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Audi R18 e-tron Quattro Overview

1) Audi captured the top three spots at the 2012 24 Hours of Le Mans race thanks in part to its diesel-hybrid R18 e-tron Quattro cars, marking the first time a hybrid has won the prestigious race. 2) While Toyota provided stiff competition early on with its gasoline-hybrid cars, mechanical failures eliminated their cars from contention. 3) Audi's victory was historic as the first brand to win with a hybrid vehicle, continuing their dominance with 10 wins in the last 12 years at Le Mans.
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100% found this document useful (2 votes)
162 views18 pages

Audi R18 e-tron Quattro Overview

1) Audi captured the top three spots at the 2012 24 Hours of Le Mans race thanks in part to its diesel-hybrid R18 e-tron Quattro cars, marking the first time a hybrid has won the prestigious race. 2) While Toyota provided stiff competition early on with its gasoline-hybrid cars, mechanical failures eliminated their cars from contention. 3) Audi's victory was historic as the first brand to win with a hybrid vehicle, continuing their dominance with 10 wins in the last 12 years at Le Mans.
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
  • Introduction to Audi R18 e-tron Quattro
  • Development and Features of R18
  • Design and Technology Advancements
  • Engine and Powertrain Details
  • Racing Specifications and Performance
  • Hybrid System and Components
  • Race Circuits and Event Highlights
  • Toyota's Hybrid Racing Innovations

Audi R18 e-tron Quattro

Flywheel KERS Hybrid System (2012)


[Link]

From 16th to 17th June 2012, the 24 hours of Le Mans has taken place at the Circuit
de la Sarthe for the 80th time, and again Audi didnt mind pushing the envelope a
little further than most people would and has proven that with the release of a new
Le Mans race car. Audi has captured all three spots on the podium thanks in part to
its diesel-hybrid R18 e-tron Quattro race cars. This marks the first time in the race's
illustrious history that a hybrid has come out on top of the pack.
That doesn't mean that Audi was in a class of its own. During the first part of the
race the they faced stiff competition from Toyota's gasoline-hybrid TS030 Hybrid
powered by a non-turbo or compressed version of its 3.4 L V8 helped with a
supercapacitor energy storage system developed by Nisshinbo. One of them even
took the lead of the race at about 8pm on Saturday night but a series of crashes and
mechanical failures ended up sending the Toyotas to the paddock for good. On the
end, the first two spots went to the R18 e-tron while third and fifth went to the R18
Ultra, a non-hybrid variant of the car. The winning Audi lapped the Le Mans track 378
times.
"This is no doubt a historic victory for Audi," said Dr. Wolfgang Ullrich, the head of
Audi Motorsports. "We were the first to win Le Mans with a direct-injection turbo
gasoline engine and the first to be successful with a diesel engine. Its a great result
that Audi is now the first brand to have achieved victory with a hybrid vehicle."
As far as racing, Audi won 10 out of the last 12 races at Le Mans, conceding the
2003 victory to Bentley that anyhow stayed in then family. This is a particularly
amazing record considering the 24 hour race of Le Mans is grueling and extremely
unforgiving. How many cars have we seen lead at twilight only to witness their
demise from the slightest problem.
And how all this started?
A significant reduction of the displacement limits put additional emphasis
onaerodynamic efficiency ahead of the 2011 season and prompted Audi to develop
the first closed cockpit sports racer for over a decade. Named the R18 TDI, the

technicians focused from the very beginning of the R18 project on a compact 3.7
liter V6 TDI with innovative architecture. R18 TDI was still equipped with twin turbos,
but with future in mind. The engineers left room in the design for future
developments, including the adoption of a hybrid KERS drive system.

On the rear wing we can see this


serrated gurney flap, with a V
shapes cut into the edge. Cuts only
appear on the outer edge of the
gurney have some role in dealing
with the dirty air from the front
and rear wheels.

For 2012, Audi introduced an evolution of the R18 TDI, last year Le Mans winner,
called the R18 Ultra. In addition to the changes required by the regulations (reduced
air intake restrictor and 60 litre fuel tank) the car was completely reworked to reduce
weight. These changes included a completely new, fully carbon fiber gearbox housing
(which is a first in endurance racing) and changes to the one piece
improvedmonocoque (about 10cm longer then on R 18 TDI) making the ultra the
lightest Le Mans prototype that Audi Sport has ever built. As for the closed cockpit,
its there to give Audi a better chance and after R10, R15, and R18 TDI, the R18
Ultra has moved to a closed cockpit design again. A closed car has clear
aerodynamical advantages. Its not the first closed-cockpit Audi endurance racer
though: in 1999 the companys first entry into the Le Mans 24hrs included two R8C
Coupes.

The R18 ultra is the basis that has


made it possible to make the R18
e-tron quattro reality in the first
place.
Click on picture to get wallpaper
1280x853

One of the main reasons additional weight had to be shed was for the additional
weight required for the hybrid system. Two versions of the evolution car were
prepared; the 'conventional' R18 Ultra and the R18 e-tron Quattro equipped with
KERS with two additional electric motors and a flywheel to store and distribute the
generated energy. The base of both cars (undertray, monocoque, cockpit, body
panels, and engine) is completely identical, which is why the additional logistical
effort could be reduced for Audi Sport and Audi Sport Team Joest. The compact
engine requires very little installation space, is light and plays its role in
compensating for the hybrid systems additional weight. In spite of the latest
restrictions imposed by the Automobile Club de lOuest (ACO) and FIA, Audi Sport
still extracts over 375kW (510 hp) and a maximum torque exceeding 850 Nm from
the power unit thanks to the efficiency of the overall concept.
Work on the Audi R18 E-tron Quattro only started on February 2010 so Audi is being
cautious. This is a relatively short cycle for a technology that has never been tested
in motorsport and which still doesnt even exist in production. So just to cover itself,
Audi entered the 2012 Le Mans 24hrs field with two R18 E-tron Quattros, but also
two 2012-spec (and non-hybrid) Audi R18 Ultras.

Audi's Head of Motorsport Dr.


Wolfgang Ullrich: "We would have
had no chance if we hadnt
achieved the weight saving
between our 2011 Le Mans winner,
the R18 TDI, and the current R18
ultra because we had to
additionally package the entire
hybrid system in the vehicle." Click
on picture to get wallpaper
1280x853

Despite the focus on light weight,


safety is still a primary concern.
The carbon monocoque is intended
to to protect the driver even in
high-speed accidents. Thats the
real one. Click on picture to get
biger 1023x682 size

At first glance the R18 ultra or e-tron does not look


much different to last years Le Mans winning R18 TDI.
However, under the guidance of Head of Technology Dr.
Martin Mhlmeier the Audi Sport engineers have done a
great job and left hardly a single area of the car
untouched. The result is a largely new LMP1 prototype
including a modified carbon-fibermonocoque, which
continues to excel through its one piece construction.
Despite the rigid structure of the monocoque, however,
the drivers must pay close attention when entering and
exiting the car. A small area marked by four red
triangles is the only portion strong enough to bear the
drivers' weight.

The extremely advanced aerodynamic configuration from 2011 was initially adapted
to suit the new regulations, but later heavily modified. Production of new car
demanded a further significant reduction in aerodynamic drag despite the increased
cooling requirements for the hybrid components. Vision out of the closed cockpit was
also improved. The engineers also improved the area illuminated by the full LED
headlights in shape of number 1. Fundamentally, the hybrid drive, in combination
with the four-wheel drive resulted in an extension of the front section of the
monocoque. However, it also has positive effects on the overall balance of the
conventionally powered twin brother. Because it is the lightest Le Mans Prototype
that Audi Sport has ever built, engineers can position the additional ballast weight
exactly where it is required for the races even if both
cars have exactly the same overall weight, 900 kilograms
stipulated by the LMP1 regulations.
Both versions of the car sport a gearbox that features a
complete carbon-fiber casing and has been the source of
much of the weight saving. This kind of casing is a first in
a Le Mans Prototype racing. The system is seen
in Formula 1 cars, but in the R18 Le Mans prototype, the
load borne by the structural transmission is much higher
and has to last through 24-hour races that cover
thousands of kilometers. Even the torque generated by
the R18 e-tron Quattro exceeds the torque of an F1
engine, about 850 Nm, putting that much more stress on
the lightweight design. This is mated to the wide-angle
V6 with the single turbo-charger wedged between the
cylinder banks.
Like the R10 and R15, the R18 is a diesel powered. But while the R10 had a 5.5-litre
V12, and the R15 had a 5.5-litre V10, the engine in the new R18 is a 3.7-litre V6.
The engine has been downsized to a V6 because of new regulations which aim to
reduce CO2 emissions and overall fuel consumption by reducing the power and
performance of these endurance racers.

Rear wheels get their power from


the cars 510-horsepower wideangle V6 TDI engine with the
single variable geometry turbocharger between the cylinder
banks to ensure it is effective
throughout the rev-band. Click on
picture to get 1600x1067
wallpaper.

Audi relies on a highly efficient engine concept in the R18. In an effort to increase
the parity between the diesel and petrol powered machines, further restrictions were
imposed on the diesel engines, lowering the V6's output to a claimed 510 bhp. The
fact that the V6 3.7 TDI was voted Race Engine of the Year 2011 by a high-caliber
judging panel at the beginning of the year is a nice reward for the forward-thinking
work of the entire team of engineers.
The interaction between the merely 3.7-liter V6 TDI unit with an unusually designed
single turbocharger and VTG (Variable Turbine Geometry) technology is both complex
and intriguing. TDI race engines provide a particularly striking example of the
progress that has been achieved. In 2006, Audi won with a V12 engine which had
5.5 liters of displacement. Now, only six cylinders and 3.7 liters. This means that in
total the engine used in the current car generation makes with half of the cylinders,
has 32 percent less cubic capacity and in the 2012 season made it possible for the
R18 to improve its lap time by 2.8 percent nonetheless. To achieve such increases
the combustion chamber of the engine operates with much higher pressures and

temperatures today than in the past. This has resulted in considerably higher
performance of the piston areas and the cylinders. Now, each cylinder has to deliver
around 60 percent more performance than it did in the Audi R10 TDI in 2006. Also,
injection pressures which in current production engines rise to around 2,000 bar, in
the Le Mans TDI engines are 2,600 bar are already being surpassed by far. This has
a positive influence on fuel
consumption, performance and
exhaust gas quality, yet
increases the thermal and
mechanical loads particularly in
the combustion chamber.

The
new
engi
ne
has a
singl
e
Garr
ett
TR30
R
VGT
turb
ocha
rger.
The
R18'
s V6
engi

ne exhausts inwards between the


cylinder banks, where the
turbocharger is placed. This is
called a 'hot side inside'
configuration and is opposed to
the traditional configuration with
each cylinder bank of a V engine
exhausting outwards to their
respective turbochargers. Blue
arrows are fresh air, and red
arrow are exhaust path. Click on
picture to get 1600x1067
wallpaper.

The charging concept of the Audi R18 has been a particularly well-kept secret up to
now and is of radically new design. The engineers designed a central mono turbo
system in the inside V of the engine which in combination with the inboard exhaust
manifolds makes it particularly efficient. A single large turbine Garrett TR30R VGT
(as opposed to the twin configuration of the previous Audi R18 TDI) increases overall
efficiency, as gap losses are significantly reduced. Consolidating the entire exhaust
flow in a single turbine leads to higher turbine performance and more uniform
loading by exhaust gas surges. Clearly, less thermal energy is lost in the extremely
short pipes of the exhaust system in front of the turbo. This increases performance
plus the turbines exhaust gas temperature due to the higher energy content of the
exhaust gas and makes the required capacity available on the compressor side where
around 2,000 cubic meters of air per hour must be compressed for efficient
combustion. The mono turbocharger thus has to put through a similar amount of
charge air for over 375 kW (510 hp) as the two previous turbochargers in the V10
TDI for 404 kW (550 hp).
The exhaust manifolds located on the inside, between the banks of the engine, let
the exhaust gas flow radially into the charger from both sides. The housing of the
turbine wheel has two inlets for the exhaust gas flow and one axial outlet. The
compressor side is of a very similar design. The charger aspirates air in axial
direction from a central influx. After compression, the air exits again on two sides to
optimally supply both cylinder banks. It is cooled down in two intercoolers before
being routed to the combustion chambers of the V6 engine.
The variable turbine geometry of the turbocharger has provided another key to this
technological breakthrough. It makes it possible to guide the exhaust gas flow in a
way that the turbine can continuously be adjusted to varying operating conditions
such as load changes. Without that the entire concept of a compact downsized
engine with an inboard single turbocharger would have been inposible. Without VTG
the response of a single, large charger would be far too low.
Turbocharger work at extreme temperatures of up to 1,050 degrees Celsius in the
turbine and in the VTG can only be handled by high-temperature-resistant steel
alloys. A technology that is heat-resistant and withstands large expansion must,
conversely, not exhibit any increase in clearances when temperatures are low and all
parts has to remain mobile at all times. These are exactly the technologies which
Audi has developed together with its long-standing turbo partner Honeywell Garrett.

The two hybrid cars was driven by last years Le Mans winning trio of Marcel Fssler,
Andr Lotterer, and Benot Trluyer, with Dindo Capello, Tom Kristensen, and Allan
McNish in the other car. The R18 Ultra was driven by Loc Duval joined by Timo
Bernhard and Romain Dumas,
with the other R18 Ultra driven
by Marco Bonanomi, Oliver
Jarvis and Mike Rockenfeller.

LMP1 Audi R18 e-tron


Quattro
Technical Specifications for the Audi
R18 e-tron Quattro (and Ultra)
Introduced: February 2012
Model: Audi R18 e-tron Quattro / Ultra
Vehicle type: Le Mans Prototype (LMP1)
Monocoque: Carbon-fiber composite with aluminum honeycomb monocoque (build by Dallara) with fully
stressed engine, tested according to the strict FIA crash and safety standards.
Engine
Turbocharged 120 V6, Mid, longitudinally mounted, 4 valves per cylinder, DOHC, Single Garrett
turbocharger, mandatory intake air restrictor of 1 x 45.8 mm diameter and turbo boost pressure limited
to 2.8 bar absolute, diesel direct fuel injection, Fully stressed aluminum cylinder block and head, diesel
particle filter
Fuel: Diesel
Engine management: Bosch MS24
Engine lubrication: Dry sump, Castrol
Displacement: 3,700 cc
Power: > 375 kW / 510 hp
Torque: > 850 Nm
BHP/Liter: >138 bhp / liter
Hybrid system
Type of accumulator: Electric flywheel accumulator, max 500 KJ, WHP (Williams Hybrid Power)
Motor Generator Unit (MGU): Bosh MGU on the front axle, water cooled with integrated power
electronics, 2 x 101 bhp/75 kW
Drive: e-tron quattro All wheel drive
Drive/Transmission
Type of drive: Rear wheel drive, traction control (ASR), four-wheel drive e-tron Quattro from 120kmh
Clutch: Carbon clutch
Gearbox: Xtrac, Sequential, electrically activated 6-speed racing gearbox
Differential: Limited-slip rear differential
Gearbox housing: Carbon-fiber composite with titanium inserts
Driveshafts: Constant velocity sliding tripod universal joints
Steering/Suspension/Brakes
Steering: Electrical assisted rack and pinion steering
Front suspension: double wishbones, push-rod actuated torsion bar springs and fully adjustable dampers
Rear suspension: double wishbones, pull-rod actuated torsion bar springs and fully adjustable dampers
Brakes: Brembo, hydraulic dual circuit brake system, monobloc light alloy brake calipers, ventilated
carbon ceramic disc brakes front and rear, infinitely manually adjustable front and rear brake balance.
Wheels: O.Z. magnesium forged wheels
Tires Michelin Radial, Front: 360/710-18, Rear: 370/710-18
Weight/Dimensions
Length: 4.64m
Width: 1.99m
Height: 1m
Minimum weight: 900 kg
Fuel tank capacity: 58 liter (e-tron)/60 liter

Sports prototype is where you will see the latest technologies thoroughly tested,
which eventually trickle down to our every day cars. The Germans have done a great
job fine tuning diesel over the past decade and the Audi R18 e-tron Quattro pushes
the envelope further. It will go against other forms of electric motor hybrids with a
flywheel.
The 24 Hours of Le Mans have seen its average speed go from 125 mph to now well
north of 210. Audis V12, 5.5 liter 700 hp R10 TDI clocked in at 204 mph in the 2006
race. A year later it reached 211 mph.

Both the Ultra and e-tron Quattro


made their racing dbuts at the
2012 6 Hours of SpaFrancorchamps in Belgium as part
of a four-car Audi entry in the FIA
World Endurance
Championship, and after that it hit
the 12-hour race at the US
Sebring circuit.

Both the Ultra and e-tron Quattro made their racing dbuts at the 2012 6 Hours of
Spa-Francorchamps as part of a four-car Audi entry in the FIA World Endurance
Championship. The #3 car of Romain Dumas, Loc Duval and Marc Gene gave the
Ultra victory over the e-tron Quattro. Audi finished 1-2-3-4 in the race. Audi has
entered a four car line-up for Le Mans but they intend to run one of each model for
the remaining five races in the season. The e-tron Quattro finished first and second
at the 24 Hours of Le Mans with the Ultra finishing in third and fifth. The leading car
covered 5151.8 km, making 33 pit stops.

The energy is stored in an electric


flywheel that is mounted alongside
the driver. Supplied by Williams
Hybrid Power, the flywheel spins
in a vacuum at speeds of up to
45,000 rpm.

As in other areas Audi Sport also cooperates with external manufacturers during the
manufacture of components for the hybrid system. Instead of a heavy battery pack,
R18 e-tron Quattro utilize a Williams Hybrid Power designed magnetic loaded
composite flywheel accumulator system for energy storage which delivers 500 kJ to
the front wheels via an electric motor, giving the car four (quattro) wheel drive. This
system was originally designed for F1 by Williams Hybrid Power (similar design
Porsche used with much success on their GT3 R hybrid between 2010 and 2011)
and, as per the regulations, is only available at speeds above 120 km/h. The car is
fitted with a smaller 58 litre fuel tank. WHP designed an entirely new, ultralightweight electric flywheel and associated power electronics for the Audi R18 e-tron
Quattro, working closely with Audi engineers to fully integrate the system into the
car. The key features and benefits of the WHP system are highly suited to endurance
racing and this made the WHP flywheel the prime candidate for Audis project when
compared to other technologies such as batteries, ultra-capacitors or mechanical
flywheels. Design of the Motor Generator Unit (MGU) integrates two electric motors,
two planetary transmissions and two converters, essentially the meat of the hybrid
drive system, into a single compact package, and is designed by long-standing
technology partner Bosch.

The rear wheels are driven by a 3.7-liter V6 TDI turbodiesel and do not get power
from the hybrid system. The hybrid system provides 500 kilojoules of power in the
front wheels when the flaywheel spin at full speed of 45,000 rpm (fully charged). The
advantage of a flywheel system compared to other hybrid designs is that it is a high
power density with low mass, high efficiency energy transfer system, and a long life
cycle and wide temperature range. Compared to conventional batteries, a flywheel
can be charged and de-charged quickly and also does not suffer from degradation.

The system integrated into the front axle is comprised of two driveshafts (one for
each wheel of cours), the two Motor Generator Unit including planetary gears, an

insulation monitoring unit for high voltage safety and the control system. The
flywheel itself is housed in the passenger seat area of the cockpit which has been
redesigned to improve visibility, with the side windows enlarged and the head
restraints reworked. It was a question of perfectly balancing weight, performance,
hybrid concept, regulation constraints and the packaging. The distribution of all the
components in such a way that no appreciable disadvantages arise in the
conventional vehicle since both cars are absolutely identical, with the exception of
the hybrid system, in design and construction.

Both cars are so identical that the


front wheel driveshaft of the R18
hybrid means that a hole is
required in the front of the
chassis. This hole is present on
both the hybrid and the
combustion car though on the
latter a blanking plate is used.

Audi have stated that if needed one type of car could be converted in the other
version without much effort. Both cars are so identical that the front wheel driveshaft
of the R18 hybrid means that a hole is required in the front of the chassis. This hole
is present on both the hybrid and the combustion car though on the latter a blanking
plate is used. On combustion car, ballast is placed in the void left by the absent
electric motor. There are some minor differences between the two cars including
around the nose duct, where is a small interchangeable panel on the outside edge of
the duct, which is probably related to cooling of the brakes, and in the case of the
hybrid possibly the e-motor, although that is liquid cooled via a radiator in the left
sidepod. On the hybrid car the shape of the duct is different and the aperture
slightly larger. The modifications made to the front crash-structure in order to
accommodate MGUs are also incorporated in the Ultra.

Suspension is more conventional with double wishbones all around. Push-rods are
used at the front while the new rear-end features pullrod actuated springs and dampers. Another novelty is a rear-view camera that is
connected to a small screen in the cockpit and improves the drivers' rearward
visibility.

First two Hybrid LMP1 race cars,


diesel Audi R18 e-tron quattro and
Toyota's gasoline-hybrid TS 030.

The hybrid systems of Audi and Toyota recover the energy generated under braking.
Previously this was lost; it is now stored and transmitted under acceleration. In order
to limit the size of these systems and the budgets required for their development,
the ACO and the FIA have imposed a maximum quantity of energy that can be
transmitted between two braking phases: 500 kilojoules. Each hybrid car can take
advantage of additional electric power without exceeding the minimal aid down in the
technical regulations.

The process of energy recuperation is explained relatively easily, the technical


implementation is, in contrast, extremely challenging. The recuperation of energy
occurs only during braking. In the process, the wheels drive the MGU (the braking

zones permitted are defined by the regulations). The MGU, now as electric motor,
electrically spins a carbon-fiber flywheel that runs in a highvacuum to 45.000 RPM.
In this way kinetic energy is generated and stored in rotating flywheel. After the
corner is taken and driver pushes the gas pedal, and above a speed of 120km/h,
oposite happend. The flywheel delivers kinetic energy to MGU (now as generator
unit) and spins it to generate electric power for electric motor that drive the front
wheels, giving the car an acceleration boost. Following protests from a rivalling
teams, it was decided that front motors could only be used at speeds of over 120
km/h. This removes most of the all-wheel drive benefits provided by the driven front
wheels. For Toyota, on the other hand, in which the energy is fed to the rear drive
train there is no minimum speed.
The planetary gears adapt the transmission ratio of both driveshaft of the MGU
during acceleration and braking. The two independently powered front axles on the
e-tron Quattro are synchronized exclusively via electronic control strategies. This
control occurs automatically without driver intervention. The entire charging process
(recuperation, harvesting) is controlled by two parameters: the braking process and
the flywheel accumulators state of charge (actualy speed of it, fully charged =
45.000 RPM). The energy emission process (boost) is defined by the minimum speed
of 120km/h stipulated by the regulations, the race strategy selected, the throttle
pedal movement and acceleration of the car. The e-tron has six automatic modes
that are driver selectable on the steering wheel. The modes manage engine
mapping, short bursts accelerating from corners, quattro four wheel drive, wet
weather, etc. Allan McNish said "I don't have to press a button ... It does it
automatically ... It is like traction control."

To cool the electric motors and the flywheel an additional cooling system is fitted in
left sidepod, which is responsible for a slight increase in weight and drag compared
to the conventional R18 Ultra.

In order to establish clearly-defined hybrid zones, those allowing energy to be


transmitted between two braking phases, the Automobile Club de lOuest and the FIA
have defined the zones where braking is sufficiently heavy to be taken into account,
for every circuit during racing season. There were five on the Spa-Francorchamps

circuit in the second round of the FIA World Endurance Championship on 5th May
2012 in which this system was used for the first time. On the 13,629-km Le Mans
circuit there were seven zones.
Zone no. 1: Dunlop chicane (no. 8 marshals post)
Zone no. 2: Forza Motorsport Chicane (no. 42 marshals post)
Zone no. 3: Michelin Chicane (no. 60 marshals post)
Zone no. 4: Mulsanne corner (no. 76 marshals post)
Zone no. 5: Indianapolis Corner (no. 96 marshals post)
Zone no. 6: Porsche Corner (no. 115b marshals post)
Zone no. 7: Ford Corner (no. 131 marshals post)

The entry to each zone is 50 meters before the corner in question. All entrants have
to respect these zones.

Audi presented the e-tron Spyder


in January 2011 at the Las Vegas
Consumer Electronics Show as $5
million concept car. Based on a
shortened, widened, heavily
modified R8 platform, the E-Tron
Spyder mounts a 3.0-liter, 296 bhp
turbo diesel behind the passenger
compartment and two electric
motors up front developing a total
of 88 bhp. The lithium ion
batteries are also located under
that front hood, stowing a total of
9.6kWh of electricity. The car can
run on either power source alone
or combine them for some
seriously impressive, and ecofriendly, acceleration. Though the
diesel fuel tank carries just 50
liters, the e-tron Spyder has an onpaper range of more than 1,000
kilometers per fill-up thanks to its
lithium-ion-fueled parallel help,
which translates to just 2.2l of
diesel/100 km. Limited top speed
of 250 km/h, reaching 100 km/h
from a standing start in just 4.4
seconds.

September 17, 2012

Toyota's first World Endurance win with


supercapacitor hybrid TS030 car

The battle of the hybrid racing cars in World Endurance Racing took an interesting
turn this weekend when Toyota's TS030 Hybrid won the fifth round of the FIA World
Endurance Championship in Sao Paulo, Brazil, Wurtz and Lapierre as a drivers. In
Interlagos Toyota took pole by a whopping 0.784 second margin and led
unchallenged for most of the first hour.
The TS030 Hybrid uses a petrol 3.4 litre V8 engine and, instead of battery, a
Nisshinbo 500 kJ supercapacitor energy recovery unit which only feeds energy to the
rear wheels via a Nippondenso drive unit. Toyota was not expected to seriously
challenge the Audi R18 e-tron quattro for some time.
Many people believed the rear-wheel-drive Toyota system would prove to be inferior
to the four-wheel-drive Audi design, but the speed of the TS030 has been very
impressive, particularly in its second race at Silverstone on August 24 where it
finished second to the Audi e-tron quattro but set the fastest lap of the event and
had a higher top speed than the Audi.
The "Toyota Hybrid System - Racing" development project finally proved itself, and
the race was a personal triumph for Hisatake Murata, who has headed the project
since its inception 6 years ago, and is now Hybrid Project Leader at Toyota Racing.
The project took its first win in July 2007 when a Toyota Supra became the first
hybrid car to win a race at the Tokachi 24 Hour event in Japan that year. An early
version of the TS030 supercapacitor hybrid system was used in the Supra.

Common questions

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Audi overcame several engineering challenges with the R18 e-tron Quattro's hybrid system. They had to integrate a flywheel KERS from Williams Hybrid Power, which required significant weight reduction elsewhere in the car. This was achieved through the introduction of a carbon-fiber monocoque and gearbox . Managing the hybrid system's additional weight required optimization of the car's aerodynamics and balance . Moreover, the integration of the VTG turbocharger within the 'hot side inside' system, allowed for improved engine efficiency and higher performance . These engineering feats not only supported hybrid system integration but also maintained compliance with racing regulations .

Audi's strategic deployment of both hybrid and non-hybrid vehicles during the 2012 Le Mans race was significant for testing and validation purposes. Fielding two R18 e-tron Quattros and two non-hybrid R18 Ultras allowed Audi to compare performance variations under race conditions. This dual strategy offered a safety net, ensuring competitive participation irrespective of the hybrid system's performance or reliability. It also facilitated data collection and optimization for future development of hybrid systems . This tactic enabled Audi to achieve a 1-2 finish with the hybrid vehicles, proving the e-tron Quattro's potential while maintaining competitiveness with the Ultras .

Audi's R18 e-tron Quattro addressed regulatory challenges by developing a car that complied with stringent limits on fuel capacity and air intake while incorporating a hybrid system. The Audi engineers adopted a smaller, more fuel-efficient 3.7-liter V6 engine with a single turbocharger to conform to CO2 emissions and performance regulations . This compact engine, combined with a flywheel energy recovery system that complied with kinetic energy recovery regulations, ensured compliance without sacrificing competitiveness . The strategic weight reduction tactics, including carbon-fiber components, allowed the inclusion of the hybrid system without exceeding weight restrictions, balancing regulatory requirements with the need for high performance .

Aerodynamic efficiency and weight reduction were critical in the development of the Audi R18 Ultra and e-tron Quattro. Regulations necessitated a smaller air intake and a 60-liter fuel tank, prompting Audi to focus on weight reduction, including using a carbon-fiber gearbox housing. This made the car the lightest Le Mans prototype Audi had built, allowing room for the hybrid system's weight . The closed cockpit design offered aerodynamic advantages, contributing to reduced drag and improved performance . These factors were essential for compensating for the added hybrid system weight while maintaining competitive performance standards .

The Audi R18 e-tron Quattro's diesel-hybrid configuration influenced future race car designs by demonstrating the viability and competitive advantage of hybrid technology in endurance racing. Its use of a flywheel-based KERS provided insights into alternative energy storage solutions beyond traditional batteries . The integration of a lightweight yet powerful TDI engine with advanced turbocharging and hybrid systems showcased the potential for reduced emissions and improved fuel efficiency without sacrificing performance. These innovations encouraged further exploration and adoption of hybrid systems in motorsport, pushing technological boundaries and setting new performance benchmarks .

The Audi R18 e-tron Quattro contributed to advancements in endurance racing by integrating a pioneering hybrid system with a flywheel KERS, marking a significant evolution in hybrid technology used at Le Mans. The system, developed in collaboration with Williams Hybrid Power and Bosch, utilized a magnetic loaded composite flywheel for energy storage, diverging from traditional battery packs. This enabled a more efficient and lightweight system, providing kinetic energy recovery and all-wheel drive capabilities. The car's design also featured a highly efficient 3.7-liter V6 TDI engine with an innovative turbocharging setup to balance power and fuel efficiency. These technological innovations set a new standard for endurance racing vehicles, demonstrating the potential of hybrid systems in motorsport .

The success of the Audi R18 e-tron Quattro at Le Mans significantly impacted the perception of hybrid technology in motorsport, demonstrating its viability and potential performance benefits. By achieving a historic victory, the e-tron Quattro dispelled doubts about the practicality and reliability of hybrid systems in the demanding context of endurance racing . This success highlighted the technological advancements achieved through innovative hybrid solutions, encouraging other manufacturers to explore and invest in similar technologies. It helped shift hybrid technology from a perceived experimental component to a competitive edge in motorsport, influencing future engineering directions in the field .

External collaborations played a crucial role in the development of Audi's hybrid system for the R18 e-tron Quattro. The team worked closely with Williams Hybrid Power to integrate a flywheel-based KERS, which offered a lightweight alternative to battery storage solutions . Bosch contributed by designing the Motor Generator Unit, which encompassed the core hybrid components into a compact package . These partnerships facilitated the incorporation of advanced technologies and expertise, enabling Audi to develop a sophisticated hybrid system that provided a competitive advantage in endurance racing . The successful integration of these components exemplified the importance of leveraging external expertise in motorsport innovations.

The Audi R18 Ultra introduced several technological innovations, including a full carbon-fiber gearbox housing, which was the first of its kind in endurance racing. This contributed significantly to weight reduction, making it the lightest prototype Audi had built . The car also featured aerodynamic modifications for improved efficiency, such as a closed cockpit design for reduced drag. These innovations enhanced its performance, allowing for a competitive edge in terms of speed and fuel efficiency while maintaining reliability in the challenging conditions of endurance racing .

Audi addressed the thermal and mechanical challenges faced by the R18 e-tron Quattro's turbocharging system through the use of a 'hot side inside' configuration. This setup placed the single turbocharger within the V of the engine, optimizing exhaust flow and minimizing thermal energy loss . The use of variable turbine geometry (VTG) technology allowed for precise control of exhaust gas flow, enhancing the turbocharger's response across various load conditions. High-temperature-resistant steel alloys were utilized to withstand the extreme temperatures in the turbine, ensuring durability and efficiency . These design choices facilitated effective temperature and stress management, crucial for maintaining performance and reliability in endurance racing .

Audi R18 e-tron Quattro
Flywheel KERS Hybrid System (2012)
 http://www.formula1-dictionary.net/kers_audi_e_tron.html
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technicians focused from the very beginning of the ‘R18’ project on a compact 3.7 
liter V6 TDI with innovative architecture.
The R18 ultra is the basis that has 
made it possible to make the R18 
e-tron quattro reality in the first 
place. 
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Audi's Head of Motorsport Dr. 
Wolfgang Ullrich: "We would have 
had no chance if we hadn’t 
achieved the weight saving 
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The extremely advanced aerodynamic configuration from 2011 was initially adapted 
to suit the new regulations, but later heav
Rear wheels get their power from 
the car’s 510-horsepower wide-
angle V6 TDI engine with the 
single variable geometry turbo
temperatures today than in the past. This has resulted in considerably higher 
performance of the piston areas and the cylind
ne exhausts inwards between the 
cylinder banks, where the 
turbocharger is placed. This is 
called a 'hot side inside' 
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The two hybrid cars was driven by last year’s Le Mans winning trio of Marcel Fässler, 
André Lotterer, and Benoît Tréluyer, w
Sports prototype is where you will see the latest technologies thoroughly tested, 
which eventually trickle down to our every

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