Powertrain layout and component design with topology optimization for an electric truck
| dc.contributor.author | Deng, Liang | |
| dc.contributor.supervisor | Dong, Zuomin | |
| dc.date.accessioned | 2025-06-10T15:27:19Z | |
| dc.date.available | 2025-06-10T15:27:19Z | |
| dc.date.issued | 2025 | |
| dc.degree.department | Department of Mechanical Engineering | |
| dc.degree.level | Master of Engineering MEng | |
| dc.description.abstract | This report presents the design, optimization, and prototyping of an electric medium-duty truck (eMDT) retrofitted from a Toyota Dyna, addressing challenges in spatial constraints, weight distribution, and structural integrity. The project focuses on developing an optimized powertrain layout, lightweight structural components, and efficient integration of electric powertrain systems to meet standard and performance requirements. Reverse engineering was employed to create a detailed CAD model of the chassis, facilitating the analysis of spatial constraints and component placement. The powertrain layout was modelled and analyzed in terms of weight distribution and payload capacity. Structural modifications to the chassis and mounting systems were validated using finite element analysis (FEA). The motor bracket design underwent topology optimization using the Solid Isotropic Material with Penalization (SIMP) algorithm combined with hyperparameter optimization (HPO) to achieve a 48% weight reduction while maintaining structural reliability under operational loads. The project demonstrated the effectiveness of integrating advanced computational techniques with practical engineering to overcome the challenges of vehicle electrification. Key outcomes include an optimal powertrain layout, validated structural modifications, and a lightweight motor bracket design. These contributions advance the development of sustainable, efficient, and cost-effective electric medium-duty trucks, laying the groundwork for future vehicle electrification innovations.This report presents the design, optimization, and prototyping of an electric medium-duty truck (eMDT) retrofitted from a Toyota Dyna, addressing challenges in spatial constraints, weight distribution, and structural integrity. The project focuses on developing an optimized powertrain layout, lightweight structural components, and efficient integration of electric powertrain systems to meet standard and performance requirements. Reverse engineering was employed to create a detailed CAD model of the chassis, facilitating the analysis of spatial constraints and component placement. The powertrain layout was modelled and analyzed in terms of weight distribution and payload capacity. Structural modifications to the chassis and mounting systems were validated using finite element analysis (FEA). The motor bracket design underwent topology optimization using the Solid Isotropic Material with Penalization (SIMP) algorithm combined with hyperparameter optimization (HPO) to achieve a 48% weight reduction while maintaining structural reliability under operational loads. The project demonstrated the effectiveness of integrating advanced computational techniques with practical engineering to overcome the challenges of vehicle electrification. Key outcomes include an optimal powertrain layout, validated structural modifications, and a lightweight motor bracket design. These contributions advance the development of sustainable, efficient, and cost-effective electric medium-duty trucks, laying the groundwork for future vehicle electrification innovations. | |
| dc.description.scholarlevel | Graduate | |
| dc.identifier.uri | https://hdl.handle.net/1828/22373 | |
| dc.language.iso | en | |
| dc.subject | electric medium-duty truck (e-MDT) | |
| dc.subject | layout design | |
| dc.subject | topology optimization | |
| dc.subject | design of experiments | |
| dc.subject | hyperparameter optimization | |
| dc.subject | FEA | |
| dc.title | Powertrain layout and component design with topology optimization for an electric truck | |
| dc.type | project |