For 2024, our team had the oppurtunity to replace our 7+ year old Emrax 228 Medium Voltage Combo Cooled (228MV CC) with a Emrax 208 Medium Voltage Liquid Cooled (208MV LC). The 228 is a larger, heavier, more powerful motor compared to the 208. Older 208 designs were unable to peak above the FSAE rules maximum of 80kW, but the latest 208 design is able to peak 86kW. The winding configuration was reevaluated as the team is working towards a higher voltage architecture. A simple instantaneous power model developed by another team member was used to compare the different configurations and the MV configuration was chosen because of its higher break speed and ability to operate without d-axis current.
Currently, the motor's peak power rating does not matter too much as the accumulator can only output 62kW at the DC bus and 55kW at the wheels shown by the dynamometer plot to the left.
A final drive change was made to accommodate for the lower torque produced by the 208. The motor was scheduled to arrive well after starting car testing, so the front and rear sprocket sizes were chosen to allow for the most optimal final drive for both a 228 and a 208. The larger rear sprocket takes more material to produce so the rear sprocket size was fixed at 37 teeth for both motors while the front sprocket would change from a 16 tooth for the 228 to a 10 tooth for the 208. Lap simulations done through a Optimum G point mass and python based acceleration simulation were used to determine the most optimal ratios for each motor while considering size limitations of the front and rear sprockets. Because the point mass simulation had very little sensitivity, the python acceleration model with additional research was used to guide the final drive selections.