College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
College - Author 4
College of Engineering
Department - Author 4
Mechanical Engineering Department
Degree - Author 4
BS in Mechanical Engineering
Date
1-2021
Primary Advisor
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
This paper serves as the Final Design Report (FDR) for the senior project developed by our team. This FDR builds on our CDR, in which the main deliverable was the detailed design of a planetary gearbox delivering a 5:1 reduction to be mated to an Emrax 188 motor. This planetary gearbox would allow for the possibility of implementing a dual-motor torque-vectoring rear-wheel-drive system in Cal Poly Racing’s electric FSAE car, which has demonstrated in simulation to yield significant performance gain over the current single motor/mechanical LSD system. As this project’s scope is purely mechanical, the intent is for the Cal Poly Formula team to use this project as a foundation to continue developing a complete system with proof of gearbox functionality. Our FDR focuses on the steps we took to select the gear ratio and gearbox configuration, the detailed design of the gearbox itself, and the manufacturing/assembly procedures used to complete the project. Due to the outbreak of COVID-19 and long manufacturing lead times, it eventually became evident we would not be able to gather the required data to validate the design in time for FDR submission. Although consideration had been taken for an in-car system during the PDR and CDR stages, this prompted the move to designing a gearbox case with mounting points for use in a bench testing scenario, rather than a full in-car mounting structure design. This way, the team can proceed with our proposed design validation plan before deciding whether to continue with full in-car system development.
URL: https://digitalcommons.calpoly.edu/mesp/636