Powertrain EV

Division Overview 

Powertrain EV is the division responsible for the development and integration of the vehicles electric propulsion system. Our team designs and manufactures the accumulator, including cell selection, as well as the development of its mechanical and electrical components. We also implement monitoring and protection systems to ensure the safety and reliability of the system. Similarly, our division focuses on the drivetrain system of the vehicle maximizing power output from the motor to our wheels. Additionally, our team develops thermal management solutions to guarantee battery safety, reliability, and performance. Our division also works on the integration and optimization of the electric motor, motor controller, and drivetrain. Through a multidisciplinary approach, Powertrain EV aims to maximize energy efficiency, performance, and the vehicles competitiveness in competition.

---

Components 

1. Accumulator 

• Provides high-voltage DC energy storage for the electric motors. 

• Segmented for safety, cooling, and modularity.

• Integrated with a Battery Management System (BMS).

2. High Voltage Harness  

• Transmits energy between the accumulator, inverter, and motor.

• Requires precise sizing, shielding, and insulation. 

• Designed for minimal resistance and safe rotation through the chassis.

3. Motor Controller

• Converts DC from the accumulator to AC for the motors.

• Manages torque delivery and regenerative braking.

• Generates heat that must be removed through cooling.  

4. Pre-charge Circuit and Isolation Relays 

• Gradually charges capacitors to prevent damaging current spikes. 

• Provide isolation between the accumulator and the rest of the HV system. 

• Essential for both functionality and safety compliance. 

5. Cooling System

• Removes heat from motors, inverters, and the accumulator. 

• Typically, liquid-cooled with pumps, radiators, and fans. 

• Prevents overheating, loss of efficiency, or system shutdown. 

---

Software 

• Computer-Aided Designs (CAD): SolidWorks 

---

Requirements/Characteristics

• Basic knowledge of electricity, such as voltage, current, power, and energy, as well as a general understanding of electrical materials and their applications.

• Knowledge of SolidWorks and ANSYS 

• Basic experience in CAD design SolidWorks is recommended)

• Basic knowledge of how electric motors and battery systems work is valued.

Recommended Courses

• INGE 3016: Algorithms and Programming 

• INEL 3105: Circuits I 

• INEL 4201: Electronics I 

• INEL 3105 Electrical System Analysis I

• INGE3809 Creative Design I

---

Division Knowledge Guide 

Firstly, every member must understand the difference between AC and DC. Direct Current flows continuously in one direction and is stored in the accumulator. Alternating Current (AC) changes direction periodically and is required by the electric motors. The motor controller acts as the bridge, converting DC from the accumulator into AC for the motors. In FSAE EV, any system above 60V is considered high voltage, which requires strict safety measures like insulated gloves, face shields, and lockout-tagout systems.  

Battery packs can be connected in series (to increase voltage) or in parallel (to increase capacity and runtime). Designing an HV harness requires attention to wire gauge, insulation thickness, shielding against interference, and secure routing. The Battery Management System (BMS) is critical for monitoring cell health, balancing charge, and ensuring safe pack operation. The precharge circuit protects the motor controller from sudden current spikes when the system is energized, while isolation relays provide safe disconnection when the car is off. 

Thermal management is another vital area. Unlike IC cars, where cooling handles combustion heat, EV cooling systems manage electronics and battery safety. Common issues include air bubbles trapped in coolant lines or water pump failures, both of which must be diagnosed and fixed quickly to prevent overheating.   

---