Flybrid, Torotrak and Xtrac mechanical KERS system nominated for prestigious Professional MotorSport World Expo award

Following the announcement in September 2007 of the first application of their mechanical ‘kinetic energy recovery system’ (KERS) with a major Formula 1 (F1) team, Flybrid, Torotrak and Xtrac have been shortlisted for a Professional MotorSport World Expo Award.

Competing in the category of Engine Innovation of the Year, the KERS development is among four finalists drawn up from nominations submitted to the Professional MotorSport World Expo website.  The nominations will be finally assessed by an independent, international jury of motorsport team managers, engineers and journalists.

Light, compact and efficient, the mechanical KERS system developed for F1 is designed to meet the requirement outlined by FIA president Max Moseley – of developing technology directly relevant to improving fuel efficiency in road cars – by recovering energy from the vehicle under braking and re-using that energy to accelerate and drive the vehicle.

The mechanical KERS system comprises a toroidal traction drive CVT (continuously variable transmission) and a mechanical flywheel.

The lightweight flywheel, developed by Flybrid Systems, is used to store the moving vehicle’s kinetic energy which is otherwise wasted when the vehicle is decelerated.

This energy is recuperated from the driveline, through Torotrak’s CVT, as the vehicle decelerates.  This energy is subsequently released back into the driveline - again through the CVT - as the vehicle accelerates, 

Torotrak’s CVT has been engineered for the F1 application by Xtrac, who will also manufacturer the device.  In June 2007, both companies entered into a licence agreement to enable Xtrac to develop and sell the highly efficient and compact CVT for motorsport applications. 

The FIA has defined the amount of energy recovery for 2009 season as 400kJ per lap giving the driver an extra 80hp over a period of 6.67 seconds, which is ideal for overtaking manoeuvres

“Building on the confidence shown within F1, the nomination received for this prestigious award demonstrates the level of excitement and rapid progress being made with the mechanical KERS system,” said Dick Elsy CEO Torotrak.

“We’re delighted to have been nominated for this award,” said Adrian Moore technical director Xtrac.  “We’re also excited with the prospect of motorsport helping to introduce this technology into road cars,”

Jon Hilton, managing partner Flybrid, commented further by saying: “Flybrid Systems is delighted to be nominated for this prestigious award. This is a further demonstration that the very strong interest in green technologies already apparent in consumer markets is now being felt in the motorsport world.”

Finalists will be announced and trophies presented during a gala dinner at PMW Expo in Cologne, Germany, on 6th November 2007, in front of nearly 1,000 motorsport professionals and members of the press.

Media contacts:
Peter O’Neill, Marketing Executive, Torotrak
Tel: +44 (0) 1772 900318 Email: peter.oneill@torotrak.com

Rob Palmer, Media Communications, Xtrac
Tel: +44 (0) 1582 763255 Email: rpalmer@palmerpr.com

Jon Hilton,Flybrid Systems LLP
Tel +44 (0)1327 856106 Email: jon.hilton@flybridsystems.com

 Notes to editor:

Torotrak is a world leader in the development of full-toroidal traction drive technology for use in automotive, truck, bus, off-highway, OPE and ancillary drive markets.

Xtrac specialises in vehicle transmission technology focussed on clients in the aerospace, automotive, defence, marine and motorsport sectors.

Flybrid Systems LLP is an innovative engineering company taking a fresh look at hybrid vehicle technology in F1, motor sport and automotive applications

 Technical notes on toroidal variable drive technology

The components within each variator include an input disc and an opposing output disc. Each disc is formed so that the gap created between the discs is ‘doughnut’ shaped; that is, the toroidal surfaces on each disc form the toroidal cavity.

Two or three rollers are located inside each toroidal cavity and are positioned so that the outer edge of each roller is in contact with the toroidal surfaces of the input disc and output disc.
As the input disc rotates, power is transferred via the rollers to the output disc, which rotates in the opposite direction to the input disc.

The angle of the roller determines the ratio of the Variator and therefore a change in the angle of the roller results in a change in the ratio. So, with the roller at a small radius (near the centre) on the input disc and at a large radius (near the edge) on the output disc the Variator produces a “low” ratio. Moving the roller across the discs to a large radius at the input disc and corresponding low radius at the output produces the “high” ratio and provides the full ratio sweep in a smooth, continuous manner.

The transfer of power through the contacting surfaces of the discs and rollers takes place via a microscopic film of specially developed long-molecule traction fluid. This fluid separates the rolling surfaces of the discs and rollers at their contact points.

The input and output discs are clamped together within each variator unit. The traction fluid in the contact points between the discs and rollers become highly viscous under this clamping pressure, increasing its ‘stickiness’ and creating an efficient mechanism for transferring power between the rotating discs and rollers.

Ends

(L to R) Adrian Moore technical director Xtrac, Dick Elsy CEO Torotrak and Jon Hilton managing partner Flybrid, demonstrate the light, compact, efficient CVT and flywheel KERS components (Picture supplied by: Glyn Merga)