motorsport

Transcription

motorsport

MOTORSPORT
Winning Through Technology
Contents
3 Ricardo plc
4 Motorsport Engineering Services
6 Motorsport Technology Roadmap
8 Ricardo Expertise in Motorsport
Systems
9 Ricardo Software
10 Ricardo Expertise in Manufacture
and Assembly for Motorsport
12 Case Studies
13 McLaren MP4-12C GT3 Engine
13 Petronas
14 GT Racing
14 McLaren MP4-12C GT3 Transmission
14 FIA GT1
15 LMP1/LMP2
15 World Series by Renault (FR3.5)
15 Rally
16 Advanced Engineering Support
16 Supervisory Controller for HighPerformance Electric and Hybrid
Applications
17 KERS/Battery Hybrid
17 Kinergy™
18 Ricardo’s Corporate Strategy
19 Ricardo’s Global Locations
20 Contact Details
MOTORSPORT
Ricardo plc
A history of motorsport innovation & world class technology
Ricardo are unique in our ability to provide full engineering
and production service across all the major systems in the
motorsport powertrain comprising engine, transmission
and energy management together with the associated
systems integration and control.
We are a global, world-class, multi-industry consultancy for
engineering, technology, project innovation and strategy. With
a century of delivering value, we employ over 1600 professional
engineers, consultants and staff.
Our people are committed to providing outstanding value
through quality engineering solutions focused on high
efficiency, low emission, class-leading product innovation and
robust strategic implementation.
Our client list includes the world’s major transportation Original
Equipment Manufacturers (OEM), supply chain organisations,
energy companies, financial institutions & governments.
Guided by our corporate values of respect, integrity, creativity
& innovation and passion, we enable our customers to achieve
sustainable growth and commercial success.
Ricardo Motorsport is an integrated team functioning
across the whole Ricardo Group
It is built on
• A long history in motorsport
(more than 70 years)
• Proven race-winning capability
• Established engineering software
• Experienced motorsport personnel
• Ricardo high technology base
Our services include
• Integrated powertrains - design, procurement,
testing and support
• Research activities off-line from mainstream
race engine development programmes
• Developing new technologies
(e.g. DI, advanced boosting systems, sensors,
energy recovery systems)
• Overall concept design
• Component design and analysis
• System modelling and optimisation
Ricardo - Innovation in world-class products
Recent technologies include:
Flywheel
SGDI
Battery
Developments in flywheels, based on ideas
patented by Ricardo, have resulted in significant
increases in performance and reliability
Gasoline engines with exceptional performance
yet Diesel levels of efficiency
Advanced chemistries, universal battery
management systems and engineering for high
performance battery packs
Delivering Value Through Innovation & Technology
3
MOTORSPORT
Motorsport Engineering Services
Our motorsport engineering services ensure that our clients benefit from
the game changing technologies and products that we deliver to help
you win through technology whilst ensuring regulatory compliance
Road Relevance
Efficiency Improvement
Developing innovative solutions that benefit both road-based
and motorsport applications (e.g. DI, advanced boosting
systems, sensors, energy recovery systems, lightweight
structures.)
Maximum performance from the minimum quantity of fuel
(e.g. engine downsizing and down-speeding, advanced
boosting, thermal management, waste heat recovery, reduced
friction, combustion optimisation.)
Cost Reduction
Targeted Solutions
Performance
Improvement
Improving the affordability and reducing barriers to entry for
motorsport (e.g. modular solutions, increased reliability, optimised
materials and manufacturing processes, mechanical energy storage.)
A relentless drive for better results and performance
improvement from innovative engineering, weight reduction
and improved reliability
Solutions for the whole product life cycle across the whole
range of motorsport products
Advanced Engineering
Development
• Future combustion systems
• New technology solutions
• Advanced architectures
• Performance & mechanical
• Calibration / EMS / NVH
Design & Analysis
Manufacturing
and assembly
• Concept, definitive
and upgrade
• DFM&A
• Simultaneous CAE
• System modelling
Design
Product
Engineering
Capability
Manufacture
• Sourcing, purchasing,
inspection
• Kitting, build books
• Supply chain management
Race Support
• Track support
• Logistics
4
Ricardo plc
MOTORSPORT
Motorcycle
WRC
Touring Car
F1
One-make Series
GT
Prototypes
5
MOTORSPORT
High Level Technology Roadmap for Motor
The motorsport technology roadmap focuses on chasing performance efficiently
with cost-effective CO2 reduction
F1
DRS
KERS
LMP
Drivers
Performance: reduce CO2 and increase kW/l (engi
Engine
Transmission /
driveline
Vehicle
Energy
Management
ITS
2005
6
Ricardo plc
2010
MOTORSPORT
rsport
Internal
Combustion
Engines
5 priority R&D areas have been
identified for the automotive industry
Electric
Machines and
Power
Electronics
Strategic
Technologies for
the Automotive
Industry
Lightweight
Vehicle and
Powertrain
Structures
New F1 engine
regulations in 2014
Energy Storage
and Energy
Management
Intelligent
Transport
Systems
New LMP regulations
in 2014 (TBD)
Road relevance, technology transfer
Cost and sustainability
Market engagement - spectators, customers (especially ageing demographic), the show, service industry
ne) and Nm/kg (transmission) for efficiency and “green” image
Safety
Engine down-sizing and down-speeding
Direct injection
Advanced boosting systems
Energy recovery / split cycle
Cost effective fast-shifting semi-autos
Materials, structures and manufacturing processes
Integrated hybrid systems
Moveable aerodynamics
Lightweight structures
Enclosed cockpits, covered wheels
Thermal management, efficient power electronics
Brake electrification (linked to energy storage)
Tyres
Kinetic energy recovery
Energy storage (batteries, flywheels, ultra-caps, hydraulic...)
Waste heat recovery
Battery / system charging / management at venue
Telemetry, data/information feed direct to customers
2015
2020
2025
7
MOTORSPORT
Ricardo Expertise
in Motorsport Systems
An independent, impartial, full systems view of motorsport projects. Ricardo
Motorsport is backed by a global world class engineering capability that can
deliver within compressed time scales
Engine design and analysis
Transmission design and analysis
• Concept design and detail design
- NA and boosted
- PFI and DI
• Integrated analysis and optimisation including
- Engine performance simulation
- Computational fluid dynamics
- Mechanical system analysis
- Structural finite element analysis
- Thermal management
• Integrated with manufacturing, assembly and supply chains to
ensure high quality
• Controlled through design process and PLM
• Concept and detailed design of complete transmission systems
including final drive
- Manual transmissions (xMT)
- Semi-automatic transmissions (xAT)
- Dual clutch transmissions (DCT)
• Integrated analysis and optimisation
- Shaft and bearing analysis
- Gear Topology Optimisation
• Integrated with manufacturing, assembly and supply chains to ensure
high quality
Engine development and durability
Transmission development and durability
• Engine testing
- Steady state and transient for performance and fuel economy
development
• Steady state and dynamic flow rigs
• Hydropulse rig
- Accelerated durability assessment
• Fatigue rigs
- Torsional (crankshaft)
- Axial (con-rod)
• Full driveline transient dynamic testing (unrivalled in Europe)
- Transient 2WD rig (3E) – 450Nm
- Transient 4WD rig (5E) – 1000Nm
- Option for additional dynamometer to test power take off in 3E and
5E rigs
• Fully automated gearshift and clutch actuation
• Gearshift durability test rig
• End of line production test rigs
• Lubrication, deflection, tilting & hydraulics rigs
8
Ricardo plc
MOTORSPORT
Ricardo Software
A suite of products focused on powertrain and driveline solutions used
extensively in motorsport applications
WAVE: a comprehensive engine system
simulation software designed for 1D
analysis
VECTIS: a CFD code developed
specifically to address fluid flow
simulations in the vehicle and engine
industries
VALDYN: a multi-body dynamic
simulation tool specifically developed for
valvetrain and drive system analysis
ENGDYN: a dedicated engine analysis
code developed to aid the design and
analysis of the crank train and engine
structure
FEARCE: a finite element (FE) pre- and
post-processing environment written
specifically to support engine and vehicle
analysis
PISDYN: an advanced simulation
package for the design and analysis of
piston assemblies
RINGPAK: a simulation tool used for the
design and analysis of a piston ring pack
SABR: a simulation package which
has been specifically developed for
transmission shaft and bearing analysis
9
MOTORSPORT
Ricardo Expertise in Manufacture
and Assembly for Motorsport
Quality processes, techniques and tools for achieving production
Low Volume Production
Overview
Engine Assembly
• Ricardo has a set of processes and systems that support low volume
production
• These can be scaled and customised to support a wide variety of low
volume production programmes
• They provide integration between design, production readiness and
production execution
• They can be implemented at any Ricardo site, with support provided by
existing expert users
• Previous programmes have covered a range of product types,
complexities and volumes
- Gearboxes and complete transmission systems
- Complete engines or engine upgrades/conversions
• The facilities are able to produce <100 to several thousand units per
year
• State of the art 600m2 facility producing up to 4,000 engines per year
- 10 station main assembly line
- Cylinder head sub-assembly line
- Hot test cell
• Standard work incorporated into HMI
• No faults forward concept with inbuilt tests and poke-yokes
• Full serial and lot control for in service traceability of components
10
Ricardo plc
Driveline and Transmission Manufacture
• Our high performance transmissions group operates from a 4,884m2
manufacturing facility to produce complete transmissions and driveline
systems
- Turning and milling
- Wire erosion
- Hobbing and shaping
- Spiral bevel-axles
- Computerised heat treatment
- Gear grinding
• The capability to produce parts wholly in house enables Ricardo to
improve product quality and reduce lead times
MOTORSPORT
Accreditation and
Industry Awards
Ricardo’s capabilities have been recognized through the
achievement of industry accreditation and awards
•
•
•
•
• Royal Automobile Club Dewar
Trophy 2006
• MIA export excellence 2007
AS9100B
ISO9001
ISO14001
OHSAS18001
Low Volume Production
Approach
Advanced Product
Quality Planning
Production Process
Verification
Supplier Selection
& Development
Product Technical
Specification
Design
Verification Plan
Design Failure
Mode Effects
Analysis
Design Failure
Mode & Assembly
Process Failure
Mode Effects
Analysis (risk
analysis)
Design and
engineering
process
Production
process
Built-in quality
Process Part
Approval Process
(PPAP) and
readiness review
ISIR by
manufacturing
batch
Production readiness
11
MOTORSPORT
Ricardo Case Studies and Capabilities
Key
Engines
Transmissions
Hybrid and Energy Storage
Cost Reduction Targeted Solutions
Road Relevance
Efficiency Improvement
Performance Improvement
12
Ricardo plc
MOTORSPORT
Petronas
Complete turn-key engine design,
development and race support program
McLaren MP4-12C GT3
Engine
Ricardo have developed a GT3 version of
the McLaren MP4-12C based on the Ricardodesigned and developed road engine
Situation and objective
• Ricardo were engaged to improve reliability, quality (consistency) and
performance of a World Superbike engine whilst
- Showcasing customer technology/engineering capabilities on the
world stage
- Exposing and training customer engineers in high performance
gasoline engine design and development tools/techniques/
processes
Ricardo role
• The OEM wanted a race version of the new MP4-12C to help promote
the brand
• They were looking for a turn-key engine development and production
programme to mate to the Ricardo 6-speed semi-automatic transmission
commissioned for the race programme
• Ricardo were engaged to develop the engine incorporating a new ECU
and to manufacture engines for customer race cars
Ricardo role
• Development of engine against engineering targets in a balance of
performance category
- Performance, fuel economy and driveability
• Convert engine to operate with new ECU provided by TAG/McLaren
- Adapt to new sensors/actuators
• Calibration of the engine to various performance levels to assist with
balance of performance
• Manufacture of >30 race engines for McLarenGT and customer cars for
2012 season
• Project leadership, technical direction and innovation, processes and
racing culture
• Program team of >25 people
- Integration of customer engineers
• Full responsibility for design, analysis, development, procurement, engine
build and re-build, logistics and race support
Results and benefits
• Start of project to first race in less than 5 months
• Engine reliability and consistency dramatically improved
• Engine speed increase from 14,000 rev/min to over 16,000 rev/min
- Performance increased by 15% with improved drivability
• 3 pole positions (despite 10% capacity deficit)
• Engine engineering processes and component lifing systems developed
and enforced
• Customer engineer integration
• Engine successfully updated to GT3 specification
- Removal of unwanted components
• Engine calibrated on new ECU to various performance levels to support
balance of performance testing
- Supported development of new control strategies for ECU
• First race successfully completed in 2011
• Manufacture of customer race engines scheduled for late 2011
13
McLaren MP4-12C GT3
Transmission
Designed, developed and produced by
Ricardo in conjunction with McLaren
GT Racing
• McLaren wanted a GT race version of the MP4-12C to help promote the
brand
• The production DCT was unsuitable for racing and needed to be
replaced with a light-weight 6-speed semi-automatic transmission
Increased performance and improved
reliability to reduce operating costs
Ricardo role
Super GT
• Ricardo were tasked with a full transmission re-design to provide a
lower weight, higher durability and therefore lower overall running cost
solution
Ricardo role
• Initial supply of a transmission system to Nissan led to Ricardo supplying
all Japanese Manufacturers
• Transmission budget s were reduced by approximately 50% when using
a Ricardo transmission system when compared to previous supplier
• Gearbox weight was reduced whilst increasing part life, all objective
targets were exceeded setting a new transmission benchmark for the
series
FIA GT1
700Nm Sequential Transaxle
axle Gearbox
Our 6-speed sequential gearbox includess race-proven
technology and components designed for high
performance GT racing worldwide. As used
sed by the
2011 FIA GT1 World Champions JRM-Nissan.
san.
14
Ricardo plc
• Ricardo were engaged to design and develop the new transmission
leveraging the proven internals from the transverse SuperGT
transmissions and repackage them into a longitudinal installation to suit
the MP4-12C
• Ricardo has developed a compact, longitudinal gearbox for the MP412C using a range of race proven components wrapped in a bespoke
casing. The gearbox arrangement allows easy access to the gear
cluster and the differential can be removed without disturbing the
crownwheel and pinion.
• A generic bell housing profile and starter motor integration allows the
gearbox to be adapted to other vehicle applications.
MOTORSPORT
LMP1/LMP2
World Series by Renault (FR3.5)
750Nm Transverse Transaxle Gearbox
500Nm sequential Transaxle Gearbox
Our Championship winning*
nning*
6-speed sequential gearbox
arbox
can be configured for
either LMP1 or LMP2
vehicles, including high
h
performance GT track cars. It
uses optimised and proven
oven
Le Mans winning components
ponents
and technology.
Our 6-speed sequential transaxle is
designed for high powered singleseater racing.
Currently used by the entire grid in
both the Firestone Indy Lights Series
and World Series by Renault (FR3.5) as
well as independent hill climb and
sportscar vehicles.
* 2011 LMP2 Championss Greaves Motorsport
Rally
Design, development and manufacture of a
broad range of successful transmissions
In collaboration with our customer M-Sport, Ricardo were engaged to
provide a sophisticated 4WD complete transmission solution from clean
sheet. Durability, reliability and low mass were key objectives.
Utilising all our design, manufacturing and 4WD rig testing expertise we
achieved the objectives and provided another class leading, lightweight,
high performance, reliable, sophisticated transmission solution in an
accelerated timescale
15
MOTORSPORT
Advanced Engineering
Support
Providing advanced engineering services
to many sectors of motorsport
Supervisory Controller for
High-Performance Electric
and Hybrid Applications
Safe and flexible control in automotive
applications
• As new technologies emerge, customers need an accelerated route to
understanding and application whilst in-house capability is established
• Ricardo offer services in research and advanced engineering to assess
and apply new technologies and processes e.g.
- Research in DI fuel systems at high engine speeds
- Application of advanced boosting systems
- KERS technology selection
- Cylinder-to-cylinder air/fuel ratio distribution measurement
Situation and Objective
With increases in vehicle complexity from the integration of complex
systems, Ricardo needed a high-integrity, supervisory controller for electric
and hybrid vehicles with a wide range of I/O types to enable the unit to be
used for many different applications.
Ricardo Role
Ricardo role
• System simulation of available technologies and architectures
• Development of advanced instrumentation and test rigs/methods
• Application of specialist simulation techniques to gain understanding
and provide development direction
• Provision of specialist skilled resource on an as-needed basis
• Customers gain understanding of the key factors affecting performance
of new technologies
- Off-line from on-going development - avoids distractions
- Parallel activity ensures rapid results into future plans
- Technology transfer via tools, techniques and reports enables
in-house capability to be built quickly and efficiently
• Cost-effective deployment of skilled resource/functions during periods of
intense activity
16
Ricardo plc
Based on the Ricardo generic rapid prototyping controller “rCube2” our
Vehicle Supervisory Controller combines the advantages and flexibility
of a rapid prototyping controller with a design intended for low volume
production. Ricardo provides the base software, all necessary device drivers
and configuration utilities.
• Robust mechanical enclosure designed for in-vehicle use
• Comprehensive automotive tool chain support for algorithm
development, calibration and testing
• Large number of input circuits designed for interfacing to sensors and
switches found in electric/hybrid vehicle systems
• Large number of output drivers designed for controlling loads found in
electric/hybrid vehicle systems
• Multiple CAN, Lin and Flexray bus interfaces
• Designed specifically for use in safety critical systems
• Development environment for incorporating control algorithms
developed in Simulink
MOTORSPORT
KERS/Battery Hybrid
Kinergy™
Battery systems for F1 – BMS, pack design,
development, validation and production
Kinetic energy storage and
management by flywheel
Situation and Objective
The introduction of KERS to F1 in 2009 presented challenges to teams as
they had to assess, develop and deploy completely new technologies in
race-ready form in a very short time
Recent developments in flywheels,
based on ideas patented by
Ricardo, have resulted in a
significant increase in specific
energy as well as greater reliability.
Ricardo Role
Ricardo were first able to apply our breadth and depth of engineering
knowledge to assess many potential technologies (including hydraulics,
pneumatics, and flywheel systems) before identifying Li-Ion battery electric
as the most promising to meet the KERS targets.
Ricardo were then able to apply our in-depth knowledge of battery
chemistry, battery management, power electronics and electric machine
design to develop systems and deliver race-winning solutions to the track.
Results and Benefits
Ricardo were able to accelerate our clients’ programmes by bringing
experienced personnel from different industry sectors and provide
knowledge in disciplines new to motorsport. By understanding the
fundamentals of these technologies, we were able to push the boundaries
of performance beyond even the expectations of the component suppliers,
and to deliver engineering services and components leading to race
winning performances
Ricardo role
Ricardo have identified advanced kinetic hybrids as very effective
energy storage systems for a number of applications involving
frequent speed changes such as motorsport originally initiated by new
opportunities in Formula 1.
The technology behind conventional electrical hybrids is well
understood, but the systems remain costly and have low overall
efficiencies due to the conversion of kinetic energy to electrical energy
and then to chemical energy for storage.
Ricardo has developed expertise in all components of mechanical
hybrid systems and has a suite of patents to protect IP
To eliminate the need for vacuum seals a non-penetrative magnetic
coupling system is used to transfer kinetic energy through the housing
High efficiency bearing solutions are being developed for the flywheel
A variety of CVT solutions can be used to connect the flywheel to the
driveline.
Description
Touring car power boost
F1 KERS (current)
Future system
Power
30kW
60kW
120kW
Energy
300kJ
400kJ
1MJ
Weight
30kg*
38kg*
52kg*
*Weights are predicated on the safety stance of race series
17
MOTORSPORT
Ricardo’s Corporate Strategy
Ricardo is a global world-class, multi-industry consultancy for engineering,
technology, project innovation and strategy. With a century of delivering value,
we employee over 1600 professional consultants, engineers and staff world-wide
MARKET SECTOR
Marine
GLOBAL ENGINEERING
DELIVERY CAPABILITY
Clean Energy & Power Generation
Project Management
Research & Development
Defence
Passenger Car
GEOGRAPHY
Italy
France
Russia
Korea
Japan
India
China
Government
Malaysia
Vehicle Systems
Hybrid & Electric Systems
High Performance Vehicles & Motorsport
Czech Republic
Driveline & Transmission Systems
Motorcycles & Personal Transportation
Germany
Engines
Commercial Vehicles
United States
Computer Aided Engineering
Test & Development
Facilities
Agricultural & Industrial Vehicles
United Kingdom
Powertrain
Vehicle
Electrical & Electronics
Rail
Intelligent Transportation Systems
Performance Products
Software
Strategic Consulting
PRODUCT
Our people are committed to providing outstanding value through quality
engineering solutions focused on high efficiency, low emission, classleading product innovation and robust strategic implementation.
Our client list includes the world’s major transportation Original Equipment
Manufacturers (OEMs), supply chain organisations, energy companies,
financial institutions & governments.
18
Ricardo plc
Guided by our corporate values of respect, integrity, creativity & innovation
and passion we enable our customers to achieve sustainable growth and
commercial success.
MOTORSPORT
Ricardo’s Global Locations
Local project delivery through Technical Centres in Europe, North America and Asia
Ricardo US
Ricardo UK
Chicago Technical Centre
Detroit Technical Centre
Shoreham Technical Centre
Midlands Technical Centre
Cambridge Technical Centre
Ricardo Prague
Czech Republic
Ricardo
Deutschland
Ricardo
Korea
Schwäbisch Gmünd (HQ)
Seoul
Ricardo
India
Delhi
With offices and technical centres around the world we can support projects
locally and work closely with our clients wherever they are in the world.
Ricardo
China
Ricardo
Japan
Yokohama
Shanghai
Global test facilities
78 Engine test facilities
Steady state, semi anechoic and high dynamic test beds. Road Load
Simulation (RLS), Constant Volume Sampler (CVS) and heavy duty transient
capability.
Performance and Emissions beds. Steady state and dynamic. Configurable
to utilise advanced techniques such as auto-mapping and Vehicle
Calibration on Testbed (VCOT).
Durability beds configurable to undertake most current test sequences
including those with thermal, shock and motoring stages. Operation on a
24/7 schedule as appropriate.
Prototype manufacturing and assembly
Fully equipped manufacturing and inspection workshops capable of
low-volume production capability.
Battery System Development Centre
Ricardo has two battery development centres, one based in Detroit to
service the American market and one in England for the rest of the world
focusing on the safe development of Li-Ion and NiMH battery packs.
Driveline
2 and 4WD fully dynamic rigs, semi-anechoic chamber, gearshift durability,
functionality and lubrication development rigs.
Mechanical development
7 Vehicle test facilities
Emissions chassis dynamometers up to 150kW climatic capability (-25
to +40°C). Dedicated gasoline dilution tunnels, motorcycle emissions,
durability and semi anechoic vehicle chamber for emissions testing,
calibration development, NVH development and durability testing.
Chemistry
Full chemical capability. On- and off-line techniques (GC, MS, FTIR, TGA).
Specialists in particle sizing (facilities incl. SMPS, MOUDI & Aerosizer).
Intelligent Transport Systems
Hardware in the loop (HiL) is used to replace or supplement the validation
of ECUs & systems on vehicles or test beds.
Comprehensive mechanical development capability on components or
sub-systems. Component motoring (incl. engine simulator), tilt rigs (loaded
and unloaded), torsional vibration, bending and fatigue, coolant and
lubrication flow, hot gas rig, block testing, FIE
19
Contact
Steve Sapsford - Engines and general enquiries
Ricardo Motorsport
Global Market Sector Director - High
Performance Vehicles and Motorsport
E-mail: [email protected]
Ricardo Midlands Technical Centre
Southam Road, Radford Semele
Leamington Spa, CV31 1FQ, UK
Tel: +44 (0) 1273 794301
Tel: 01926 319319
Iain Wight - Transmissions
Motorsport Business Devt Director
Product Group Head - HES
Ricardo UK
Shoreham Technical Centre
Shoreham-by-Sea
West Sussex
BN43 5FG
UK
Tel: +44 (0)1273 455611
Tel: +44 (0) 1273 794194
Tel: +44 (0) 1926 477152
Dave Greenwood – Hybrid & Electric Systems
Sector Focus
Ricardo delivers increased value and sustainable
solutions to a number of market sectors:
Passenger Cars
Commercial Vehicles
Agricultural & Industrial Vehicles
Motorcycles & Personal Transportation
High Performance Vehicles & Motorsport
Clean Energy & Power Generation
Marine
Rail
Defence
Government
The information provided in this brochure contains merely general descriptions or
characteristics of performance which in case of actual use do not always apply as described
or which may change as a result of further development of the products. An obligation to
provide the respective characteristics shall only exist if expressly agreed in the terms of
contract. Availability and technical specifications are subject to change without notice.

motorsport

Transcription

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