READ: Battery – What does our battery consist of?

Článek Production: Completion of control units and bundle se nejdříve objevil na E-bullet.

READ: Production – Painting, subframe assembly and wheel suspension assembly

Článek Battery: What does our battery consist of? se nejdříve objevil na E-bullet.

On wheels

The next days will be marked by putting the E-bullet on the wheels, installing the electronics and brake system.

READ: Production – Drive assembly (gearbox + wheel unit)

Článek Production: Painting, subframe assembly and wheel suspension assembly se nejdříve objevil na E-bullet.

READ: Production – The complexity of a race car floor

Článek Production: Drive assembly (gearbox + wheel unit) se nejdříve objevil na E-bullet.

The parts are ready to be welded into the body, here we have to pay attention to the exact technological procedure and sequence of the welding itself. In the first step, it is necessary to stack the sheets and then stab them according to the established sequence. Between each welding operation, the welder takes care of the thermal management of the system, i.e. he lets the components cool down before the next welding.

READ: Work continues – We are now reinforcing the bodywork with a protective frame

Článek Production: the complexity of a racing car floor se nejdříve objevil na E-bullet.

The actual seating and impaling of these tubes was carried out without complications. The bodywork, temporarily weakened by the missing floor, was able to maintain its dimensional accuracy. The welding and welding of the safety frame to the bodywork is carried out by a certified welder, thus guaranteeing good rigidity, strength and thus protection of the pilot. At the moment, the special battery holders are being assembled and at the same time the edges for attaching the carbon battery protection cover are being prepared.

READ: Construction – Battery cooling system

Článek Work in progress: We are now reinforcing the body with a protective frame se nejdříve objevil na E-bullet.

Battery cooling

Battery cooling As part of the finalisation of the component selection process, the all-important battery cooling system was completed.

The complete battery module is divided into three zones, each of which will then be fitted with its own control circuit. The individual circuits are controlled by a microcontroller based on precise parameter measurements in each battery cluster.

Key temperature information is displayed in real time on the driver’s touchscreen. The driver will be able to get immediate data on the system status and can change the system behaviour via buttons.

READ: Design – Gearbox optimisation

Článek Design: battery cooling system se nejdříve objevil na E-bullet.

Unexpected modifications

During the tender for the electric motors, we were forced to change the supplier. This required additional design modifications to the sub frames and gearboxes. The frames had to be adapted to the new build as well as to marginal changes in wheel suspension.

Gear ratio optimisation (2nd version)

The drive ratio was modified synergistically. However, the e-Bullet project envisages interchangeable gears in several variants. The individual gears can be changed and thus the driveability of the entire car can be modified. Finally, the team is to be commended for the exemplary optimisation of the size and position of the gearbox. These modifications have a positive effect on the car’s moments of inertia, while achieving a better mass distribution.

READ: Body modification – Floor cut

Článek Design: gearbox optimization se nejdříve objevil na E-bullet.

Battery compartment

We have managed to finalize the selection of the core propulsion components of the e-Bullet project, including finalizing their specifications. This gives us confidence in the final installation of the drive battery.

We can now proceed with further body modification work, specifically cutting out part of the floor of the production body to create a hole for the drive battery. We will be able to insert it into the car as required after removing the carbon protective cover at the bottom of the car.

Video

READ: Body modification – Creating space for subframes

Článek Body modification: floor cut se nejdříve objevil na E-bullet.

For the purposes of the e-Bullet project, it is necessary to modify the body shape of the production Hyundai i30. The new body must be lightened and modified to retain maximum torsional and bending rigidity. In the next steps, the modified body will be reinforced with a protective frame designed according to FIA rules.

Body section

The frame itself will be made of 25CrMo4 chrome-molybdenum tubes.
Therefore, it is necessary to first cut off the front parts, remove parts of the floor and make modifications to the rear. This will achieve the desired lightweighting of the bodywork while creating space for the front and rear sub frame. The strategy for removing parts must be chosen very carefully, as “less is sometimes more” or “measure twice and cut once” also applies here.

Video

READ: Construction – Wheel suspension and gearing

Článek Body modification: creating space for subframes se nejdříve objevil na E-bullet.