Torotrak, Xtrac Discuss Specialised Transmission Technology Required for Energy Recovery at Cleaner Racing Conference

January 10, 2008 -- Transmission technology specialists Torotrak and Xtrac have joined eminent motorsport personalities participating today in the 2nd International Cleaner Racing Conference, which precedes the opening of the Autosport International Show at the Birmingham NEC.

Organised by the Motorsport Industry Association the conference will explore with experts, not only the technical issues of energy efficient motorsport, but also the possibilities for transferring new and advanced motorsport technology to the automotive mainstream.

In their joint presentation to the conference, Chris Brockbank, business manager with Torotrak and Adrian Moore, technical director with Xtrac, will focus on their innovative continuously variable transmission design, which forms an essential part of a mechanical flywheel (KERS) Kinetic Energy Recovery System, which the FIA has permitted under its revised regulations for the 2009 F1 racing season.

In their presentation, Brockbank and Moore will pick up on important points made recently by FIA technical consultant Tony Purnell, who commented that ‘car manufacturers are already working flat out to develop optimal low-emission engines and there is little that engine development programmes in F1 will add to this effort. However, in five years or so, their attention will turn more and more to subsidiary devices incorporating energy recovery. By opening up this area now, F1 can make a real difference to this important facet of future car technology. The technical challenge is huge and there will be very little constraint on it.’

To meet this technical challenge Xtrac has used its motorsport honed skills to rapidly design and manufacture a CVT variable transmission to be used as the ancillary gearbox required for an F1 KERS system. The advanced traction drive technology incorporated in the variator is produced under license from Torotrak. It forms a critical part of the design, which provides for the all-important speed matching between the flywheel and main vehicle driveline.

“With rising fuel costs and the need to reduce CO2 emissions this highly efficient technology, developed initially for F1, is also particularly relevant to the automotive mainstream,” says Brockbank.

“A flywheel based mechanical KERS system which uses our CVT has a very good power density,” says Moore. “It avoids the use of exotic and expensive materials, and is significantly lighter and more compact than a battery electrical system, and yet offers the potential for excellent efficiency. It also offers low operating costs and long-life components. Moreover, for the mainstream automotive industry it is also scaleable to meet the different power and energy requirements of many different types of vehicle.”

Brockbank and Moore’s technical presentation will provide an overview of new F1 regulations and the sophisticated transmission design required for a mechanical based KERS system, which has been developed to recover and store braking energy in the most efficient manner possible.

For the F1 application, the Xtrac CVT variator can handle 90Nm of torque and weighs approximately 6kg. Xtrac’s first customer is Flybrid Systems, a motorsport company which very impressively has developed a complete KERS system, initially for use in F1, from concept to rig testing in less than 12 months.

Flybrid, Torotrak and Xtrac all see the potential for wider application of a mechanical flywheel-based KERS system beyond motorsport; particularly as a means of developing vehicles with reduced fuel consumption and CO2 levels. Applied to road cars the system supports the current motor industry trend for smaller powertrains; a lightweight kinetic energy recovery system ironically providing a means of boosting acceleration and overall performance, which could allow engine downsizing, as well as improving fuel economy.

Brockbank and Moore are participating in this high level conference alongside influential figures from the world of motorsport including Renault F1's engineering guru Pat Symonds, Audi engine legend Ulrich Baretzky, former head of GM Motorsport Herb Fishel, and top international racer and committed environmentalist David Brabham. They will each bring their particular expertise to bear on the subject of motorsport technologies playing a key role in the development of more energy efficient road vehicles and racing cars.

The conference has attracted an international audience of 150 motorsport leaders, key influencers, advanced engineers, R&D specialists and marketing executives together with trade and business media. The conference takes place today (Wednesday 9 January 2008) at the Birmingham NEC. It precedes the Autosport International Show, where Xtrac will be exhibiting a wide range of motorsport and high performance transmission systems.

Source: Xtrac

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