1. AWD Electric Utility
Vehicle
Ryan Burke, Brett Isakovic, Pablo Marx,
Shane Mitchell, Mohammad Rajabi, Brian Turnquist

2. Introduction
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV
Render
Analyze
Prototype Final Product

3. Background
● Objectives
○ To engineer and fabricate an electric
utility vehicle
○ All Terrain capability
○ Safely transport two occupants and their
cargo
○ Ability to charge on a standard household
electrical outlet
● Design Criteria
○ Off Road capability
○ 5-10+ mile range on a single charge
○ Curb weight: 1500 lbs or less
○ Cargo: 400+ lbs
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

4. Theoretical Traction Analysis
● In the case of AWD,
grade capability is only
limited by traction.
● Increasing tire contact patch
and/or increasing weight will
result in greater traction.
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

5. Design Matrix
Property Steel Aluminum Titanium Composite
Strength vs Weight 5 7 8 10
Tensile Strength 5 5 6 9
Fatigue Resistance 5 5 8 10
Creep 10 8 10 6
Impact Resistance 10 8 6 4
Corrosion Resistance 4 6 9 10
Reparability 10 8 2 2
Constructability 10 6 3 1
Price vs Weight 10 6 1 5
Total 69 59 53 57
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

6. FEA Frame
● Loads & Constraints
added for “worst case
Scenario”
● Analysed in Bending
(top) and Torsion
(bottom)
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

7. Spring Analysis
From calculation
From theory
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

8. Front Suspension
● Double A-Arm design
● Provides good camber profile
throughout travel
● Lightweight design means less
unsprung mass
● Components spec’d to allow 8” of
travel
● Adjustable mounting positions for
coilover allows tuning flexibility
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

9. Rear Suspension
● Independent semi-trailing arms with transverse damped leaf spring
● Simple, robust design that is proven for high loads
● Allows tuning by adding or removing individual leafs
● Semi-trailing design balances simplicity with handling
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

10. Ball joint adapters
● Adapts off the shelf Polaris ATV
ball joint to factory GEM car
upright.
● Allows 50+ degrees of angular
sweep to accommodate over 8”
of suspension travel.
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

11. CV Shaft Press Fit Analysis
● Class FN5 Fit
○ .003” interference per Machinery
Handbook 25th
● Resists 2900 Lb-Ft Torque
● Requires 6500 LbF to Press Parts
● Performed Thermal Calculations on
parts
● Heated Axle Tube to 500 Degrees F
and Froze Axle Shafts
● Opened tolerances to slip fit for easier
assembly
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

12. Spring & Damper
Analysis
Comfortable Ride
= 1 to 1.5 Hz
High Performance Sports Car
= 2 to 2.5 Hz
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

13. Electronics Analysis
● Each motor capable of 42 amp maximum draw
● Upsized Main Battery Cables maximum current 150A (1/0 ga.) vs typical 60A (4 ga.)
● Upsized to 30 Amp DC to DC converter vs 10 Amp
● Ground to Chassis Resistance > 1 MOhms
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

14. Electrical Wiring Schematic
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

15. Testing & Results
Theoretical Calculations &
Goals:
Suspension Travel: 8”
Calculated Range
(60% capacity & 90% efficiency):
12.3 miles
Goal: 10+ miles
Charging Time: 6 hours
Maximum Speed: 20+ mph
Actual Results:
Suspension Travel: 8.25”
Range: 13.7 miles
Charging Time: 7 hours
Maximum Speed: 25 mph
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

16. Future Work & Improvement
● Traction Control System to synchronize both DC
motors
● Address bump steer issue by implementing custom
steering rack
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

17. Video
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV

18. Questions?
Sponsors/Supporters
Introduction
Background
Design
Electronics
Results
Future Work
Video
Questions?
AWD
EUV