Competition in the auto industry has existed from the time the second carmaker was established, and competing has been in not just business but also in the performance of the products. Carmakers have challenged each other on the streets and on racetracks, with supremacy putting a shine on their brand’s image.
3-company partnership
DEUS Automobiles, a new company born two years ago in Austria, is teaming up with Italdesign and Williams Advanced Engineering to make a statement of superiority in luxury electric hypercars. The partnership aims to design and create the most powerful electric hypercar in history with ground-breaking electrification technologies.
The Vayanne, as their hypercar is to be known, will go beyond today’s output levels and cross the 2,200 horsepower (1,640 kW) mark, generate over 2,000 Nm of torque, and be able to run beyond 400 km/h after passing 100 km/h in under 1.99 seconds.
Just how that amount of power will be produced and the nature of the powertrain is not explained at this time but will largely be the job of Williams Advanced Engineering. The British company and Italdesign are no strangers to collaboration; in April 2021, they announced a unique partnership for a high performance, flexible EV platform; EVX, supporting a long-term vision for EV architecture. This rolling chassis utilises Williams Advanced Engineering’s expertise in electrification, light-weighting, innovative chassis structures and vehicle and system integration.
Symmetry and geometric alignment
For now, DEUS is focussed on the design concept and a full-sized prototype is on display this week at the 2022 New York International Auto Show. To showcase the harmony of design, functionality and cutting-edge technology, the Vayanne is stylised around the idea of symmetry and geometric alignment of its lines and design features. In this regard, the shape of the front and rear grilles is made to represent the infinity loop.
The parametric grilles convey even more of a holistic approach through the meticulously aligned pattern that gradually increases in fade intensity. The pattern of the parametric grilles is represented by hexagonal shapes that continuously flow into each other to create the desired effect of angel wings being enclosed by the uninterrupted taillight strip in the rear and to further increase the premium feeling of the car’s stance in the front.
For every air duct, there is another matching vent to keep the styling in line with the symmetry while ensuring the angles of those ducts are geometrically aligned. This is the result of DEUS and Italdesign styling and engineering departments working hand-in-hand to make no compromises between design and feasibility and to achieve maximum performance.
Sustainable production process
The interior, themed in a green colour, of the Vayanne has smooth yet dominant curves combined with refined geometry. The natural leather selected for the upholstery was treated and produced combining sustainable, technologically advanced solutions throughout the production process, with strong commitment to zero waste for a circular economy model.
DEUS is the first in the automotive industry to implement the Halo Infinity mirror throughout a vehicle’s interior. This innovative design feature as applied in the Vayanne is vital to carrying over the infinity theme from the hypercar concept’s exterior to its interior. It embraces the whole interior from the doors throughout the dashboard. The effect changes in regard to the viewing angle, a trait incorporated to suggest that everyone’s view is unique.
99 units to be built
Following its debut in New York, the Vayanne will continue to be refined taking into consideration feedback from the public and potential customers. The company plans to make only 99 units for sale, with the first delivery in 2025.
The advancement of battery technology over the past 20 years has accelerated as electrification by the auto industry becomes more extensive. The battery has a vital role in an electrified powertrain (hybrid or fully electric), influencing performance and operating range. New technologies, materials and chemical processes have enabled the batteries to be more compact and store more energy, a trend which will continue.
Inevitably, motorsports are also going electric with Formula E and Extreme E, the latter a pioneering off road championship which is in its first season this year. These events push electric powertrains to extremes and will certainly help in the development of new technologies that can be used for road cars.
Supplier to Formula E and Extreme E
To get the best available batteries, the organisers of both Formula E and Extreme E brought in Williams Advanced Engineering (WAE) as a partner. The company (which is related to the racing team) is a major force in the electric motorsport arena, having been the original and only battery supplier to the Formula E series when it began in 2014.
Williams Advanced Engineering provided the batteries for Formula E (above) and with all the expertise gained in developing and manufacturing batteries for motorsports, it was in a good position to also be a supplier for Extreme E (below).
“Following the on-track successes we’ve had at Le Mans (providing engineering support for Porsche’s sports car racing programme), through the hybrid F1 era, then 4 seasons supplying batteries to the first-generation Formula E grid (and due to supply the Gen 3 batteries), together with being technical partner for Jaguar Racing, we have learned a lot about how to extract the highest levels of performance from a battery,” said Craig Wilson, CEO of Williams Advanced Engineering.
Greater challenges with Extreme E
Their expertise put them in a good position to gain a sole developer role in Extreme E. But while the basic technology would be the same, Extreme E presents a greater challenge because of its off-road nature. “In Extreme E, we are taking battery technology away from the traditional race circuit and into hostile environments, where humidity, dust, extremes of temperature, shock and vibration will play a huge part and to that end, the batteries have had to be uniquely tailored for the environment,” explained Glen Pascoe, WAE Principal Engineer.
“And with races being head-to-head over short distances, the batteries are sized to manage high intensity operation over a shorter time than in other e-racing series, but in a far harsher environment,” he added. “As a result, we have developed a whole new module that can produce 400kW peak power in a bespoke battery construction along with an entirely new pre-race conditioning system to maximise robustness and minimise mass.”
Simplicity, serviceability and modularity were all critical design requirements. Commercially available cells were selected and designed into a pack in conjunction with the series to align both with the race format and the vehicle performance duty cycle. “Working with limited space in the car, we had to meet tough power and mass performance targets and deliver a bespoke battery pack design in under 12 months!” recalled Pascoe.
Environments change with each round
Each venue of Extreme E has different environments and in the opening round in Saudi Arabia in April, sand and high temperatures were the big challenges, as well as thin air. “The first run simulation took part at the hottest time of the day and a battery rebuild we carried out was intensive and not helped by strong winds and even a sandstorm providing an unwelcome interruption, which covered all battery parts and electronics with a fine grit. We had to bring out the vacuum cleaner to deep clean for all components in time for the team-wide shakedown runs,” he said.
The Senegal event brought a mixture of similarities but also differences to Saudi Arabia in the challenges faced. Whilst not as hot, ambient temperatures in the seaside area still remained high, accompanied by 90%+ humidity levels. This brought its own unique challenges in actively managing the battery temperature both during the on-track action and between races.
“Alongside this, the Senegal event showed the cars tackling a very demanding, technical and aggressive track. The batteries were constantly punished with heavy impacts and harsh vibrations as the cars bounced around the dunes and deep ruts. Ensuring battery health throughout the weekend was key to ensuring a successful event,” Pascoe revealed.
He added that the batteries performed flawlessly even with the severe impacts that happened in the Desert X Prix as well as the intense head-to-head battles on the 6-km long harsh, technical course, through woods and beach sand of the Ocean X Prix.
The paddock area in the Desert E Prix in Saudi Arabia. On the left side is AFC Energy’s hydrogen fuel cell station to recharge the e-SUVs with zero emissions generated except water.
On-site servicing and recharging
Unlike being at a closed racing circuit, Extreme E’s tracks are in the open, without the usual facilities. Nevertheless, the WAE team was able to work on the batteries on location without difficulty. “Servicing and maintaining the batteries throughout the events went well, which is a reflection of all the design work that went into them,” said Pascoe.
After two rounds, the ODYSSEY 21 racing SUVs have covered 1,070 kms, of which 480 kms were recorded in Senegal. Cumulative energy discharge has been nearly 2,000 kWh, with about half drawn in Senegal. In total, over 12 hours of on-track running has taken place.
The first two rounds of Extreme E in Saudi Arabia and Senegal (above and top) have had a lot of sand and high temperatures. The third round – the Arctic X Prix – will be in a very different environment in Greenland (below).
The third round next month is the Arctic X Prix which will take place in Greenland. The engineers will be glad for no more sand, but the climate and track conditions will be vastly different. “There will be very new challenges of snow and of course, water and mud. There will be stone impact and less grip resulting in more drift and vertical impact. In addition to the physical challenges, the remoteness of the location means we need to forward plan for every eventuality before arriving on location as there will be no opportunity for late deliveries or freight, no additional transport available or indeed, supplies!” noted Pascoe.
Unlocking further vehicle performance
As the season progresses, the engineers at WAE will gain more data on battery and overall powertrain performance and behaviour. This will allow them to unlock further vehicle performance so the performance envelopes will be extended. “The batteries have been designed for multi-season use so WAE will inspect, re-test and go again. Any incremental improvements available will be implemented during the turn-around. Once the batteries reach the end of their final racing season, the cells can be easily removed as module ‘building blocks’ and configured into a suitable second-life application. Some components are targeted for reuse in alternative applications, and some will be recycled in order to recover valuable raw materials,” said Pascoe.
Whatever is learnt during the events and the solutions found may be transferred into production cars. With the R&D opportunities that the series gives, innovations can filter into the consumer market. “Specifically in areas such as fast charging, battery management and software development,” said Wilson. “Essentially, affordability comes with volume production. By pioneering and showcasing EV technology in a series such as Extreme E, manufacturers will be able to ‘carry over’ technology into road cars and in doing so, enable the technology to become more affordable.”
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Henry Ford believed in his company owning and managing every aspect of making cars – including even owning the plantations of rubber trees that provided rubber for his cars. But as the years went by, specialisation began and while carmakers focussed on designing and manufacturing cars, some activities were also farmed out to other companies. Design, for instance, was sometimes done by external consultants more specialised in the work, notable Italian studios like Pininfarina, Ghia and ItalDesign being among them.
In the 21st century, as the whole idea of making cars changes with the transition to electric vehicles, there are many newcomers (especially in China) who want to get into the game. Some of these have experience in other types of manufacturing, eg batteries or mobilephones, but no experience in engineering cars. For them to gain that experience as the global players did will take too long; today’s companies do not have the luxury of time to learn themselves as the market is so competitive.
So the answer has been to commission companies that specialise in certain areas. In fact, Chinese companies have been doing this, not just for design but also for powertrains. There are top-notch engineering consultancies in Europe like Lotus Engineering that can develop a car on par with any experienced manufacturer – and even the established ones sometimes ask Lotus to help.
Manufacturers sometimes ask experienced design studios to propose designs for future models. This was the EMAS hybrid concept for Proton by Italdesign Giugiaro which was displayed at the 2010 Geneva Motorshow.
So there’s a growing business in offering a full range of services to develop cars and Italdesign has formed a partnership with Williams Advanced Engineering (WAE) to provide such services to those who want to produce and sell high-performance EVs. WAE is the technology and engineering business that was established by Williams F1. It takes technology originally developed for Formula One cars and adapts it for commercial applications.
Combining a state-of-the-art composite electric vehicle rolling chassis from WAE with turn-key vehicle development services from Italdesign, the joint venture will enable both newcomers and customers to benefit from the expertise of two global leaders in EV engineering and vehicle design, supporting them in the creation of a range of upper premium EVs from high performance GTs, crossover and sedans.
The foundation of this new venture is WAE’s innovative EV architecture – a new rolling chassis which distils WAE’s expertise in electrification, light-weighting, innovative chassis structures and vehicle and system integration into one advanced architecture known as ‘EVX’.
Differentiating itself from other EV platforms currently in the market, EVX integrates the battery pack casing with elements more commonly perceived as part of the body structure. Front and rear chassis structures mount to the carbonfibre composite case and crash loads can be transferred via internal reinforcements to the integral side sills.
The resulting higher profiled cross section achieves much of the torsional stiffness needed to deliver the full potential of the platform. These two design philosophies reduce reliance on the upper structure, which then gives greater design freedom for a variety of ‘top hats’.
Starting from WAE rolling chassis, Italdesign’s Engineering Team then complete the vehicle architecture adding safety systems, structures, and UX devices to constitute the modular platform that will be the base to build-up several different high-performances vehicles.
The innovative modular platform is ready for customisation by the Italdesign styling team who will shape the final vehicle to match the brand’s requirements in terms of marketing positioning, design direction etc. As well as being a structural component of EVX, the platform can accommodate wheelbases from 2900 mm to 3100 mm, with customers able to choose rear-wheel drive and 4-wheel drive layouts.
Combining recycled composite materials with aluminium, EVX is lightweight and sets new standards for static and torsional stiffness. With class-leading performance and mass targets, EVX will provide the perfect basis for tomorrow’s electric vehicles, supporting a flexible range of powertrain options with outstanding aerodynamics and safety performance.
Majoring on high performance, reduced time to market, flexibility and affordability at low-to-medium volumes, the new platform is capable of supporting production runs up to 10,000 units, up to 500 of which could be manufactured by Italdesign at its facilities in Italy.
WAE was the original supplier of batteries to all participants of the FIA Formula E World Championship cars in 2014, a relationship that has been revived for the 2022-23 season. WAE also supplies battery systems to ETCR and Extreme-E and has considerable experience in high-performance electrified road car programmes stretching back more than a decade.
“We are delighted to join forces with Italdesign on this exciting and timely joint collaboration” said Paul McNamara, Technical Director at WAE. “Demand for high performance electric vehicles is continuing to show considerable growth but to date, there has not been a complete EV production solution. This unique relationship brings together state-of-the-art EV rolling chassis technology with one of the world’s leaders in vehicle body engineering.”
Ever wondered how fast a tractor can go? No? Neither have we but the folks from Williams Advanced Engineering wanted to find out and with the help of the very popular Isle of Man TT racer / TV presenter, Guy Martin, they actually found out earlier this week. (more…)
Aston Martin has confirmed that the RapidE, which was unveiled two years ago in concept form, will enter production in 2019. It will be a limited production run vehicle with just 155 cars being produced in total. And it will be the first fully-electric model to be produced by the Gaydon based manufacturer.
No word yet on whether there would be styling changes or if the production car will retain the same curves and contours as the concept. But the car will be based upon the forthcoming Rapide AMR concept, which means that styling and vehicle dynamics wouldn’t deviate too much from that of the Rapide S albeit the electric motor(s) will take the place of the standard car’s glorious V12.
Speaking of the RapidE, Aston Martin President and CEO, Dr Andy Palmer, said, “RapidE represents a sustainable future in which Aston Martin’s values of seductive style and supreme performance don’t merely co-exist alongside a new zero-emission powertrain, but are enhanced by it. RapidE will showcase Aston Martin’s vision, desire and capability to successfully embrace radical change, delivering a new breed of car that stays true to our ethos and delights our customers.”
The RapidE will be jointly developed with Williams Advanced Engineering who also worked on the original concept car. Together the team are striving to meet Aston Martin’s goal of producing an energy-efficient vehicle that retains the style and soul of the legendary sports cars of the past that have bared the company’s name.
Aston Martin has yet to release substantial information pertaining to performance other than a statement that the car will offer the kind of experience that has been absent from other Aston Martin cars. That said, it might be awhile before the automaker divulges more data.
