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Download (6Mb) University of Warwick institutional repository: http://go.warwick.ac.uk/wrap A Thesis Submitted for the Degree of PhD at the University of Warwick http://go.warwick.ac.uk/wrap/58303 This thesis is made available online and is protected by original copyright. Please scroll down to view the document itself. Please refer to the repository record for this item for information to help you to cite it. Our policy information is available from the repository home page. ADVANCING THE DEVELOPMENT OF HYBRID ELECTRIC VEHICLES IN MOTORSPORT Innovation Report Stephen Lambert 31 st May 2013 Innovation Report ABSTRACT Club motorsport, a low cost, amateur form of motorsport, forms a significant part of the motorsport industry in the United Kingdom. If efforts are not made to move towards more environmentally friendly technologies, then this form of motorsport is at risk of becoming irrelevant. One approach taken by other motorsport sectors has been to implement hybrid electric vehicle technology, which can result in improved vehicle performance on the race track. However, the companies that operate in the club motorsport sector do not typically have the resources and experience necessary to develop these technologies. An innovative process was used to guide the design of a new hybrid electric vehicle drivetrain for use in club motorsport. This process made use of the ability for vehicle manufacturers to set the vehicle specifications in club motorsport. A conjoint analysis of customer requirements was carried out, a first for the industry, and led to the development of a market simulation tool. A vehicle simulation tool was then developed to assist in the evaluation of the hybrid electric drivetrain design options. The result of following this process was a new and innovative hybrid electric drivetrain installed in a Westfield Sportscars Sport Turbo, reducing 0-60mph acceleration time from 5.4 seconds to 3.8 seconds. An innovative type of system control was implemented, by where the driver is given a finite amount of boost energy for use throughout the race. The drivetrain can also be easily transferred to other vehicle platforms, as the first shelf engineered hybrid drivetrain for motorsport, allowing its use by multiple manufacturers across the club motorsport and niche vehicle sectors. This project has shown that it is possible to implement environmentally friendly technologies, such as hybrid electric vehicle technology, into club motorsport and be able to meet customer, technical and cost requirements. The process that has been developed enables innovation in hybrid electric race car design. This has been shown in the development of a hybrid electric vehicle suitable for use, and sale, in the club motorsport industry. Page i Innovation Report ACKNOWLEDGEMENTS This work could not have been completed without funding from the Engineering and Physical Sciences Research Council (EPSRC) and the Warwick Innovative Manufacturing Research Centre (WIMRC), expertise on club motorsport and additional funding from Dr Paul Faithfull at Potenza Technology and academic support from Dr Steve Maggs, Adrian Vinsome and Dr Kevin Neailey at Warwick Manufacturing Group. I would also like to thank my wife, Claire, and my son, Jackson for all their help and for putting up with the many hours of write up and for keeping me going throughout the whole process. Page ii Innovation Report CONTENTS Abstract ................................................................................................................................... i Acknowledgements ............................................................................................................... ii Contents ................................................................................................................................ iii List of Tables ........................................................................................................................ ix List of Figures ....................................................................................................................... xi List of Abbreviations .......................................................................................................... xiii 1 Introduction ................................................................................................................... 1 1.1 Project Partners ....................................................................................................... 2 1.2 Innovations .............................................................................................................. 2 2 Methodology .................................................................................................................. 4 2.1 Introduction ............................................................................................................. 4 2.2 Portfolio and Innovation Report Structure .............................................................. 5 2.3 Technology and Literature Review ......................................................................... 5 2.4 Requirements Capture and Analysis ....................................................................... 6 2.5 Technical Investigations ......................................................................................... 7 2.6 System Design and Testing ..................................................................................... 7 2.7 Process Design ........................................................................................................ 8 2.8 Published Papers and Articles ................................................................................. 8 3 Technology Review ....................................................................................................... 9 3.1 Introduction ............................................................................................................. 9 3.2 Hybrid Architecture Theory .................................................................................... 9 3.3 Hybrid Architectures for a Westfield Sportscars Racing Car ............................... 15 3.3.1 Series Hybrid Architectures ............................................................................ 16 3.3.2 Parallel and Combined Hybrid Architectures .................................................. 17 3.4 Electrical Energy Storage Systems ....................................................................... 19 3.4.1 Introduction ..................................................................................................... 19 Page iii Innovation Report 3.4.2 Ultracapacitor Systems .................................................................................... 19 3.4.3 Electrochemical Systems ................................................................................. 21 3.4.4 Battery Management Systems ......................................................................... 22 3.4.5 Thermal Management ...................................................................................... 23 3.4.6 Energy Storage System Use in Motorsport ..................................................... 24 3.5 Electric Drives ...................................................................................................... 25 3.5.1 Motors .............................................................................................................. 25 3.5.2 Motor Controllers and Inverters ...................................................................... 27 3.5.3 Electric Motor Performance ............................................................................ 27 3.6 Discussion ............................................................................................................. 28 3.7 Conclusions ........................................................................................................... 29 4 Literature Review ........................................................................................................ 30 4.1 Introduction ........................................................................................................... 30 4.2 Hybrid Electric Vehicle Use in Motorsport .......................................................... 30 4.2.1 FIA Formula One World Championship ......................................................... 30 4.2.2 Endurance Racing ............................................................................................ 34 4.2.3 Formula Hybrid ............................................................................................... 38 4.2.4 Formula Student Class 1A ............................................................................... 44 4.2.5 Club Motorsport .............................................................................................. 45 4.3 Importance of Motorsport ..................................................................................... 46 4.3.1 Motorsport Valley ........................................................................................... 47 4.3.2 Technology Transfer........................................................................................ 47 4.4 Summary of Key Points ........................................................................................ 48 4.5 Conclusions ........................................................................................................... 49 5 Requirements Analysis ...............................................................................................
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