WR-217e

Wisconsin Racing took a multifaceted approach to developing the WR-217e. Before we could begin to build a car, we first had to build a team. This goal was achieved through proactive recruitment of new members, team-building activities, and presentation of technical concepts to widen the knowledge base of new members.  After forming a strong team, we turned our focus to a design process utilizing points analysis, vehicle dynamics tools, component optimization, and high quality construction. This engineering approach yielded the WR-217e.

 

Power train Architecture

  • Fully electric All-Wheel Drive
  • 1.4g max longitudinal straight-line acceleration
  • 2g max lateral acceleration
  • Modeled 0-60 time: 2.5 seconds
  • Top speed: 70 mph
  • Novel torque-vectoring algorithm and traction control system
  • 80 kW / 107 HP peak

In-hub front drivetrain

Plettenberg Nova 15

  • Brushless DC, six-step commutation
  • 15 kW peak
  • SPM rotor
  • Water-cooled stator

Planetary gear reduction

  • Straight-cut spur gears
  • Optimized 7.5:1 ratio
  • 180 N-m peak at each front tire

 

inboard rear drivetrain

Plettenberg Nova 30

  • Brushless DC, six-step commutation
  • 30 kW peak
  • SPM rotor
  • Water-cooled stator

Two-stage single speed gear reduction

  • Straight-cut spur gears
  • Optimized 4.5:1 ratio
  • 275 N-m peak at each rear tire

Accumulator

  • LG HG2 lithium ion 18650 cylindrical cells
  • Energus 1S8P Submodules with built-in fusing and thermistors
  • 7.78 kWh total energy capacity
  • 126V at full charge
  • 80 kW peak discharge, 50 kW continuous discharge
  • Orion Battery Management System

Electronics

  • In-house developed electronic systems designed for robustness and modularity
  • LCD steering wheel display to give driver insight on car speed, power draw, system faults, and more
  • All systems are constantly being monitored using an extensive sensor network and the car will automatically shut down if an issue arises

Chassis

  • Hybrid carbon fiber monocoque coupled with 4130 steel tubular rear space frame
  • Front Pullrod-Side Mounted Dampers
  • Rear Pushrod- Horizontal Mounted Dampers
  • Driver Adjustable Anti-roll
  • Keizer 10” 3-piece wheels

Aerodynamics

  • Selig s1223 rtl profile for high lift coefficient and high stall angle
  • Genetic Algorithm to modify size, angle of attack and position of each element in 2D ANSYS Fluent CFD
  • Full-car 3D simulations in ANSYS CFX with complete bodywork, suspension linkages, cooling ducts, 95th percentile male driver, simplified powertrain compartment, rolling tires and moving ground plane

Controls

Traction control

  • Slip angle state estimator
  • Aerodynamic downforce estimation
  • Wheel slip control and friction coefficient estimator

Torque vectoring

  • Improve vehicle’s transient steering response by using electric motors to generate an independent steering moment

On-the-fly calibration changes via wireless transceiver

Vector GL2010 CANbus datalogger for performance evaluation