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A race car primarily aims at maximizing performance and handling. This can be accomplished by selection and design of powertrain, vehicle dynamics and braking in accordance to the requirements of the car. This paper focuses on selection of suitable electrical powertrain, designing and optimizing a wheel hub assembly having minimal weight and satisfying the technical rules provided in the Formula Bharat rulebook. An in-hub motor design was chosen incorporating Plettenberg Nova 15 motors for a Rear Wheel Drive (RWD) configuration. The motor is attached to an epicyclic gear train that provides a reduction ratio while staying within the limitations of the suspension kinematics. The 3D modelling was done using SolidWorks 2016, structural analysis and topology optimization was carried out in ANSYS Workbench 18.1. The epicyclic gear train validation was done using ADAMS. The best possible configuration of the assembly was selected through the iterative optimization technique.

Formula Electric Vehicle Wheel Hub Design and Optimization for in-Hub Motor in Rear Wheel Drive Configuration