Racing Team.

Based on these experience I have decided to design an electric motor for and all-wheel-drive electric racecar where the motors are contained within the wheel hub itself. Nowadays, this concept represents the leading-edge techical solution in the electic vehicle drivetrains.

In-wheel motor systems offer many advantages over conventional drivetrains including fewer moving parts, lower transmission losses, and space savings.

All the major automobile manufacturers have released or announced development of electric vehicles, and it is clear that the zero-emission transport is our future. I hope my thesis is a little piece to contribute shaping this future as well.

This master thesis deals with the design of a high-speed permanent magnet synchronous machine for an in-wheel motor application in the Formula Student Electric racing series. The document describes the whole analytical design process from the specification of the machine to the validation. I optimized the free parameters of the design process to minimize the weight and maximize the efficiency based on Genetic Algorithms. Finally, the optimized machine performances were checked through Finite Element Analysis experiments. The results presented in this study may form as basis of an electric machine, built in a Formula Student electric vehicle.

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