DUKE ELECTRIC VEHICLES

Worked as a member of the two time world record holding Duke Electric Vehicles team, helping to create the world's most efficient electric vehicle, Eta (pictured here), in the spring of 2019 and competing in the 2019 Shell Eco Marathon.

PROJECT FEATURES

FEA

CAM & Manual Machining

Carbon Fiber Layup

DUKE ELECTRIC VEHICLES

DESIGN GOALS

EFFICIENCY

To set the world record for electrical efficiency, we would have to perform 6% better than the team's car from the previous year which set the record for fuel efficiency. Finding that additional performance in a design that had already been honed to near perfection required dedication and precision.

RELIABILITY

World record attempts required the team to rent a racetrack to preform the run, rent a trailer to move the car and equipment, and hire a professor from NC State to serve as independent verification for the run to be recognized by Guiness. So attempts were limited and even minor problems would be enough to drive efficency below the mark.

SAFETY

While the car was run primarily on a closed course at relatively low speeds, the driver was forced into a confined area for long duration runs, so it was imperative that the team not endanger her safety in the pursuit of the record.

STEERING ASSEMBLY FEA AND MACHINING

My primary role in the construction of the car was in regards to the front steering mechanism. I performed a weight reduction analysis on the previous year's design using Solidworks FEA, and used a hybrid of CNC and manual milling to manufacture the assembly. The aluminum inserts which hold the assembly to the body were turned on a CNC Lathe.

CARBON FIBER LAYUP

The carbon fiber monocoque body was one of the key improvements over the previous year that allowed us to break the record. I traveled with some other team members to VX Aerospace in Charlotte to layup the body by hand in professionally milled molds. The facility's tools and expertise led to a vastly improved build quality and surface finish versus the previous year.

WORLD RECORD

On June 23rd, 2019, Eta set a new world record of 27,482 MPGe at Galot Speedway. Verified by Guiness 3 days later, this marked two world records for the team in as many years. You can read more about the team and record here.