Formula Bharat: EV Kit for Teams – Models and Specifications

Formula Bharat has been working with Flauta Customs to develop an EV kit specifically designed for Formula Student teams who are interested in beginning their FS journey in the Electric Vehicle category. The purpose of realizing this EV kit is to provide teams with a robust foundation for developing their EV powertrain systems. 

Vendor

Flauta Customs LLP will assist teams in procuring components within the EV kit. They have been supporting Formula Student teams with electrical components for several years.

How to apply for the EV kit?

Teams interested in the EV kit should fill out the form linked below. Details on cost, lead time, and other queries will be addressed upon form submission. A session will be hosted on June 7, 2024, at 6 PM IST to answer any questions. Interested teams should complete the form to participate. The deadline to fill out the form is 11:59 PM IST June 6, 2024.

Form link –  https://forms.gle/DnSRAoLhAnTgMzw68

Shortlisted Components

The kit’s components selection process has been based on an FS vehicle weighing approximately 300 kg, driver included. The components selected are widely used and tested within the Formula Student EV community.

1. Motor

The motor selected is one of the most widely used brands in the Formula Student Community. Key selection criteria include torque, speed, power, power-to-weight ratio, efficiency, control method, cost, and availability.

Model –

• Emrax 228 MV Liquid Cooled Axial Flux AC Synchronous Motor

Associated Components –

• Straight Coolant Fittings 2pcs
• Bearings for Radial Axial forces: PP Mode
• Standard Motor Shaft
• Encoder RM44Si on the back side of the motor (For DTI Motor Controller)
• Resolver TS2620N1095E161 with bracket for the back side of the motor (five pole pair resolver with bracket) (For Bamocar Motor Controller)
• Lead Time – 21 weeks 
• Datasheets – Motor Datasheets
• The motor is available in two configurations: one with an encoder compatible with the DTI controller and another with a resolver compatible with the Bamocar controller.

2. Motor Controller

The shortlisted controllers are highly compatible with the motor as recommended by its manufacturer.

Option A) 

Model – 

• DTI HV550 Liquid Cool

Associated Components – 

• USB -CAN Diagnostic Tool
• OBD Connector Set
• Main Wiring Harness
• Motor Position sensor’s connector
• Surlock 50mm² right angle receptacle
• High Voltage cable assembly

Lead Time – 19 weeks 

Datasheets- DTI HV550 Datasheets

Option B) 

Model – 

• Unitek Bamocar PG D3 700-400

Associated Components –

• Connector X1 M16 19 pole female control signals
• Connector X7 M16 19 pole male motor feedback
• Connector X9 m12 5pol male CAN
• Serial Programming cable 

Lead Time – 8 weeks

Datasheets – Bamocar PG D3 Datasheets

3. Cells

The cells part of the EV kit are cylindrical cells. The factors considered while selecting are – cell chemistry, nominal voltage, discharge current, mechanical stability, cost per Wh, energy density, and cost.

Option A)

Model –  

• Molicel INR – 21700 – P42A 600 qty.

Lead Time – 2 weeks

Datasheets – Molicel P42A Datasheets 

Option B) 

Model –  

• Molicel INR – 21700 – P45B 600 qty. 

Lead Time – 7 weeks (to Amravati)

Datasheets – Molicel P45B Datasheets 

4. Battery Management System (BMS)

Model – 

• Orion BMS 2 (108 cells)

Associated Components – 

• Cell Tap Wiring Harness, 108 cell, 6ft wire, gold plated – includes 3x CWH366G
• Main Connector Wiring Harness 6ft. (CAN1 wires – 12ft, CAN2 wires – 4ft)
• Current Sensor Harness for Orion 2 – includes 8 thermistors.
• 500A dual range current sensor
• CANdapter CAN to USB converter
• Thermistor Expansion Module (Includes CWHTHEXPO2 power harness) 2 qty
• 20x thermistor pack (0.2meter length, bare terminated wire) 8 qty
• Wiring Harness for 20x thermistors (6ft length) 8 qty
• Tap Validation tool for Orion BMS 2

Additional Components (If needed) – 

• Other accessories can also be added – connect remote wifi module, data logging display, basic SOC display at extra cost

Lead Time – 15 weeks (to Amravati)

Datasheets – Orion BMS Datasheets 

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FAQ

1. Can teams opt to purchase individual items from the EV kit, instead of the whole kit?

• Yes.

2. Is it required for all EV teams participating in Formula Bharat to use only the components listed in the EV kit?

• No. The purpose of the EV kit is to allow for teams starting out in the FS Electric Category to transition smoothly into the design and procurement phase. By no means are teams restricted to using the components listed in the EV kit.