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
Date
6-2026
Primary Advisor
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
This report outlines a custom hub motor dynamometer requested by the Cal Poly Racing FSAE team. The need for this testing platform is to characterize an existing Formula SAE planetary gearbox for a proposed 4WD powertrain. Hub motors, compact electric machines integrated directly into each outboard wheel, offer significant advantages in efficiency, traction, and chassis packaging compared to conventional RWD drivetrains. By mapping torque capacity, efficiency, lubrication method effectiveness, and fatigue life, the team can validate gearbox design and performance.
This senior project group designed and built a dynamometer according to these specifications which will allow for successful testing to demonstrate the feasibility of a lightweight, high-efficiency 4WD architecture for Cal Poly Racing’s next Formula SAE vehicle. The result of this project is an assembled and functional test bench with the option to reconfigure the stand in order to test the new hub motor and gearbox safely off the vehicle. Since the FSAE team was not able to provide a fully functional gearbox at the time of this report, there is not any gear characterization data that has been recorded. To ensure this project fully meets the needs of Cal Poly Racing, we recommend continuing to use these testing platforms built in modularity to integrate any sensors or new gearbox mounting fixtures as required to obtain proper testing and validation results.
URL: https://digitalcommons.calpoly.edu/mesp/867
Included in
Computer-Aided Engineering and Design Commons, Electro-Mechanical Systems Commons, Manufacturing Commons, Other Mechanical Engineering Commons