Just like the automotive trade, motorsport is shifting in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal part is changing into much less vital than up to now, except for the WRC, which lately took a step again to cut back prices.
In different four-wheel classes, reminiscent of WEC or Method 1, hybrids play a key function. In Method 1, as an example, the brand new energy models debuting in 2026 will see a rise within the electrical part, contributing as much as 50% of the full energy output of the automobiles.
Alongside hybrid powertrains are absolutely electrical ones, reminiscent of these in Method E. A hybrid system naturally differs from a completely electrical one, however there are shared components, reminiscent of the truth that power recovered throughout braking passes by means of a battery earlier than powering a motor-generator to maneuver the automotive.
The battery itself is likely one of the most fascinating components, not solely as a result of technological developments have enabled vital progress in just some years but additionally as a result of every class has particular wants. Primarily, 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 produce batteries for the upcoming Gen 4 Method E automobiles. Podium already boasts intensive expertise in different classes. Based in 2011, Podium started its journey in motorsport by growing hybrid programs for automobiles 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 received the Dakar, and provides batteries for MotoE, the absolutely 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 means of a young because the unique provider of batteries for all Method E groups beginning in 2027.
With regards to batteries, the primary main distinction is the ability profile, which varies relying on every collection’ rules and the distinct necessities of hybrid and absolutely electrical programs.
Energy Profiles and Dimensions: How Batteries Range
“Every battery pack has its personal distinctive traits, significantly 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 Automobiles 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. Nevertheless, 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 characteristic hybrid programs, 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 potential 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 power saved within the battery. “Battery packs for electrical purposes usually 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 elementary think about how motorsport batteries are designed and constructed, ranging from the preliminary challenge section. Every pack contains quite a few cells, however not all cells are appropriate for each software, making the collection of the fitting cell essential.
“This has vital 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 software. 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, reminiscent of laser or ultrasonic welding, choosing essentially the most applicable one based mostly on the battery pack’s utilization profile.”
Cooling Methods Range 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 programs. In F1, as an example, the place batteries must ship vital power and are positioned to maintain the middle of gravity low and preserve aerodynamic effectivity, discovering the fitting steadiness between reliability and efficiency is crucial.
“The design and improvement of cooling programs differ relying on necessities as a result of battery packs with very excessive C-rates generate plenty of warmth in every cell, so an environment friendly option to dissipate that warmth have to be devised,” Ciancetti explains.
Podium begins battery improvement 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 automotive 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 all the pieces across the cell, together with the module idea, cooling programs, connections, and different points.”
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