This week, designs for the rotor removal jig and dyno motor stand were finalized and approved. BOMs are being completed and distributors contacted so that these projects can be completed within the next 1-2 weeks. Upon completion, motor reassembly can begin in order to perform dyno testing.
CAD model of rotor removal jig.
From these tests, more accurate data can be utilized to model and predict FE2’s performance. Preliminary analysis using Optimum Lap shows a gear reduction of approximately 6:1 for a 75-7 motor, sourced from Zero Motorcycles, will yield the best possible lap times– this is based on the 2012 FSAE Nebraska Endurance track. Running FE1 with different torque limits and comparing our results with simulations run in Optimum Lap will verify our basic analysis.
Simulation showing vehicle speed with various gear ratios around a previous FSAE Endurance course.
Our gearbox will be composed of two stages: the first being a set of planetary gears. Several options are being investigated until we finalize where the planetary gear set will be sourced. The second stage of reduction will be through a belt drive going to the rear axle to achieve our desired reduction ratio.