Just like the automotive business, motorsport is shifting in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal part is changing into much less important than previously, excluding the WRC, which lately took a step again to cut back prices.
In different four-wheel classes, reminiscent of WEC or Components 1, hybrids play a key function. In Components 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 entire energy output of the vehicles.
Alongside hybrid powertrains are totally electrical ones, reminiscent of these in Components E. A hybrid system naturally differs from a totally electrical one, however there are shared parts, reminiscent of the truth that vitality recovered throughout braking passes by a battery earlier than powering a motor-generator to maneuver the automotive.
The battery itself is without doubt one of the most fascinating parts, not solely as a result of technological developments have enabled important progress in just some years but in addition 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 Components E vehicles. Podium already boasts intensive 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 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 received the Dakar, and provides batteries for MotoE, the totally electrical bike world championship that accompanies MotoGP.
This intensive 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 by a young because the unique provider of batteries for all Components E groups beginning in 2027.
With regards to batteries, the primary main distinction is the ability profile, which varies relying on every sequence’ rules and the distinct necessities of hybrid and totally electrical methods.
Energy Profiles and Dimensions: How Batteries Fluctuate
“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 Street Vehicles and Motorsport Enterprise Strains 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. 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 Components 1 or the WEC, which function hybrid methods, are notably compact in comparison with these in Components E. In F1 or WEC, the place inner combustion engines nonetheless play a serious function and take up important area alongside the gasoline 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 Components E, and extra typically in totally electrical sequence, 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 giant 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 includes quite a few cells, however not all cells are appropriate for each software, making the number of the proper cell essential.
“This has important impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the proper cell should be chosen for the proper 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, reminiscent of laser or ultrasonic welding, deciding on probably the most applicable one primarily based on the battery pack’s utilization profile.”
Cooling Programs Fluctuate with Energy
The upper the ability output, the larger the warmth that must be dissipated, necessitating a devoted cooling system. This presents a posh problem for each hybrid and electrical methods. In F1, for example, the place batteries have to ship important vitality and are positioned to maintain the middle of gravity low and preserve aerodynamic effectivity, discovering the proper 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 a whole lot of warmth in every cell, so an environment friendly method to dissipate that warmth should be devised,” Ciancetti explains.
Podium begins battery improvement with a mathematical mannequin that defines the primary facets of the system earlier than delving into particulars. “We now reside in an period the place design is usually model-based. Whether or not it’s for a automotive 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 every thing across the cell, together with the module idea, cooling methods, connections, and different facets.”
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