Just like the automotive trade, motorsport is transferring in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal part is changing into much less important than previously, except the WRC, which lately took a step again to cut back prices.
In different four-wheel classes, corresponding to WEC or Formulation 1, hybrids play a key position. In Formulation 1, for example, the brand new energy models 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 totally electrical ones, corresponding to these in Formulation E. A hybrid system naturally differs from a totally electrical one, however there are shared components, corresponding to the truth that vitality recovered throughout braking passes by way of 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 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.
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 Formulation E vehicles. Podium already boasts intensive 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 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 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 them by way of a young because the unique provider of batteries for all Formulation E groups beginning in 2027.
In terms of batteries, the primary main distinction is the ability profile, which varies relying on every collection’ 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, 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 Highway Vehicles 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. 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 Formulation 1 or the WEC, which characteristic hybrid methods, are notably compact in comparison with these in Formulation E. In F1 or WEC, the place inner combustion engines nonetheless play a significant position and take up important area alongside the gas tank, the main focus is on making battery packs as compact and light-weight as attainable whereas sustaining effectiveness by way of energy output.
In Formulation E, and extra typically in totally 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 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 elementary consider 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 utility, making the number of the fitting cell essential.
“This has important impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the fitting cell have to be chosen for the fitting 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 varied connection strategies, corresponding to laser or ultrasonic welding, deciding on probably the most acceptable 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 must ship important vitality and are positioned to maintain the middle of gravity low and keep aerodynamic effectivity, discovering the fitting stability between reliability and efficiency is important.
“The design and growth of cooling methods fluctuate 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 solution to dissipate that warmth have to be devised,” Ciancetti explains.
Podium begins battery growth 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 mostly model-based. Whether or not it’s for a automobile or a battery, we all the time 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 facets.”
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