FormulaE-McLaren.pdf

Formula E Powertrain

All details should be treated as preliminary. This document is proprietary and confidential

McLaren systems supply/integrate all Electronics on the Formula E racing car.

Data System, Motor Controller, eMotor, Gearbox, integration with XAP Steering Wheel/Display, Data Logging, integration with WAE BMS, data transfer to and from FIA Logger and ADR

Powertrain starts at receiving DC High Voltage at the Motor Controller, and ends at the Driveshafts

Developed from Formula 1 Systems and adapted for the challenges of Formula E


TAG-400i controlling Motor, Gearbox and Data Acquisition.


Standard ECU for Indycar and McLaren GT MP4-12C

Connected to McLaren Chassis harness

Controls all car systems

Gearbox

Pit Limiter

Rainlight/Ready To Move light

Water Pump

Includes many F1 style safety systems

Throttle/Brake Overlap

Gearchange inhibit

Redundant throttle inputs


MCU-510 controlling the eMotor.


Motor Control Unit derived from McLaren P1 Hybrid road car

Includes many of the Automotive Safety Systems required for road use

Water Cooled unit. DC Voltage in, 3 Phase output. CAN Controlled from ECU.

Built-in DC/DC Converter to charge 12V Auxiliary battery

Rated to IP66


eMotor (derivative of McLaren P1 hybrid motor).


Based on the eMotor from McLaren P1 Hypercar

Water Cooled radial motor

130Nm maximum torque

17,500 maximum rpm

200kW maximum battery power

~91% efficient (battery to motor shaft)

Rated to IP67

Features HVIL to protect users from live areas


5 Speed Sequential Gearbox. Hewland supplied, based on F3.


5 Speed Sequential Gearbox

Geared for 225kph

Splash Lubricated

Pneumatic Gear change system

2:1 input shaft reduction ratio

Powerflow Differential


Data Acquisition Sensors 4 Wheelspeeds (passed via FIA Logger for TC prevention)

4 Damper Position Sensors (Linear Potentiometers)

4 Infrared Brake Disc Temp sensors

Front and Rear Brake pressure

Steering Angle

Cooling Water Temperature and Pressure

Gearbox Oil temperature

Gearbox Pneumatic Air Pressure

Accelerometer and Gyro data taken from ADR (TBC)

Microwave Lap Trigger

3 Channel Throttle Sensor (2 for ECU Control, 1 for FIA Monitoring)

Layshaft and Mainshaft Speeds

All available MCU, Motor and BMS parameters


Wiring Harnesses Chassis Loom

C7

Dash Split

AS6-12-35SAC9

Column

AS1-10-35SN

C22

Speed FR

ASL1-06-05SN-HE

C21

Speed FL

ASL1-06-05SN-HE

C25

Throttle

AS1-10-35SN

C28

Brake P F

ASL1-06-05SN-HE

C29

Brake P R

ASL1-06-05SB-HE

C30

Steering

ASL1-06-05SC-HE

C31

Damper FL

ASL1-06-05SE-HE

C32

Damper FR

ASL1-06-05SE-HE

C51

Brake T FL

ASL1-06-05SB-HE

C52

Brake T FR

ASL1-06-05SB-HE

C10

Lap Trigger

FGS0F303YLM

C55

Safety Lights

ASU6-03-05SA

C56

Neutral Switch

ASU6-03-03SA

C101

Spares

AS1-16-35SN

C12

IP Dongle

ASL1-06-05SD-HE

C11

Radio

ASL1-06-05SN-HE

C13

Fire Unit

ASL6-06-05PN-HE

C8

ADR

AS6-10-35SN

C16

Master Power

AS6-14-97PA

C17

Fused Power

AS6-12-35PB

C5

FIA Logger

AS6-16-35SA

C126

RESS Water Power

4 socket DTP

C38

Water Pressure

ASL1-06-05SB-HE

C47

Energised LED

ASU6-03-03SN

C48

ESS LH

13440AD2G25X1156C49

ESS RH

13440AD2G25X1156

Bottom Left

Top Right

C14

MCU Split

AS1-10-35SN

C45

Battery LV1

AS6-12-35SN

C46

FIA Sensor LV2

AS6-12-35SB

C1

ECU Engine

AS6-16-35SN

C2

ECU Chassis

AS6-18-35SN

C3

ECU Auxillary

AS6-16-35SA

Bottom

Right

C6

Rear Split

AS1-14-35SN

310

310

250

310

540

540

660

2000

LV1 and LV2 Main

Keyway direction (red

arrow) in direction of boot

Refer to photo for keyway position

240

180

400

400

510

510

400

400

280

510

1430

100

200

150

530

220

690900

900

530

630 630

400 450 550

1100

620

620

620

860

250

ADR boot to be in

direction of master

keyway (as per red

arrow)

Right angle boots for

both Water pump

connectors. Exiting in

direction of release tab.

Right angle boot for

Water pump connector.

Exiting opposite

direction of release tab.

C26

Water Pump Power

4 socket DTP

C27

Water Pump CAN

6 socket DTM

C128

RESS Water In

2 Pin Jetronic

1928402078

C129

RESS Water Out

2 Pin Jetronic

1928402078

1000

1000

1200

C130

Transponder

ASL1-06-05SD-HE

400

C4

FIA Logger

AS6-16-35SN


Wiring Harnesses Gearbox Loom

C24

Speed RR

ASL1-06-05SN-HE

C23

Speed RL

ASL1-06-05SN-HE

C33

Damper RL

ASL1-06-05SE-HE

C34

Damper RR

ASL1-06-05SE-HE

C53

Brake T RL

ASL1-06-05SB-HE

C54

Brake T RR

ASL1-06-05SB-HE

C6

Rear Split

AS6-14-35PN

C25

Speed Layshaft

ASL1-06-05SA-HE

C26

Speed Mainshaft

ASL1-06-05SB-HE

C11

Gbox Oil Temp

ASL1-06-05SD-HE

C15

Gbox Barrel pos

ASL1-06-05SC-HE

C16

Gbox Air Pressure

ASL1-06-05SN-HE

C27

Shift Up

ASU1-03-03SN

C28

Shift Down

ASU1-03-03SA

C29

Pressure Release

ASU1-03-03SB

C30

Rainlight

AMP 963040-3

330

330

330

330

400

330

330

330

220

220

220

220

620

310

310

340


Wiring Harnesses MCU Loom

C4

MCU-510

726-6963 Ampseal

C35

Resolver

8 Pin DTM

C97

Motor HVIL

ASL6-06-05SE-HE

C98

MCU HVIL

ASL6-06-05SE-HE

C99

DC HVIL

ASL6-06-05SE-HE

C14

MCU Split

AS6-10-35PN

790 (from C4)

380

990 (from C4)

250

980

C36

Water T to Motor

ASL1-06-05SD-HE

Resolver and motor HVIL should both run

inside an additional heatshrink sleeve as

they run to the same location.

Sleeve should stop 50mm before

Resolver (and 250mm before Motor

HVIL)

300


Wiring Harnesses Dashboard Loom


How it goes together.


Control Systems

Throttle Driver throttle Demand via a shaping map (user defined) goes into a look up

table (6 selectable preconfigured maps) which translate to a torque application.

Preconfigured maps will provide different power curves to suit different periods of the race.


Control Systems

Brake Regen Braking Demand via a shaping map (user defined) is translated to an Engine

Braking demand to provide retardation and energy harvesting during the braking zones.

Preconfigured maps will provide different regen curves to suit different driver requirements and match the need for different amounts of energy saving throughout the race.


Control Systems

Regen Paddle An analogue paddle exists that will provide an input (similar to a hand

throttle) to allow the driver to apply variable amounts of engine braking, irrespective of mechanical Brake Pressure.

This will allow drivers a more flexible approach to Coast and Lift when saving energy.

All torque demands are summed.


Safety and Switches


Communications


Dyno running

Completed 4,200 kms (equivalent to ~3 seasons)

Completed 4,000 gearshifts


Track running

Testing with Low Power battery has validated majority of on car systems.

Next step 200kW!


Future Developments

System is modular which will allow any component to be upgraded

or updated as new technologies become available without obsoleting the rest of the system.

Chassis Harness has specifically broken out a number of spare signals (CAN, Serial, USB, Ethernet, Analogues, Digitals) to provide for future expansion and to minimise costs of additional requirements (Power Indicators, additional sensors, driver biometrics, TPMS).

Questions?


Documents

FormulaE-McLaren.pdf