Just like the automotive trade, motorsport is transferring in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal element is changing into much less important than up to now, except for the WRC, which lately took a step again to scale back prices.
In different four-wheel classes, resembling WEC or System 1, hybrids play a key position. 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 full energy output of the vehicles.
Alongside hybrid powertrains are totally electrical ones, resembling these in System E. A hybrid system naturally differs from a completely electrical one, however there are shared components, resembling the truth that power recovered throughout braking passes by a battery earlier than powering a motor-generator to maneuver the automotive.
The battery itself is among the most fascinating components, not solely as a result of technological developments have enabled important 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 System E vehicles. Podium already boasts in depth expertise in different classes. Based in 2011, Podium started its journey in motorsport by creating hybrid techniques 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 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 out them by a young because the unique provider of batteries for all System E groups beginning in 2027.
On the subject of batteries, the primary main distinction is the facility profile, which varies relying on every collection’ rules and the distinct necessities of hybrid and totally electrical techniques.
Energy Profiles and Dimensions: How Batteries Fluctuate
“Every battery pack has its personal distinctive traits, notably 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 Automobiles and Motorsport Enterprise Traces 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. Nonetheless, 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 function hybrid techniques, are notably compact in comparison with these in System E. In F1 or WEC, the place inner combustion engines nonetheless play a serious position and take up important area alongside the gas tank, the main focus is on making battery packs as compact and light-weight as potential whereas sustaining effectiveness when it comes to energy output.
In System E, and extra usually in totally electrical collection, a lot bigger capacities are required to finish the race distance utilizing solely the power saved within the battery. “Battery packs for electrical functions usually have decrease C-rates as a result of they’ve massive 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 elementary consider how motorsport batteries are designed and constructed, ranging from the preliminary venture section. Every pack includes quite a few cells, however not all cells are appropriate for each software, making the collection of the appropriate cell essential.
“This has important impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the appropriate cell should be chosen for the appropriate 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, resembling laser or ultrasonic welding, choosing probably the most applicable one primarily based on the battery pack’s utilization profile.”
Cooling Programs Fluctuate with Energy
The upper the facility output, the higher the warmth that must be dissipated, necessitating a devoted cooling system. This presents a posh problem for each hybrid and electrical techniques. 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 appropriate steadiness between reliability and efficiency is crucial.
“The design and improvement of cooling techniques 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 technique to dissipate that warmth should be devised,” Ciancetti explains.
Podium begins battery improvement with a mathematical mannequin that defines the principle points 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 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 the whole lot across the cell, together with the module idea, cooling techniques, connections, and different points.”
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