Innovative Design and Development of Electrical System for FRATEC EV Race Car

Abstract

Electric vehicles (EVs) are increasingly seen as a sustainable alternative to internal combustion vehicles, especially in high-performance areas like competitive racing. Designing compact, efficient, and reliable electrical systems for motorsport environments remains a challenge. This paper details the design and implementation of a fully integrated electrical control system for the FRATEC EV Race Car, developed for the 2025 Next Generation Vehicle (NxGV) competition. The goal was to create a lightweight, modular electrical architecture that ensures stable propulsion, robust safety features, and real-time diagnostics. The system includes a 96V lithium-ion battery with a
Battery Management System (BMS), a Green Motor Technology controller, a DC-DC converter, an onboard AC charger, and auxiliary subsystems like Electric Power Steering (EPS) and brake pumps, all connected via a Controller Area Network (CAN Bus). The design distributes power across high and low voltage domains and coordinates subsystems using shielded CAN communication. Bench testing and field trials, including a full race simulation at NxGV 2025, evaluated performance metrics such as temperature rise, current load distribution, communication integrity, and system efficiency. The system achieved a peak efficiency of 91.5%, fault- free CAN communication across over 50,000 messages, and safe thermal behavior with controller and battery temperatures below 45°C. The successful race event completion without system failure demonstrated the design's robustness and scalability. The results suggest this system could serve as a reference model for educational, research, and prototype-level EV projects. The FRATEC EV’s electrical system represents a practical, high-performance solution for next-generation EV applications, combining safety, efficiency, and modularity.