Define
Establish the requirements and constraints for the individual vehicle systems.
VEHICLE DESIGN · CFD · VEHICLE DYNAMICS · INTEGRATION
ELECTRIC MOTORSPORT CAR
Collaborative development of an electric competition vehicle, combining mechanical design, simulation and complete vehicle integration.
PROJECT OVERVIEW
Developing a complete electric vehicle as an integrated system.
This project involved the collaborative development of an electric motorsport vehicle, with students working across different areas of the car before integrating the individual systems into a complete vehicle concept.
My involvement covered mechanical design, steering, wiring, suspension development, powertrain calculations and aerodynamic analysis, giving me experience across multiple areas of vehicle engineering.
The project required each subsystem to be considered as part of the wider vehicle, with packaging, performance and component compatibility influencing the final design.
DEVELOPMENT PROCESS
From individual systems to a complete vehicle.
Design
Develop steering, suspension and supporting mechanical systems using CAD.
Analyse
Use engineering calculations and simulation to assess vehicle and subsystem performance.
Integrate
Combine the mechanical and electrical systems into the complete vehicle architecture.
01
MECHANICAL DESIGN
Steering System
The steering mechanism was developed as part of the wider mechanical package, with geometry and component placement considered alongside the suspension and chassis.
- Developed steering-system geometry in CAD.
- Considered packaging within the available vehicle envelope.
- Evaluated component interfaces and mechanical movement.
- Integrated the steering system with the wider front-corner design.
02
VEHICLE DYNAMICS
Suspension Development
Suspension geometry was developed alongside the steering system to define the behaviour of the vehicle while maintaining compatibility with the wider mechanical package.
- Developed suspension geometry and component positioning.
- Considered vehicle kinematics during CAD development.
- Evaluated suspension packaging within the chassis.
- Integrated the suspension with the steering and wheel assemblies.
VEHICLE INTEGRATION
Each subsystem was developed as part of the complete vehicle, rather than as an isolated component.
03
SYSTEM INTEGRATION
Wiring & Electrical Packaging
The electrical architecture also had to be considered during vehicle development, ensuring that the wiring and associated systems could be packaged within the mechanical design.
- Considered wiring routes during vehicle packaging.
- Integrated electrical components within the CAD assembly.
- Managed interfaces between mechanical and electrical systems.
- Considered accessibility and practical assembly requirements.
04
PERFORMANCE CALCULATIONS
Powertrain Development
Engineering calculations were used to support powertrain development and ensure that the selected system could meet the performance requirements of the vehicle.
Requirements
Define the performance requirements of the vehicle and corresponding powertrain demands.
Calculate
Use engineering calculations to investigate power, gearing and vehicle performance.
Integrate
Package the selected components within the wider vehicle architecture.
05
COMPUTATIONAL FLUID DYNAMICS
Aerodynamic Analysis
CFD analysis was used to evaluate the aerodynamic behaviour of the developed vehicle and identify areas for further design refinement.
- Evaluated airflow around the complete vehicle.
- Investigated the aerodynamic behaviour of the bodywork.
- Used simulation results to support design development.
- Developed further experience using STAR-CCM+.
FINAL DESIGN
Electric Motorsport Car
The final vehicle brought together the suspension, steering, electrical systems, powertrain and bodywork within a complete integrated vehicle package.
PROJECT REFLECTION
Developing an understanding of the complete vehicle.
This project developed my CAD capability while expanding my understanding of CFD, vehicle dynamics and multidisciplinary vehicle integration.
Working across several vehicle systems reinforced the importance of understanding the interactions between individual components and the performance of the complete car.