Overview

Customer Specifications

In 2014, FIA introduced new regulations for Formula One racing, requiring more efficient power units. The FIA reduced the racecar engine from a 2.4 L V8 to a 1.6 L V6, requiring comparable horsepower output with 40% reduction in fuel consumption. Our customer, a race engine manufacturer was looking to develop an energy recovery system (ERS) to meet the new FIA regulation and improve performance of their engine.

The energy recovery system was comprised of a motor generator unit (MGU) that is mechanically coupled to the engine’s turbocharger and a control unit (CU) connected to a battery to exchange power with the MGU. As the vehicle traverse racing circuits, energy is seamlessly transmitted to and from the engine via the ERS. The MGU operating in motoring mode can speed up the turbocharger to pump air into the engine and eliminate thermal lag. At high engine speeds, the MGU operating in generating mode converts engine’s exhaust into electrical power and charges the battery. The result is a highly responsive and extremely efficient power unit.    

Solution

Calnetix was responsible for the design of the motor generator unit and integration of the MGU and CU to optimize performance for the energy recovery system. The Magnaforce™ motor generator unit developed by Calnetix can provide up to 100 KW of electrical power at 105,000 RPM with a weight of 7.5 kg (16.5 lbs) and in approximately 2 liters volume.

Challenges

The challenge for this development effort was to optimize both the MGU and CU for efficiency while minimizing weight and packaging space. This was accomplished by using Calnetix’s Magnaforce™ high speed permanent magnet generator motor for the MGU and a high-power density inverter for the CU.

Results

Calnetix’s Magnaforce™ high-speed motors and generators were designed to provide maximum power density while maintaining high operating efficiency and good thermal performance consistent with design requirements.