Preliminary Design of an Electric Drive Unit for Hypercar Application

The Hypercars Automotive Sector is generally defined as the ultimate sector in terms of vehicle performances and cost. As an order of magnitude, it is characterized by vehicle that typically exceed the 1000 horsepower and above one million euro of cost, and volumes rarely exceed 200 units per year and 1000 units lifetime. This sector has a relatively short history, if compared to other more consolidated vehicle segments, and it has been characterized in the last 5 years by the introduction of some vehicle lines that have dramatically increased its technological complexity. Among the most important elements of innovation we can highlight: •??High Voltage Electrification hybrid concept (above 48 V systems) •??4 Wheel Drive Powertrains (4WD) •??Total combined power exceeding 1000 PS •??Multiple torque source components in the whole Powertrain concept (in some cases even more than 4). Entering this market with a brand new vehicle requires a careful evaluation of the competitors products, and a detailed technical benchmark analysis is needed in order to select the best possible Powertrain compound that can be competitive in the upcoming years. Bugatti Rimac has officially declared its willingness to produce such a vehicle in the upcoming future, besides its current pure thermal vehicles (Bugatti Chiron, Bolide, Mistral and derivatives) and BEV (Battery Electric Vehicle) like Nevera. Among all Powertrain components, the front EDU (Electric Drive Unit) represents one of the key components and one of the biggest enablers of the vehicle performance and key attributes in terms of longitudinal and lateral characteristics. The purpose of this master thesis is to: •??Analyze Competitors Powertrain layouts for Hypercar application; •??Analyze Competitors front EDU layout for Hypercar application; •??perform a preliminary sizing of a bespoke front EDU for a Hypercar application and analyze all main steps of its design like the component attributes definition, duty cycles and vehicle mission, mechanical and electrical design and DVP (Design Validation Plan).