Just like the automotive business, motorsport is shifting in direction of progressive electrification. Even in classes with hybrid powertrains, the thermal element is changing into much less vital than prior to now, apart from the WRC, which not too long ago took a step again to scale back prices.
In different four-wheel classes, similar to 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 element, contributing as much as 50% of the full energy output of the vehicles.
Alongside hybrid powertrains are totally electrical ones, similar to these in Method E. A hybrid system naturally differs from a completely electrical one, however there are shared parts, similar to the truth that vitality recovered throughout braking passes by way of a battery earlier than powering a motor-generator to maneuver the automotive.
The battery itself is among the most fascinating parts, not solely as a result of technological developments have enabled vital progress in just some years but in addition 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 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 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 them by way of a young because the unique provider of batteries for all Method E groups beginning in 2027.
In terms 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 methods.
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 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 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 methods, are notably compact in comparison with these in Method E. In F1 or WEC, the place inside combustion engines nonetheless play a serious function and take up vital area alongside the gas tank, the main target is on making battery packs as compact and light-weight as doable whereas sustaining effectiveness by way of energy output.
In Method E, and extra usually 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 purposes 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 undertaking part. Every pack contains quite a few cells, however not all cells are appropriate for each software, making the number of the correct cell essential.
“This has vital impacts on many areas, beginning with cell choice. Not all cells can carry out the identical job, so the correct cell have to be chosen for the correct 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, similar to laser or ultrasonic welding, deciding on probably the most acceptable one based mostly on the battery pack’s utilization profile.”
Cooling Techniques Range with Energy
The upper the facility 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, as an example, the place batteries must ship vital vitality and are positioned to maintain the middle of gravity low and keep aerodynamic effectivity, discovering the correct steadiness between reliability and efficiency is important.
“The design and growth of cooling methods differ relying on necessities as a result of battery packs with very excessive C-rates generate a number 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 points of the system earlier than delving into particulars. “We now stay 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 every little thing across the cell, together with the module idea, cooling methods, connections, and different points.”
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