Project Objectives Contribute to climate change prevention Demonstrate that electric vehicle is a...

Project Objectives• Contribute to climate change prevention

• Demonstrate that electric vehicle is a viable option for individual mobility

• Win X-PRIZE competition in the alternative class

• Add a new business to automotive industry

• Make Metropolia Automotive recognized worldwide

• Promote Finnish engineering

Design Objectives

• Design and build the most advanced AWD electricvehicle suitable for small series manufacturing

• Registered to road traffic

• Green: modern technology, efficient, recyclable, lightweight

• Part of the RaceAbout family: sporty, simple and desirable

• Using existing components in feasible areas

• Simple structure, usability, serviceability

• Vehicle simulated to meet safety regulations

• Performance- Total motor power 282 kW (383 bhp)- Acceleration 0-100 km/h ~ 6 sec.- Top speed 260 km/h (162 mph)- Oper. Range ~ 200 km- Consumption ~ 145 Wh/km

Fuel equivalent ~ 1.6 l/100 km

• Curb weight 1720 kg• Lithium-Titanate battery pack• Four wheel direct drive with 4 inboard mount motors• Carbon fiber monocoque

• Advanced, next generation stability control• Optimal weight distribution & very low centre of gravity• 2 Seats & 100 l of cargo space

E-RA Specification

Powertrain

• Four wheel direct drive

• 4 inboard electric motors manufactured by AXCO-Motors Oy

• 4 inverters from Semikron GmbH / Visedo Oy

• Total efficiency ~80 %

• Advanced, next generation stability control

Motors• Permanent Magnet Synchronous Motor with saliency

• Designed jointly with Lappeenranta University of Technology

• 250 Nm nominal / 800 Nm peak torque• Available from 0 to 1800 rpm

• Water/air cooled

• Direct drive through drive shafts → No need for gears or differential

• Weight ~50 kg / motor

Batteries• 286 Altairnano Lithium-Titanate cells (50 Ah each @ 2.3 V) in

143s2p configuration

• Capacity 33 kWh

• Voltage 243 – 415 V

• Power 200 kW continuous, 330 kW (10s)

• Fast charging capability (10mins @ 250 kW)

• Weight 620 kg (1.6 kg/cell)

• Each cell monitored and the

whole system balanced

• Operating temperature -60 - 75°C

• Charge temperature -50 - 75°C

• Lifetime ~5 000 cycles

Charging• Built in Charger (Brusa NLG5)

- Power 3.3 kW- Mains connection 230 V / 16A- Charging time ~ 10 h- Efficiency ~ 91 %

• Fast Charger (AeroVironment EV250)- Power 3 - 250 kW- Mains connection 3ph 480 - 600 V- Charging time ~ 10 min- Efficiency ~ 90 %

• 24 carbon fibre composite parts bonded together to form E-RA monocoque

• Self supporting structure

• BIW weight ~150 kg

• Torsional stiffness similar to today’s production vehicles (>14 000 Nm / deg)

• Audi R8 brakes and suspension

Body and Chassis

• Nokian Z G2 (225/40R18 front and 245/40R18 rear )

• Nokian Hakkapeliitta 7 studded tyres (225/40R18)

Tyres

E-RA Appearances

Automotive X-Prize Michigan 2010, 2nd place

Challenge Bibendum Berlin 2011Winner: EV rally + Design Award

Le Mans vers le Futur24 Heures du Mans 2011

e-miglia 2011800 km Transalp EV rally - 9th

Nürburgring NordschleifeRoad EV lap record 14.9.2011

8:42,72 Driver: Ralf Kelleners

World’s fastest EV on iceLake Inari, Finland 17.3.2012

252.09 km/h Driver: Janne Laitinen

Planned next• Demo for 10 min fast charging

• Development of a heat pump for car use

• Further development for the electric motors and the inverters

• Further development for the control system

Contact

Sami RuotsalainenProject Leader and Chief EngineerHelsinki Metropolia University of Applied Sciences

Automotive and Transport Engineering

firstname.lastname@metropolia.fi

www.raceabout.fi/era

Partners• A-Katsastus• AeroVironment• AEZ• Audi Finland• Axco-Motors• Bayermann Recaro• Bender GmbH• Bodycote• Bosch Engineering• Brusa Elektronik• Centrafuse• Colornet• Componeering• Datalex• Diagno• Digia QT Commercial• Diarc• Elektrobit Automotive• Engys• Ensto Electric• Fevt• Finnish Cultural Foundation• Finnish Funding Agency for Technology and Innovation• Finnsco • Flexible Products• Flinkenberg• Fortum• Henry Fordin Säätiö• Idesco• ITW Plexus• IWS International• JJ-Tuonti• Kaha• Keraplast• KhreliX Design• Lahti University of Applied Sciences• Lappeenranta University of Technology • Meca-Trade• Nemko• Nokian Tyres

• Patria Land & Armanent• Penny&Giles • Pilkington Automotive• PKC Group• Prinel• Rallysystems• RM Michaelides Software & Elektronik GmbH & TireCom• Ruukki• Sandvik Mining and Construction• Sarlin Race Team• Savo Consortium for Education• Scan Mould• Schaeffler Finland• Seemoto• Semikron• Sheet Metal Innovations• Sika Finland• Sika Tooling & Composites• Simtools GmbH• Simulia Finland• St1• Southern Illinois University Carbondale• Suomen Taksidata• Taipale Automotive• Technology Industries of Finland Centennial Foundation• Tele-Exxi• Test World• Tesveka• Tuneko Ltd• Tyco Electronics• US-Parts Finn-Am• Unilink Oy• Vacon• Valmet Automotive• Visedo• VTI Technologies• Wela• YTM-Industrial• Örum• WinNova Lasepro

Videos1. RaceAbout

http://www.youtube.com/user/progautoxp#p/u/28/UPcU3e3qzBY

2. Inside RaceAbouthttp://www.youtube.com/user/progautoxp#p/u/37/3nPiR3wZep4

3. Combined Performance and Efficiencyhttp://www.youtube.com/user/progautoxp#p/u/35/T3tooDtKjVk

4. Accelerating the futurehttp://www.youtube.com/user/progautoxp#p/u/8/y26iwAnmEGM

5. Challenge Bibendum 2011http://www.youtube.com/user/ElectricRaceAbout#p/a/u/0/tvYsYrECJtk

6. e-miglia 2011http://www.youtube.com/watch?v=JfDq1ssgkvo

7. Nürburgring Nordschleife lap recordhttp://www.youtube.com/user/ElectricRaceAbout#p/a/u/0/TGob7Gs44ZA

8. Ice speed recordhttp://www.youtube.com/watch?v=OsqTltpP52w

http://www.youtube.com/watch?v=Ix8TN4jMAeo