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of 2026 power unit regulations Peter Wright on his 1979 Lotus T80 friendly composites for racing
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Alfa Romeo NASCAR enters its Porsche 963 Formula E

How the C42 has shaken
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Next Generation First look at the 2023
LMDh Prototype Gen 3
Aero chief Eric Jacuzzi Behind the scenes
Toyota TS010 reveals the new car’s in testing for new
One great car, two
radically different development Season 9 cars
aero assessments
process

F1 2022
What teams can
expect from the
new aero rules United
PORSCHE 992 GT3 R ELECTRIC MOTORS INDYCAR STRATEGY HYDROGEN TECHNOLOGY ’BOXING CLEVER HOW LE MANS WAS WON Autosports
HONDA’S BOX OF TRICKS TYRE MODELLING ELECTRIC TOURING CAR
All-new incarnation Efficiency gains Is this motorsport’s The alternative for zero Xtrac on keeping ahead Race strategy analysis We visit the
of a racing legend for EV racecars biggest challenge? Super GT project Mysterious world of New ETCR series carbon emission racing in the racing market of 2022 24-hour event FIA WEC team
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ALPINE FORMULA 1 PERFORMANCE BALANCING MCR SPORTS 2000

Tech chief reveals the Questions and answers Welsh constructor with
secrets of GP challenger on the black art of BoP a university challenge

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Racecar Engineering is the world’s leading technical
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engineering since 1990. From concept to track, each
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contributors include Peter Wright, Claude Rouelle and
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>> Technology controversy

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Ferrari 296 GT3 – Lead engineer
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BTCC Hybrid – How Cosworth met
the targets set by TOCA to introduce

directly to discuss bespoke creative solutions. a cost-effective hybrid system to

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Capgemini – Computing giant and
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ADVERTORIAL – DRUCK MOTORSPORT ADVERTORIAL – EVOSCAN ADVERTORIAL – V SYSTEM SRL

Specialist in
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Offset reduction
We’re excited about our latest innovation, 4400T Summary
the 4400T, a combined pressure and • Available pressure ranges:- 1.6 to 600bar
temperature sensor, developed specifically
• Pressure output:- Amplified

hydroforming technology
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engineers with a number of key benefits: applications. In addition, we have an into finished pressure Editor's Picks
• Firstly, 4400T provides unrivalled levels expanded range of performance pressure is at a premium,
of accuracy and reliability across pressure controllers and handheld indicators and sensing products’ and high-precision
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location resulting in more consistent data. be a market leader. It also reflects our will also enable customers to access a aerodynamic pressure measurements accurate and can be
investment in state-of-the-art R&D and range of supporting instrumentation and
made of exotic alloys

A
As per the existing 4400 range, the manufacturing facilities. For example, interface equipment helping provide
new 4400T has a maximum operating Druck is one of just a few companies the critical edge in competition. s aerodynamic points of interest are connected via a tube to the measuring
Druck’s 4400T, a combined pressure temperature of 175degC and is available across the globe with the capability of instruments, there can be detrimental effects in the measurement known such as titanium
across a range of pressures from 1.6bar turning raw silicon into finished pressure Multi-channel interface as frequency response effects. It is a hugely complicated subject, with many
and inconel
and temperature sensor, is specifically to 600bar. With excellent thermal sensing products, utilising our advanced Elite Sensors also specialises in the studies undertaken over the years by universities, research establishments and With numerous inconsistencies due to the tubes connecting
even NASA to try to understand and correct for this phenomenon. pressure sensors, limiting the length of tube runs offers a benefit
designed for the motorsport sector to compensation, the sensor provides
unrivalled levels of accuracy and reliability
and comprehensive in-house silicon
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provision of technology to capture
and interface with the sensor signal It is usually unavoidable too, as physical size makes it difficult to locate the pressure
provide unrivalled levels of accuracy across the full temperature range. produce pioneering products that provide and can supply miniaturised amplified scanner exactly where you want to measure.

H
The 4400T has been tested to the customers with the accuracy and reliability output conversion PCBs for probes and With so many variables that contribute to the offset created by the tubing, the effect is
and reliability. By combining two same high levels of shock and vibration they need to optimise their operations. multi-channel interface units to capture hard to quantify. For a start, there is a delay between the input at one end and air reaching ydroforming is a manufacturing In recent years, V System Srl has gained of universal clamping systems allows us to Hydroformed component after the forming process is
results from an array of sensors. the pressure measurement device. Whilst in the tubing, air is highly compressible and its process which uses a high- extensive experience in the creation be competitive in terms of price, being able complete, ready to be removed from the tool
sensors into one, race engineers Elite partnership temperature, density and velocity of sound all affect the frequency response, as does the

USER 01.
‘I’m proud that Druck technology is pressure fluid to achieve the of hydroformed exhaust systems for to offer customers effective and sufficiently
length of tube itself. Then there’s the elasticity of the tube wall, which bends to absorb plastic deformation of metal motorsport. For this type of application inexpensive technical solutions, regardless
don’t have to accommodate extra Determined to build upon our strong
track record in the motorsport sector,
established across a wide range of sectors
often in very harsh environments,’ says some of the energy in the pressure wave. Kinked tubes will produce false, or no, readings, components, specifically tubes. where on-the-car space available is very of quantity. Moreover, we can perform
sensors into complex engine designs, expand our footprint and develop new Michael Thomas, project manager, Druck. which adds further complexity when working with 16, 32 or even 64 individual tubes.
So how different is the pressure when it arrives at the point of measurement?
The technology expands pipes, or
specific pre-formed shapes, from the inside
limited, the routing of the pipeworks is first
optimised by performing CFD simulations.
accurate thickness analyses on hydroformed
components using an ultrasonic thickness
technologies, Druck has recently partnered ‘From the bottom of our oceans, to the
and they will also benefit from with Elite Sensors Ltd. Specialists in the highest mountains. From the latest military There is a systematic offset created by the tube, so it is best to use the smallest diameter out by means of a liquid working medium in Unlike other metal forming techniques,
LOGO
Increased part strength, lower part weight
GUIDE
design and manufacture of sensors for the aircraft to missions to outer space. From tube possible, use the same length of tube and the same tube material for every location, a closed die. This method makes it possible hydroforming allows for increased part
simple and quick verification motorsport sector, Elite Sensors helping to provide clean water to even to ensure that offset is always the same. This might not be easy to achieve in every
situation as the tube bend radius, compatibility and pressure and temperature limitations
to manufacture hollow components with a
complex external shape, or with localised
A hydroforming press equipped with a hydro tool. Examples of what can be achieved in the foreground strength, lower part weight and greater
design flexibility, while also improving
and greater design flexibility
COLORS
I
has become Druck’s route saving lives in hospitals, our accurate,
n all levels of motorsport teams are However, some sensors are unable to to market, which enables reliable robust technology is making a may make it unsuitable for certain measurement tasks. The minute size of EvoScann® scanners allows their placement in section variations, from a single piece. overall part quality. In our factory we can
looking for fine margins of performance deliver accurate and reliable results in the the rapid introduction of difference right across the globe. critical areas of racecars where larger scanners cannot fit The peculiarities of the deformation count on a 1,000 tonne hydraulic press
that can help attain a podium finish. harsh motorsport environment. With speeds a new range of pressure ‘I’m excited too that we’re on the cusp of Tight fit technique are very effective in the equipped with an injection system able gauge, specific intermediate and final
Pressure and temperature sensors are of up to 350kph, high vibration and extreme sensors that will push the expanding an already strong track record However, The EvoScann® range of miniature pressure scanners can help simplify this construction of exhaust systems, for to achieve a pressure up to 2,200bar. vacuum heat treatments and NDT testing.
For further information, please
critical components for all fluid and air operating temperatures it doesn’t come boundaries of innovation in motorsport, where there is no room for complex process by fitting into the tightest of spaces. In an F1 car, for example, the scanner example, where the need to build parts V System Srl is able to supply any type
And how about cost? contact V System Srl via
Scuderia AlphaTauri AT03
pressure applications. By adopting the right much tougher. Druck, a Baker Hughes for the motorsport industry. error in the toughest of environments,’ could be mounted directly in the location where measurement is needed, rather than with complex routings and with the aim of of hydroformed parts according to the
measurement technology, manufacturers business, has a strong track record across Entrenched in motorsport, the Thomas adds, going on to observe: ‘I would running 4-5m of tubing back to a traditional scanner, eliminating the tube offset entirely. optimising the fluid dynamic performance You might think hydroforming technology customer’s requirements, and also more website: www.vsystem.it
can better optimise vehicle performance, motorsport. We know that success in Elite Sensors team have worked with the want Druck technology in my engine on the The EvoScann® scanner is also rugged, light and insensitive to vibration, making it within is very relevant. is not suitable for small and medium- complex TIG-welded assemblies made from
perfect for locating in the aero section without affecting aerodynamic performance. Design and optimisation of sized production runs, due to the initial different types of components, such as
email: info@vsystem.it
safety and reliability, which can make the motorsport depends on thousands of highest performing teams across the starting grid for a race!’
difference between first and second place. components working seamlessly together. Whilst the headline spec of a scanner may be way less than 0.1 per cent of a very hydroforming processes require knowledge high tooling investment. However, the simple curved or hydroformed pipes, ’phone: +39 0536 035 111
For more on Druck Motorsport go to
small pressure value, when it’s installed in real-world applications, the total system error,
including tubing, creates a very different picture. By using EvoScann® and keeping the
of the fundamentals to determine the
necessary process loads, estimate feasibility
Read more competence developed by V System Srl
in designing and manufacturing the steel
CNC-machined parts
or items obtained
‘Druck has a strong track record across motorsport and we know that success www.bakerhughesds.com/druck-high-performance-sensors-motorsport tubing as short as a few centimetres, much of the system uncertainty is removed, ensuring and obtain an improved comprehension of dies necessary for the process in house, the through additive
Telephone: +44 8000 260864 (UK), +1 8 44 9910 494 (USA) accurate measurement is done at the point of interest, delivering digital data directly via influences on the reliability and quality of The basic principle of tube hydroforming – expanding a smaller shape enclosed design philosophy of combining multiple manufacturing GROUP
depends on thousands of components working seamlessly together’ For Elite Sensors go to elitesensors.co.uk CANbus without the need for special software or hardware interface. component manufacturing. within the hydroforming matrix into a different shape using a fluid under pressure components during forming and the use technology processes.

70 www.racecar-engineering.com OCTOBER 2021 OCTOBER 2021 www.racecar-engineering.com 71 MAY 2020 www.racecar-engineering.com 77 16 www.racecar-engineering.com AUGUST 2020 AUGUST 2020 www.racecar-engineering.com 17
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