The 2023-2024 was UAlberta Formula SAE Racing team's first full year in the electric vehicle (EV) division. As such, most of our drivetrain components had to be redesigned. My responsibility was with design the driving sprocket, an adapter to attach it directly to the differential housing, and the motor mount (all pictured above).
This post is a small overview of my finalized designs and validation of them, but my previous posts include slightly more detail and can be found via the following links:
FSAE - Motor Shaft Bracket
In addition to the prototyping and analytical work shown in the first link above, the sprocket was also further analyzed by my group in our Finite Element Method course (MEC E 563). Below is the body of our report. For the entire report which includes hand-calculated approximations to validate our simulations, please click here.
Note: Click on the images to enlarge them.
Below are the drawings I sent to local machinists to have the three components made.
After we got them back from machining, the sprocket got hard-anodized and the other two components were regular anodized. We tested their fitment on the differential and the entire assembly on the car several times throughout the process.
