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Projekt E technical partner STARD has joined an elite club of world-renowned motor sport engineering names by passing the FIA’s HV crash test with its in-house developed motor sport battery system.

By applying for and passing the FIA Formula E-derived crash test, STARD joins a select group of companies, including Williams Advanced Engineering and McLaren Applied Technologies, to have achieved such an undertaking for a full scale traction battery. The STARD battery system is at the heart of the REVelution electric powertrain kit for the new Projekt E series this year, the official support category for FIA World Rallycross Championship.

The stringent FIA crash criteria includes deceleration tests, where values are substantially higher than those of electric road cars, which have a significantly bigger impact for the design of traction batteries for BEVs [Battery Electric Vehicles] compared to smaller and lighter batteries as for example used in KERS and WEC Hybrid systems.

Mechanical tests are also part of the FIA’s scrutiny, with extremely high static loads – equating to multiple tonnes of force – used to check impact and protrusion resistance of the RESS [rechargeable energy storage system] casing.

Prior to the completion of STARD’s liquid cooled and heated battery pack, designed in-house using individual ultra-high-performance Lithium Ion cells, and before being subjected to the FIA’s intensive testing process, the prepreg carbon fibre casing layout, design,

FEA analysis and crash simulations of the prepreg carbon fibre casing that houses STARD’s liquid cooled and heated battery pack were all carried out at STARD’s base in Austria. Due to the in-depth FEA processes at base, trial crash testing was not required prior to the FIA’s testing process, which the battery passed at the first attempt.

Media images (https://www.dropbox.com/sh/3ybl29l6cmh3ru1/AABKrJZutjx5Ye-MdLaIokRpa?dl=0)

QUOTES

Michael Sakowicz, STARD CEO and founder:
“We have invested a lot in our high voltage traction battery development competence. Motorsport and very high-performance battery systems are dramatically different to road car applications for two main reasons: safety requirements and power density. In the area of safety, the FIA has imposed very strict criteria for BEV (battery electric vehicle) traction batteries. That STARD is in a very elite group of industry leading companies like Williams and McLaren, by being able to offer FIA crash tested high performance battery systems for motorsport application, is the result of many years hard work. As part of our turnkey REVelution powertrain package as used in Projekt E, this is immediately available to customers.”

Philipp Thonet, STARD CTO:
“The entire development process we carried out in-house started from individual lithium ion cell level upwards. That included CAD packaging of all mechanical and electronic components, CFD simulation of the cooling system, FEA optimisation and crash analysis of the prepreg carbon fibre reinforced casing and especially with in-depth understanding of the electrochemical and electric requirements and limits of state-of-the-art lithium Ion cell technology. In addition to the simulation and CAD methods we are also processing physical lithium ion cell and module dyno testing in house. This has enabled us to deliver top level motorsport grade battery development and production, conforming with FIA safety requirements for virtually any application with the smallest development time.”

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