Lessons from Formula E: The proving ground for ground-breaking EV technology

18th April 2023  |  Electric vehicle

Formula E is a pioneer in sustainable vehicle racing as the world’s first all electric international single-seater championship. Since its debut in 2014, it has helped drive electric vehicle (EV) engineering forwards by pushing its limits on the racetrack. Formula E vehicles are constantly being innovated to improve speed, performance and efficiency, which are all directly transferable to commercial EV manufacturers.

As a direct result of Formula E innovation, ground-breaking technologies have been adopted by commercial EVs to bring better efficiency, thermal management and battery performance. But what are these ground-breaking technologies, and how did Formula E directly drive this innovation?

Thermal management

Challenges

High temperatures are a critical factor that negatively impacts the performance and efficiency of batteries. Lithium-ion, the most commonly used battery technology in EVs, has an operational temperature of between approximately −20 °C to 60 °C; any temperatures outside of this region can lead to degradation in performance and damages such as lithium plating and thermal runaway. Regular high temperatures directly reduces the capacity of EV batteries and hinders their charging capabilities/speeds.

Solution

Fortunately, modern EVs are equipped with advanced thermal monitoring and regulation systems that have been developed via the innovation of Formula E engineering. The extreme and constant high speeds of Formula E places thermal damage as a prominent issue. As a solution, engineers developed a combination of hardware and software systems; One example is a proprietary heat sink and water jacket cooling system that is controlled by a Lumped Parameter Thermal Network (LPTN). This software network is designed to predict which components need cooling based on the driving inputs and speeds. The result is effective battery cooling being applied as it is needed to avoid breaching the 60 °C mark.

Many modern EVs have adopted the thermal monitoring and regulation systems that have been developed by Formula E engineers. A key example of this is the Jaguar I-PACE design; the EV has an inbuilt thermal management system that cools and transfers heat from the battery to other locations, such as heating up the driver’s cabin. A result of this thermal management is an increased range of up to 50 km and increased longevity of battery life.

Battery size & efficiency

Challenges

Battery size is a shared challenge for both Formula E and commercial EVs, but for slightly different reasons. For Formula E, battery weight is a crucial optimisation factor that affects both speed and efficiency. For standard EVs, battery size is one of the biggest influences in the commercial price of vehicles. Where they both meet the same hurdle is with efficiency and charge range; both Formula E and standard EVs demand the maximum levels of efficiency in order to be viable in their respective applications.

Solution

Formula E has pushed the boundaries of battery efficiency by developing enhanced systems that have been adopted by commercial EVs. GKN Automotive’s partnership with Jaguar’s e-racing team led to innovation in increasing the voltage of systems to 800V. This almost doubles the charging speed without generating additional stress on the battery. As a result, EV designers have been able to reduce battery size without affecting charge range to reduce cost, or improve charge speed and range by maximising efficiency.

Energy management software

Challenges

When it comes to any form of electric mobility, dedicated software acts as the central orchestrator of its functionality. Even more so than a combustion engine in a conventional car. Software is the foundation of each and every EV function; motor controllers monitor batteries and accelerators, thermal management systems prevent overheating, monitoring software detects any issues with the vehicle, and so on. These systems need to be efficient and effective, or otherwise result in complications and a loss of efficiency.

Software is particularly vital for Formula E designers that seek to push the boundaries of technology in terms of efficiency, speed and performance. They need a system that is able to deliver the perfect amount of power at the right time, without expending any more than required. Moreover, each technical system on a Formula E car needs to run like clockwork under the intense strain of high speeds and G-forces.

Solution

Formula E engineers’ efforts to develop and improve vehicle software has had a direct effect on the performance and efficiency of commercial EVs. This is due to the fact that any discovered improvements to software is directly transferable to EVs via software updates. For example, analysis of a team’s Formula E vehicles generated efficiency solutions that were applicable to standard EVs. A resulting software update optimised powertrain and control systems to improve efficiency, boosting single charge range of their commercial vehicles by approximately 20 km.

Be in-line with EV innovation with Dalroad

Formula E has brought a range of improvements to EV technology. From battery efficiency and size optimization to improved thermal management and software, it is likely to continue innovating into the future. To stay up-to-date with these innovations as they arrive in commercial EV infrastructure, Dalroad has all the resources you need. Get in touch with one of our in-house engineers to find out more and/or discuss your EV project.

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