Technology at the cutting edge


The eRally competition car is zero-emission at point of use and fully-electric.


This is achieved through a number of key components:
Battery
AC Motors
Motorsport Controller
Fuel Cell


eRally is working with leading manufacturers to develop new cutting edge technologies, apply them to the eRally car and test them to the absolute limits in competitive rally sport. This rigorous testing will help boost advances in EV technologies, which will be fed back to the road cars we all want to drive.

EV’s store chemical energy in a battery. Lithium-ion batteries are currently being used in high-end EV’s because of their high energy density. Converting chemical energy to electrical energy can be more than 90% efficient.

In conventional fossil fuel cars, chemical energy is stored as petrol or diesel. The chemical energy is converted into thermal energy by combustion. The shocking truth is that the vast majority “fossil” fuelled cars are only 15-25%* efficient, as the majority of energy stored in the petrol & diesel is lost as heat.



Ragone chart (source Nexergy)


Batteries
eRally is working with Europe’s largest independent provider of EV battery systems to develop a battery for use in electric vehicles that outlasts and outperforms current batteries. Latest EV battery technology is based on lithium-ion.

eRally are looking beyond lithium-ion to develop a battery based on emerging technologies that will outperform current EV batteries.

Motors
Electric motors are rated on KW and voltage.  Most electric vehicles run at 48 volts.  The motor being developed for the eRally car will run at 400-500 volts and is based on latest purpose-built AC motor technology.  Higher voltage results in lower resistance and less heat which results in higher performance. Additional liquid cooling is employed for maximum performance on the rally stage.

Controller
Controlling the power is essential with high performance electric motors. With full torque available from zero rpm the controller software will limit the flow of electricity to the motors to prevent damage to the drive-shafts or the car simply spinning its tyres and digging a hole in the forest track.

Fuel Cell
Hydrogen fuel cells are used as a supplement or an alternative to using batteries. The range of the car can be significantly increased by deploying fuel cell technology, where Hydrogen is converted in the fuel cell to electricity and fed either directly to the motors or to top up the existing batteries.