Dallara Formula-E Project

1. [electric vehicle development project]
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FORMULA CLUB-E

2. “I love Formula One, dearly. If I live for 100 years I will still love Formula One. But the world is
going in the direction of electric, we don't know how long it will take but we have to make a
change. It's not that we want to, it's almost mandatory.
If we continue like this for 100 years there will be no planet so basically there is no option.”
Alejandro Agag, Formula E founder and CEO
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“A goal of all formal education should be to graduate students to lead lives of consequence.”
John Henry Brookes, Spiritual founder of Oxford Brookes University
Brookes alumni in employment at major Formula 1 teams
in collaboration with

3. THE VISION
At the very pinnacle of the Motorsport world, Formula E is currently leading the way for the electric racing market. At the low
budget end, Formula SAE electric has demonstrated that electric vehicles can dominate over their combustion-engined
counterparts.
Currently, there are very few affordable electric racing cars, so there is a clear gap in the market.
?
Formula SAE Electric Formula E


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in collaboration with
Year 1 - Concept: Feasibility study & concept design
Year 2 - Analyse: Identify market opportunities & design specification, design & virtually prototype vehicle
Year 3 - Develop: Establish partnerships, detailed simulation modelling, final design, prototyping & model validation
Year 4 - Refine: Build, test & finalise complete prototype vehicle

4. The Players
Andrea Toso, Head of R&D and US Racing
Business Leader at Dallara Automobili shares
design ideas with OBU students
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Dallara
Automobili
Competing in all F3 championships
around the world, Dallara is the sole
supplier of cars to the IndyCar, Indy
Lights, GP2, GP3, World Series by
Renault and Japanese Super Formula
championships.
Coupled with their experience of
supplying the chassis for Formula E,
Dallara’s impressive motorsport
pedigree ideally places them to deliver
an electric racing vehicle.
Mechanical Engineering &
Mathematical sciences
Nestled in the heart of Motorsport
Valley, 92% of our graduates go on to
employment - many in F1, Formula E
and major suppliers to the motorsport
industry.
Oxford Brookes has an enviable
reputation as the number one institution
for Motorsport education, training the
Automotive, Motorsport and Mechanical
Engineers of the future.
BUSINESS SCHOOL
The Business School provides strength in corporate, competitive & growth
strategy, global business, international trade and foreign direct investment with
subjects that focus on leadership, culture, motivation, practices, strategic
human resource management and the management of the globalisation
process. This allows us to consider both the mechanical and business aspects.
Unparalleled Team
Bringing together one of the World’s
largest race car manufacturers, and the
leading motorsport education provider,
the Formula Club-E project is the work
of an unparalleled team.
in collaboration with

5. The Objectives
Leading
Racing Car
Manufacturer
Renowned
Motorsport
University
100
Postgraduate
MSc Students
Four
Year
Programme
60,000
Development
Hours
in collaboration with
Determine the market opportunities & customer requirements
Identify market leading technologies & suitable powertrains
Develop a complete 3D CAD model of the vehicle
Simulate the vehicle performance in DYMOLA
Analyse various powertrain configurations
Undertake Driver-in-Loop testing in Dallara’s simulator
Establish partnerships & customers
Produce a complete business plan, BOM and costing
Prototype and test the complete vehicle
Prepare students for employment
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6. The team: Design
Chassis & Crash
Aser Murias Closas
Quentin Gueriot
Ronan Antonelli
Michael Booker
Battery Development
Pelayo Acevedo Llanes
Daniel Simula
Aero & Cooling
Wayne Diggines
Vivek Jigalur
Mikey Twigge
Marc Ricart Rius
Electric Safety
David Garcia Coz
Team Leader
David Lopez Almirall
Business Plan
Rodrigo Velasco Ramos
Shaunt Avanessian
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Suspension
David Briant
Michael Rooney
Xavier Bas Ferrer
Motor
Tom Driscoll
Siddhant Shah
Adil Adil
Project Chairman: Andrea Toso - Head of R&D and US Racing Business Leader, Dallara Automobili
Academic Principal: Andrew Bradley - Senior Lecturer in Motorsport Engineering
in collaboration with

7. The team: Simulation
Powertrain & Battery
Nikolas Siikkis
Pedro Gonzalez Lorenzo
Shreerama Manjunatha
Javier Herrero de Vicente
Jesus Guiterrez de Quevedo
Team Leader
Cristian Garcia Moya
Pau Joaniquet Calderon
Suspension & Braking
Ana Sanchez Ponce
Alexandre Santos
Raul Ubeda Sala
Driver & Laptime
Alvaro Fraile Martinez
Beñat Pildain Olalde
Sree Varshini
Miguel Freitas
Bruno Braga
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Suspension & Tyres
Rohan Shankar
Federico Sanchez Motellon
in collaboration with
Academic Chair: Professor Gareth Neighbour - Head of Department of Mechanical Engineering & Mathematical Science
Academic Lead: Gordana Collier - Programme Lead for Postgraduate Taught Mechanical Engineering
Simulation Support
Alessandro Picarelli, Claytex

8. Ideally suited to the UK’s racing circuits
Rear wheel drive
Easy to maintain
Exciting to drive
Affordable
The team at the Formula E London ePrix
The Concept
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Carheight[mm]
Car Length [mm]
Mass DistributionComponent CoG
Global CoG
Mass distribution
in collaboration with

9. Define
Product or
Service
Strengths and
Weaknesses
Opportunities
and Threats
Research
Target Market
Competition
Pricing
Customer
Requirements
Develop
Design
Specification
Operational Plan
Sales Strategy
Sales Projections
Financial Docs
The Market
Strongly
Agree
15%
Agree
39%
Disagree
but could
be
convinced
31%
Strongly
Disagree
15%
Electric racing is the future of Motorsport:
Analysis of the progress of Formula E
Detailed surveys of hundreds of potential customers & fans
Focus groups discussing people’s concerns about electric racing
Identification of desired vehicle design specification
Race schools to offer electric test drives
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How much would you pay for an electric racing car?
in collaboration with

10. in collaboration with
The Car
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11. The Car: Energy Efficiency
Lithium Polymer batteries have around 1/30th of the energy density of petrol, so a large proportion of the vehicle mass is due
to the volume of batteries required. Conserving energy is therefore of prime importance in the development of the vehicle.
Gearing ensures the motor operates at ~3x the efficiency of a combustion engine
CFD simulations performed and aerodynamics optimised to reduce drag
Energy recovery using regenerative braking improves the range
Simulations identify energy usage and battery requirements
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6,00%
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9,00%
0 20 40 60 80 100 120 140 160 180
DepthofDischarge
Time [s]
Depth of discharge comparison
Depth of discharge Depth of discharge w/o regenerative braking
Motor efficiency mapEffect of regenerative braking upon energy consumption
CFD simulations to estimate the drag coefficient
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in collaboration with

12. The Car: Battery Design
The size and weight of the battery have a significant impact
upon the overall vehicle design & handling, and the high
voltage, crash safety & thermal management of the battery
present a challenging design problem.
A few of the design requirements are as follows:
Cell specification for power demand requirements
Safety in the event of an accident
Thermal management
Lightweight design
Electrical safety
Battery design and assembly
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in collaboration with
Current flow from banks of cells

13. The Car: Crash Safety
images
PRIMER
• Element types
• Section
• Material models
• Contact types
• Crash speed &
load
LS-DYNA
• Explicit
• Implicit
D3-PLOT
• Results
• Validating
• Verifying
Crash performance is of primary importance in any racing car, but the high voltage batteries used in an electric race car are
potentially lethal, and their behaviour in the event of an accident must be considered. The following safety precautions have
therefore been taken:
Crash simulation in LS-DYNA of front, rear & side impacts to FIA specifications
Development of instantaneous battery shut-off circuits
Analysis of the battery enclosure during an accident
Insulation Monitoring Device to detect high voltage leak
Side impact affecting the battery enclosure Direct impact to the battery enclosure
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Insulation Monitoring Device & High Voltage Safety
in collaboration with

14. The Car: Vehicle Dynamics
The significant mass of the batteries leads to a rearward weight distribution for the car. In order to ensure that the vehicle
handling is maintained, detailed simulations have been undertaken to simulate a variety of handling manoeuvres and
optimise the vehicle suspension & tyre selection.
ADAMS models of the complete vehicle developed
Models used to cross-validate Dymola simulations
Detailed tyre models created
Sensitivity studies undertaken to inform the vehicle design
Optimisations used to tune the ride and handling
4-Post Rig Adams model4-Post Rig at Oxford Brookes University
High speed damping sweep
in collaboration with
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Wishbone loading during dynamic conditions

15. The Car: ‘Keeping Our Cool’
Brake disc cooling Thermal DYMOLA model of batteryMotor core CFD analysis
Velocity streamlines through the radiator
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in collaboration with
The driver’s throttle demand, coupled with the motor’s efficiency, results in a
varying heat generation in the motor, batteries and controller.
Thermal management is therefore essential to avoid damage to the motor
and batteries, so the following steps have been undertaken:
Thermal FEA and CFD analysis of motor core and coolant flow
CFD analysis of flow through the radiator
Thermal modelling of motor and batteries in DYMOLA vehicle model
Simulations give real-time component temperatures during lap simulation

16. Sensitivity studies inform design decisions
The Simulator: Driver Model
Velocity profile using different driver models
ChassisSim
Default
Brookes
Brookes driver model
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Dallara’s Driver-in-Loop simulator
in collaboration with
To identify the performance of the vehicle and the energy consumed during a lap of the track, it is necessary to run lap
simulations. Vehicle models are built using DYMOLA modelling software, tested at Oxford Brookes University and then
implemented in Dallara’s Driver-in-Loop simulator in Italy. A driver model has been developed to perform laptime simulations.
Basic driver models used to perform handling manoeuvres
Detailed driver developed for Laptime Simulation using forward preview technique
Simulations validated against ChassisSim, ADAMS and MATLAB
Driver model used to perform sensitivity studies and aid design decisions
Driver-in-Loop simulator used for validation and driver feedback

17. The Simulator: vehicle model
Tyre Model
Various tyre sizes and
compounds are modelled
to enable selection of ideal
tyres for rearward weight
distribution
Suspension Model
Includes kinematic
behaviour, damper models,
masses & inertias from CAD
Body & Powertrain Model
Accounts for inertias &
weight distribution from 3D
CAD, and motor, controller
& drivetrain details
Aerodynamic Model
CFD simulation data at
various pitch and yaw
angles gives dynamic aero
balance
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in collaboration with
Driver-in-Loop Interface
Custom driving simulator
interfacing and visuals have
been created to enable real
driver feedback at both OBU
and Dallara

18. The Simulator: Powertrain
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in collaboration with
Motor Model
Detailed model including
efficiency, mechanical,
and thermal properties
from FEA and CFD
Battery Model
Simulates intensity and
thermal effect at cell level
Drivetrain Model
Optimisations used to
select gear ratios for
maximum efficiency
Controller Model
Converts driver throttle
demand into electrical
input to the motor

19. The Simulator: Battery
Battery model Battery thermal model
Voltage[V]
Battery voltage discharge and charge cycle
Time [s]
Voltage[V]
Battery I
Battery II
Battery III
Battery IV
Voltage discharge for different battery cells
Time [s]
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in collaboration with
The battery makes up a significant proportion of the vehicle mass, so it is necessary to accurately simulate and predict the
range of the vehicle. An in-house battery model has been developed which can predict individual cell discharge and
temperatures.
Simulations of an entire race weekend, including discharge / recharge cycles
Cell-level modelling of entire battery pack
Thermal models of individual cells

20. The Simulator: Results
Speed[km/h]
Time [s]
Motor I
Motor II
Motor III
Motor IV
Motor V
Speed profile for different motors
Time [s]
Intensity[A]
Intensity comparison between default model and Brookes model
Time [s]
Power[W]
Heating and cooling power
Time [s]
Heat[W]
Heat dissipation for different battery cells
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in collaboration with
The main aim of simulating the vehicle is to find the balance between the vehicle’s performance, drivability and cost that
meets the customer requirements - whilst ensuring that the battery will last the race duration.
Assorted motor and battery combinations analysed to determine cost / performance trade-off
Thermal performance of motor, battery and cooling system analysed in real-time
Range prediction in both laptime and Driver-in-Loop simulation
Multiple UK circuits and race formats simulated

21. In-wheel motor design
CFD analysis with wing model
Torque vectoring Simulink model
In-wheel cooling analysis
The Ideas that didn’t make it
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Torque vectoring effect
in collaboration with
If you’re wondering ‘Why didn’t they do it another way?’ the answer is ‘We probably did’.
During the development of the vehicle several concepts were considered in detail and rejected for various reasons. A few of
the vast array of ideas explored, modelled, simulated and analysed include:
Multiple battery pack locations
4-wheel drive powertrain configuration
2 on-board motors
2 in-wheel motors
Front and rear wings
Torque vectoring

22. The Business case
2%
4%
24%
42%
4%
3%
13%
8% Brake System
Drivetrain & Cooling
Frame & Body
Electrical
Miscellaneous, Fit & Finish
Steering System
Suspension & Shocks
Wheels & Tires
The business case for the Formula Club-E is being carefully considered in order to ensure that the output of the project is not
just a ‘pie-in-the-sky’ idea; the Formula Club-E will be a fully designed, developed, prototyped, tested and budgeted vehicle,
with a business plan to match.
Detailed bill of materials for the vehicle allows accurate costing
Market research provides projected sale price and volumes
Detailed simulations provide data for cost / performance decisions
Various business models thoroughly considered
Detailed financial projections
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Cash Postion Area Expenses Revenues Cash Position
2017 2020
Cash flowCost breakdown
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in collaboration with
Competitor's Car Price 0-60 mph [s] Top Speed [mph] BHP
BRDC Formula 4 £39.980
N/A N/A 230
MSA Formula £36.000
5,8 127 157
Radical SR1 £37.500
3,6 138 185
Radical SR3 RS £40.000
3,1 155 210
Radical SR3 SL £58.200
3,4 161 300
Radical SR3 RSX £66.958
3,1 155 210
Caterham Seven CSR £46.495
3,1 155 260
Caterham Seven 420 £26.995
3,8 136 210
Formula Ford 1600 £15.000
6,0 130 115
Competition Average £40.792
4,0 145 209
Dallara Electric Emrax228 £41.000
6,90 110 134
Dallara Electric Yasa400 £45.000
5,80 134 221
Formula E N/A 3,0 140 268
Competitor analysis
V1
V2

23. “What we are trying to do is make driving clean cars exciting and fun, and to try to encourage manufacturers to come into
this area because, if they don’t, they are going to be left behind.”
Richard Branson
If you are interested in joining the project, please email mems-enquiry@brookes.ac.uk with the subject “Dallara”.
In particular, we are particularly interested in hearing from the following:
Race organisers, schools & race car rental companies
Motor / controller manufacturers & suppliers
Battery manufacturers & suppliers
Potential customers & distributors
Sensors and electrical suppliers
Tyre manufacturers & suppliers
Financial investors
Get involved!
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in collaboration with

24. The following have provided exceptional levels of support to the project, and have been instrumental in the development of the vehicle:
Simulation Support: Alessandro Picarelli - Claytex Services
Market Research: Jaqui O’Rourke, Madelaine Robinshaw & Nicoletta Occhiocupo - Business School
Electric Powertrain: James Broughton & James Larminie - Department of Mechanical Engineering & Mathematics
Chassis Development: Allan Hutchinson & James Balkwill - Department of Mechanical Engineering & Mathematics
There are also many more people who contributed to the project - thanks, we couldn’t have done it without you!
YASA Motors Amlin Aguri Cooper Avon Tyres Mark Preston Brian Sims
Tim Woolmer Neil Fellows Shpend Gerguri Denise Morrey Geoff Goddard
Nick Bowler Daniel Bell Colin Bell Khaled Hyatleh Andrew Baxter
John Twycross Gabor Lukacs Tom Elsworth Eric Cassells Ana Domingos Canhoto
Miguel Ferreira Adrian Ward Terrance Floyd Kevin Hort Ian Spacksman
Dom Daly Mashael Alnosayan Quiyang Ge Viktor Weber Xinyi Xu
The department’s digital printing facilities used in the creation of this book were provided & supported courtesy of:
Artwork & print design by David Lopez Almirall and Andrew Bradley. Binding by Maltby’s the Bookbinders, Oxford
The PARTNERS
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in collaboration with