Warwick Racing evGP
1.0 Introduction
The Warwick Racing evGP (Electric Vehicle Grand Prix) Project involves developing
an electric go-kart to compete in the annual worldwide evGP event in the United
States. The ultimate aim of evGP Project is to promote a green future for
motorsports through the use of electric vehicle technology.
7.3 Battery Cycling
Battery Cycling data was analysed to rearrange our cells
according to their maturity, allowing us to produce the
most reliable and efficient set of cells.
Improving the Warwick Racing Electric Grand Prix Vehicle
Through Light Weighting and Powertrain Optimisation
Warwick Racing has competed in the last two years, coming an impressive first
place in 2012. This year we are looking to securing this title whilst increasing our
outreach in the U.K., through the development of a local evGP event.
This improvement will allow an increase of 1.5% in
energy available for the race.
7.0 Design Improvement Objectives
Our Aim:
To defend our championship title in the 2013 evGP and pave
the way for a future U.K. evGP event.
Chassis: To reduce the mass of the kart by using advanced, sustainable materials and optimising components through design.
Powertrain: To optimise and improve our kart’s battery, motor and power electronics performance.
Left
7.4 Battery Cases
7.1 Electronics Mount
2.0 Our Schedule
The main phases of our project can be seen in the Gantt chart below.
These are scheduled to ensure the deadline for shipping (8th March) is
met.
Currently, designs have been finalised, and are just about to begin
the manufacturing stage of the project.
Right
Newly designed battery cases redistribute
weight to improve the balance and handling of
the kart. The combination of improved cell
orientation and material selection means a
reduction in strapping, reducing weight from
12.6kg to 4.75kg.
The redesigning the control box was focused on waterproofing rather than light
weighting. This allows easy access to the power electronics without having to
completely remove the top panel.
Original Design
Alternative Design
Improved Design
Weight (kg)
1.40
2.70
1.70
Material
Al / Perspex
Al / EOS PrimePart
Al / Perspex
Manufacture
In-house
EOS ALM
In-house
Weight (kg)
Nerf bars have been redesigned in magnesium to
support this, saving a further 3.5kg.
Material
2.1 Project Gantt Chart
New
Old
New
Manufacturer
Old
Old Design
60.40
New Design
55.65
Aluminum
6061 T6
Aluminum/
In-house
In-house/
Magnesium
Elektron
7.5 Steering
The stub axle transfers the steering motion
to the wheels. FEA was used to optimize
design through removal of unnecessary
material.
The stub axles will be made using selective
laser sintering by our sponsor, EOS. This
technology offers a new freedom in
design by removing traditional
manufacturing limitations.
4.0 UK Event
3.0 Finance & Sponsorship
In collaboration with
Coventry University and
Cheltenham motorsports,
we are organizing an
inaugural event at the
2013 Sustainable Motor
Expo in September.
7.6 Other Improvements
7.6.1 Floor Tray
6.0 Outreach
The kart’s performance will be optimised through track
testing and virtual simulations of the official track (see
below).
We aim to raise awareness,
through outreach events
promoting engineering and
eco-friendliness in the
wider community.
We have participated in the
Imagineering Fair,
Nissan Formula Student
Event and the MIA
International Low
Carbon Racing
Conference.
Track tests will consist of altering
variables in kart setup to obtain
optimum lap times.
Dynamometer Testing is currently
being carried out (see right) to
optimise the performance of the
powertrain system for racing
conditions.
New
Design
Design
0.716
0.466
Material
Steel
Manufacturer Tony Kart
Maraging steel
EOS
Meet the Team
7.6.2 Sponsorship Panel
Removal of
unnecessary
brackets and
weight

Made from light
Tritek composite
Name: Evangelos
Contoleon
Role: Project Leader &
Sponsorship

This will feature up to 10
UK and US teams
competing in a Wheel-to
-wheel race, ecochallenge and design
competition.
5.0 Testing & Track Analysis
Weight (kg)
Old
79% Weight
Saving


Material change from Aluminium to Titanium

0.32kg saved
Name: Sean Oliver
Role: Chief Engineer &
Powertrain Team Leader
7.6.3 Footrest
7.2 Protection

Part number reduced from 6 to 1

0.16kg saved
Name: Matthew
Duckhouse
Role: Public Relations &
Chassis Team Leader
8.0 Overall Weight Improvements
Part
Last year, the kart endured many impacts resulting in damaged parts, e.g. chassis, axle, steering.
Therefore, lightweight bumpers and side pods will be added to provide additional protection.
FEA was used to compare design alternatives and ensure designs could withstand impacts.
Weight (kg)
Material
Manufacture
Original Design
Alternative Design
Improved Design
1.77
Steel
Tony Kart
1.30
ABS
Tony Kart
0.73
Foam and Tritek
In-house
All protection components will be manufactured in-house using a polypropylene composite,
Tritek, formed on polyurethane foam. Parts will be lightweight and impact resistant.
Name: Jenny Chan
Role: Project Manager &
Chassis Team
Weight (kg)
Improved Weight (kg)
Weight Saved (kg)
Battery Packs
60.40
55.65
4.75
Nerf Bar Bars
3.90
0.65
3.25
Rear Bumper
1.77
0.96
0.81
Floor Tray
1.20
0.88
0.32
Stub Axle
0.72
0.47
0.25
Footrest
0.33
0.17
0.16
Sponsorship Panel
0.32
0.07
0.26
Chain Guard
0.03
0.01
0.02
Total Weight Saved: 9.71kg
Total Percentage Weight Saving: 14.14%
1.68 seconds saved per LAP!
Name: Luke Lynch
Role: Test Engineer &
Outreach
Name: Alex Kullmann
Role: Finance & Chassis
Team
Name: Sam Tracy
Role: CAD Manager &
Powertrain Team
Name: Mauricio Cavalieri
Carreiro
Role: Health & Safety
Officer & Powertrain Team