Just like the automotive business, motorsport is transferring in the direction of progressive electrification. Even in classes with hybrid powertrains, the thermal part is changing into much less vital than prior to now, aside from the WRC, which lately took a step again to cut back prices.
In different four-wheel classes, equivalent to WEC or Method 1, hybrids play a key function. In Method 1, for example, the brand new energy items debuting in 2026 will see a rise within the electrical part, contributing as much as 50% of the whole energy output of the vehicles.
Alongside hybrid powertrains are absolutely electrical ones, equivalent to these in Method E. A hybrid system naturally differs from a completely electrical one, however there are shared components, equivalent to the truth that vitality recovered throughout braking passes via a battery earlier than powering a motor-generator to maneuver the automobile.
The battery itself is without doubt one of the most fascinating components, not solely as a result of technological developments have enabled vital progress in only a few years but in addition as a result of every class has particular wants. Basically, whereas each collection makes use of batteries, not all batteries are appropriate for each collection.
It is a matter Motorsport.com mentioned with Podium Superior Applied sciences, the Italian firm set to provide batteries for the upcoming Gen 4 Method E vehicles. Podium already boasts in depth expertise in different classes. Based in 2011, Podium started its journey in motorsport by creating hybrid methods for vehicles competing within the 24 Hours of Nürburgring, such because the P4/5 Competizione, and later expanded to different collection.
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 absolutely 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 out them via a young because the unique provider of batteries for all Method E groups beginning in 2027.
On the subject of batteries, the primary main distinction is the ability profile, which varies relying on every collection’ laws and the distinct necessities of hybrid and absolutely electrical methods.
Energy Profiles and Dimensions: How Batteries Range
“Every battery pack has its personal distinctive traits, notably by way of 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 Street Vehicles and Motorsport Enterprise Traces at Podium, in an interview with Motorsport.com.
“In a hybrid system, the battery pack normally has a really small capability measured in kWh as a result of it must be light-weight. Nonetheless, it additionally has a really excessive energy profile because it should ship vital 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 Method 1 or the WEC, which function hybrid methods, are notably compact in comparison with these in Method E. In F1 or WEC, the place inner combustion engines nonetheless play a serious function and take up vital area alongside the gasoline tank, the main target is on making battery packs as compact and light-weight as attainable whereas sustaining effectiveness by way of energy output.
In Method E, and extra typically in absolutely electrical collection, a lot bigger capacities are required to finish the race distance utilizing solely the vitality saved within the battery. “Battery packs for electrical functions sometimes have decrease C-rates as a result of they’ve massive capacities. Even when they ship excessive energy, the ability 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 undertaking part. Every pack contains quite a few cells, however not all cells are appropriate for each utility, making the number of the appropriate cell essential.
“This has vital impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the appropriate cell have to be chosen for the appropriate utility. There’s additionally the matter of connection applied sciences between cells, as completely different present ranges between cells require completely different connection strategies,” Ciancetti explains.
“We use numerous connection strategies, equivalent to laser or ultrasonic welding, choosing probably the most applicable one based mostly on the battery pack’s utilization profile.”
Cooling Programs Range with Energy
The upper the ability output, the better 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 vital vitality and are positioned to maintain the middle of gravity low and keep aerodynamic effectivity, discovering the appropriate stability between reliability and efficiency is crucial.
“The design and growth of cooling methods fluctuate relying on necessities as a result of battery packs with very excessive C-rates generate lots of warmth in every cell, so an environment friendly approach to dissipate that warmth have to be devised,” Ciancetti explains.
Podium begins battery growth with a mathematical mannequin that defines the primary points of the system earlier than delving into particulars. “We now stay in an period the place design is usually 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 completely different inputs and traits relying on the cell we’ll use and the mission we have to obtain. From there, we begin designing every part across the cell, together with the module idea, cooling methods, connections, and different points.”
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