Just like the automotive business, motorsport is transferring in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal element is turning into much less important than up to now, except the WRC, which just lately took a step again to scale back prices.
In different four-wheel classes, corresponding to WEC or System 1, hybrids play a key function. In System 1, for example, the brand new energy models debuting in 2026 will see a rise within the electrical element, contributing as much as 50% of the whole energy output of the vehicles.
Alongside hybrid powertrains are totally electrical ones, corresponding to these in System E. A hybrid system naturally differs from a totally electrical one, however there are shared parts, corresponding to the truth that power recovered throughout braking passes via a battery earlier than powering a motor-generator to maneuver the automobile.
The battery itself is likely one of the most fascinating parts, not solely as a result of technological developments have enabled important progress in just some years but additionally as a result of every class has particular wants. Primarily, whereas each sequence makes use of batteries, not all batteries are appropriate for each sequence.
This can be a matter Motorsport.com mentioned with Podium Superior Applied sciences, the Italian firm set to provide batteries for the upcoming Gen 4 System E vehicles. Podium already boasts in depth expertise in different classes. Based in 2011, Podium started its journey in motorsport by growing hybrid methods for vehicles competing within the 24 Hours of Nürburgring, such because the P4/5 Competizione, and later expanded to different sequence.
The Italian firm contributed to the event of the SCG 007C, the Glickenhaus Hypercar that competed within the WEC for 3 seasons, collaborated with Audi on the RS Q e-tron that gained the Dakar, and provides batteries for MotoE, the totally electrical bike world championship that accompanies MotoGP.
This in depth expertise has allowed Podium to deeply analyze the nuances of assorted championships. Their high quality as a producer additionally led the FIA to pick them via a young because the unique provider of batteries for all System E groups beginning in 2027.
In the case of batteries, the primary main distinction is the facility profile, which varies relying on every sequence’ rules and the distinct necessities of hybrid and totally electrical methods.
Energy Profiles and Dimensions: How Batteries Range
“Every battery pack has its personal distinctive traits, significantly when it comes to energy profiles—i.e., the quantity of kW enter and output and its ratio to the pack’s capability,” explains Luca Ciancetti, co-founder and head of the Highway Automobiles and Motorsport Enterprise Strains at Podium, in an interview with Motorsport.com.
“In a hybrid system, the battery pack often has a really small capability measured in kWh as a result of it must be light-weight. Nevertheless, it additionally has a really excessive energy profile because it should ship important energy when in use. So, in a hybrid system, the C-rate—the indicator of energy relative to the pack’s capability—is excessive.”
For instance, the batteries utilized in System 1 or the WEC, which characteristic hybrid methods, are notably compact in comparison with these in System E. In F1 or WEC, the place inside combustion engines nonetheless play a serious function and take up important house alongside the gas tank, the main target is on making battery packs as compact and light-weight as attainable whereas sustaining effectiveness when it comes to energy output.
In System E, and extra typically in totally electrical sequence, a lot bigger capacities are required to finish the race distance utilizing solely the power saved within the battery. “Battery packs for electrical purposes sometimes have decrease C-rates as a result of they’ve giant capacities. Even when they ship excessive energy, the facility output is a small or comparatively small a number of of their capability,” provides Ciancetti.
Not All Cells Are Appropriate
This distinction in energy profiles is a basic think about how motorsport batteries are designed and constructed, ranging from the preliminary mission part. Every pack includes quite a few cells, however not all cells are appropriate for each software, making the collection of the correct cell essential.
“This has important impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the correct cell should be chosen for the correct software. There’s additionally the matter of connection applied sciences between cells, as totally different present ranges between cells require totally different connection strategies,” Ciancetti explains.
“We use varied connection strategies, corresponding to laser or ultrasonic welding, deciding on essentially the most applicable one primarily based on the battery pack’s utilization profile.”
Cooling Techniques Range with Energy
The upper the facility output, the larger the warmth that must be dissipated, necessitating a devoted cooling system. This presents a fancy problem for each hybrid and electrical methods. In F1, for example, the place batteries have to ship important power and are positioned to maintain the middle of gravity low and preserve aerodynamic effectivity, discovering the correct steadiness between reliability and efficiency is important.
“The design and improvement of cooling methods differ relying on necessities as a result of battery packs with very excessive C-rates generate quite a lot of warmth in every cell, so an environment friendly approach to dissipate that warmth should be devised,” Ciancetti explains.
Podium begins battery improvement with a mathematical mannequin that defines the principle features of the system earlier than delving into particulars. “We now reside in an period the place design is mostly model-based. Whether or not it’s for a automobile or a battery, we at all times begin with a mathematical mannequin representing the system we’re designing,” Ciancetti says.
“Within the case of batteries, the mannequin of the cell, the module, and the battery pack has totally different inputs and traits relying on the cell we’ll use and the mission we have to obtain. From there, we begin designing all the pieces across the cell, together with the module idea, cooling methods, connections, and different features.”
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