On the Selection, Design, and Integration of a Rare Earth Metal Free All-Wheel-Drive Electric Vehicle Powertrain

Abstract

This thesis outlines the mechanical design and integration of an all-wheel drive electric powertrain for a 2023 Cadillac LYRIQ. The vehicle is being designed as part of the EcoCAR Electric Vehicle Challenge, an Advanced Vehicle Technology Competition series. This competition gives students the opportunity to develop a new powertrain to better suit the market requirements for a luxury electric sport utility vehicle and develop new autonomous driving features. Engineering principles related to electric machines, drivetrain configurations, and complex application considerations are researched. Reflections from the previous EcoCAR competition are also investigated. The design of McMaster’s vehicle will be thoroughly examined starting with a deep dive into the vehicle’s architecture selection process including market analysis, architecture simulation, packaging studies, initial mechanical design, and project planning. Architecture selection spans the majority of the first year of the competition. Next the design process of the front and rear powertrains will be examined, including component selection, design, analysis, and integration. Powertrain design and integration encompasses the majority of the second year workload. Current status of the vehicle and future vehicle development areas are discussed.