Design and manufacture of a chain driven motor shaft for Formula Electric applications

Abstract

This document describes the design, manufacture, and testing of a motor shaft assembly that is a subcomponent of the drivetrain system in a Formula Electric racecar. The design covers detailed analysis of the bearing, sprocket, shaft, pins, and spacer created to meet a set of functional requirements. The process of determining these requirements is also covered, along with a set of best practices for thoughtful design in general. An initial phase of testing is covered as well, from the design of the testing apparatus to the execution of a torsional test on the shaft. With limited data, conclusions are hard to draw with certainty, but initial results seem to indicate that the shaft performs as expected. The intent of this document is to serve as an example of the level of detail and thoroughness that is expected when designing racecar components. To that end, this document should provide a number of unique examples of how specific problems were modeled and addressed in the design. It should also serve as a template for future documentation of such design efforts.