Electric Superbike Twente faster out of the pit lane with Telerex

Accelerate battery swap with ODU connectors

The smell of gasoline and roaring engines are inextricably linked to motorcycle racing. If it's up to Electric Superbike Twente, this will change. Every academic year, a new group of students from Saxion University of Applied Sciences and the University of Twente builds the ultimate electric motorcycle. In 2023-2024, the focus was, among other things, on accelerating the battery change in the pit lane.

With the development of a fully electric motorcycle, Electric Superbike Twente wants to secure the future of motorcycle racing. According to Alex Platteeuw, Technical Manager of the team, this is an important mission. "Innovations such as power steering and ABS, which you see in regular cars, originate from motorsports. This innovative power must be preserved for future generations, even as the development of combustion engines comes under increasing pressure."

Strategic Racing

Since the establishment of Electric Superbike Twente in 2017, the electric superbike has undergone an impressive development. The current showpiece is the Vector-ST. This fifth-generation motorcycle weighs 200 kilograms and has 214 horsepower. This allows for an acceleration from 0 to 100 km/h within three seconds. The top speed is 300 km/h. "With the Vector-ST we are at the top of possibilities in terms of power and speed," says Platteeuw.

The Vector-ST distinguishes itself from the competition with a revolutionary battery swapping system. This innovative design makes it possible to change the battery in just 30 seconds during a pit stop. Platteeuw: "Now that range is no longer a limiting factor, electric races can last longer and offer more room for tactical racing strategies."

Shorter pit stop

The 2023-2024 academic year was all about further optimizing the Vector-ST, to make racing the superbike as safe and as fast as possible. For example, the team aimed to reduce the time needed to swap the battery pack from thirty to twenty seconds. This improvement can make the difference between winning and losing at the finish line. "Especially on the straight sections, the Vector-ST beats traditional motorcycles at speed, but we are still losing that advantage in the pit lane," said Platteeuw.

In the first version of the battery swapping system, a switch required pulling a lever and manually disconnecting and reconnecting two cables. "These manual actions not only take time, but could also pose safety risks in the pit lane," says the Technical Manager. "Your hands come very close to a high-wattage battery."

From plug to connectors

On Telerex' advice, the team replaced the loose cables and plugs with ODU connectors from the ODU-MAC Silver-Line. This allows the battery to be removed from the motorcycle and a new one to be inserted in a single smooth motion.

"We did encounter a challenge during the design," Platteeuw noted. The battery is guided into the motorcycle via rails, but the use of lightweight, flexible materials can cause play. " Telerex provided excellent advice in this area. The ODU-MAC Silver-Line connectors are ideal for absorbing various clearances during docking. Despite the plays, the connection is guaranteed for at least 100,000 mating cycles."

Thermal management

It was not the first time that Telerex contributed to the Electric Superbike of Saxion University of Applied Sciences and the University of Twente. A previous team faced issues with an overheating battery during the hot summer. "A battery can heat up to about 50 degrees Celsius before the cells become unstable, but when starting temperatures are above 30 degrees, that limit is quickly reached. You only have a limited range to work in," Platteeuw explains.

The solution was found in a special enclosure in which the battery is not only charged, but also cooled to approximately 13 degrees. "This gives you about 20 degrees more leeway," Platteeuw explained. For the thermal management, Telerex supplied a Temperature Controller and Thermoelectric Cooler Assembly from Laird Thermal Systems.

Pleasant collaboration

Platteeuw looks back on a pleasant collaboration with Telerex. "Telerex was very supportive and considerate of our needs. they advised us on which cables would be most practical to keep the solution as compact as possible. They also provided tips for designing the housing around the connectors to prevent water ingress. In addition, they lent us a crimping tool to mount the connectors on the cables. That was very helpful, as such a tool is quite expensive."