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arXiv · 2610.09006

Electric Racing Kart with BLDC Drive, LiFePO4 Battery System, Traction Control and Regenerative Braking

Johannes Stockhammer·Tom Rettenwander·Philipp Huber
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Abstract

This diploma thesis documents the conversion of a petrol-powered go-kart into a battery-electric kart with a 10 kW BLDC drive, a LiFePO$_4$ traction battery with battery management system, a slip-based traction control and regenerative braking. The traction control estimates the slip of the driven rear axle from three Hall-effect wheel-speed sensors as $λ= (v_R - v_F)/v_R$ and reduces the torque command of the throttle pedal when the axle slips. It runs on a 32-bit ARM Cortex-M3 microcontroller (SAM3X8E) in the signal path between pedal and motor controller, with galvanic isolation and an emergency stop. Regenerative braking uses the generator mode of the motor controller in three stages: motor brake on throttle release, light braking via a steering-wheel button, and blended braking with the hydraulic brake. Drivetrain calculations show that the kart is traction-limited. At rated torque, the drive force at standstill exceeds the transmissible traction force by a factor of 1.7 to 2.0, up to approx. 27 to 43 km/h. Traction control is therefore a functional requirement of the drivetrain. The calculated top speed is approx. 65 km/h. Regenerative braking reaches approx. 0.45 g and could cover up to about 30 % of the energy demand on a winding track. With 80 % of the nominal battery energy, approx. 44 min of driving at 50 % motor load result, so the target of one hour is missed. The initial charging measurement quantifies the flat LiFePO$_4$ voltage plateau at 0.7 to 1.8 mV per percent state of charge, which makes voltage-based state-of-charge estimation unreliable. Cold cells showed a voltage sag under load that triggered the low-voltage alarm. Validation of the control functions by instrumented driving tests is the main open point.

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Johannes Stockhammer, Tom Rettenwander, Philipp Huber. 2026-10-06. Electric Racing Kart with BLDC Drive, LiFePO4 Battery System, Traction Control and Regenerative Braking. https://doi.org/10.5281/zenodo.23072034

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