Re: Formula One 1.6l V6 turbo engine formula
Posted: 14 Aug 2013, 08:18
Ok, I missed that bit about the weight limit for the ES. So our target has to be 25 kg of mass for the ES. This is even worse with regard to power density than assumed. You want to charge 2MJ with 120 kW ideally and your battery charge rate for the best cells is 1.1 kW/kg. Your ultra capacitors are giving you 7.8 kW/kg. Lets see how much mass we need to charge with 120 kW.
1. Batteries by power density:
120 kW/ 1.1 kW = 109 kg (massively over weight)-> you cannot use this material exclusively
2. Ultra capacitors by power density:
120 kW / 7.8 kW = 15.4 kg (9.6 kg weight reserve)
It follows that from a power density point of view we cannot use batteries because we would run out of available mass long before we get the required power. And now we check for the energy density. You need to fit the full 4MJ ES capacity into 25 kg mass budget. We are already committed to use 15.4 kg of ultra capacitors. Ultra capacitors will give us 31Wh/kg or 0.1116 MJ/kg. Batteries will give us 88 Wh/kg or 0.317 MJ/kg.
3. Ultra capacitors by energy density:
15.4 kg * 0.1116 MJ/kg = 1.72 MJ (2.28 MJ still missing)
4. Batteries by energy density:
2.28 /0.317 MJ/kg = 7.19 kg
This tells us we need 22.59 kg total ES mass to satisfy both the power density and the energy density requirements in the mass constraints of the regulations. It also means you cannot use either batteries or ultra capacitors exclusively because neither of the materials will deliver the required power and energy density from one material only. Only a combination from both materials will do the job. You probably want to install the full 9.6 kg of batteries because your energy density will degrade relatively faster in the battery cells than the power density in the ultra capacitor cells.
I can now see why Toyota in LMP1 uses ultra capacitors only. They do not degrade which is important if you want to do thousands of charge and discharge operations with the same energy pack over 5000 km distance. In F1 you can throw away your batteries after 400 km. It makes a difference. Toyota can probably do a full WEC season with their energy storage where F1 teams will use at least 30 to 35 battery packs. From an environmental point of view LMP has the better regulations I think.
The other issue discussed is the reliability of the Red Bull KERS system. I believe the reliability does not suffer from the mixed storage design that Re Bull runs reportedly. I have very sound reasons to believe that Red Bull use higher overload factors in their KERS MGU than other teams in order to get away with lower weight. You never use the rated capacity of these units because they are designed to be working continuously at that power level. 2013 F1 does not use the KERS machine anywhere near 100% of the time. It is probably used 20 seconds out of the 95 seconds of an average lap. This represents a thermal utilization of 21%. It follows that Red Bull may be overloading their MGU by as much as a factor of 5. Other teams have usually more tolerance in their cooling capacities. Perhaps they use overload factors of 3-4 instead of 5 and accept a bit of higher weight. This would be consistent with the KERS failures we have seen from Red Bull. They predominantly happen when the cars get very hot, like the last race in Hungary where Vettel's KERS was temporarily overheating.
1. Batteries by power density:
120 kW/ 1.1 kW = 109 kg (massively over weight)-> you cannot use this material exclusively
2. Ultra capacitors by power density:
120 kW / 7.8 kW = 15.4 kg (9.6 kg weight reserve)
It follows that from a power density point of view we cannot use batteries because we would run out of available mass long before we get the required power. And now we check for the energy density. You need to fit the full 4MJ ES capacity into 25 kg mass budget. We are already committed to use 15.4 kg of ultra capacitors. Ultra capacitors will give us 31Wh/kg or 0.1116 MJ/kg. Batteries will give us 88 Wh/kg or 0.317 MJ/kg.
3. Ultra capacitors by energy density:
15.4 kg * 0.1116 MJ/kg = 1.72 MJ (2.28 MJ still missing)
4. Batteries by energy density:
2.28 /0.317 MJ/kg = 7.19 kg
This tells us we need 22.59 kg total ES mass to satisfy both the power density and the energy density requirements in the mass constraints of the regulations. It also means you cannot use either batteries or ultra capacitors exclusively because neither of the materials will deliver the required power and energy density from one material only. Only a combination from both materials will do the job. You probably want to install the full 9.6 kg of batteries because your energy density will degrade relatively faster in the battery cells than the power density in the ultra capacitor cells.
I can now see why Toyota in LMP1 uses ultra capacitors only. They do not degrade which is important if you want to do thousands of charge and discharge operations with the same energy pack over 5000 km distance. In F1 you can throw away your batteries after 400 km. It makes a difference. Toyota can probably do a full WEC season with their energy storage where F1 teams will use at least 30 to 35 battery packs. From an environmental point of view LMP has the better regulations I think.
The other issue discussed is the reliability of the Red Bull KERS system. I believe the reliability does not suffer from the mixed storage design that Re Bull runs reportedly. I have very sound reasons to believe that Red Bull use higher overload factors in their KERS MGU than other teams in order to get away with lower weight. You never use the rated capacity of these units because they are designed to be working continuously at that power level. 2013 F1 does not use the KERS machine anywhere near 100% of the time. It is probably used 20 seconds out of the 95 seconds of an average lap. This represents a thermal utilization of 21%. It follows that Red Bull may be overloading their MGU by as much as a factor of 5. Other teams have usually more tolerance in their cooling capacities. Perhaps they use overload factors of 3-4 instead of 5 and accept a bit of higher weight. This would be consistent with the KERS failures we have seen from Red Bull. They predominantly happen when the cars get very hot, like the last race in Hungary where Vettel's KERS was temporarily overheating.