15 March 2024
Formule ETS, a student club at ÉTS, has embraced the energy transition movement by taking on a major challenge: switching from a combustion engine to an all-electric unit. This transformation paved the way for a number of improvements and better performance in competitions. Last year, Formule ETS took 1st place at the FSAE Michigan, the most prestigious competition in North America.
In 2020, Formule ETS—which participates in university competitions organized by the Society of Automotive Engineers (SAE), U.S., and Formula Student in Europe—launched a project to reduce the ecological footprint of its vehicle. At the heart of the project is the electrification of its prototype.
2020-2021: From Gas Engine to All-Electric
The original combustion engine in the chassis of the ÉTS prototype was replaced with electric motors in each of the four wheels. This transition required a great deal of design work from the ground up to create space for the motors, planetary gear sets and cooling systems, in addition to the standard brake and suspension components.
A 500 V battery with a capacity of about 6.7 kWh was built from 3.8 V commercial cells in accordance with SAE safety standards.
The acceleration system has also become much more complex. Previously, the accelerator pedal was simply connected to a cable that regulated the air supply to the engine. Now, a series of electrical signals passes from a potentiometer (the pedal) to the on-board computer, then to the inverters to regulate the speed of the motors. Several components also need to be powered, making the electrical harness highly elaborate.
2022: Consolidating the Changes
The team focused on five assemblies to correct problems that occurred during competitions.
- The battery was rebuilt to prevent overheating.
- The electrical harness was completely redesigned to address a few issues, including lost connections and short circuits.
- The gear trains were improved.
- The cooling system was changed.
- Four-wheel drive was introduced.
In a friendly competition, this prototype finished 2 seconds ahead of the previous combustion prototype (2019).
2023 to Today: Reaching New Heights
The chassis was redesigned and lightened, the suspension system and battery, reworked. In all, 36 kg was shaved off the car. The performance of the on-board computer was greatly enhanced. The power supply to the motors is now actively controlled through algorithms, allowing to minimize energy loss at the wheels. What are the next projects in the pipeline? Engines and an on-board computer built entirely by club members.
ÉTS Student Clubs: Putting Your Studies Into Practice
Student clubs offer an opportunity to put into practice theoretical concepts learned in the classroom, and to take learning even further. One thing’s for sure: Formule ETS has a lot to offer.
