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Powertrain - Wheel Hub Development
Powertrain - Wheel Hub Development
Contribute to Design, Assembly, and FEA of Wheel Hubs on REV8.
Machined from 7075 Al using CNC Lathe and Milling operations. Material selection guided by high strength to density ratio using Ashby Charts.
Lightweight design (1.32 lbs rear, 1.12 lbs front). Efficient and consistent performance through positive locking wheel nuts and integrated 2 piece tripod interface.
Yield Safety Factor 4.6, Max Stress 96 MPa with 5075 N on bearing axial force.
Rear Wheel Hub FEA
Rear Wheel Hub FEA
Hub Assembly Render
Hub Assembly Render
Front Right Wheel Hub Assembly Stackup Render
(Made in Solidworks)
Machined Wheel Hub
Machined Wheel Hub
Hub Standalone Render
Hub Standalone Render
Rear Left Wheel Hub Render
(Made in Solidworks)
Electrical Integrations
Electrical Integrations
PCM (Power Control Module) Box
PCM (Power Control Module) Box
Designed and tested IP-65 (Water Resistant) housing to hold electrical board stackup on REV8.
Consisted of quick-disconnect autosport connectors out rear face interfacing with adapter board.
Quick release front face removed with four latches which sustain pressure on gasket seal. All boards slide out quickly and easily. Elastically interfacing, custom machined heat sinks hold water seal while still servicing heat dissipation for internal PDU.
Internal Section View
Internal Section View
Board interface enabled by Solidworks and Altium Designer
Internal Board Stackup
Internal Board Stackup
All boards interface with a snap-in-place connector board allowing ready maintenance and flashing.
Laser-cut jig for mounting tab (AISI 4340 Steel) positioning during welding.
Exploded pressure sealed heatsink diagram
PCM Box within REV8 master assembly. Secured with welded tabs. Protected within chassis envelope, above motor control unit.
Firewall
Firewall
Built a UL-94 (fireproof), water resistant firewall to protect the driver from potential mechanical disassembly events and electrical shocks from the power-section of the car. Firewall body comprised of bent sheet metal with a Kapton coating layer
Easy-Mounting
Easy-Mounting
Rivet secured buttons snaps and 2 half, 3 panel design allow quick removal while still meeting blast force thresholds.
Welded Mounting Pattern
Welded Mounting Pattern
Secured to chassis using welded tabs and sheet metal brackets. Panels seal to edge of carbon fiber body panels.
Optimized Fit
Optimized Fit
Optimized geometry for weight around seat and headrest in cockpit and accumulator in rear-section
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