F1-SP2e All
F1-SP2e All
F1-SP2e All
On December 5, 2008, Honda announced its withdrawal from Formula One racing. For me personally, as for all the
members of the Honda team directly involved in the Formula One projects and for everyone related to Honda racing,
this was a great disappointment and represented a very difficult decision. Honda was not isolated from the global
economic turmoil occurring at the time, and it was a period in which threats to the continued existence of the company
were developing rapidly.
It is no exaggeration to say that Formula One was a symbol of the Honda brand, and the companys withdrawal
from competition increased the sense of crisis throughout the Honda organization. This fact contributed significantly to
the rapid implementation of a variety of crisis measures, and now, 10 months later, Honda is recovering somewhat
more quickly than its competitors.
Hondas challenge during its third Formula One era was to compete and to win at the pinnacle of the worlds motor
races, and in doing so, to increase its technological capabilities, foster the development of its engineers, and boost its
brand value. Above all, in our third era we set ourselves the tremendous goal of focusing not merely on the engine, but
of achieving improvements in technologies throughout the vehicle.
While withdrawal from Formula One with the title within our grasp remains a great regret, I will be delighted if the
discussions of the technologies that Honda developed during its period of competition, published in this special issue
of the Technical Review, are read by a wide variety of specialists and prove useful in stimulating future advances in
related areas.
Having achieved incredible development as the leading industry of the 20th century, the automotive industry is now
confronted by a number of deep-rooted issues, including the reduction of CO2 emissions, the implementation of measures to deal with the depletion of fossil fuel resources, and the determination of ways to improve the balance of supply
and demand for resources on a global level. What is now demanded of Honda is for the company to demonstrate even
greater energy and passion than it poured into Formula One in taking up the challenge of these global issues and
carving out a new future for the automotive industry.
Takeo Fukui
CONTENTS
Development Overview
Looking back on Hondas Third-Era Formula One Activities .................................................... Takeo KIUCHI ...................2
Transition of Regulation and Technology in Formula One ................................................ Hiromasa TANAKA ...................5
Summary of Honda Formula One Engine in Third-Era Activities ................................ Kazuo SAKURAHARA .................14
Overview of Gearbox Development for Formula One ............................................................... Atsushi MANO .................19
Summary of Honda Third-Era Formula One Chassis Development
......................................Akio TONOMURA, Shun KAWABE, Nobuhisa NAKAYOKU .................25
Development of Materials during Third Formula One Era ........................................................ Masami HOSHI .................34
Activity Reports
Looking Back on Assembly Activities Racing Spirit
...................................................................... Atsushi NORIHARA, Motoaki ISHIZAKA
Tsuyoshi ISHIHARA, Naoto SUNAKO ............... 300
Activities of Honda Racing Development
.................................... Yusuke HASEGAWA, Shiro HISATSUNE, Tatsuya KODAMA ............... 312
Concluding Remarks for Hondas Third-Era Formula One Activities ................................ Katsuhiko SUZUKI ............... 317
Race Records
Specification Summary for Hondas third-Era Formula One ................................................................................................320
2000-2008 Honda Formula One Racing Data Tables ...........................................................................................................330
Development Overview
Takeo KIUCHI*
Author
Takeo KIUCHI
Hiromasa TANAKA*
ABSTRACT
The Formula One regulations are established with consideration of fairness, competition, safety, sustainability, and
entertainment value.
In order to ensure free technological competition, the technical rules of Formula One, under which constructors
are obliged to compete using original vehicles, are essentially free, other than specifying minimum basic items.
From the beginning of the 1990s to 2009, despite continuous changes in the regulations to increase vehicle
performance control and safety, lap times improved almost every year due to the development of technologies that
exceeded regulation stipulations. As a result of these battles, the letter count of the Formula One technical regulations
has increased more than three-fold over 19 years.
Detailed technological development spanning a broad range of elements and involving the use of computers, in
addition to a comprehensive management approach that brings these elements together, are essential to the Formula
One of the 2000s. In recent years in particular, Formula One has responded to rapid social change, for example with
measures to cut costs in line with worsening global economic conditions, and the development of environmental
technologies, as exemplified by responses to global warming, in addition to measures to highlight competition the
essence of Formula One racing and to increase the spectacular nature of the races. This is a period in which Formula
One is reflecting upon the very meaning of its existence.
1. Introduction
1991
Supercharging
Capacity
Number of cylinders
3500
1992
cm3
1993
1994
Transition of F1 regulations
1995
1996
1997
maximum
Free
Hybrid systems
Free
KERS
permitted
Prohibited
Commercial fuel or fuel in development
for future commercial use
Free
Prohibited
7 maximum
Free
Prohibited
Twin clutch prohibited
Free
Free
Mileage
Free
Rear wing
maximum width
Rear maximum
600 mm
overhang
Rear center diffuser
maximum width
Limitations on
fundamental
dimensions
and materials
1 gear box for 4
race events
(Excluding FP1
& FP2)
595 kg
600 kg (with driver)
(with
driver)
Free
2000 mm maximum
2150 mm maximum
Flat bottom
Commercial fuel
5.75% (m/m) biofuel
Commercial fuel
Sampling at circuit
Approval before use
Free
Minimum: 4; maximum: 7
Prohibited
1000 mm above
ground
Homologated
Clutch
Prohibited
Moving ballast prohibited and area of skid block fasteners limited
1800 mm maximum
Stepped bottom
950 mm
above ground
950 mm
above
reference
plane
1000 mm
750 mm
500 mm
600 mm
1000 mm
300 mm
Rear diffuser
maximum height
1000 mm
125 mm
maximum 175 mm
(without
center maximum
area)
Free
Bodywork
Front wing
and
maximum overhang 1200 mm 1000 mm
dimensions
Front wing
maximum width 1500 mm
Up to height of front wheel rims (end plates)
Front wing height
2400 cm maximum
8
Specification
limitations
Rear wing
maximum height
Free
2009
500 kg
(without
driver)
2008
Free
Specific
gravity
controlled
Sampling
2007
Limitations
on
fundamental
dimensions,
weight,
and
materials
Prohibited
EPS
Ballast
Overall width
Facing ground
2006
Free
Free
Fuel
Chassis
2005
Free
Rev limit
Inlet systems
Cooling system
water pressure
Machine weight
2004
10
Mileage
Properties
Minimum
weight
of car
2003
Free
Gear box
2002
12 maximum
Homologation or
limitation of
specifications
Engine
and
powerplant
900 mm
1000 mm
1400 mm
1800 mm
Between
75 mm
At least
At least 25 mm above 40 mm
above
reference plane
reference
plane
reference
plane
Side wing
prohibited
No body Height
work reductions
just
area
around front
front of rear
wheel wheel
Enforcement of
other bodywork
limitation and
deflection test
Tire width
Front
wing test
(downward)
Rear
wing
assembly
test
(rearward)
Tires
Tire supplier
Electronically
controlled
devices
Traction control
Launch control
Chassis devices
Materials
Safety
Prohibited
Software validation in advance
Prohibited
Software validation in advance
Free
Free
Suspension tether
Grooved
Front-4
Rear-4
Slick
Single supplier
Prohibited
(Single ECU)
Free
Prohibited
(FIA logger observation)
Free
Prohibited
40 GPa/
(g/cm3) limit
for engine
moving
parts
Specific modulus
Material designation
Frontal crash test
speed
Side impact test
Side panel
penetration test
Designated
front
center
wing
Front 305-355 mm
Rear 365-380 mm
Single supplier
Free
Rear
wing
element
bridge
mandated
test
test
(rearward) (downward)
Grooved
Front-3
Rear-4
Slick
Tire tread
Rear
wing
Splitter wing
top
front
test
(upward) element element
Front 305380 mm
Rear 365380 mm
15 inch maximum
18 inch maximum
Rear
Test just
front of
rear
wheel
(downward)
11 m/s
12 m/s
14 m/s
15 m/s
Mandated
Specific
designation
Single tether
Mandated
Double tether
3.2. Gearbox
A semi-automatic gearbox based on a sequential shift
mechanism developed in the early 1990s, by means of
which gears are shifted using a paddle attached to the
steering wheel, has been continuously used as the
standard Formula One gearbox type. As will be
discussed below, from mid-2001, a significant relaxation
in the regulations concerning electronically controlled
systems temporarily enabled the use of automatic shifting
systems that were not operated by the driver, but
regulations were tightened to once again prohibit these
systems in 2004 (as part of driver aids ban) over
concerns that they would obscure differences in levels
of skill between the drivers.
With regard to the number of forward gear ratio,
there has basically been no change since the regulations
stipulated a maximum of seven in 1994, but a prohibition
on the use of continuously variable transmissions was
added from the fifth round of the 2001 season. Following
this, in 2002, regulations prohibited dual-clutch
transmissions, which enable uninterrupted switching to
the next pre-engaged gear stage. It was considered that
a de facto prohibition existed on shift mechanisms that
produced no discontinuity in torque, the ideal form of
gearbox, but in 2005, BAR-Honda introduced a seamless
shift using a one-way mechanism that the team had
developed based on a close study of the regulations.
Other teams sought to keep pace, and this has now
become the standard technology in use in Formula One.
Since the 1980s, every team has employed original
designs and methods of manufacturing gearbox case, which
is a structural element of the chassis to which the
suspension is mounted. In the first half of the 1990s, most
gearbox cases were cast from magnesium, but after this a
variety of methods came into use in attempts to produce
lightweight, high-rigidity cases, including the manufacture
of the cases from thin-walled titanium castings and welded
plates, and the use of CFRP reinforcing. In 2004, BARHonda became the first team to produce a practicallyapplicable all-CFRP gearbox case.
With regard to the gears and shafts inside the
gearbox, even in the early 2000s it was still standard
practice, with some exceptions, to employ existing parts
manufactured by gearbox makers. However, teams began
to develop their own original gears as development
competition seeking weight savings and greater
compactness intensified. Based on concerns over
spiraling costs, from 2008 the regulations have stipulated
that forward gears should be manufactured from iron,
and have also specified minimum gear width, gear
weight, distance between shaft centers, and the like.
In 2008, the long-mileage concept was also applied
to gearboxes, and a single gearbox is now required to
be used for four race events. However, the adjustment
of the gear ratios to match the characteristics of specific
circuits and the replacement of the dog rings is allowed
conditionally.
two race events (from 2007, the Friday free practice (FP)
session was excluded from the regulation). In 2009, the
total number of engines that a team could use per year
was limited to eight.
From 2006, in order to avoid cost increases resulting
from excessive development competition, common basic
dimensions for engines were established, and minimum
weight and center of gravity of an engine were specified.
Then, from the next year, 2007, a system of engine
authorization (homologation), under which major engine
specifications could not be modified once they had been
registered, was introduced one year earlier than initially
scheduled. At the same time, the use of variable
geometry intake manifolds, previously allowed, was
prohibited. The introduction of this homologation system
represented a significant change in orientation for the
Formula One philosophy, which as indicated above is
based on free technical competition. Broad-ranging
development efforts, seeking even minor enhancements
of basic performance, were concentrated in the period
immediately before the submission deadline for engine
homologation applications, but following this, engine
development was largely limited to subtle modifications
within the allowable scope or tuning of characteristics.
In order to more thoroughly embody the way of
thinking that sources of drive power other than engines
should not be basically allowed, and to prohibit the
hybrid systems that some teams were said to be using,
in 1999, power sources other than 3000 cm3 engines
were prohibited, and the maximum recoverable stored
energy was restricted to 300 kJ (the maximum stored
energy recoverable at a rate greater than 2 kW was
restricted to 20 kJ). From 2009, however, the use of a
type of hybrid system called a Kinetic Energy Recovery
System (KERS) has been allowed with the intention of
promoting the development of environmental
technologies through the medium of motor sports. These
are the only systems excluded from the regulations
discussed above. The maximum energy that can be input
to or output from a KERS is 60 kW, and a maximum
of 400 kJ can be recovered per lap.
Refueling during a race was prohibited for some
time, but this prohibition was lifted from 1994, focusing
attention on pit stop timing and the amount of refueling
as aspects of race strategy. In line with this, technologies
associated with aircraft refueling systems were applied,
and from 1995 regulations stipulated the use of identical
refueling systems able to safely and rapidly supply at a
fixed refueling speed.
With regard to the composition of the fuel employed,
while the interpretation that Formula One fuels should
fundamentally be based on commercial fuels was upheld
in the 11 th round of the 1992 season(2), from 1999 to
2002, detailed rules concerning the ratio of various
hydrocarbons in the fuel made it possible to use fuels
that had been developed for the purpose of enhancing
commercial fuels in the future. In addition, as a response
to worldwide efforts to ameliorate global warming, from
2008, the regulations have stipulated the use of fuels
containing a 5.75% ratio of biofuels.
3.3. Chassis
In line with advances in electronic chassis control
10
3.4. Control
It is the fate of control systems in Formula One to
be constantly subject to regulations from the perspective
of driver aids ban. It is more challenging to regulate
engine-based torque control systems such as traction
control than chassis-based control systems, in the case
of which it is comparatively simple to make a judgment
based on whether a device is fitted or not. Since 1997,
a software validation in advance has been mandatory, but
even if the FIA inspections were to confine themselves
to a hotel room with the team members for several days
for each team in order to check source code, it would
still not be possible to achieve complete restriction.
Perhaps because regulations relating to this area had
reached their limit of operability, from the 5th round of
the 2001 season, regulations were abolished for all forms
of software excluding safety-related software, and engine
torque control became effectively free.
This did not only affect traction control. Development
has also proceeded in other areas, including engine brake
control and over-run control, which achieves a type of
ABS effect by using engine torque during braking to
help keep the rear wheel brakes from locking.
Launch control, which increases acceleration by
making maximal use of the tire grip at race start, which
changes moment by moment, also advanced
considerably. However, from 2004, launch control was
prohibited through detailed regulation of the method of
using the engine and the clutch, and the introduction of
a method of using standardized FIA data loggers which
should be fitted to vehicle to monitor the way of using
them.
Following this, from 2008, torque control, including
traction control, was once again prohibited because the
requirement to fit a standardized FIA ECU to vehicles
made it possible for the first time to accurately manage
the regulation.
3.6. Safety
The deaths of Roland Ratzenberger and Ayrton Senna
in accidents in 1994 resulted in a large-scale revision of
the regulations seeking a rapid enhancement in passive
safety. Continuous changes to the regulations have also
been made since then, and as a result no Formula One
driver has been killed in an accident in the intervening
15-year period. More details can be found in two
previously published papers(1),(4).
In the opening round of the 2001 season, the BARHonda vehicle being driven by Jacques Villeneuve ran
head-on into another vehicle and became airborne before
suffering a severe crash. Protected by a robust carbon
monocoque, Villeneuve escaped with almost no injuries.
Tragically, however, a wheel torn off the vehicle struck
and killed a track official. Since 1999, regulations had
already stipulated the use of suspension tethers between
the uprights and the chassis in order to help reduce this
type of accident, and standards have been raised each
year. However, given the fact that the achievement of
complete safety is not a realizable goal, the regulations
have continued to be enhanced since the following year.
3.5. Materials
There had previously been few rules in the
regulations concerning materials of formula one vehicles,
but attention was directed to them when the use of
beryllium alloys, which are harmful to human health,
became an issue, ultimately leading to restrictions on the
use of expensive lightweight and high-rigidity materials.
In 2000, materials with a specific modulus of elasticity
of greater than 40 GPa (g/cm3) were prohibited from use
in any part other than the moving parts of the engine,
and in 2001 this prohibition was extended to the entire
vehicle. In 2003, methods of testing compliance were
detailed.
While materials development programs had
previously been focused exclusively on the achievement
of low weight and high rigidity, in response to these
changes, fine control began to be applied to the
composition and process of production of materials, and
more advanced technologies were pursued, for example
11
102%
No tire
change
Enforcement of
parc ferme rule
Enforcement of
2 engines for 1
race event rule
Mel
Sep
Sil
Mza
Int
Average
100%
1 engine
for 1 race
event
Introduction
of 2.4L V8
engines
98%
96%
94%
Introduction of
engine
homologation
92%
Prohibition
of traction
control
90%
2000
2001
2002
2003
2004
year
2005
Competition between
multiple suppliers
Single tire
supplier
Fig. 1
12
2006
2007
2008
References
5. Conclusion
Formula One encompasses a variety of aspects,
including competition, technical rivalry, and
entertainment, and the like. Having failed to achieve a
good record of victories, it would be difficult to say that
Hondas activities during its third Formula One era
achieved their purpose in increasing recognition of the
company or enhancing its image. However, we applied
ourselves with a respect for sportsmanship, a dedication
to technical development, and an indomitable spirit. The
various technical outcomes and primary experiences that
were obtained are valuable assets to the Honda, and the
process itself can be said to be emblematic of the Honda
approach.
Author
Hiromasa TANAKA
13
Kazuo SAKURAHARA*
ABSTRACT
Honda has entered six models of V-type engines with 10 cylinders (below, V10 engine) and three models of Vtype engines with eight cylinders (below, V8 engine) as third-era Honda Formula One engines. The goals of
development were to achieve output approaching that of the second era, the turbocharged engine era, with natural
aspiration, and to realize a smaller, lighter engine with a low center of gravity, focusing on the vehicles height of
gravitational center, weight distribution and aerodynamics. Revising the structures of different parts, modifying materials
and surfacing processes, and making design engineering and evaluation technique progress among other advancements
resulted in per-liter power that is 100 kW/L greater than a second-era naturally aspirated V10 engine, as well as having
approximately 6500 rpm higher engine speed for peak output, being more than 50 mm shorter in length and about 70
kg lighter, having about 50 mm lower crank center height and more than three times the mileage. Honda has proceeded
with development of V8 engines with the goal of high engine speed and won a third-era victory. However, because
of regulations restricting maximum engine speed and an engine development freeze due to homologation regulations,
issues relating to drivability (below, DR) have been left unsolved.
1. Introduction
2.1. Regulations
Development of second-era engines continued for 10
years, 1983-1992, with Honda as an engine supplier.
During that period as well, engine regulations were
changing greatly, and in 1983, when Honda restarted
Formula One racing, the 1.5 L turbocharged engine was
the most common type. Subsequently, regulations
limiting boost pressure and total amount of fuel
consumption were put into place to limit outputs of more
* Automobile R&D Center
14
1984
1986
1987
1988
1989
1991
1992
1993
1995
1999
2000
2001
2002
2003
2004
2006
2007
2009
F1 engine regulations
2.3. Weight
This part discusses changes in the weight of engines.
As Fig. 2 shows, the weight of the engine alone was
120-130 kg even during the V6 era, and there have even
been some naturally aspirated V10 or V12 3.5 L engines
weighing 155-160 kg. Magnesium and titanium were
used at the time as materials to make engines lighter, but
even so engines could hardly have been called very light.
In 1992 and beyond, although this was not a works
activity for Honda, engine output seemed to stagnate, as
Fig. 1 shows, in part because of the impact of regulation
change and, the lack of competition among works engine
suppliers. For that reason, the chassis constructor teams
started emphasizing weight distribution and
aerodynamics, and making the engine lightweight with
a low center of gravity became more important than
before. As a result, engine development advanced year
by year during the era when Honda was racing as
Mugen-Honda, and engine weight reached as low as 122
kg by 1998.
Coming into the third era, there was even greater
need for lightness of weight, and development has
continued until V10 engines finally weighed just 89 kg.
780
740
Power (kW)
700
660
1.5L V6 T/C
620
3.0L V10
3.5L V10 or V12
580
2.4L V8
540
500
460
From Hungary GP
Mugen-Honda
420
1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008
Year
Fig. 1
170
3.5L V10 or V12
160
Weight (kg)
150
140
130
1.5L V6 T/C
3.0L V10
120
With out T/C system
110
2.4L V8
100
90
Mugen-Honda
80
1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008
Year
Fig. 2
15
RA005E
72
90
Power (kW/L)
143
240
Ps peak Ne (rpm)
12250
18700
633.0
581.5
160
89
109.0
58.5
Mileage (km)
400
1400
RA100E
Fig. 3
RA005E
Engine photo
16
3D design
CAE
Fig. 4
CATIA V5
17
5. Conclusion
This paper has looked back on Hondas Formula One
engines, using numerical values to compare the second
and third eras, which reminds us anew of how amazing
the technical advances have been over the course of 15
years. Because there are presently so many regulations,
there is little room for further advances such as these,
but it is still supposed that the technology will advance
bit by bit hereafter. Regardless of whether Honda returns
to Formula One racing, the company feels it must
endeavor to preserve the information network it has
created and pursue further technical advances (concepts).
Otherwise, in such a rapidly advancing world, it may
take a great deal of time to catch up if we again get the
chance to take part in Formula One engine development.
4. V8 Engines
Development of V8 engines, the use of which has
been obligatory since 2006, began in November 2004.
In May 2005, before any other team did so, Honda
conducted test runs on the Jerez circuit in Spain with a
prototype engine, a V8 adapted from the 2004 V10
model. Having a goal of maximum engine speed of
20000 rpm in Hondas 2006 racing engine, development
was carried on at a quick pitch, with first firing test on
dynamometer in August 2005. The result was Hondas
only third-era victory, at the summer Hungarian Grand
Prix, which proved the excellence of Hondas V8 engine.
Development was proceeding that sought an even higher
engine speed for 2007, but regulations limited engines
to a maximum of 19000 rpm. Meanwhile, homologation
regulations limited annual development of engines
themselves, and engine specifications have been
determined that have become the basis for the
development freeze since 2008, specifications that Honda
was unable to deal with satisfactorily. As a result,
transient combustion has not stabilized, and the 2008
prohibition on traction control has additionally caused
DR issues to emerge. Honda has taken measures as far
as development is possible, but has not achieved any
fundamental solutions. Since DR was still insufficient,
the season was a disappointing one. Talks with the FIA
resulted in a partial lifting of the development freeze for
2009, and Honda began development in October 2008
to solve DR issues in anticipation of the opening of the
next season, and confirmed in December that
performance was as targeted. Unfortunately, Honda has
withdrawn from Formula One activities, so it has not
been possible to prove the results of enhancements. The
emphasis in current Formula One engine development is
not to put the foremost priority on maximum output,
which has always been considered Hondas strength, but
rather on improving output characteristics, particularly in
the range where they affect DR, and on somehow
eliminating irregular combustion. The reason is because
even if output were increased by 10 kW, it would only
improve lap times by less than 0.1 seconds, whereas in
comparison poor DR makes the driver lift off the throttle
pedal while coming out of the corners, resulting in a loss
of more than 0.5 seconds. Honda engineers need to do
Author
Kazuo SAKURAHARA
18
Atsushi MANO*
ABSTRACT
In the racing world, the transmission is ordinarily referred to as the gearbox. Honda first tried developing an Formula
One racing gearbox with its third-era Formula One activities. To do this, it was necessary not only to develop the
technology, but also to solve several problems, including production, supply and operation. This article recounts how
Honda overcame these problems to bring a number of technological firsts to the racing world and gives an overview
of the advancement of Formula One gearbox technology.
1. Introduction
Fig. 1
Appearance of F1 gearbox
Final gear
Differential
Bevel gear
Clutch
Fig. 2
20
Ratio gear
Dog ring
Shift barrel
Shift fork
Rotary actuator
Fig. 3
21
Fig. 4
22
Clutch
Fig. 5
23
Twin
hydraulic
plungers
Bearings
20%
Churning
14%
Pump
21%
5. Conclusion
Although the third-era Formula One activities
resulted in only one race victory, they also gave birth
to seamless shifting and a number of other industry-first
technologies, so Hondas engineers could at least take
pride in such developments as they faced the closing of
this era. As development began, it was marked by one
failure after another, but the engineers learned many
things and grew along the way. This is the prize won
from participation in Formula One racing and will
certainly be an asset for Honda into the future.
References
(1) Mano, A.: Development of Gearbox Technology for
Formula 1, Journal of Society of Automotive Engineers
of Japan, Vol. 59, No. 9, p. 8-11 (2005)
(2) McBeath, S.: F1 transmission trends, Racecar
Engineering, p. 34-42 (2005)
Author
Fig. 6
Seals
2%
USD
Gears
62%
RA108
Atsushi MANO
24
Akio TONOMURA*
Shun KAWABE*
Nobuhisa NAKAYOKU*
ABSTRACT
The third era of Hondas Formula One participation started in 1998 with a stage of preparation for the return to
actual racing, which began in 2000 and extended up to their withdrawal in 2008. A summary view of the Honda
Formula One cars that were developed every year during this period of participation in competition is presented from
the perspective of chassis technology. An overview will be given of each years aims regarding the chassis and the
technology that was required for third-era Formula One racing, accompanied by photographs of the chassis. Each years
regulations and the aims of chassis development will also be surveyed from the separate perspectives of aerodynamics,
the chassis, and the like. The points on which development was successful will be discussed on the basis of racing
results, and points calling for rethinking will also be examined.
1. Introduction
26
27
28
29
30
31
32
12. Conclusion
The decade-long flow of Formula One chassis
development in the third era can be generally
summarized as follows. The years from 1998 to 1999
were the period of initial involvement with Formula One
racing in recent years, with the fundamentals being
learned from Dr. Postlethwaite and the Dallara engineers.
The years from 2000 to 2001 were a time of working
to get the cars at least up to a certain level by reducing
the weight in every part in order to reduce the height of
the center of gravity. The other main focus was assuring
reliability. In 2002, an attempt was made to take a step
forward from the fundamentals and address such issues
as suspension stiffness and body stiffness. However, the
vehicles that were the base for this effort had individual
unit variations because of the manufacturing quality, the
driving data evaluation methods and related matters did
not evolve to match the effort, and the development
stalled. The year 2003 brought advances in the
manufacturing quality of CFRP and all other parts, as
well as a new ability to engage in design while making
limited predictions of how it would affect the
maneuverability of the overall chassis package, including
the engine. This became the year of transition from
development of constituent technologies to development
with a view to the balance of a single whole vehicle. The
year 2004 represented a maturation and an evolution
along normal lines from 2003, with new aerodynamic
evaluation methods proving their worth. The car reached
the top level. The second place in the constructors
ranking earned in this year, however, turned out to be a
peak. In 2005 and thereafter, efforts were made to
overcome the differences between phenomena in the
actual machine and testing in a wind tunnel, and to
determine techniques for obtaining the optimal
performance from the tires, but these core technologies
proved elusive, and the car slipped back in the rankings.
It became apparent in 2007 that the regulations on
aerodynamics would be changed significantly in 2009.
This was taken as an opportunity to recover from a
moribund situation, and work was begun on development
of 2009 specification aerodynamics. The year 2008
turned out to be the final year of the third era. Although
the car finished eighth in the rankings, the preparations
for 2009 were steadily taking shape, and after Hondas
withdrawal, that technology was inherited by the Brawn
GP Formula One team and contributed to their finish in
the two top places in the opening race.
Formula One development in recent years has been
a puzzle about how to bring mutually antagonistic factors
that govern car performance into balance with each other
so that the level of the car as a whole can be raised. In
order to achieve a high-level balance among complexly
interrelated factors, it is necessary to evolve technology
that can accurately grasp the degree of contribution made
Author
Akio TONOMURA
33
Shun KAWABE
Nobuhisa NAKAYOKU
Development of Materials
during Third Formula One Era
Masami HOSHI*
ABSTRACT
The realization of high-power and high-efficiency powertrains, lightweight and compact vehicle frameworks, and
a high level of durability and reliability are necessary to increasing the competitiveness of Formula One race vehicles,
and material technologies are an essential factor in this. Honda has developed high-strength, high-stiffness, and lowdensity materials such as titanium-aluminum and aluminum metal matrix composite (MMC) materials in order to achieve
weight-savings in structural parts. The company has also developed low-friction and high-durability surface modification
technologies, in particular DLC coatings, for friction materials. For use in hybrid systems, Honda has developed
magnetic materials for use in motors and highly functional materials such as high-thermal-conductivity materials. These
material technologies have enhanced vehicle performance and increased race competitiveness.
Performance requirements
Engine
High power /
High thermal efficiency
Combustion efficiency
Enhanced intake and exhaust efficiency
Low friction
Mechanical loss reduction
Pumping loss reduction
Oil agitation loss reduction
Lightweight / Compact
Low-density materials
Low-friction materials
High wear resistance materials
Lightweight and
complicated (hollow)
structural technologies
Low friction
Transmission
High transmission efficiency /
Lightweight and compact
Narrow gears
Chassis
Lightweight / High stiffness /
Vehicle dynamics
Functional materials
High-efficiency magnetic materials
Fig. 1
F1 material development
35
Battery materials
PDU (Power Delivery Unit)
Electrical assembly technologies
3. Conclusion
For examples and more detailed discussion of
Hondas work in the development of materials
technologies, the reader is referred to the special edition
of the Technical Review dealing with materials(1)-(18).
While few of these materials are employed in massproduction vehicles due to cost, the knowhow and
guidelines in the area of element technologies gained
from their development do encompass aspects that can
be extensively used in development for mass production.
In conclusion, the author wishes to express his sincere
gratitude to Hondas suppliers, both domestic and
international, for their generous assistance in these
development projects.
References
(1) Ito, K., Asami, M., Koinuma, H.: High-performance
Shell Bearing from New Material, Honda R&D
Technical Review 2009, F1 Special (The Third Era
Activities), p. 240-242
(2) Mizoue, K., Kawahito, Y., Mizogawa, K.: Development
of Hollow Crankshaft, Honda R&D Technical Review
2009, F1 Special (The Third Era Activities), p. 243-245
(3) Munemura, T., Yamada, H., Ohnuma, T.: Development
of Titanium Exhaust Pipe, Honda R&D Technical
Review 2009, F1 Special (The Third Era Activities), p.
266-268
(4) Konagaya, D., Tanahashi, T., Tanaka, T.: Development
of High-performance Gear Materials, Honda R&D
Technical Review 2009, F1 Special (The Third Era
Activities), p. 271-272
(5) Sanada, T.: Development of Titanium Hollow Valve
and Study of Sodium-potassium Valve, Honda R&D
Technical Review 2009, F1 Special (The Third Era
Activities), p. 257-259
Author
Masami HOSHI
36
Kiyoshi KONDO*
Hajime ENDO*
Yasuhiro MOTOHASHI*
Satoshi NAKAMURA*
Kazushi OGIYAMA*
Nagao YANAGISAWA*
ABSTRACT
During the third era Formula One engine development, as a measure for increasing the engine power through an
increase of engine speed, the enhancement of the induction static efficiency and weight reduction of the moving parts
was focused on. From 2007, restrictions on the maximum engine speed and development of the engine except for the
induction and exhaust system were introduced. Therefore, the focus of the development changed to practical use of
dynamic effect of induction and exhaust pressure. Moreover, the driver-aids including traction control was banned in
2008, so attention moved to the development with the objective of shortening lap times, and including drivability
enhancements.
Also, to comply with new regulations concerning the longer use of engines, the restriction of use of materials, and
to respond to changes in actual usage in circuit running in accordance with the change of regulations, the subdivision
of the endurance mode and results feedback was performed, which achieved durable reliability in parallel with
performance enhancement.
This document describes the evolution of the engine as outlined above, and includes descriptions of technology
such as the lap time evaluation method and tools.
1. Introduction
2. Power
2.1. Era of High Engine Speed and High Output (2000
to 2006)
2.1.1 Increased engine speed and enhanced induction
performance
If Pse: Shaft output, Pmi: Mean effective pressure,
Vs: Stroke displacement, Ne: Engine speed, Psf: Friction,
then: Pse = (Pmi Vs Ne/2) Psf.
Thus, an effective way to increase the power is to
raise the engine speed, and Honda competed with the
other teams in increasing the engine speed and power.
Figure 1 shows the trend for the maximum engine
speed.
Hondas V12 engines in 1992 had an engine speed
of only 14400 rpm, but by the time the third era started
in 2000, the level was 17000 rpm. Although the
introduction of mileage extension regulations to make
one engine last over one race event, and then two race
events, slowed this growth, by 2006 it had still reached
20000 rpm in tests on dyno. However, for reasons of lap
time contribution and engine durable reliability, an upper
limit of 19600 rpm was set for the actual races.
When the target of the maximum power and engine
speed are fixed, the power peak engine speed is
determined from maximum engine speed, and the output
value can be estimated as shown in Fig. 2. This means
that the target output shortfall should be compensated for
by reducing the friction and enhancing the combustion.
The induction performance target for the power peak
engine speed was decided using a steady flow test, and
development was performed of the cam profile and port
layout, including the valve diameter, that was required
for achieving the desired horsepower by controlling
engine speed.
3.0L V10
2nd era
3rd era
2.4L V8
2600 rpm
Friction loss
and combustion
enhancement
Power (kW)
V12
V10
Mileage guarantee
2008
2007
2006
2005
2004
2003
2002
2001
2000
1992
1991
1990
400 km
500 rpm
Year
Fig. 1
Friction loss
enhancement
20 kW
Engine
speed
limitation
2000 rpm
3.5L
Fig. 2
39
2 deg
2.1.3. Combustion
In Formula One engines that require higher engine
speed and power, increasing the bore diameter is an
effective method of enhancing the induction and exhaust
performance.
However, increasing the bore diameter also increases
the combustion duration, which leads to decreased
thermal efficiency, power, resistance to misfiring, and the
like. As a result, measures for making combustion faster
were required. In the third era Formula One engine, the
bore diameter was increased to 97, and combustion
was enhanced to raise the compression ratio to 13.0. In
2003, a compound angle was added to the inlet valve to
enhance the in-cylinder flow and make the combustion
faster. Figure 4 shows the effects of shortening the main
combustion duration.
Compound valve
angle
1000 rpm
Fig. 4
6th
7th
Up to 2006
From 2007
Fig. 5
Bolt
180
Crankshaft
Valve
160
140
600
Conventional IM
25 GPa/g/cm3
2006 regulation
500
120
100
Time (sec)
200
1st
19000
240
40 GPa/g/cm3
2001 regulation
Gear
2.1.4. Friction
When reducing the engine friction, a factor that had
a particular effect was the friction in the valve train
system. The behavior of the valves was enhanced by
reducing the reciprocating mass and minimizing the
angular velocity fluctuations, which reduced the spring
load. In addition, the oil agitation resistance in the
cylinder of the Pneumatic Valve Return System (PVRS)
220
Conventional
Connrod
Piston
Piston
80
Piston
Block, Head
60
2007
2006
400
300
200
100
40
Cam cover, Fr cover
20
0
13000
0
0
4
5
6
Density (g/cm3)
10
Fig. 6
Fig. 3
40
14000
15000
19000
20000
2.2.2. Drivability
In 2008, the use of a common ECU was made
compulsory, and driver aids were banned. In the engine,
attention was focused on the fact that the banning of
traction control and restrictions on control resulting from
the common ECU affected lap times because of issues
of drivability (abbreviated here to DR) when coming
out of corners. Figure 10 shows two DR issues: (a) the
initial torque following at 8000 rpm, and (b) the torque
hole generated by misfiring as the air-fuel ratio becomes
-0.02
-0.04
-0.06
Power (kW)
N
o
d
a
t
a
20 kW
12 kW
Effect of end of straight engine speed (18500 19000 rpm) on lap time
0.00
Curve B
Curve A
15000 15500 16000 16500 17000 17500 18000 18500 19000 19500
Engine speed (rpm)
-0.08
-0.10
Mel Sep Bah Bcn Mco Mtl
Ind Mgc
Sil
Nur Bud
Ist
Fig. 9
Int
Circuit
Fig. 7
308
Lap time
Max car speed
95.45
95.4
304
95.35
95.3
18000
306
302
18100
18200
18300
18400
18500
Pedal
Engine throttle
95.5
Engine speed
Target lambda
Lambda
Target
torque
300
18600
Actual
torque
Fig. 8
Fig. 10
41
Drivability issues
Load
classification
Minimum load
Low load
Medium load
High load
Maximum load
3. Reliability
3.1. Guaranteed Endurance Distance
In the third era Formula One, engine operation (use
distance) has changed greatly since 2004 due to changes
in the regulations. For this reason, each year a review
was held of the guaranteed durable reliability distance
for the engine. Descriptions of the specific regulations
for each year are omitted here, but the required
guaranteed distance for each session was determined
from the previous years results and the regulation
changes, and was used in the endurance tests on dyno
(Fig. 11).
3.2. Guaranteed Endurance Mode
In order to guarantee the Formula One engine durable
reliability, an endurance test mode needed to be set.
However, this could not be set only through engine
operation (use distance); the loads of each circuit also
had to be taken into account.
In the third era Formula One, loads were classified
into 5 levels to guarantee durable reliability.
3.0L V10
1350 km
2008
2007
2006
2005
1500 km
2004
2003
2002
2001
2000
1992
1991
1990
800 km
420 km
Time (sec)
Engine
homologa
-tion
20 kW
Power/L (kW/L)
Power (kW)
50 kW
Power
Power/L
400 km
Year
Fig. 11
Typical circuits
Monaco
Magnycours, Budapest
Bahrain, Barcelona
Istanbul, Fuji
Monza, Spa
2.4L V8
23% increase
Mileage guarantee
3rd Era
3.5L
2nd Era
800
750
700
650
600
Guarantee frequency
550
500
Actual frequency in race
450
400
350
300
250
200
150
100
50
0
10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000
Engine speed (rpm)
Fig. 12
42
340
330
320
310
300
290
280
270
#1
Fig. 13
#2
#3
#4
#5
#6
#7
Cylinder
#8
#9
#10
Ave.
4. Conclusion
In the third era Formula One development from 2000
to 2008, high performance Formula One engines were
developed that achieved high engine speed and high
output, and durable reliability for one engine over two
races, with the following results.
(1) An increase in the specific output of more than 230 kW/
L was achieved by increasing the engine speed, using
the dynamic effects of the induction and exhaust pressure
wave, enhancing the combustion, and reducing friction
in various areas.
(2) Circuit simulations were used to optimize the use of the
power peak engine speed, shift-up engine speed, and end
of straight engine speed for each circuit, and lap times
were shortened. Also, knowledge was gained about the
output characteristics for shortening the lap times.
(3) Verification of various operating conditions was
performed on dyno through the segmentation of the
endurance evaluation mode, maximizing performance
and providing durable reliability.
(4) In response to regulations regarding material restrictions
and extension of the use of engines, durable reliability
was provided by using CAE technology and through the
development of engine oil.
Author
Kiyoshi KONDO
Yasuhiro MOTOHASHI
Kazushi OGIYAMA
Hajime ENDO
Satoshi NAKAMURA
Nagao YANAGISAWA
Acknowledgements
The authors would like to express their deep gratitude
to Nippon Oil Corporation for their cooperation in
engine oil development and in the transportation of oil
for the Grand Prix.
43
Kiyoshi KONDO*
Hajime ENDO*
Tetsuo GOTOU*
ABSTRACT
Through the third Era of Honda Formula One challenge, it was the technical trend that the Formula One engines
were considered to be one of the elements of entire race vehicle. The engines were carefully designed to have such
characteristics as compact size, light weight, low center of gravity and enough stiffness. These characteristics of engines
were very important to increase aerodynamic and vehicle dynamics performance in order to reduce lap times on the
race tracks. Moreover, Honda engines were always expected to have the highest power output amongst the all Formula
One engine constructors.
This paper describes how the engines, including the lubricating and cooling systems, were designed from the early
stage of development in order to satisfy all demands above.
1. Introduction
Oil cooler
Monocoque
Fig. 1
Radiator
Gearbox
Engine
(Mugen)
3.0L-V10
72
620
122
194.7
94.4
106
11.6
70.5
2000
2001
2002
2003
3.0L-V10
94
600
604.5
111
99
177
177.2
80
588
111.7
191.3
108
191.3
95
106
11
68.5
108
68.5
Oil tank
Warm air
Gas bag
Radiator
2. Engine Technologies
2.1. Engine Size, Weight, and Height of Center of
Gravity
Figure 3 shows annual changes in the total length,
weight, and height of the center of gravity (COG) of
Honda Formula One engines. Table 1 shows the engine
650
400
Fig. 3
2008
80
2007
450
2006
100
2005
500
2004
120
2003
550
2002
140
2001
600
2000
160
Length (mm)
180
2005
2006
2007
2.4L-V8
2008
90
581.5
90.9
171.6
88.6
163.5
97
103
6
63
490
95.2
165.5
95.1
165.1
106.35
9.35
58.5
700
Weight (kg)
COG (mm)
Length (mm)
Mugen
200
106
9
66
2004
Oil cooler
Cold air
Fig. 2
Year
45
A
2000
Mugen
A
Water jacket
between inserted
sleeve and
cylinder block
SECTION AA
2000
Honda
SECTION BB
Fig. 5
Drilled hole
(D = 3 mm)
Shell core
(t = 3 mm)
Water pump
Water pump
Radiator
Water pump
Radiator
Radiator
L-head
Block
R-head
2000 - 2001
L-head
Block
R-head
2003
(twin radiators for 2002)
Fig. 4
46
L-head
Block
R-head
2004 - 2008
Cylinder sleeve
Molding condition
Fig. 6
Drying condition
before casting
Material specs of
sand and binder
Cam case
(yellow)
2002
2003
5
Thrust gap from main journal to
counterweight
Radial gap from crank case to
conrod locus and counterweight
4
3
2
1
0
0
Gap (mm)
Fig. 7
Fig. 8
47
2004
4.2
2005
M10X1.25
M9X1.0
20
24.5
35
38.5
Fig. 11
48
50
2005
2004
Fig. 9
Fig. 12
35
35
35
34
34
9.4
10
9.4
10
9.4
10
6.4
10
5.4
10
19.5
20.5
20.5
20.1
2000
2001
2002
2003
Bolt size
Pin journal diameter
1.5
1.5
1.5
1.5
34
34
34
34
19.1
5.4
9
15
5.4
9
15
5.4
9
15
5.4
9
15
2004
2005
2006
2007
2008
Scavenging pump
and air separator
Lower mounts
Year
Fig. 10
Fig. 13
48
23.7
Vertical
Torsional
1.21
1.10
1.34
1.50
1.23
1.16
19.2
73.5
Fig. 14
Lateral
29
19.2
49
Original port
Fig. 16
80
VLV train
60
Crank pin
Crank main
40
Oil jet
Others
20
Modified port
120
Flow rate (l/min)
Leakage
protection
Centrifugal
force
leakage
t = 8 mm
x 2 rotors
Modified port
80
t = 8 mm
x 2 rotors
40
t = 16 mm
x 1 rotor
Total
0
0
0
Fig. 15
4000
7000
10000
13000
Oil distribution
Fig. 17
50
own inertia (Fig. 19). This design was not optimal for
stable collection of oil, because the oil did not collect
in the SCAV pump inlet when cornering G force was
produced in the opposite direction. The use of an oil trap
in the SCAV pump inlets from 2004 increased the
efficiency of oil collection (Fig. 20).
An internal compression SCAV pump was introduced
in 2003 in order to increase pump efficiency. Formula
One SCAV pumps collect a mixture of oil and blow-by
gas from inside the crankcase at an absolute pressure of
20 to 40 kPa, and send the mixture through exhaust
channels pressurized to levels of between 150 and 250
kPa. This represents a compression ratio of between 4
and 12. Used at such high compression ratios, a
compression pump is more efficient than a conventional
displacement pump (Fig. 21). Torocoid pumps are able
to be used for internal compression, and a torocoid pump
could be modified for the purpose simply by changing
the port shape for delayed opening. Pump damage when
oil alone was absorbed would become an issue, and this
was responded to by positioning a relief valve on the
rotor side. A compression ratio of 2 was employed to
help ensure performance and reliability. This measure
reduced SCAV pump drive resistance by 30% and
engine friction by 3 kW.
SCAV
rotor
Fig. 19
Straight suction
To air box
Oil tank
3rd
SCAV
rotor
2nd
Main
Oil
cooler
Oil filter
Oil feed
pump
Fig. 20
Centrifuge
LHS
cylinder
head
Trap-type suction
t20
Crankshaft
Piston
oil jet
t11.5
t21.5
t16.5
t16.5
t16.5
P2
P2
Scavenging
pump
t16.5
t21.5
RHS
cylinder
head
Fig. 18
P1
P1
t11.5
t20
V1
Displacement pump
Oil system
Fig. 21
51
V2
V1
Compression pump
Output (kW)
Minimum water
jacket to prevent heat
transfer from exhaust
port
Heat
Water
10
Fig. 23
130
300
Water gallery
to prevent heat
transfer to
suction port
2003
2004
250
200
150
100
50
0
Head
(between
exhaust valve
seats)
Head
(between inlet
valve seats)
Head
(bore-bridge)
Block
(bore-bridge
upper)
Block
(bore-bridge
middle)
Place
Fig. 24
Fig. 22
90
100
110
120
Operating water temperature (C)
80
Temperature (C)
Thermal insulation of
exhaust gas
2000
Honda
Conventional
engine
52
3. Conclusion
A compact, lightweight, low center of gravity, highstiffness and high-power Formula One engine framework
with an excellent vehicle fit was progressively developed
to reduce lap times on the circuit by enhancing total
vehicle performance. The following results were
obtained:
(1) The reduction of engine size and weight progressed
through a fusion of material technologies, manufacturing
technologies, and framework design, including the design
of the cooling and lubrication systems. As a result, in
2005 (the final year in which 3L V10 engines were used
in Formula One) Honda reduced the weight of its engine
to 88.6 kg, producing one of the lightest and the most
compact engine among the Formula One teams.
(2) Reciprocating system parts and a high-efficiency
scavenging pump were developed in order to lower the
center of gravity, helping to enable the height of the
crankshaft to be reduced to 58.5 mm with a minimum
increase in friction.
(3) Making maximal use of the stipulations of significantly
revised engine regulations in 2006, the stiffness of the
engine was increased for the sake of the dynamic
performance of the vehicle. 2006 engine contributed to
an increase of 50% in the vehicles lateral bending
stiffness against that of the previous years.
(4) Feed pump technologies were developed to accept high
speed operation and hence enable more precise response
to oil demands in each part of the engine, a lightweight
and compact design, and a reduction in drive loss.
(5) The use of independent SCAV pumps provided with oil
traps at their suction ports increased oil collection
efficiency. The use of an internal compression technology
reduced drive loss by 30%, and the use of substitute
materials in the rotors halved their weight.
(6) The optimization of the water jacket configuration
reduced heat rejection and helped to ensure reliability
with operation at high water temperatures while
controlling performance loss, thus contributing to
enhancing the aerodynamic performance of the vehicle.
Author
Kiyoshi KONDO
53
Hajime ENDO
Tetsuo GOTOU
Tetsuo GOTOU*
Nagao YANAGISAWA*
ABSTRACT
Reciprocating parts and crankshafts for race use must display reliability and achieve low friction levels. Increasing
engine speed is an effective method of increasing the power of natural aspiration engines, and Honda increased engine
speed to 19600 rpm in 2006, prior to the introduction of upper limits for engine speed. In 2005, Formula One regulations
were changed to increase the distance for which engines would be used from one race event (400 km) to continuous
use for two race events (1500 km). In order to balance performance under severe use conditions with the achievement
of reduced friction, the shapes, materials, and manufacturing methods used for the reciprocating parts and crankshaft
were modified to reduce weight and increase strength and stiffness. In FY2008, the weight of the reciprocating parts
was reduced to 358 g, representing a weight saving of 41 g against the FY2000 figure of 399 g. This paper will
discuss the development process, focusing on each component part.
1. Introduction
2. Changes in Specifications of
Reciprocating Parts and Crankshaft
Table 1 shows annual changes in the use conditions,
specifications, and materials of the main reciprocating
parts, and Fig. 1 shows changes in the weight of the
parts.
The weight of the reciprocating parts increases in
some years. This is due, in 2002, to the change in the
cylinder bore diameter, in 2005 to responses to
regulations stipulating increased use distances, and in
2006 to the introduction of regulations prohibiting the
use of aluminum metal matrix composites (MMC) for
the pistons.
In 2004, despite the extension of use distances by the
regulations, the use of CAE analysis in MMC piston
design helped to enable the achievement of weight
savings in the pistons. The upshift engine speed was
basically increased each year, but regulations limited
engine speed to 19000 rpm in 2007.
2000
2001
2002
2003
2004
2005
2006
2007 & 08
400
1500
420
800
1350
17500
17800
18600
18800
19200
19200
19600
19000
95x42.24-V10
97x40.52-V10
97x40.52-V8
Bridge #rib
Radialy rib
# rib
Rectanglar
WR
Mono R
Titanium WR
18.7-MAS1C
17-MAS1C
17TiAl
17-HD200
I-section
Hollow
I-section
( 34/45)
( 36/48) ( 34/46) ( 33/45) ( 34/46)
( 35/52) NT100
GKHYW GKHYW GKHYW
GKHYW
NT100
400
Weight (g)
350
Piston
Recipro
total
Conrod
big end
300
250
200
150
00 01 02 03 04 05 06
Model year (year)
Fig. 1
'07 and 08
3. Piston Development
The pistons are directly affected by the energy of
combustion gases, and must withstand maximum
combustion pressures of 7 t and inertial forces exceeding
2 t while being exposed to temperatures in excess of
2000C.
The general orientation of the development program
was to reconcile high strength with low weight. CAE
was introduced at an early stage to assist in the
realization of optimal designs. In the initial stages of
development, Honda CAE specialists were requested to
perform simulations, but by degrees designers themselves
became able to construct 3D models, and made
judgments regarding strength and stiffness from the
results of CAE analyses incorporating combustion
pressure and inertial forces. CAE also helped to enable
designers to study temperature distribution, thermal
deformation, and thermal stress, and the ability to predict
lifespans and allowable operating conditions for parts
from the results of such simulations increased the
accuracy with which the shapes of parts were evaluated
(Fig. 2).
The use of these analytic techniques led to a variety
of changes being made in the shapes of pistons. The
initial external shape of the pistons featured a skirt
extending around the circumference, and ribs radiating
for equal lengths in eight directions. To reduce the
weight of the pistons, their shape was modified to use
curb ribs (# ribs). This helped to enable the realization
Temperature distribution
Thermal deformation
Fig. 2
Radial rib
Fig. 3
55
# rib
# bridge rib
Development of Reciprocating Parts and Crankshaft in Hondas Third Formula One Era
Thermal stress:
50 MPa
Fig. 4
Thermal stress:
75 MPa
Fig. 5
56
Inlet
Exhaust
Inlet
Exhaust
Fig. 6
High
jet
Low
jet
High
jet
Low
jet
At TDC
At BDC
Fig. 7
57
Development of Reciprocating Parts and Crankshaft in Hondas Third Formula One Era
Outer ring
Steel
Piston
Fig. 8
CrN
DLC
Ti
Piston
Fig. 9
WCC
Pressure
(kPa)
Blue: Titanium
expanded ring
Time (sec)
Fig. 10
Probe
Expander
Outer ring
Scanning
Outer jig
Inner jig
Fig. 11
58
6. Conrod Development
Fig. 13
Hollow conrod
7. Bearings Development
Fig. 12
59
Development of Reciprocating Parts and Crankshaft in Hondas Third Formula One Era
Table 2
Si-Cu
Thermal conductivity
0.2
Youngs modulus
159
50
(MPa)
570
420
(GPa)
148
210
15 m
Overlay
(PbSnInCuSiN)
0.2 mm
1.8 mm
Lining
(CuPbln)
Fig. 15
Backmetal:
Steel
20 m
20
Overlay
(PbIn)
0
20
20
20
40
2 mm
(W/mK)
40
40
Former
metal
60
40
F1
Production car
60
Horizontal bearing load (kN)
Fig. 14
Fig. 16
60
Lining =
Backmetal:
Si-Cu
8. Crankshaft Development
Crankshaft
Clutch
Fig. 17
Crankshaft
Fig. 18
Fastened clutch
Input shaft
Clutch
Heavy
metal
Dowel pin
M9 Bolt
Former weight
Fig. 19
61
Tightened weight
Development of Reciprocating Parts and Crankshaft in Hondas Third Formula One Era
9. Conclusion
(1) In the engine development process conducted during
Hondas third Formula One era, development efforts
related to the reciprocating parts and crankshafts, which
can be considered the core of the engine, produced
technologies that helped to enable the engine to satisfy
the stipulation for a lifespan of 1500 km at an upshift
engine speed of 19600 rpm, without having to protect
the parts through retardation of the ignition timing.
(2) The achievement of weight savings, reduction of sliding
resistance, and modification of the lubrication method
helped to reduce friction and realize a high level of
durability and reliability.
(3) During the third Formula One era development process,
designers became able to formulate 3D models and
conduct CAE analyses, helping to enable the realization
of greater accuracy in initial designs and more rapid
response to issues. The pistons and bearings are crucial
to the achievement of durability and reliability, and the
ability to reflect the results of analyses of cooling and
heat dissipation performance in designs in particular
helped to enable responses to be effected to demands for
increased lifespans.
(4) While the individual technologies developed for Formula
One engines and the development methods employed
Fig. 20
Oil
inlet
Fig. 21
Friction welded
Fig. 22
Hollow crankshaft
62
Author
Tetsuo GOTOU
63
Nagao YANAGISAWA
Shuichi HAYAKAWA*
Kazushi OGIYAMA*
Masanori TATE*
ABSTRACT
From 2000, the development teams involved in Hondas Formula One engine development program worked as
one in development efforts focused on the achievement of increased power through increased engine speed. As part
of these efforts, the configuration of the valvetrain was reexamined from the bottom up, and new mechanisms were
developed.
To enable the realization of high speed and high lift in the valvetrain, a finger follower system was employed as
the valve drive method in place of a bucket tappet system. In addition, the application of a measurement method
applying Bezier curves to the acceleration of the valve lift curves and the optimization of the gear train reduced
fluctuations in the angular velocity of the camshafts and enhanced valve motion.
Furthermore, it was necessary to reduce the excessive friction due to increased engine speed. In response to this,
the pneumatic valve return system was advanced by reexamining the configuration of the cylinder heads. The
development of electronically-controlled regulator system also contributed to reducing friction.
1. Introduction
2. Overview of Valvetrain
Table 1 shows the main specifications of the
valvetrain used in Hondas 2008 Formula One engine,
and Fig. 1 shows an external view of the components
of the valvetrain.
A variety of studies were conducted of the valve,
including those on the angle of the intake and exhaust
valves from the perspectives of increased volumetric
efficiency and enhanced combustion. For the intake side,
a compound valve layout that also displays an angle of
inclination in the longitudinal direction of the engine was
adopted. The intake and exhaust valves were the
components in which the maximum weight savings were
sought, and development proceeded on materials for
valves so that weight could be minimized within the ratio
Year
Engine code
Head
Control
Air bottle
PVRS
Gear train
Lift , valve timing
Material
IN
Surface treatment
Cam
Lift , valve timing
Material
EX
Surface treatment
Stem diameter
Valve diameter
IN
Material
Surface treatment
Valve
Stem diameter
Valve diameter
EX
Material
Surface treatment
Material
Finger follower IN/EX
Surface treatment
Air spring seal
IN/EX
IN
Reciprocating mass (g)
EX
Maximum engine speed for valvetrain (rpm)
Upshift engine speed (rpm)
2008
Honda RA808E
J-Valve
P2/P3EAR control
Carbon bottle 570 cm3
AVRS-G
13.5 mm 19/64
SCM435 nitriding
DLC
13.0 mm 19/64
SCM435 nitriding
DLC
5.8 (hollow stem 3.5)
41.6
Ti6246
DLC
5.8
32.4
KS64411Ta
DLC
SNCM815 carburizing
DLC
PTFE
50.0
45.6
20300
19000
2.4 L
V8
View of valvetrain
Air bottle
V10
2000
Fig. 1
3.0 L
Engine speed
limitation
V12
V10
Material
limitation
Mileage guarantee
420 km
400 km
2008
2007
2006
2005
2004
2003
2002
2001
2000
1992
1991
1990
Year
Air regulator
Fig. 3
Fig. 2
800 km
1350 km
1500 km
65
Camshaft
Shim
PVRS
piston
Cotter
Seal
Valve
80
Reciprocating mass (g)
Finger
follower
Others
PVRS piston
Valve
Finger follower
70
60
50
40
30
20
10
0
2000
Fig. 4
2002
Year
2008
2001 model
2008 model
Tensile stress
by inertia
Tensile stress
by seating
Thermal stress
Fig. 5
Fig. 6
66
Inlet valve
shape
50 mm/rad2 or more.
In the design of the valvetrain, considerations of
reliability and durability and the realization of increased
speed made it essential to set a level of valve lift
acceleration that considered the achievement of a balance
between the lift load for the PVRS and inertial forces.
A Bezier curve was therefore applied to the lift curve.
This type of curve enables designers to freely set valve
lift acceleration, and at the same time, vary the lift curve
in real time, simplifying the realization of the desired lift
curve. By this means, the negative acceleration of valve
lift was optimized with consideration of the PVRS
pressure characteristic, enabling the valve lift load and
inertial forces to be balanced to the limit point and the
maximum allowable speed for the valvetrain to be
increased by 1000 rpm. In addition, in order to balance
increased lift with a high compression ratio, the positive
acceleration of the valve lift was designed to display two
stages, with the level of lift being reduced only when
the clearance between the pistons and the valves was
low. This enabled the compression ratio to be increased
by 0.3. Figure 8 shows the two-stage acceleration
designed using the Bezier curve.
60
45
10
30
15
0
0
45
90
135
180
225
-5
0
270
-15
-10
-30
Speed
Acceleration
-15
-45
-20
14
Bezier acceleration
Previous acceleration
40
30
10
20
Lift (mm)
12
10
0
Difference in lift
between previous
acceleration and Bezier
4
2
0
100
125
150
175
Cam angle (deg)
Fig. 8
67
-60
Fig. 7
Acceleration [mm/rad2]
15
200
-10
-20
-30
225
Acceleration (mm/rad2)
Lift
Rear mass
Camshaft
Rear gear
Cam gear
Fig. 9
View of AVRS
Fig. 11
2000
2000
Angular velocity
[deg/sec]
2000
2000
Angular velocity
[deg/sec]
View of AVRS-G
AVRS
AVRS-G
AVRS
Fig. 10
Fig. 12
68
Cam quill
Viscous damper
Angular velocity
[deg/sec]
2000
2000
2.4 L V 8
Engine speed
limitation
V10
Material
limitation
5.0
Fig. 13
3.0L V 10
V10 engine
V8 engine
V8
Mileage guarantee
1350 km
2008
2007
1500 km
2006
2003
2002
800 km
Year
Fig. 15
Fig. 14
2001
2000
Cam damper
420 km
2005
400 km
2004
AVRS-G
Check/relief
J-Valve
Relief valve
Orifice jet
Oil
:Air flow
Fig. 16
69
4.2.3. Control
The J-valve mechanism was fundamentally designed
as a configuration in which there was no oil inflow to
the PVRS cylinder. However, the seals did allow tiny
amounts of oil into the cylinder, which would increase
the internal pressure of the cylinder if not dealt with. An
increase in the internal pressure of the cylinder would
lead to increased friction, and in addition seal ruptures
and sliding abnormalities could occur and lead to engine
troubles. In addition, the volume of oil inflow to each
PVRS cylinder was unknown. To respond to this issue,
a system of air line purge control was developed
enabling forced discharge of the oil that had accumulated
in the PVRS cylinder. Air line purge control enabled
variable control of the pressure in the PVRS cylinder by
means of electronic control of each EAR unit, and forced
air flow through the air channels. Figure 20 shows a
diagram of the P2 EAR unit.
The forced discharge of oil in the air line purge was
conducted by increasing the pressure on the inlet side
200
3.0 kW
-2.0
-1.0
0.0
1.0
2.0
3.0
4.0
10
8
6
4
2
0
-2
-4
-6
-8
-10
Friction (kW)
Setup of Check/relief
PVRS piston
PVRS liner
Jacket
(seal ring)
Quad ring
(seal ring)
5.0
Oil line
Fig. 19
Fig. 17
Front
IN
IN
EX
Air injector
Air injector
Oil tank
EX
Air bottle
P3 sensor
P1R sensor
P2 sensor
Air charge
Rear
From engine (P3)
Air injector
To engine (P2)
P2 EAR assembly
Fig. 18
P1 sensor
Mechanical
regulator
Fig. 20
70
View of P2 EAR
Maintenance of speed
Low engine speed
Delay
time
High
Low
Time
Fig. 21
5. Conclusion
During Hondas Formula One engine development
program between 2000 and 2008, the company
developed a valvetrain reconciling the achievement of
high speed with low friction. The following results were
achieved:
(1) Finger followers were employed as the valve drive
method, and materials development was conducted and
measurement technologies and CAE introduced to
respond to materials and long mileage regulations,
resulting in a 21.7 g (30%) reduction of the reciprocating
mass of the valvetrain.
(2) To respond to the necessity for increased power in order
to maintain competitiveness, valve lift acceleration and
the gear train layout were reexamined, enabling the
allowable speed for the valvetrain to be increased by 2700
rpm.
Author
Shuichi HAYAKAWA
71
Kazushi OGIYAMA
Masanori TATE
Ken NISHIMORI*
Masayoshi TAKAHASHI*
Yasuhiro MOTOHASHI*
Ryuichi FURUKAWA*
ABSTRACT
Induction and exhaust systems determine the amount of air intake supplied to the engine, and as such are critical
elements affecting engine output.
In addition, the layout of the induction and exhaust systems affects the vehicles aerodynamic performance, and
so it must be considered together with vehicle development.
At first, there were few CAE software and computer resources available, and induction and exhaust system
components were produced by measurement and guesswork so that development was largely performed on a trial and
error basis, but in recent years, the 3D-CAD and CAE software has advanced so quickly, and computer resources
have expanded so much, that development is done by simulation.
The enhanced phenomenon elucidation and forecast precision have made it possible to shorten the time it takes to
determine specifications and reduce development costs.
1. Introduction
2. Induction
Fig. 1
Fig. 3
Fig. 2
Fig. 4
73
Development of Induction and Exhaust Systems for Third-Era Honda Formula One Engines
Fig. 7
300
Torque [Nm]
Fig. 5
250
200
Without ABX and without splitter
With ABX and without splitter
With ABX and with splitter
150
6000
Fig. 6
8000
10000
Fig. 8
74
Effect of splitters
18000
20000
Fig. 9
Fig. 10
75
Development of Induction and Exhaust Systems for Third-Era Honda Formula One Engines
(b)
(a)
Fig. 12
Upper
Base
Fig. 13
76
3. Exhaust System
3.1. Exhaust Port
During the study of single-cylinder engines, it was
learned that flow rates from exhaust ports rose to nearly
the speed of sound and caused choking. In steady flow
tests, the flow velocity did not come close to the speed
of sound due to equipment capacity, and thus choking
was not recognized.
While in choke, flow depends on cross-sectional area
and the state of the fluid, so performance tests were
conducted after expanding the part with the smallest
cross-sectional area. Some enhancement of performance
was seen with the single-cylinder engine, but none was
observed in the V8 engine. In a single-cylinder engine,
choking occurs during the period of valve overlap from
blowdown, but in the V8 engine, there is a range where
pressure within the exhaust pipe is high compared to that
of a single-cylinder engine because of the effect of intercylinder interference, so it is believed that a high
pressure differential such as would cause choking does
not exist, so the same effect could not be achieved.
The cause of this is that, at exhaust-pipe diameters
that would be realistic on board a vehicle, it is not
possible to produce a diffuser effect that would cause
choking of the throat of the exhaust port of a V8 engine,
as shown in Fig. 15. However, by using expanding pipe
that brings flow velocity close to the speed of sound
within the exhaust port, staying within the range of
equipment that can be mounted on board and without
expanding port diameter, performance could be enhanced
at high engine speeds.
10
8
1.4
1.2
12000
13000
14000
15000
16000
17000
18000
19000
-4
-6
-8
V8 on dyno
Single cylinder engine on dyno
(correlated to V8)
Mach number
Ps [kW]
2
0
-2
1.0
0.8
0.6
0.4
0.2
0
-10
90
180
270
360
450
540
630
Fig. 14
Fig. 15
77
720
Development of Induction and Exhaust Systems for Third-Era Honda Formula One Engines
Tail
Collector
For dyno
Fig. 16
Primary
Section AA
A
Fig. 17
Stepped primaries
Fig. 19
78
Fig. 20
Fig. 21
10
-5
7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000
Engine speed [rpm]
Fig. 22
79
Casting collector
Development of Induction and Exhaust Systems for Third-Era Honda Formula One Engines
Fig. 25
20
15
10
5
0
-5
-10
-15
-20
6000
Balance pipes
4-2-1
8000
10000
Fig. 26
200
14000
16000
18000
150
12000
Section AA
Fig. 23
Balance pipes
25%
100
50
14%
10%
4%
-50
-100
7000
Fig. 24
Fig. 27
80
9000
11000
13000
Engine speed [rpm]
15000
4. Conclusion
Through engine development during Hondas thirdera Formula One activities, we have learned the
following about induction and exhaust systems.
(1) The importance of induction and exhaust system design
that is mindful of the vehicle package became apparent
once again, and development techniques were created
that extract maximum performance from Formula One
cars.
(2) Even with racing engines, it is necessary to be aware of
torque characteristics at low and medium speeds, and is
important to design exhaust systems as a technique for
their enhancement.
(3) Induction system development techniques were created
that use CFD and can predict dynamic characteristics
from the design stage. If it is possible to predict the
dynamic characteristics of exhaust systems in the future,
this will enhance development efficiency even more.
(4) Test part-production techniques were implemented to suit
a short development cycle, and the time required to
optimize power characteristics and determine
specifications was shortened.
References
(1) Nakamura, S., Motohashi, Y., Hayakawa, S.:
Development of Wind Simulator Equipment for Analysis
of Intake Phenomena in Formula One Engines, Honda
R&D Technical Review 2009, F1 Special (The Third
Era Activities), P. 89-94
(2) Hanada, N., Hiraide, A., Takahashi, M.: CFD Technology
for Formula One Engine, Honda R&D Technical Review
2009, F1 Special (The Third Era Activities), P. 82-88
Author
Ken NISHIMORI
Ryuichi FURUKAWA
81
Yasuhiro MOTOHASHI
Masayoshi TAKAHASHI
Naoki HANADA*
Atsushi HIRAIDE*
Masayoshi TAKAHASHI*
ABSTRACT
Simulation technology has advanced markedly in recent years, and various types of CFD models have come into
use for Formula One engine development.
However, to use such simulation modeling it is necessary to establish simulation technology for the unique conditions
for Formula One engines, such as that for high engine speed.
The pressure of each engine part was measured and in-cylinder gas motion and fuel spraying behavior were also
measured using a single-cylinder optical engine, enabling CFD technology that can be applied to Formula One engines
to be created.
1. Introduction
Test
CFD
Pressure [Pa]
200
Cylinder 6
150
100
50
0
0
180
360
Crank angle [deg]
540
720
180
360
Crank angle [deg]
540
720
180
360
Crank angle [deg]
540
720
180
360
Crank angle [deg]
540
720
360
Crank angle [deg]
540
720
Pressure [Pa]
200
Cylinder 7
150
100
50
0
0
Pressure [Pa]
200
Cylinder 8
150
100
50
0
0
Pressure [Pa]
200
Cylinder 9
150
100
50
0
0
3-dimensional
model
Pressure [Pa]
200
1-dimensional
model
Cylinder 10
150
100
50
0
0
Fig. 1
Simulation model
Fig. 2
83
180
Parameter
Old value
New value
Auto
0.8
Auto
0.5
Atmospheric temperature
400 K
1.0
2.0
(a) Test
(b) WAVE / not validated
(c) WAVE / validated
300
Pressure [kPa]
12000 rpm
200
100
0
Pressure [kPa]
300
14000 rpm
200
100
0
Pressure [kPa]
300
Fig. 3
16000 rpm
200
100
0
Pressure [kPa]
300
17800 rpm
200
100
0
0
180
360
540
Fig. 5
Fig. 4
84
720
Calculation region
Whole engine
4 cycles
Mesh density
(for combustion chamber)
1.5 mm
3. In-cylinder Behavior
Enhancing the combustion status is indispensable for
achieving engine performance enhancements. Besides
that, the current Formula One engine has longer
combustion duration than commercial engines because of
its high engine speed and big bore. Therefore, shortening
the combustion duration is necessary.
To shorten combustion, it was considered necessary
to adjust the in-cylinder gas motion and fuel distribution.
To do this, it is indispensable to be able to predict incylinder gas motion and simulate fuel spray and mixture
distribution formation.
Seeding
equipment
Airbox
Head
Laser
Camera
Engine
PC
Controller
Fig. 6
Fig. 7
85
Laser
sheet
View
Simulation
PIV
Simulation
PIV
PIV
Simulation
Vortex center
2 vortexes
(a) Port length 200 mm
Fig. 8
86
This shows that with both the 1.2 MPa and 10 MPa
injectors, the calculations were able to sufficiently
express the actual spray form.
It was learned that for in-cylinder mixture forms to
converge in calculations of fuel spray in the engine,
about five cycles are necessary. Figure 10 shows the
cycle history of in-cylinder average A/F and A/F
variance when calculating sprays in an engine using a
10 MPa injector. Fuel injected from the trumpet end face
begins to enter the cylinder on the second cycle after
injection, but the amount is small. This figure can be
read as showing in-cylinder fuel behavior converging
from the fourth to fifth cycle. To give some margin, it
was decided to conduct the analysis with five cycles.
Figure 11 shows the results of photographing incylinder spraying and the calculation results.
The measurement results are colored to represent the
degree of photographed brightness. In the calculation
results, spray droplets are represented by dots, and the
broken line shows the approximate area in which the
droplets occur.
With the pintle, the fuel spray has large particles and
the spray has great inertia. That is why, as the
photograph taken at crank angle 120 deg shows, the
spray entering the cylinder from the intake valve passes
below the exhaust valve and collides with the cylinder
wall. In contrast, the high pressure injector spray has
little inertia, and after it enters the cylinder, it rides the
flow of air down the cylinder toward the piston. In
addition, the spray entering from the intake valve enters
not only from the exhaust side but also from the port
bottom side that is opposite it.
To make the fuel pass through the entire combustion
chamber, it would be effective to reduce particle size and
inertia.
CFD
CFD
CFD
CFD
Test
CFD
Test
Fig. 9
14
A/F and variance
CFD
Averaged A/F
12
10
CFD
8
6
4
Variance of A/F
0
1
Cycle
Fig. 11
Fig. 10
87
References
Pressure [MPa]
(1) Takabayashi, T., Hotozuka, Y., Tsushima, H.: The Threedimensional Pulsation Flow Simulation and Its
Application for Engine Intake and Exhaust Systems, 2000
FISITA World Automotive Congress, F2000A091
(2000)
(2) Ishikawa, N., Hiraide, A., Takabayashi, T.: Air/Fuel
Distribution Simulation in a Port-Injected Gasoline LeanBurn Engine, SAE Paper, 2001-01-1230 (2001)
(3) Zhu, G., Reitz, R. D., Xin, J., Takabayashi, T.:
Characteristics of Vaporizing Continuous MultiComponent Fuel Sprays in a Port Fuel Injection Gasoline
Engine, SAE Paper, 2001-01-1231 (2001)
(4) Yang, X., Ohashi, T., Takabayashi, T., Kubota, S.,
Katsuyama, H., Urata, Y.: Ignition and Combustion
Modeling with G-Equation in Spark Ignition Engines,
The 13th International Pacific Conference on Automotive
Engineering (2005)
(5) Ohashi, T., Yang, X., Takabayashi, T., Urata, Y., Kubota,
S., Katsuyama, H.: Ignition and Combustion Simulation
in HCCI Engines, SAE Paper, 2006-01-1522 (2006)
(6) Yanagisawa, N., Hanada, N., Hamakawa, T., Ogiyama,
k., Goto, T.: Measurement Technologies for Formula One
Engines, Honda R&D Technical Review 2009, F1
Special (The Third Era Activities), p. 101-108
Test
CALC
330
360
390
420
450
Pressure [MPa]
Test
CALC
330
360
390
420
450
Fig. 12
4. Conclusion
Creating simulation models has been attempted to
allow development of Formula One engines with more
performance more quickly.
Simulations which use various models cannot
demonstrate their ability unless reliable validation is
conducted for each subject of calculation.
In the future, we hope to use the model validated and
created with Formula One to develop CFD technology
for engines that will be friendlier to the global
environment.
Author
Naoki HANADA
88
Atsushi HIRAIDE
Masayoshi TAKAHASHI
Naoki HANADA*
Yuji IKEDA**
Atsushi HIRAIDE*
Atsushi NISHIYAMA**
Kohei YAMADA*
ABSTRACT
Combustion diagnosis of a Formula One engine during wide open throttle (WOT) acceleration and deceleration
operations was performed using a micro-Cassegrain system.
The air/fuel mixture (A/F) in each cylinder was measured, which helped in the development of controls to minimize
the torque loss due to unstable combustion.
In transient conditions where acceleration and deceleration are performed repeatedly, the air/fuel mixture around
the spark plugs becomes too rich or too lean, and results in unstable combustion. In addition, the air/fuel mixture
formation is different inside each cylinder.
The fuel distribution to each cylinder needed to be controlled to a high degree of accuracy, and to do this, a highly
responsive air/fuel ratio sensor (LAF sensor) is required.
1. Introduction
Flame
speed
A/F
IMEP
Cycles
Fig. 1
2. Measurement Device
A V8 race engine in 2008 that had a displacement
of 2400 cm3 was used. Figure 2 shows the exterior of
the engine.
A micro-Cassegrain system (made by Imagineering,
Inc.) was used to measure the A/F around the spark
plugs.
When the flame passed a certain point (about 0.1 x
0.1 mm), the chemiluminescence intensities of four
r a d i c a l s ( O H , C H , C N , C 2) f r o m t h e f l a m e
chemiluminescence was measured using a band-pass
filter and a photomultiplier.
The intensity ratios of these radicals have an
unambiguous correlation with the equivalence ratio in the
flame(8)(16). This means that an approximate measurement
can be made of the flame propagation speed and the A/
F in the flame.
The measurement system was comprised of an optical
fiber sensor that measures the local chemiluminescence,
hardware that processes the chemiluminescence intensity
ratio in high-time resolution, control software, and a
monitor.
The sensor type used was an M10 spark plug with a
built-in Cassegrain optical element. The distance of the
focal point from the ignition position was 3 mm.
The effect on combustion by inserting the sensor into
the spark plug was checked. Figure 3 shows the results
of the evaluation of the combustion variation using the
pressure sensor. Normal spark plugs were installed for
cylinders 1 to 4, and spark plugs with the built-in microCassegrain sensors were installed for cylinders 5 to 8.
120
100
107.74
100.66 98.59 104.35 97.27
90.99 93.15
80
60
Normal plug
Sensor plug
40
20
0
#1
#2
#3
#4
#5
#6
#7
#8
Cylinder
Fig. 4
Fig. 2
107.25
90
Fig. 5
Ex. Ex.
Ex. Ex.
Ex. Ex.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
In.
(Rear)
(Front)
Ex. Ex.
Ex. Ex.
Cylinder 5 Cylinder 6
TDC
Cylinder pressure
Intake pressure
LAF output, etc
Fig. 6
Ex. Ex.
Ex. Ex.
Cylinder 7 Cylinder 8
Optical input
SPB2000
PC
DS2000
PC
DS2000
PC
120 km/h
300 km/h
300 km/h (Other Intake Box)
Cylinder 5
IMEP [MPa]
Pmax [MPa]
Cylinder 6
10
9
8
7
6
2.0
1.8
1.6
1.4
1.2
1.1
Lambda
1.0
0.9
0.8
FPS [m/s]
20
15
10
5
0.8
Fig. 7
91
0.9
LAF-L
1.0
0.8
0.9
LAF-L
1.0
IMEP [MPa]
Pmax [MPa]
Cylinder 5
Cylinder 6
10
6
2
2.0
1.6
Lambda
1.2
1.1
0.9
FPS [m/s]
0.7
20
15
10
5
0.8
1.0
0.8
0.9
LAF-L
1.0
Pmax [MPa]
10
0
2
1.0
0.8
1.2
Lambda
(a) MCS
(b) LAF
(c) Target
0.8
0.6
30
30
20
10
0
4500
4550
Cycle
4600
(a) MCS
(b) LAF
(c) Target
1.0
0.6
FPS [m/s]
Lambda
1.2
Fig. 9
Cylinder 8
2
IMEP [MPa]
IMEP [MPa]
Pmax [MPa]
10
FPS [m/s]
Fig. 8
0.9
LAF-L
20
10
0
4500
4550
Cycle
4600
92
4. Conclusion
The results obtained when combustion diagnosis of
a Formula One engine has been performed using a
micro-Cassegrain sensor are described below.
(1) Except under certain conditions, in WOT operations with
an engine speed of 18500 rpm, average cylinder Lambda
and Lambda around the spark plugs are approximately
equal and so are in a desirable state.
(2) Under the operating conditions described above, the FPS
is not influenced by the Lambda.
(3) The tendencies of the A/F distributions between cylinders
differ under WOT and partial throttle conditions.Even if
the average A/F in the cylinder is set to an appropriate
value using the LAF sensor, the A/F around the spark
plug may not be appropriate.
(4) The A/F behavior during transient operation was shown
to be different from that during steady operation. When
torque loss or unstable combustion occurred during
transient operation, the A/F around the spark plug was
too rich or too lean. Further, it was shown that the A/F
behaviors were different between cylinders even during
the same cycle.
(5) In the future, highly accurate fuel control will be required
under transient conditions, and to achieve this, highly
responsive measurement instruments will be required.
The micro-Cassegrain sensor provides this function, and
by using this instrument, it may be possible to accelerate
future engine development.
Pmax [MPa]
0
2
1
0
100
50
0
Lambda
1.5
(a) MCS
(b) LAF
(c) Target
References
1.0
FPS [m/s]
0.5
30
20
10
0
6900
6950
7000
Cycle
Fig. 10
93
20055017 (2005)
(4) Ikeda, Y., Nishiyama, A., Kawahara, N., Tomita, E.,
Baritaud, T.: Application of IR Absorption Method to
a Racing Engine, 2007 JSAE Annual Congress
proceedings, No.13-07 (2007)
(5) Ikeda, Y., Nishiyama, A., Bariatud, T.: Flame Speed
Measurement of a Racing Engine by IR Method and
Chemiluminescence Method, 14th Lisbon International
Symposium on Applications of Laser Techniques to
Fluid Mechanics (2008)
(6) Ikeda, Y., Nishiyama, A., Kim, S. M., Takeuchi, A.,
Winklhofer, E., Baritaud, T.: Cyclic Variation of Local
A/F and Mixture Quality in SI Engine Using Local
Chemiluminescence, Proc. of 7th international
symposium on internal combustion diagnostics, p. 277284 (2006)
(7) Ikeda, Y., Jeong, H., Nishiyama, A., Baritaud, T.:
Cylinder to Cylinder A/F Fluctuations Measurement
in a Racing Engine by Chemiluminesence, Porc. of 7th
International Conference on Modeling and Diagnostics
for Advanced Engine System, p. 535-540 (2008)
(8) Lee, J. G., Kim, K., Santavicca, D. A.: Measurement
of Equivalence Ratio Fluctuation and Its Effect in Heat
Release During Unstable Combustion, Proc. of the
Combustion Institute, 28, p. 415-421 (2000)
(9) Ohyama, Y., Ohsuga, M., Kuroiwa, H.: Study on
Mixture Formation and Ignition Process in Spark
Ignition Engine Using Optical Combustion Sensor,
SAE Paper, 901712 (1990)
(10) Ikeda, Y., Kaneko, M., Nakajima, T.: Local A/F
Measurement by Chemiluminescence OH*, CH* and
C2* in SI Engine, SAE 2001 Transactions, Journal of
Engines, Section 3, 110 (2001-01-0919) (2001)
(11) Ikeda, Y., Nishihara, H., Nakajima, T.: Measurement
of Flame Front Structure and Its Thickness by Planar
and Local Chemiluminescence of OH*, CH* and C2*,
SAE 2001 Transactions, Journal of Engines, Section
3, 110 (2001-01-0920) (2001)
(12) Ikeda ,Y., Kojima, J., Hashimoto, H.: Local
Chemiluminescence Spectra Measurements in a HighPressure Laminar Methane/Air Premixed Flame, Proc.
of the Combustion Institute, 29, p. 1495-1501(2002)
(13) Kojima, J., Ikeda, Y., Nakajima, T.: Multi-point timeseries observation of optical emissions for flame-front
motion analysis, measurement Science and Technology,
Vol. 14, P. 1714-1724 (2003)
(14) Ikeda, Y., Kawahara, N., Tomita, E.: Time-series A/F
Analysis in a SI Engine by Micro-Local
Chemiluminescence Technique, Proc. of 6th
COMODIA 2004, Paper No.C3-3 (2004)
(15) Kawahara, N., Tomita, E., Takeuchi, A., Arimoto, S.,
Ikeda, Y., Nishiyama, A.: Measurement of flame
propagation characteristics in an SI engine using microlocal chemiluminescence technique, SAE Paper, 200501-0645 (2005)
(16) Ikeda, Y., Nishiyama, A., Kawahara, N., Tomita, E.,
Arimoto, S., Takeuchi, A.: Spark-plug-in sensor for
initial flame analysis and its flame structure in an SI
engine, SAE Paper, 2005-01-0644 (2005)
Author
94
Naoki HANADA
Atsushi HIRAIDE
Yuji IKEDA
Atsushi NISHIYAMA
Kohei YAMADA
Satoshi NAKAMURA*
Yasuhiro MOTOHASHI*
Shuichi HAYAKAWA*
ABSTRACT
Formula One vehicles repeatedly accelerate and decelerate, reaching maximum speeds of 300-370 km/h and facing
maximum G forces of 4.0 G. Under driving conditions such as these, the vehicles wind speed (ram pressure) has a
significant effect on engine power. However, due to issues involving the fitting of measurement devices onto vehicles,
the prioritization of vehicle set-up work, and other factors, time has not been available for measurements to be taken,
and analyses of air intake phenomena due to ram pressure during circuit driving have not been conducted.
A wind simulator able to reproduce ram pressure during circuit driving was developed, enabling efficient
development of intake systems using bench tests.
In addition, dyno equipment with identical inertia characteristics to those of a vehicle drivetrain and a vehicle
simulator system able to simulate body characteristics, throttle and accelerator work, and the conditions of different
courses were added to the system. This enabled circuit driving modes to be used in bench tests, making it possible to
establish appropriate intake settings for each circuit.
1. Introduction
Development of Wind Simulator Equipment for Analysis of Intake Phenomena in Formula One Engines
2. Overview of Equipment
Air duct
Radiator
Oil cooler
Air box
Fig. 3
Inlet duct
Exhaust duct
Engine exhaust fan
Exhaust duct
Inlet duct
Inlet duct
Second floor
Air flow
Air ducts
F1 car
Blower room
First floor
Exhaust ducts
Blower motors
Fig. 1
First floor
L-side fan
L- dyno
Exhaust
duct
F1 chassis
Center fan
Current plate
R- dyno
R-side fan
Fig. 2
96
Control range
Windspeed
Max 4.0 G
Temperature
10-40 C
Humidity
30-90% (Rh)
Table 2
System specifications
<Dyno motor>
AC-motor mass Inertia
0.767 kgm2
2,000 rpm
M dnom
P mon
400 kW
N max
3700 rpm
<Gear box>
Max input speed
Transfer power
Gear ratio
22000 rpm
400 kW 2 (Max 800 kW)
9
0.015 kgm2
Inertia
Acceleration
Control speed
130000 rpm/sec
9 kHz cycle
Pitot sensor
Fig. 4
Wind direction
Helmet angle=16.5
Fig. 5
97
Development of Wind Simulator Equipment for Analysis of Intake Phenomena in Formula One Engines
Z (mm)
Area measured
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 5
10 15 20 25 30 35 40 45 50
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0.70
0.71
0.72
0.73
0.74
0.75
0.76
0.77
0.78
0.79
0.80
0.81
0.82
0.83
0.84
0.85
0.86
0.87
0.88
0.89
0.90
0.91
0.92
0.93
0.94
0.95
0.96
0.97
0.98
0.99
1.00
0 5 10 15 20 25 30 35 40 45 50
Y (mm)
0 5 10 15 20 25 30 35 40 45 50
Y (mm)
Y (mm)
Total Cp distribution
(18500 rpm, WOT, 300 km/h)
Total Cp distribution
(18500 rpm, WOT, 300 km/h)
(a) Track
(b) RV bench
Fig. 6
Dummy windscreen
Windscreen
Vertical fin
Fig. 7
Windscreen
Fig. 8
98
Front
Rear
Engine
Front side
120
115
At 120 km/h
At 340 km/h
110
105
Rear side
L_Bank
R_Bank
100
95
90
Fig. 10
85
80
35
75
5
4
3
2
1
0
-1
-2
-3
-4
-5
30
Temp. (C)
Value
Reduction
6C
Difference
(front-rear)
8C
20
15
10
5
0
Entry
Cylinder No.
Fig. 9
25
Track
RV dyno
With cooling duct
Fig. 11
99
Front
Rear
Development of Wind Simulator Equipment for Analysis of Intake Phenomena in Formula One Engines
5. Conclusion
(1) A wind simulator (ram pressure generator) and a vehicle
simulation system with circuit driving modes were
developed, and used to reproduce engine intake
phenomena during circuit driving on the bench.
(2) The establishment of a correlation between circuit driving
and bench test conditions enabled the length of time
necessary for air box development, the formulation of
settings for fuel compensation between cylinders, the
selection of intake pipe length, and other tasks to be
reduced.
(3) The use of a monocoque vehicle in the system enabled
the effects of heat damage to be verified, contributing to
the achievement of increased power in actual race
vehicles.
V bank
Fig. 12
Author
Satoshi NAKAMURA
100
Yasuhiro MOTOHASHI
Shuichi HAYAKAWA
Nagao YANAGISAWA*
Kazushi OGIYAMA*
Naoki HANADA*
Tetsuo GOTO*
Takeru HAMAKAWA*
ABSTRACT
In order to attain an accurate grasp of physical phenomena in the high-speed measurement environment of a Formula
One engine, it is necessary to be equipped with measurement systems capable of high-volume, high-speed sampling.
In addition, the accuracy of sensors and the vibration resistance of measurement equipment are important factors. It
is also necessary to reduce the size and weight of measurement systems in order to conduct measurements during
circuit driving. To respond to these performance demands, a variety of high-performance engine measurement systems
were used in Formula One development projects.
This paper will discuss combustion diagnosis using a misfire detection system, measurement of combustion pressure
and crankshaft behavior during circuit driving, oil pressure measurement, friction measurement, and the visualization
and measurement of the fuel spray and in-cylinder flows.
1. Introduction
Table 1
Item
Second era
Third era
Combustion
pressure
Crankshaft
twist vibration
Only dyno
Engine
vibration
Only dyno
Gear train
vibration
Measurement is impossible
2. Measurement Technologies
2.1. Combustion Measurements
2.1.1. Misfire detection system (MDS)
Because of the high speed of Formula One engines,
the combustion process is completed in a short period.
In addition, the on-off load when switching from wideopen throttle to fully-closed throttle is constantly
repeated. Because of this, the frequency of use of the
engines in an unstable state of combustion is high. A
misfire detection system (MDS) that is able to diagnose
the state of combustion under these conditions using
ionic current was developed, and employed in all races
from 2002.
Figure 1 shows the mechanism of generation of ionic
current. It has long been known that radical ions are
generated during the combustion process. Ionic current
is detected using the following two processes, and the
waveforms have two peak values(1):
(1) Detection of relatively long-lived C3H3+ radical ions
(chemical ions) generated when the flame surface passes
through the electrode during the initial stage of
combustion.
(2) Detection of NO2+ radical ions (thermal ions) generated
by thermal dissociation of N2 in combustion gases at
temperatures of 2000 K or higher.
Figure 2 shows the principle of ionic current
measurement. With the central electrodes of the spark
plugs used as ion probes, a positive electrical potential
of approximately 300 V is impressed, and the
C 3H 3 + ,CHO + , and NO 2 + radical ions generated by
combustion are captured.
The ignition coil energy is stored in the condenser
and used as a power source.
Hondas Formula One engines utilized a condenser
discharge ignition (CDI) system with a discharge time
of 70 s. This minimized the effect of ignition noise,
helping to enable the greater part of the combustion
period to be monitored.
Lean air-fuel mixtures are used during low fuel
consumption operation, but in this state engine
hesitation can occur and acceleration performance out
of corners can decline. Engine hesitation results from
misfires, or combustion states close to misfire, due to
ct
je
In
on
Ionic current
Injection
Combustion
Electron e
H3O+
C3H3+
Fig. 2
Ignition noise
High
Engine speed
Ignition noise
Throttle opening
100
%
Low
0
Thermal ion
Chemical ion
Lean
A/F = 14.5
Rich
Flame surface
e
e
Electron
C3H3+
2000 - 3000 K
NO2+
Thermal dissociation
H3O+
+ Radical ion
CHO
CmHn + O2
+
H2O + CO2
+
Fig. 1
A/F = 13.1
Fire
MDS output
(lean setting)
Fire
N2 + O2
NOx
+
NO2
MDS output
(best power setting)
Misfire
Time (s)
Fig. 3
102
Detected misfire
Crystal part
Combustion pressure
Seating noise
Diaphragm part
(sensing part)
Center of electrode
0
0
120
Fig. 4
240
360
480
Crank angle (deg)
600
720
Hydraulic pathway
in crankshaft
(%)
100
50
0
20
(x 1000 rpm)
18
Engine speed
16
14
12
(kPa) (km/h)
10
300
200
100
50
Car speed
Ram pressure
0
500
(kW)
300
100
Engine power of
PS plug (R + L)
(kW)
-100
300
100
Fig. 6
Engine power of gear
box sensor value
Crank pulse
from ECU
XR5000-WB
Sampling rate: 150 kHz
FV converter
KAZ-723A
Frequency
filter
FFT analyzer
P-84
Data logger
DR-R1 Mk2
Sampling rate: 200 kHz
-100
Time
Fig. 5
Fig. 7
103
On dyno
On circuit
DS2000
Measurement data
1.4
1.2
1.0
90 deg V-Angle
94 deg V-Angle
0.8
0.6
0.4
0.2
1.2
94 deg V-Angle
1.0
0.8
0.6
90 deg V-Angle
0.4
0.2
0.0
0.0
10 11 12 13 14 15 16 17 18
Ne 1000 (rpm)
Fig. 8
10 11 12 13 14 15 16 17 18
Ne 1000 (rpm)
15000 rpm
2500
1.4
#2Rr
#1Fr
#5Fr
#4Rr
Transmitter
Receiving set
Fig. 9
2000
1500
1000
500
STD crankshaft
0
Hydraulic pathway
Data analysis
Hollow crankshaft
-500
Data recorder
180
360
540
Fig. 10
104
720
Link mechanism
Single-cylinder engine
Fig. 11
350 Hz
2
425 Hz
500 Hz
1
0
18000 rpm
-1
16500 rpm
-2
CAE analysis
Failure example
18000 rpm
0
-1
16500 rpm
-2
14000 rpm
Strain gauge
Fig. 12
-3
-3
-4
10000
-4
12000
Fig. 13
105
14000
16000
Ne (rpm)
18000
14000 rpm
180
360
540
Crank angle (deg)
720
Load sensor
(3-axis type)
Outer sleeve
(beryllium)
Inner sleeve
(aluminum alloy)
Fig. 14
800
T.D.C.
700
600
Measurement system
Laser
500
400
Anti-thrust force
300
Interference
fringes
Thrust force
200
VZ
100
Laser
0
-100
-200
-300
0
180
360
540
720
B.D.C.
-1500 -1000 -500
500
1000
Measurement
area
1500
Y
X
Fig. 16
Fig. 15
106
4.E-07
2.E-07
Cylinder
head
Quartz sleeve
20
6.E-07
15
10
Quartz
sleeve
25
Fig. 17
0
-90 -60 -30 0 30 60 90
Position from center (mm)
Visual field
of stroke
Head extension
piston
20
15
10
Cylinder
block
0.E+00
-90 -60 -30 0 30 60 90
Position from center (mm)
0
-90 -60 -30 0 30 60 90
Position from center (mm)
Fig. 19
Visualization engine
View
Laser sheet
Laser
sheet
[Measurement section]
Direction of IN-EX
View
PIV
Fuel spray
Magnification proximity
photography
Simulation (Vectis)
Cross-sectional
photography
1 mm
0
Fig. 18
150 m/s
Fig. 20
107
150 m/s
3. Conclusion
This paper has discussed measurement technologies
employed in the engine development program in Hondas
third Formula One era. The vast majority of these
technologies were unavailable during Hondas second
Formula One era, and it is no exaggeration to say that
they provided the basis for the evolution of Hondas
Formula One engines during the third era. The authors
believe that the fusion of the measurement technologies
fostered by the Formula One development process with
the measurement technologies employed in the
development of mass production engines, will assist in
the development of environmental technologies and in
increasing the efficiency of the development process.
Reference
(1) Shimasaki, Y., Sakaguchi, J., Maki, H., Suzuki, H., Kato,
A., Nishizawa, K.: Study on Combustion Monitoring
System for formula One Engines Using Ionic Current
Measurement, Honda R&D Technical Review, Vol. 17,
No. 1, p. 56-64
Author
Nagao YANAGISAWA
Naoki HANADA
Kazushi OGIYAMA
Tetsuo GOTO
108
Takeru HAMAKAWA
Tetsuya TANAHASHI*
Yosuke SAWADA*
Kazuji ONO*
Atsushi SHIMIZU*
Masanori HAYAFUNE*
ABSTRACT
Important factors in boosting the performance of todays Formula One engines include: the realization of the
formation of ideal air-fuel mixtures and the achievement of greater combustion efficiency, through the use of shorter
fuel injection periods and increased spray atomization resulting from higher fuel pressures; and, in addition to this,
the achievement of stable combustion in the low-load operating range.
A comprehensive analysis of injector spray characteristics was conducted, leading to the development of a Hondamade high-efficiency, high-pressure fuel supply system. This enabled the achievement of a 15 kW increase in engine
power.
1. Introduction
16
2008 (V8)
14
12
Evolution of fuel system
+15 kW
10
8
2000 (V10)
Equivalent in V8
6
4
2006 (V8)
2005 (V10)
Equivalent in V8
2
0
0
Fig. 1
6
8
10
Fuel pressure (MPa)
12
14
Fuel pressure
regulator
Injector
Air box
Funnel
Difference in phase of intake air
pulsation (deg)
Collector tank
Throttle
valve
Gas bag
Fuel
Engine
4
10 MPa - 100 L/h_10 holes
1.2 MPa - 43 L/h_pintle
10 MPa - 100 L/h_6 holes
10 MPa - 100 L/h_24 holes
10 MPa - 120 L/h_24 holes
3
2
1
0
-1
-2
-3
-4
1.0
Fig. 2
160
In valve open
1.5
80
40
Inflow
0
-40
-80
Outflow
-120
-160
0
Fig. 3
90
4.0
Ex valve open
120
1.5
2.0
2.5
3.0
3.5
Period of effective fuel injection (msec)
180
270
360
450
Crank angle (deg)
540
630
720
1.0
2000
2006
0.5
2008
2005
2007
0.0
-0.5
-1.0
-1.5
10
Fig. 5
110
100
1.5
Difference in Pse (kW)
-1.0
0
Fig. 6
10
15
20
25
Number of holes
30
35
40
2.0
1.0
0.0
Static flow rate 100 L/h
Base value : 10 holes
-1.0
-2.0
0
Fig. 7
10
15
20
25
Number of holes
30
35
40
4
3
2
1
6 holes
10 holes
16 holes
In 6 holes + Out 10 holes
24 holes
0
-1
-2
-3
-4
60
Fig. 8
70
80
90
Penetration (mm)
100
110
111
Gear pump
Reduction
gear box
Reduction
gear pump
Plunger
pump
Plunger
pump
Final spec
Initial spec
Fig. 10
100
90
High-pressure
collector tank
Bladder
Gas bag
PRV
Filter
Low-pressure
collector tank
To engine
Primary
electric fuel pump
Secondary
electric fuel pump
70
60
50
40
30
Drive shaft
20
Fig. 9
80
112
Lowpressure
drop
Optimized
body
stiffness
Small
plunger
bore
Large
plunger
bore
Fig. 11
Modified
gear
thickness
80
70
60
50
40
30
Mass
production A
Fig. 12
Mass
production B
Mass
production
2005
Honda
2006
113
Solenoid
valve
Collector
tank
Engine
Needle
valve
regulator
Mechanical
pump
Diaphragm
regulator
FILTER
90
Orifice
Orifice
Spring
Low-pressure mode
Solenoid
valve
Collector
tank
Engine
Needle
Valve
regulator
Mechanical
pump
Diaphragm
regulator
FILTER
100
Orifice
Orifice
Spring
High-pressure mode
Fig. 13
40
Phase 1
Phase 2
Phase 3
Phase 4
00 - 03
04
05
06 - 07
08
Inj layout
Top
Top + NI
Top + NI
Top
Top
1.2
1.2
43
43 (NI:33) 55 (NI:55)
Pintle
35
Year
Response (ms)
30
25
20
Hole type
Number of holes
15
Injector type
Phase 5
10
10
78, 100
100
Pintle (NI:Multi)
Multi
Multi
(NI:6)
6, 10, 24
24
10
5
0
0
50
100
150
200
Fig. 14
6. Injector Development
Top
114
NI
Fig. 15
Injector layout 2
Year
2007
2008
Length (mm)
57
48
Diameter (mm)
20
16
Weight (g)
65
38
268
100
Coil resistance ()
2.8
1.0
Peak: 2.4
Hold: 0.6
6.0
115
Fuel pressure
Needle valve
Valve seat
Seat pressure loss
Plate feed pressure
(Upstream pressure of hole)
Hole plate
Fig. 16
2007
INJ
Fig. 17
2008
INJ
Fig. 19
Year
Static flow (L/h)
2007
2008
100
100
53
53
1.30
1.48
0.10
0.15
0.4
0.2
24
24
0.100
0.090
7. Conclusion
Fig. 18
116
Author
Tetsuya TANAHASHI
Kazuji ONO
Yosuke SAWADA
Atsushi SHIMIZU
117
Masanori HAYAFUNE
Takashi YOSHIOKA*
Katsumi KUBO*
Takeshi UCHIYAMA*
Ryo MATSUI*
ABSTRACT
Honda focused on gearbox development during its third Formula One era. The reduction of shift time is an effective
means of maximally increasing race competitiveness within the constant-mesh 7-speed gearbox regulations. In the
standard shift process, the current gear was disengaged, the system went into a neutral state, and the following gear
was engaged. Hondas seamless shift realized up-shift with a torque loss time of zero, by engaging the following
gear and then disengaging the current gear. Normally, this process would lead to damage due to double engagement,
but in the developed system double engagement was prevented and transmission of deceleration torque was enabled
by adding one-way clutches with a locking function to the conventional shift mechanism. The selective use of these
one-way clutches, positioned between the gear hubs and the mainshaft, and the use of cooperative control with the
engine, enabled the realization of seamless shift across the entire shift range. As a result, lap time was reduced by
0.4 sec per lap, and the system was used in races from 2005 as the first shift mechanism of its type in the Formula
One world.
This paper will also discuss the removal of the shift forks and shift rings as well as the fitting of the gear selection
mechanism inside the mainshaft in order to reduce the total length and weight of the mechanism while maintaining
its seamless shift performance.
1. Introduction
The shift mechanisms used in Formula One vehicles
are constant-mesh parallel twin shaft types, in which gear
stages are changed using dog clutches of the type
frequently employed in motorcycles. In the project
discussed in this paper, a shift mechanism was modified
at the initial stage of gearbox development in order to
boost the competitiveness of Formula One vehicles. The
development aim established to realize this goal was to
reconcile rapid shift (reduced shift time) with secure shift
(durability and reliability). In order to realize rapid shift,
acute chamfer angles were employed in the dog clutches,
barrel inertia was reduced, and the speed of operation
of the shift system was increased. The increase in shift
speed generated a number of issues, including
operational irregularities originating in shift fork
overshoot and inclination of the shift rings. In order to
prevent these issues, the forms of the barrel cams and
the shift forks were optimized to stabilize shift operation.
This helped to realize an equivalent level of
competitiveness with the vehicles of other teams, but
innovative technologies are essential to achieving victory
in the fast-evolving world of Formula One racing. In
2. Development Aims
Shifts using one-way clutches, as are often employed
in automatic transmissions in mass-production vehicles
for shift from 1st to 2nd gears, enable at least one shift
with no torque loss. The development aim established for
the project was to realize seamless shifts by developing
a shift mechanism in which this function could be
applied to all the gear stages in a Formula One vehicle
gearbox.
to the clutch, the lay shaft gear, the mainshaft gear, the
shift ring, the gear hub, the strut, and the mainshaft, and
is output to the tires. In a conventional shift, the gear
hubs and the mainshaft are connected by splines, but the
seamless shift mechanism employs struts that function
as one-way clutches between the gear hubs and the
mainshaft.
Figure 4 shows a state of double engagement, when
the next gear stage has commenced transmitting torque
and the dog clutch of the current gear stage is still
engaged, during up-shift using the seamless shift
mechanism.
When the dog clutch of the next gear engages and
the gear commences transmitting torque, the rotation of
the next gear stage becomes faster than that of the
current gear stage, and the strut of the current gear stage
is taken into the mainshaft pocket inside the gear hub
where it functions as the idling side of a one-way clutch,
enabling double engagement to be prevented. Because
Mainshaft gear
Shift ring
Gear hub
Strut
Mainshaft
Release bearing
Ball
Push rod
Fig. 2
Conventional shift
Drive by 5th
Strut
Neutral state
Drive by 6th
Mainshaft
Fig. 3
5th gear
Up-shift state
6th gear
Gear hub
Seamless shift
Drive by 5th
Double engagement
Strut
Drive by 6th
Mainshaft
Ball
Release
bearing
Fig. 1
Fig. 4
121
Ratcheting state
3.4. Downshift
The new system features the following major
differences from a conventional shift mechanism to
enable the realization of seamless shift:
(1) A shift barrel profile enabling a double engagement
timing to be obtained
(2) A mechanism enabling double engagement to be
prevented
To enable downshift using mechanisms that focus on
up-shift, when the release bearing has been released and
the system has downshifted from the current gear to the
next gear, the release bearing is locked again. In order
to release the release bearing, it is necessary to reduce
torque. This method increases the length of time that
deceleration torque is reduced against a conventional
shift mechanism. A shift barrel profile enabling
downshift without releasing the release bearing was
therefore proposed in order to achieve downshift in the
same short period as a conventional shift mechanism
while realizing seamless up-shift. Figure 6 shows the
shift barrel profile during up-shift. The shift rings and
the dog clutches engage when the shift fork stroke
reaches 39% or more, and the diagonally-shaded area in
the figure therefore represents a state of double
engagement.
4. Effects
The time-chart of engine speed, engine torque, and
wheel speed during up-shift were compared in order to
verify the effects of the seamless shift mechanism
developed in this research. Figures 8 and 9 show data
for conventional shift and seamless shift respectively.
The seamless shift realizes up-shift while maintaining
engine torque, enabling shift to be completed with no
loss of drive power. In a bench test simulating the
Silverstone Circuit, figures of 4 km/h when converted for
speed and 7.6 m when converted for distance at the end
of the home straight were obtained. The new mechanism
was employed in races from the 1st race of 2005.
Previous gear
80
100
Up-Shift
60
40
Next gear
20
100
0
0
20
40
60
80
Shift barrel angle [%]
Fig. 6
0
100
Shift barrel angle [%]
100
Strut
Mainshaft
Ball
80
60
Down-shift
40
Previous gear
20
Overrun state
20
40
60
80
Shift barrel angle [%]
Fig. 7
122
0
100
0
100
0
Release
bearing
Fig. 5
Next gear
Gear hub
100
100
100
5. Evolution
Engine speed
1000 rpm
Gear position
5th
5.2.2. Configuration
The in-shaft shift mechanism features an operating
range in which double engagement is used, and the
principle of preventing torque loss is the same as that
used by the seamless shift mechanism discussed above.
However, the configurations of the shift mechanisms
differ significantly. This section will discuss the parts
forming the mechanism and the roles of those parts.
Figure 12 shows the shift mechanism, including shift
gears. Each strut positioned between a shift gear and the
mainshaft moves in a seesaw fashion by means of small
and large balls, producing the following three essential
states for shift:
(1) An in-gear state, in which a strut simultaneously engages
and is locked in place, enabling acceleration and
deceleration torque to be transmitted (Fig. 13)
(2) A neutral state, in which the angle between the struts
and the mainshaft in the circumferential direction is
smaller than it is in the in-gear state and the gears and
6th
100 Nm
Input shaft torque
5 km/h
Vehicle speed
50 ms
Fig. 10
Fig. 8
1000 rpm
6th
Engine speed
Gear position
5th
100 Nm
Input shaft torque
5 km/h
Vehicle speed
50 ms
Fig. 9
Fig. 11
123
Figure 16 shows the timing of in-gear states for upshift and downshift. a shows the disengagement timing
of the current gear during downshift, b shows the
engagement timing of the next gear during up-shift and
downshift, and c shows the disengagement timing of
the current gear during up-shift. Different timings are
necessary for the disengagement of the current gear
during up-shift and downshift. This is necessary for the
same reason as was the case for the seamless shift
discussed above, but the method of achieving it differs
5.2.3. Operation
The process of shifting from the current gear to the
next gear is as follows:
(1) When the current gear is driving, the current gear is in
an in-gear state, and all the other gears are in neutral
states.
(2) Shift is commenced by the rotation of the barrel; the struts
of the current gear and the next gear are put in one-way
states simultaneously.
(3) When torque transmission shifts from the current gear
to the next gear, the strut of the current gear, which has
ceased transmitting torque, is put in a neutral state.
(4) The next gear is put in an in-gear state, and shift is
completed.
Fig. 13
In-gear state
Fig. 14
Neutral state
Idler bearing
Strut
Gear
Ball (big)
Fig. 15
Slide cam
Spring
One-way state
100
Barrel
Engage
(Up & Down)
Ball (small)
Engage area
Disengage
(Down)
Disengage
(Up)
Shift bearing
Mainshaft
Guide tube
Oil pipe
Fig. 12
Disengage area
0
10
20
ab
30
40
50
60
Barrel angle [%]
70
c
80
Shift
Fig. 16
124
Shift timings
90
100
6. Conclusion
A shift mechanism that has a modified shift sequence
to prevent torque loss during up-shift and selectively
uses one-way clutch mechanisms to prevent double
engagement was realized within the scope of Formula
One regulations. This development produced the
following outcomes:
(1) As the first shift mechanism of its kind in the Formula
One world, the new system enabled lap times to be
reduced by 0.4 sec per lap, and was used in races from
2005.
(2) The realization of up-shift with no torque loss and
minimal torque fluctuation during shifting enabled
shifting in situations of low tire grip, such as when
cornering or during rainy conditions.
The quest for increased compactness while
maintaining seamless shift performance by removing the
shift forks and dog rings and fitting the mechanism
inside the shaft enabled the total length to be reduced
by 19% and weight to be reduced by 12%.
Author
Takashi YOSHIOKA
Ryo MATSUI
125
Takeshi UCHIYAMA
Katsumi KUBO
Koichi KONISHI*
Teruoki NAGANUMA*
Hiroaki NOJIMA*
Hiroshi KIMURA*
ABSTRACT
Development programs were conducted to enable the development of Honda-made gears that balanced low weight
and compactness with reliability. Development of a technology for the formulation of gear specifications using FEM
analysis and a method of predicting the lifespan of the gears based on S-N curves, which formed the basis for FEM
analysis, helped enable continuous short-term development efforts. As gears would sometimes fail in actual vehicle
tests, a method of evaluation of lightweight gears optimized for high-load, short-lifespan race use was established
with the plastic deformation of the gears as an index. The lightweight, compact, and high-reliability gears developed
in this process were employed in races from 2003, and were entirely trouble-free.
In addition, a diamond-like carbon (DLC) coating optimized for race use was applied to all the gear tooth surfaces
to boost the performance of the powertrain, helping to achieve a transmission efficiency of 97%. The coating was
applied to different gear sets in sequence from 2007.
1. Introduction
Shift system
Carbon clutch
Fig. 1
Driven
gear
(a) 1 tooth meshing
Fig. 3
Mass production
gear shape
Fig. 2
Formula One
gear shape
Rotation
Drive
gear
1 tooth
meshing
2 teeth
meshing
1 tooth
meshing
2 teeth
meshing
2000
1500
Stress [MPa]
1000
500
Fig. 4
127
3000
2000
Reference line
1500
Tooth
deformation
1000
500
Fig. 7
0
1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07
Cycle
3000
Fig. 5
2500
2500
2000
1500
1000
11.6%
500
0
1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07
Cycle
Fig. 6
Broken gear
Fig. 8
128
2.0
Plastic deformation
2.5
1.5
1.0
0.5
0.0
0
500
1000
1500
2000
2500
3000
3500
Fig. 9
129
Churning
Non-loaded
Seals
40%
Bearings
Gears
6%
Pump
50%
4%
Loaded
14% 2% 20%
0%
Fig. 10
20%
62%
40%
60%
2%
80%
100%
34
140
33
130
32
120
2 kW
31
110
30
100
29
90
28
80
27
35
70
Carburizing
Fig. 11
Metal DLC
DLC
MoS2 spray
Sulfurizing
6. Conclusion
Gear surface
condition
Coating
Carburizing
Teeth touch
mark only
Fig. 12
Metal DLC
DLC
MoS2 spray
Sulfurizing
Acknowledgments
The authors wish to take this opportunity to express
their gratitude to the staff members of Nippon Oil
Corporation, who generously assisted in the development
of a low-friction oil.
Author
Koichi KONISHI
Fig. 13
Hiroshi KIMURA
130
Hiroaki NOJIMA
Teruoki NAGANUMA
Toshio HIYOSHI*
Haruki YOKOYAMA*
Yuichi SUENAGA*
Yoshikazu KATSUMASA*
ABSTRACT
The differentials used in Formula One vehicles comprise a differential mechanism and a differential restriction
device (LSD), which together form a bias-adjusting mechanism, and a final reduction gear set. Because the differential
is positioned close to the rear end of the vehicle, it contributes to dynamic performance. Reducing the weight of the
differential helps to centralize the mass of the vehicle, and increasing its compactness boosts aerodynamic performance.
Development efforts were concentrated on the achievement of a lightweight and compact differential, with the focus
in the initial stage on the centralization of mass. Previously mounted on the final driven shaft, the bias-adjusting
mechanism was positioned on the final drive shaft, helping to reduce the center of gravity and the yaw moment of
inertia. A full pinion engagement planetary gear was employed as the differential gear. A study of the merits and
drawbacks of the mechanism resulted in the development of an ultra-short differential (USD) employing a full pinion
engagement double pinion planetary gear positioned on the final driven shaft as the differential gear. It was predicted
that this would increase the compactness of the unit and reduce its weight by 1.2 kg.
1. Introduction
2. Development Aims
(2)
Front
(1)
Fig. 1
132
LSD piston/rod
Planetary gears
LSD clutch
Fig. 2
Final gears
Forward: 100 mm
Downward: 83 mm
Fig. 3
Diff area
LSD area
Fig. 4
Ring gear
Standard differential
Sun gear
Pinion gear
Clearance
Fig. 7
USD
133
Large
4.3. Durability
Verification of gearbox durability was essential, given
the regulation stipulates that gearboxes must be used for
four consecutive races. Rig tests were therefore
conducted using loads corresponding to four races on the
Monaco circuit, on which the frequency of use of the
differential is highest. In the initial durability test, fatigue
breakage occurred in the ring gears at approximately
60% of the target load. The following measures were
effected before the next durability test:
(1) The tooth root shape was modified.
(2) Shot peening treatment was applied.
The modification of the shape of the tooth roots
resulted in gear teeth being connected with a single
radius at the bottom. An image is shown in Fig. 9.
Previous shape
Single radius
Displacement
Engage
Disengage
Response time
Fig. 8
Modified shape
Long
Fig. 9
134
S-N
3500
Frequency
S-N without shot peening
3000
2500
2000
1500
1000
500
0
1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06
N [Cycle]
Fig. 10
3500
Stress amplitude [MPa]
+15% 3000
with
shot peening
2500
S-N
Frequency
S-N without shot peening
S-N with shot peening
2000
1500
1000
500
0
1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06
N [Cycle]
Fig. 11
5. Conclusion
A full pinion engagement double planetary gear was
employed in a differential mechanism in order to reduce
the weight of the mechanism, lower the center of gravity,
and reduce yaw moment of the vehicle. The following
results were obtained:
(1) Compared to the 2008 specifications, the weight of the
unit was reduced by 1.2 kg (-14% in terms of weight
ratio), and the vehicles inertial moment was reduced by
0.30% and its center of gravity lowered by 1.1 mm.
(2) The distance between the final drive shafts was reduced
from 125 mm to 100 mm.
(3) Tests showed that the performance of the LSD could
match the performance of the 2008 specifications.
(4) Tests showed that a sufficient level of reliability could
be achieved to satisfy the regulation that gearboxes were
not to be replaced for a four-race period.
Author
Toshio HIYOSHI
Yoshikazu KATSUMASA
135
Yuichi SUENAGA
Haruki YOKOYAMA
Koichiro INUKAI*
Ryuhei KATAOKA*
Yasuo NAKAGAWA*
Yoshiki NAGATOSHI*
Hiroyuki KUSHIYAMA*
Keiji SHIOTA*
ABSTRACT
A direct push clutch (DPC) was developed to enhance the controllability of clutch torque in a Formula One clutch
system. A direct push mechanism in which clamp force was generated by a plate with the function as lever and a
hydraulic actuator was employed in place of the previous mechanism, in which the clamp force was generated by a
diaphragm spring. The transition from stroke control to direct control of the clamp force did away with elements that
formerly produced changes in system characteristics, such as variations in the diaphragm spring characteristic and
spring hysteresis, and thermal expansion throughout the system. In combination with other enhanced control
technologies, this enabled the development targets for the system to be realized. This helped to enable half-clutch
starts (slip starts) to be employed from 2006, even after regulations prohibited the use of feedback control. As a result,
a maximum reduction in time from 0-100 km/h of 0.46 sec (corresponding to a distance of approximately 11 m) was
obtained, giving the vehicle a competitive advantage. The developed system was used in races from the first race of
the 2006 season.
1. Introduction
One of the important functions demanded from the
clutch systems used in Formula One vehicles is the
control of torque at the start of the race in order to
maximize tire performance. In 2003, feedback control
using the tire slip rate as a parameter was commonly
used to control clutch torque, enabling optimal clutch
torque to be realized. However, changes to the Formula
One regulations in 2004 prohibited the use of feedback
control, necessitating the development of a clutch system
in which clutch torque could be predicted with a high
degree of accuracy.
The friction coefficient, , of the clutch friction
material and the clamp force acting on the clutch friction
material (clamp load) are factors that affect the accuracy
of prediction of clutch torque. Of these, the clamp force
can be controlled in a clutch system.
The conventional Formula One clutch system was
termed pull clutch due to its mode of operation, and
it originated in the clutches used in mass-production
manual transmissions. A diaphragm spring was used to
apply a clamp load to the dry carbon clutch friction
material. A hydraulic actuator controlled the stroke in the
direction that would detach the diaphragm spring, and
clutch torque was controlled with the stroke as a
parameter. Factors including variations in the dimensions
2. Development Aims
The mechanism of production of clutch torque is
simple, and can be expressed by the following equation:
Tc = FNrmi
(1)
(2)
Fr: Friction
s: Friction coefficient of the seal
dp: Piston diameter
bs: Seal width
P: Hydraulic pressure
Pressure plate
Lever plate
Diaphragm spring
Fig. 1
Fig. 2
137
Fig. 3
(Inner diameter)
54 mm
(Outer diameter)
56 mm
4. Results
4.1. Effect of Use of Slip Start for Race Start
The application of the developed clutch system
enabled slip start to be used in the absence of feedback
control. Figure 5 compares time for acceleration from
0-100 km/h using slip start and dump start.
A comparison of acceleration times to 100 km/h
shows that the use of slip start provided a competitive
advantage by helping to enable a maximum time
reduction of 0.46 sec, corresponding to a distance of
approximately 11 m. This would enable the race vehicle
to overtake one lead vehicle by the first corner.
4.2. Characteristics of Clutch Unit
This section will discuss results obtained for the
differences in characteristics between the DPC and the
Clutch paddle
Clutch pressure
10.5 mm X 2
DPC
Engine speed
Pull
Acceleration
= 0.2G
Rear wheel speed
Car speed
Fig. 4
Fig. 5
138
100 kph
= 0.46 sec (11 m)
1000
800
Single-piston
600
Twin-piston
400
200
50
100
150
Actuator pressure [bar]
400
Load [daN]
Fig. 8
200
300
Race start area
240
200
0
-2
-1
Fig. 6
1
2
Release travel [mm]
100
160
120
Disengage
80
Engage
40
250
25
Disk wear = 0 mm
Disk wear = 0.6 mm
Fig. 9
200
50
75
100
125
Clutch actuator pressure [bar]
150
150
5. Conclusion
100
Race start area
50
0
0
Fig. 7
20
40
60
Actuator pressure [bar]
80
139
Acknowledgments
The authors wish to take this opportunity to express
their sincere gratitude to the staff of ZF SACHS Race
Engineering GmbH and technical consultant Leo Ress,
who collaborated in the development and manufacture of
the clutch unit discussed in this paper.
Author
Koichiro INUKAI
Yasuo NAKAGAWA
Hiroyuki KUSHIYAMA
Ryuhei KATAOKA
Yoshiki NAGATOSHI
Keiji SHIOTA
140
Atsushi OGAWA*
Takashi TAKIGUCHI*
Shujiro YANO*
Shinsuke NAKAMURA*
Susumu MASHIO*
Mitsuru SHINGAI*
ABSTRACT
The greater part of aerodynamics development for Formula One involves optimization using objective functions
of downforce and the lift-drag ratio (L/D), and verification of effects using wind tunnels and CFD in the development
process. As examples of development methodologies used to advance this optimization process, this paper will discuss
aerodynamics development tools, including wind tunnels and CFD, and the conventional development indices that
employed these tools. In addition, the paper will introduce new indices for analysis of the effect of tire deformation
on the aerodynamic load and analysis of transient aerodynamic characteristics during deceleration, and will also consider
the findings made regarding air flows using these indices.
1. Introduction
Downforce can be used to increase the side-force
limit on the tires when the vehicle is cornering and the
braking-force limit when the vehicle is decelerating. Air
resistance is an important factor in determining the
acceleration performance of the vehicle. The front-rear
downforce balance also contributes to vehicle stability.
The purpose of aerodynamics development is to
maximize either downforce or lift-drag ratio with
consideration of the trade-off between these three
elements.
During the development process, the vehicle shape
was optimized using a 50% scale model in wind tunnel
tests, following which effects were verified using fullscale wind tunnel tests. Simultaneous analysis of
aerodynamic phenomena using CFD and particle image
velocimetry (PIV) helped to enable the development in
the model-scale wind tunnel to move forward in an
efficient manner. It also became possible to a certain
extent to quantitatively evaluate aerodynamic load using
CFD, making it a tool capable of supporting part of the
optimization process. The importance of CFD is also
increasing as a bridge between wind tunnel tests and the
vehicle actually running on a race track. For example,
using CFD to reproduce the air flow when the tires were
deformed by side force, which could not be reproduced
using an actual vehicle in a wind tunnel, produced new
findings regarding the air flow around the vehicle
running on a race track. Some of these findings were
verified in wind tunnel tests.
FW load cell
Knife edge
Suction
Wind speed
Wheel drag
load cells
Blowing
Belt speed
Radiator
anemometers
Laser ride height sensors
Suction
Fig. 1
Fig. 2
143
Fig. 5
CCD camera 1
Mirror
CCD camera 2
Cylindrical lens
Traverse system
Traverse along x -axis
Fig. 3
(a) PIV
Fig. 4
Fig. 6
PIV setting
(b) CFDy+ - 1
(c) CFDy+ - 10
Fig. 7
144
Mesh propagation
Fig. 8
145
Rear RH [mm]
Fig. 9
70
65
60
55
50
45
40
35
30
25
20
10
15
20
25
30
Front RH [mm]
Fig. 10
35
40
At low-speed corners
Yaw rate
(large)
Equivalent
Vertical force
Side force
Fig. 11
Curved flow
Fig. 12
146
15000
10000
5000
(a) Baseline
-5000
120
Fig. 16
130
140
150
160
170
180
190
200
Time [s]
Fig. 13
350
345
340
335
330
325
320
315
310
305
300
295
290
120
(a) Baseline
130
140
150
160
170
180
190
200
Time [s]
Fig. 14
Fig. 17
Baseline
Fy: 9000 N
Fig. 15
Fig. 18
147
(a) Baseline
dCp
1.000e-01
5.000e-02
0.000e+00
-5.000e-02
-1.000e-01
Fig. 19
Fig. 22
Fig. 20
Outboard
Flow direction
(a) Baseline
Fig. 21
Fig. 23
148
dCp
1.000e-01
5.000e-02
0.000e+00
-5.000e-02
-1.000e-01
Fig. 24
Outbd
Inbd
Outbd
Fig. 26
Fig. 27
0.0
Downforce
Front squash
Rear squash
-2.0
-4.0
-6.0
-8.0
-10.0
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Maker A
2.0
Maker B
30 35 40 45 50 55 60 65 70 75 80
Wind speed [m/s]
Fig. 25
149
Inbd
q=
1
U 2 = const
2
Uwater =
Uair = 0.034Uair
water
Uwaterair
Reair = 0.47 Reair
Uairwater
U2
= const
gL
where g: acceleration and L: reference length, the
acceleration in water is expressed by
4.6
Fr =
4.5
4.4
CL
4.3
4.2
gwater =
Maker A
4.1
Maker B
4.0
3.9
30
35
40
45
50
55
60
65
70
75
80
Fig. 28
U 2water
gair = 0.0012gair
U 2air
Fig. 29
150
Fig. 30
Towing tank
Acrylic plate
5. Afterword
This paper has discussed aerodynamics development
indices used until 2008, and new indices such as the
analysis of the effect of tire deformation on aerodynamic
loads and the analysis of transient aerodynamic
characteristics during deceleration. These efforts
deepened understanding of the air flow around the
vehicle actually running on a race track.
Acknowledgments
The authors wish to take this opportunity to offer
their sincere thanks to all the staff members of the
former BAR and HRF1 for their many years of
assistance in aerodynamics developments, and also to the
staff of IHI Corporation who generously offered their
advice and assistance in the towing tank tests.
Author
Fig. 31
RW assembly
6000
Downforce [N]
5000
4000
Deceleration: 0.005 G
Constant speed
Constant speed
Constant speed
3000
Atsushi OGAWA
Shujiro YANO
Susumu MASHIO
Takashi TAKIGUCHI
Shinsuke NAKAMURA
Mitsuru SHINGAI
2000
1000
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Speed [m/s]
Fig. 32
151
Atsushi OGAWA*
Yasutaka MASUMITSU*
Susumu MASHIO*
Masayuki MINAGAWA*
Daisuke NAKAMURA*
Yusuke NAKAI*
ABSTRACT
Formula One vehicles are fitted with a variety of aerodynamic devices. This produces complex mutual interference
in the air flows around the vehicles, generating highly nonlinear flows. The clarification of these aerodynamic
phenomena helps to enable efficient optimization of aerodynamic devices. This paper will provide some examples of
findings regarding the air flows around Formula One vehicles obtained using wind tunnels and CFD.
1. Introduction
The shapes of the aero parts employed on Honda
Formula One vehicles were optimized using 50% model
wind tunnel tests and CFD(1). The chief consideration
during this process was the tradeoff between downforce,
the front-rear balance of downforce, and drag. Mutual
interference between the air flows around these aero
parts produced a strong non-linearity in the air flows
around the vehicles, and in practice it was not possible
to clarify the mechanism of all aerodynamic phenomena.
However, the use of CFD to analyze the core
aerodynamic phenomena did generate new findings
concerning the air flows around Formula One vehicles.
This paper will discuss some of these findings.
Upwash
Ground
Mirror
image
Fig. 1
2D ground effects
Actual inflow
Original inflow
Tip vortex
upwash of
mirror image
Tip vortex
upwash
Induced drag
Ground
Fig. 2
3D ground effects
MD + MD
Rear area
Front area
FR C1MD
LFR + LFR = (FR C1MD)C2l
Fig. 3
RR
LRR = (RR)C3l
Low
High
Fig. 4
Cone
Foot plate
Strake
Fig. 5
153
Front wing
Suspension
FW
Fig. 6
Fig. 7
0.25
0.50
0.75
1.00
2
FWEP vortex
Strake vortex
Tire vortex
4
Merged vortex
Merged vortex
Fig. 8
2 3
Fig. 9
154
Fig. 10
Bunny ears
Side wind
Fig. 11
Fig. 12
Vane
Vertical fence
Fox ear
Water wing
Barge board
Hammer head
Fig. 13
Barge board
Fig. 14
155
Barge board
Vane vortex
2
Upper vortex
Upper vortex
Lower vortex
Vane
HH
WW
Flap
Shadow plate
Fig. 15
BBD vortices
Fig. 17
O-nose fence
Fig. 18
ONF suction
TE wake
With barge board
Fig. 16
156
Vane vortex
Vane vortex
Upper vortex
Fig. 21
SPLEF
Lower vortex
1
Fig. 19
ONF vortices
Fig. 22
Surface streamlines
6. Bodywork
WW
HH
Fig. 20
Channel flow
157
(a) Flat SP
(b) Undercut SP
Fig. 23
Cp
Fig. 24
Fig. 26
Upper vortex
Fig. 25
Downwash flow
Fig. 27
158
Chimney
Upper flick up
Fig. 28
7. Diffuser
The Formula One regulations strictly determine the
dimensions of the diffuser (Fig. 31). Within the scope
of these regulations, the suction of the diffuser and the
underfloor area was increased by maximizing the
effective sectional area and minimizing the static
pressure at the exit.
7.1. Maximization of Effective Sectional Area of Diffuser
Exit
Separation in the areas in which pressure is
recovered, the in-flow from the upper section at the
diffuser tips, and the entry of the leading-edge separation
vortices of the rear tires can be indicated as factors that
reduce the effective sectional area of the diffuser exit
[Fig. 32(a)].
Pressure recovery is optimized by the kick-up shape,
the section shape, and the fence to produce as uniform
Fig. 30
(a) Closed
Fig. 29
(b) Open
Fig. 31
159
Diffuser
7700
Normalized rear downforce
Tire wake
(a) Velocity vector
(b) Cp
7600
7500
With separation
(acceleration)
7400
7300
With separation
(braking)
7200
Without
separation
7100
7000
0
20
40
60
80
Rear RH (mm)
Fig. 32
Fig. 35
8. Rear Wings
Fig. 33
Fig. 34
Diffuser Cp
160
Y300
Inflow
Upwash
distribution
Fig. 36
Fig. 39
Pressure coefficient
0.00
Red: Upwash
Blue: Downwash
Fig. 37
-1.00
-2.00
Y = -1 mm
Y = -50 mm
Y = -100 mm
Y = -150 mm
Y = -200 mm
Y = -250 mm
Y = -300 mm
Y = -350 mm
Y = -400 mm
Y = -450 mm
Y = -490 mm
-3.00
-4.00
-5.00
3.40
Total pressure
3.45
Fig. 40
3.50
3.55
3.60
X-coordinate (m)
3.65
Sectional Cp distribution
Fig. 38
Cp total around RW
Fig. 41
161
3.70
Reference
(1) Ogawa, A., Yano, S., Mashio, S., Takiguchi, T.,
Nakamura, S., Shingai, M.: Development
Methodologies for Formula One Aerodynamics, Honda
R&D Technical Review 2009, F1 Special (The Third
Era Activities), p. 142-151
RA107
Fig. 42
RA108
9. Afterword
The air flows around multiple bodies such as the
chassis of Formula One vehicles display a strong nonlinearity, and it is not possible in practice to understand
the detailed mechanisms of all the aerodynamic
phenomena involved. However, aerodynamics
developments were conducted efficiently by the use of
CFD for qualitative analysis of the core aerodynamic
phenomena, backed up by quantitative data obtained in
wind tunnel tests. These methods also enabled the
accuracy of predicting the aerodynamic performance of
the vehicle when it is actually running on a race track
to be increased.
Author
Atsushi OGAWA
Susumu MASHIO
Daisuke NAKAMURA
Yasutaka MASUMITSU
Masayuki MINAGAWA
Yusuke NAKAI
10. Acknowledgments
The authors would like to take this opportunity to
offer their sincere thanks to all the staff members of the
former BAR and HRF1 for their many years of shared
developments in aerodynamics, and to the other members
of the Honda team and staff members of other companies
who generously assisted in a wide variety of ways in
development projects.
162
Hideaki SHIBUE*
Kazuhiro TANEDA*
Yasutaka KITAKI*
ABSTRACT
No matter how superb the performance of the powerplant, unless that power can be transmitted efficiently and
effectively through the tires to the track surface, a race vehicle will not have a competitive edge. The most recent
technologies for the enhancement of the dynamic performance of Formula One vehicles are developed with a focus
on maximizing tire performance. The tires used in Formula One are designed for good performance only within an
extremely narrow range of conditions in terms of parameters such as tire contact state and tire temperature, in order
to enhance the performance of the tires to the limit. Therefore, understanding and controlling these conditions is an
important issue in the development of enhancement technologies for the dynamic performance of Formula One vehicles.
This paper will discuss suspension design and vehicle setup, two factors that affect tire performance, and the
development of a tire model to function as their theoretical basis.
1. Introduction
2. Suspension Design
x offset
Fig. 2
Standard
FPROU 10 mm rearward
FPROU 10 mm forward
-5
-10
Fig. 3
164
y offset
10
-10
-20
Pivot M
Fig. 1
Pivot M
Pivot N
Forward
0
Toe angle [deg]
10
20
Standard
FPROU 50 mm inside
-5
-10
-20
Fig. 4
-10
0
Toe angle [deg]
10
20
-4
-5
-10
-5
5
10
x offset [mm]
15
20
300
Apex
Fig. 5
2000
10
2200
0
-10
2000
2100
2300
RL (outside)
RR (inside)
2100
2200
2300
2100
2200
2300
6000
Tire vertical
load [N]
0
2000
5000
U/S
Tire longitudinal
force [N]
165
O/S
-5000
2000
2100
2200
Distance [m]
Fig. 6
2300
-40
-30
-20
-10
10
20
30
40
50
-5
-10
Delta of CoP
Delta of W/D
At low-speed corner
-15
-5
-4
-3
-2
-1
Delta of M/B
Fig. 8
10
-2
-4
-6
Low
Med.
High
-8
-10
0
10
20
Delta of M/B [%]
Fig. 9
Low
Med.
High
6
4
2
0
0
30
10
20
Delta of M/B [%]
30
3.0
3.5
2.5
2.0
1.5
1.0
0.5
0.0
Low
Med.
Turn-in braking
2500
1500
1000
500
0
-500
-1000
-1500
-2000
US
-2500
High
Low
Med.
High
Cornering speed
Cornering speed
Fig. 7
OS
2000
Fig. 10
166
T14
2
2005 Car
1.9
1.9
RA106
1.8
1.8
1.7
1.7
1.6
1.6
1
10
Timed lap
Fig. 13
10
Timed lap
85.0
2.0
84.0
1.5
1.0
Difference of
tire surface temperature [C]
2.5
Front outside
Front inside
Rear outside
Rear inside
0.5
0.0
-0.5
-1.0
83.0
82.0
2005 Car
81.0
RA106
-1.5
-2.0
80.0
-2.5
-40
-20
20
40
79.0
1
Fig. 11
5
6
Timed lap
10
2005 Car
4000
4.0
5000
Traction force [N]
RA106
3000
2000
1000
3.0
2.0
2005 Car
1.0
RA106
0.0
T2
T6
T11
T14
10
Timed lap
Turn
Fig. 15
Fig. 12
167
FL
60
60
55
55
50
50
45
45
40
40
2005 Car
35
35
RA106
30
30
1
3
4
Timed Lap
Fig. 16
3
4
Timed Lap
168
Thermal Input
Static
contact area
y
Tire workload
on contact area
x
Center line of tread belt
Fig. 17
Thermal transfer
to ground or air
Tread belt
Tire contact patch
Tread rubber
Thermal transfer
between layers
Fig. 18
169
8000
6000
4000
Force [N]
Force [N]
Force [N]
Target
Identification
Fig. 19
0
-2000
Measurement of tire longitudinal force
Measurement of tire lateral force
Measurement of tire vertical load
Calculation of tire longitudinal force
Calculation of tire lateral force
-4000
-6000
Target
Identification
Time [s]
2000
-8000
400
Time [s]
410
420
430
440
450
460
470
Time [s]
Fig. 20
170
120
80
60
40
Car speed
Measurement of tire surface temperature
Measurement of tire bulk temperature
Calculation of tire surface temperature
Calculation of tire bulk temperature
20
250
300
350
400
450
500
550
600
650
700
400
200
0
750
Temperature [C]
100
Time (s)
Fig. 21
5. Conclusion
As demonstrated by the technology introduced in this
paper, vehicle dynamics simulation technologies play a
significant role in developments relating to the dynamic
performance of Formula One vehicles. In addition to the
benefits of simulations in reducing costs and increasing
development efficiency, the very process of observing
phenomena, analyzing their mechanisms, and formulating
models to develop a simulation technology in itself leads
to dramatic enhancements in dynamic performance.
More recent developments, seeking further
performance increases and enhancements in development
efficiency, are progressing to the development and use
of a driving simulator, which represents an evolution of
vehicle dynamics simulation technology. The removal of
the various external factors associated with track tests on
a circuit enabled high quality test results to be obtained.
The driving simulator was applied not only in evaluating
the performance of development items, but also in the
formulation of vehicle development concepts and the
creation of indices for drive feeling in relation to
dynamic performance. It is expected that these
technologies will be actively employed in the
development of mass production vehicles.
Author
Hideaki SHIBUE
171
Kazuhiro TANEDA
Yasutaka KITAKI
Hajime WATANABE*
Terukazu EBISAWA*
Jun IWAI*
Kazuhiro TANEDA*
Naoki HIROMASA*
ABSTRACT
When developing Formula One chassis, reducing weight while still satisfying the functions and requirements of
each part was an issue for chassis design. The authors took into account the degree of contribution to circuit lap time,
and found a balance between functions and weight reduction during chassis development. The method used consisted
of reviewing materials and structures, and the weight of chassis parts was successfully reduced.
This paper introduces various examples of weight reduction.
1. Introduction
Rear suspension
Radiator
Rear wing
Airbox tray
Front suspension
Driver Monocoque
Nosebox
Front wing
Brake caliper
Wheel
Exhaust
Engine
Ballast
CoG
Fig. 1
Wheel
Brake caliper
173
Nosebox
(b) Four pillared structure
Fig. 2
Nosebox
(a) Conventional
cross section
Fig. 3
Weight Reduction and Stiffness Enhancement Technology in Formula One Chassis Development
Rohacell core
Fig. 5
Rollhoop structure
Distributed load
Fig. 4
Fig. 6
Pentagonal rollhoop
174
Engine cover
Anti-roll bar
Plies on sidepanel
eliminated
Fig. 7
Corner damper
Camber plate
Front track rod
Suspension mounting
area reinforcement
Brake caliper
Disc bell
Axle
Brake disc
Wheel nut
Fig. 9
Rocker
Fig. 8
Reinforcement method
175
Fig. 10
Drive shaft
Weight Reduction and Stiffness Enhancement Technology in Formula One Chassis Development
Fig. 11
Fig. 12
the spokes, and the spokes were changed from the shape
shown in Fig. 12 (a) to that shown in Fig. 12 (b). This
achieved a 56% increase in the stiffness to weight ratio,
which reached the target with a weight increase of
approximately 10%. The new wheel design was
confirmed in track tests to enhance the rear lateral force
and rear stability, and was therefore introduced to races.
3.2. Development of Brake Parts
Brake development focused on the issue of how to
achieve a high level of balance between the initial
braking force, braking force stability, and drag reduction.
One method attempted was to reduce the caliper body
weight. Formula One regulations stipulate that the caliper
body material must have a Youngs modulus of 80 GPa
or less, so this essentially limits the material to
aluminum alloy. Among various aluminum alloys, A2099
was selected, which features good durability (high
fatigue strength characteristics), low density, high
stiffness, high specific strength, and heat resistance
strength. Hydraulic stiffness is important for the caliper
body to secure a good pedal feeling, so the center bridge
shape was reviewed in consideration of the stiffness
balance, and unnecessary material was eliminated from
around the cylinder, which succeeded in reducing the
weight by 6% (Fig. 13).
3.3. Development of the Water Radiator
Water radiators and oil radiators are mounted in
Formula One cars. Water radiators radiate the heat from
engine cooling water in the same manner as those in
production cars, and are keeping the temperature ranges
at high engine efficiency. The cooling water is
pressurized to raise the boiling point and to prevent
cavitation. Current Formula One regulations stipulate to
install a pressure relief valve that opens at 3.75 bars, and
this valve is supplied from FIA.
The pressure upper limit is stipulated, and the liquid
side heat radiating area has only a small effect, so
development of the radiators was performed first for the
water radiator side with the goal of weight reduction
(Fig. 14). Development was initially started for the
qualifying specifications so that priority could be given
to weight reduction, even at the expense of durability.
Application to the qualifying specifications started from
2001, and the design was repeatedly modified for race
use thereafter, and introduced to all races from 2006.
Even though the pressure is stipulated, the radiator is still
Fig. 13
176
Brake caliper
Fig. 14
Water radiator
Fig. 15
177
Titanium exhaust
Hot stamping
Weight Reduction and Stiffness Enhancement Technology in Formula One Chassis Development
4. Conclusion
Formula One regulation stipulates a minimum weight
of 605 kg, including the driver. Therefore, the weight
reduction does not contribute to reducing the absolute
weight of the car, but to enhance vehicle dynamics
performance, which means increasing chassis
competitiveness. This is accomplished by replacing the
reduced weight with a ballast to lower the center of
gravity, concentrate the weight in the center of the
chassis, and expand the longitudinal weight distribution
adjustment range.
In addition, detailed regulations also stipulate the
materials allowed to use, so there is a limit to weight
reduction that can be achieved by simple material
replacement, which made us to work on approaches such
as structural changes based on an understanding of the
required functions and performance were needed.
(1) Reducing the weight of parts located above the cars
center of gravity is particularly effective from the
standpoint of lowering the center of gravity. This was
achieved with the rollhoop, engine cover, water radiator,
exhaust pipe, and other parts.
(2) Reducing the weight of parts that overhang from the front
and rear tires is effective from the standpoint of enhancing
turn-in performance (reducing the moment of inertia
around the Z axis (Izz)). This was achieved with the
nosebox, rear impact structure and other parts.
(3) Reducing the weight of the suspension parts and other
unsprung parts is effective from the standpoint of
enhancing vehicle dynamics performance, and targeted
parts such as the brake calipers, anti-roll bar, and wheels.
In addition, not only reducing the weight of these parts,
but also stiffness and function enhancements were
achieved.
(4) The monocoque weight was also reduced from the
standpoint of optimizing the stiffness.
In this manner, the development was performed to
Author
Hajime WATANABE
Jun IWAI
Terukazu EBISAWA
Kazuhiro TANEDA
178
Naoki HIROMASA
Hideaki SHIBUE*
Akihiro IDA*
Tomokazu SUZUKI*
Atsushi TSUBOUCHI*
Mamoru URAKI*
Yasutaka KITAKI*
ABSTRACT
Measuring and analyzing chassis data are the basics of Formula One vehicle dynamics development. The acquired
information is used in every stage of development, from design concept to race management. This paper explains
examples of data analysis techniques including competitor performance analysis, dynamic performance indices used
for chassis development and various techniques of measurement systems and sensors used in Formula One.
1. Introduction
The decisive difference of developing a Formula One
car against a passenger car is that the engineers cannot
drive and feel the cars themselves. Therefore, various
high quality onboard data and analysis tools are needed
to accurately understand the vehicle dynamics issues in
order to improve car performances. Some of them are
standardized to maximize tire performance during each
run. These data are obtained through real-time processing
using a telemetry system and being analyzed
automatically so that the engineers can determine car
setup for the next run whilst the car is still on the track.
Simulating tools had been developed as well to predict
and understand the phenomenon more in detail.
This paper introduces examples of the cutting edge
measurement systems and sensors, competitor
performance analysis technique including simulation
tools and the latest analysis techniques of the dynamic
performance indices.
Sensor
Sensor
2. Measurement Systems
ECU
VTS
Data
logger
Car settings
VAP
Sensor
Sensor
Sensor
Simulation
Lap chart
Camera
Radio
Video
logger
HRF
server
HRD/HGT
server
Data viewer
Simulation
Analysis
Design
Car system
Database
Software
Circuit network
Fig. 1
Circuit server
Support arm
for signal output
Fig. 2
180
Transmitter box
Processing box
Fig. 3
Conventional SGW
Battery box
Wireless SGW
Transmitter
measurement resolution.
In parallel with this, a method that uses an onboard
infrared camera to measure the tire surface temperature
was also developed. A compact infrared camera was
installed on the roll hoop where the video camera for TV
broadcasts is normally mounted, and temperature images
of all four tires were recorded using a four-sided mirror
(Fig. 7). There is also the method of mounting multiple
cameras aimed at each tire, but the mirror method has the
merits of light weight, compact size, and high data quality
due to recording all four tires at the same calibration. The
recorded temperature images alone are useful information
for evaluating the tire temperature distribution, but even
more information can be extracted by analyzing the
images using originally developed software, and
converting into temperature distribution data.
2.5. Strain Gauged Suspension (SGS)
The strain gauged wheels that directly measures the
force generated on the tires during running are useful in
track tests that evaluate dynamic performance, but the
increase in weight and the aerodynamic effects of the
special wheel shape cannot be eliminated, so use is
limited to tests. That is to say, a condition for the
application of measuring systems to races is that there
be no effect on vehicle dynamics if at all possible.
Therefore, development of the SGS was promoted based
on the concept of driving six tire forces from the loads
on the suspension arms (Fig. 8).
A Formula One car suspension uses a double wishbone
suspension type, but each arm is basically viewed as a
Camera
Fig. 4
Temperature sensor
Transmitter
FR
RL
RR
Fig. 7
Fig. 5
Sensor
Fig. 6
Fig. 8
181
Sensor sheet
Fig. 11
CPE sensor
DVS
CPE System
Fig. 12
T6
T9
T4
T9-10
T3-4
T9-10,end
T5
T10
T3
T8
EOS
T2
T1
Fig. 9
Straight
T7
FL
FR
RL
RR
Load cell
Fig. 10
Fig. 13
182
Temperature
120
110
100
90
80
70
60
50
40
Out
Lap1
Fig. 15
Lap2
2
1
Angle
Car speed
Lap3
Roll
0
Engine revolutions
RL
RR
-1
Outside camber
-2
-3
Inside camber
-4
Gear ratio
Fig. 14
-5
Acoustic analysis
Car A
Fig. 16
183
Car B
Image analysis
In
Car B
Car A
Fig. 17
Tire wear
Wheel speed
Sensor FL
Video FL
Fig. 18
Sensor RL
Video RL
Instantaneous
mass
Yaw rate
Inflation
pressure
Brake pressure
Engine brake
Lateral force
Tire loaded
radius
Long. force
Longitudinal acc.
Roll/Pitch
Speed
Camber
Drag
PW ratio
Damper length
Anti force
Pushrod load
Wheel stroke
Down force,
balance
Vertical force
Flexure force
Pitot pressure
Ride height
CoG position
Fuel
Pitch angular
inertia
Long. inertia
Vertical inertia
Vertical acc.
Fig. 19
Fig. 20
184
Longitudinal acc.
Instantaneous
mass
Category
Calculation
Measurement
Fig. 21
12000
y = 0.9973x + 0.2781
4000
12000
8000
4000
0
4000
8000
Fig. 22
12000
standpoint of vehicle dynamics development was realtime analysis of dynamic performance while running. At
circuits it is necessary to analyze running data, determine
the next setup, and determine which running modes need
to be added, all within the limited time after the vehicle
returns to the pit until the next run. Therefore, real-time
analysis was strongly desired by engineers engaged in
vehicle dynamics development.
With the introduction of this new telemetry system,
the logic of the automatic data analysis system was
transplanted to the Simulink model, which achieved realtime data analysis by processing data on the VTS. In
addition, the VTS can also be used as a post processing
system, and development of an integrated system is
proceeding with the aim of realizing a seamless
environment from real-time analysis to more detailed
analysis (Fig. 23).
VTS (live processing)
Car (running)
Car (running)
Telemetry
Garage
Garage
Car (back from track)
Outing D/B
vTagVAP
System monitor
ATLAS
ATLAS
ATLAS
Engineers
Fig. 23
Car data
vTAGServer
WBApps
Data offload
Outing D/B
ATLAS
VAP results
VAP
ATLAS
ATLAS
ATLAS
ATLAS
Engineers
Rear
16000
y = 0.9979x + 0.8252
8000
4000
8000
12000
16000
185
Fig. 24
Correlation coefficient
0.6
0.4
5% significance level
0.2
Insignificant
0
10
15
20
25
30
35
Number of samples
Fig. 25
45
Beginning of braking
35
Beginning of braking
CoP [%]
40
30
50
Circuit 2
45
Baseline (B)
Setup 1 (S1)
Setup 2 (S2)
40
35
Baseline 1 (B1)
Setup 1 (S1)
Setup 3 (S3)
Baseline 2 (B2)
Setup 2 (S2)
30
100
Fig. 26
150
200
Car speed [km/h]
250
50
100
150
200
250
1.0
0.8
0.6
0.4
0.2
0.447
Insignificant region
0.0
-0.2
Weak
-0.4
Medium
-0.6
-0.8
Actual load
Strong
Circuit 1
Time
T8 (S2, S3)
T8 (B2, S2)
T8 (B1, B2)
T2 (S2, S3)
T2 (B2, S2)
T1 (S2, S3)
T1 (B2, S2)
T1 (B1, B2)
-1.0
T3-T4 (B, S1, S2)
Current
car state
Significant
0.8
0.0
1.0
Forward
CoP [%]
Correlation coefficient
Circuit 2
Turn
Fig. 27
186
Acknowledgements
The authors wish to express their deep thanks to
related parties at Tokyo Sokki Kenkyujo Co., Ltd., for
their cooperation in developing the Strain Gauged Wheel,
Kyowa Electronic Instruments Co., Ltd., for their
cooperation in developing the wing load cells, TUV SUD
Automotive GmbH for their cooperation in developing
tire temperature sensors, and Bridgestone Corporation for
their cooperation in developing vehicle dynamics indices.
0.8
Correlation coefficient
0.6
0.521
0.4
0.447
0.2
Insignificant region
0.0
-0.2
Weak
-0.4
Medium
-0.6
-0.8
Strong
Author
Circuit 1
T9 (B2, S3)
T9 (S2, S3)
T9 (S2, B2)
T9 (B1, S3)
T9 (B1, B2)
T9 (B1, S1)
T8 (B2, S3)
T8 (S2, S3)
T2 (B2, S2)
T2 (B2, S1)
T1 (B2, S3)
T1 (S2, S3)
-1.0
Circuit 2
Turn
Fig. 28
Tomokazu SUZUKI
Mamoru URAKI
Akihiro IDA
Atsushi TSUBOUCHI
Yasutaka KITAKI
6. Conclusion
On a qualifying session, the lap time differences
between the top teams are usually in within 0.1 s.
Assuming a lap time of 100 s, this could be called a
competition over differences in performance of
approximately 0.1%. Therefore, the demand to have the
cutting edge technology for both measurements and
analysis is very high. In Formula One, the environmental
187
Kazuharu KIDERA*
Yoichiro FUKAO*
Tatsuya ITO*
ABSTRACT
Efforts have been made toward the development of traction control that controls the amount of tire slip at a level
that exceeds the abilities of Formula One drivers and enhances turning acceleration performance, and the development
of overrun control that is intended to prevent rear tire lockup by using engine torque when the brakes are being applied.
Numerous control systems have been applied in racing based on modern control theories, including high-precision
engine speed control and wheel speed feedback control, which is extremely challenging in Formula One, where driving
at the limit is the norm.
Launch control, which is control applied in the start of a race, has also realized complete direct control of clutch
transfer torque. Development has proceeded on start assist systems that can enhance start performance with reliable
repeatability while continuing to satisfy regulations even after prohibition of automatic clutch control. The direct push
clutch and other new technologies have been actively adopted.
1. Introduction
Traction control was extremely important to Formula
One activities of the third era, which started with the
Australian Grand Prix in 2000.
The Federation Internationale de lAutomobile (FIA)
had basically prohibited traction control until the Spanish
Grand Prix in 2001. The FIA changed its stance at that
time, completely lifted the ban, and development of
traction control started.
Vehicle dynamic performance continued to evolve
even while restrictions were subsequently placed on tire
performance. In this context, the optimal control of
traction and the maximum employment of tire
capabilities occupied crucial positions in the evolution
of vehicle dynamic performance.
In 2008, the FIA unified control specifications by
making it obligatory to install a common electronic
control unit (ECU). Even after control systems that could
be used as driver aids were completely eliminated, there
was continuing high demand for control systems to make
it easier for drivers to manage torque during cornering.
Given these circumstances, development of traction
control continued largely throughout the period of thirdera activity.
This article describes the history and development
technology of various systems, including traction control
(TC) in the acceleration range, the development of
methods for setting traction that were implemented by
2. Development Goals
The purpose of traction control in Formula One
racing is to assist the drivers so that they can drive the
car as fast as possible with repeatability. It is necessary
with racing cars in general, however, not only to bring
out their performance limits, but also to sustain that
unstable state. With mass-production vehicles, it is a
requirement of similar control systems that, for safety
reasons, they keep the vehicle inside the limit range. This
difference in what the two types of system are intended
to achieve is also the difference in the performance they
are required to produce.
Formula One cars and mass-production vehicles also
differ greatly in the hardware that is subjected to control.
Formula One cars are, of course, light in weight, in the
600 kg range, and their drivetrains are built to have the
lowest possible rotational inertia. Meanwhile, they have
engine power, braking power, and tire grip force that are
several times greater, as absolute values, than in massproduction vehicles.
For the above two reasons, Formula One cars have
much more sophisticated traction control than massproduction vehicles. They demand highly precise, highly
responsive systems. Generally speaking, bringing out the
performance limits of a vehicle will mean making the
most of the performance of its tires, which are the only
points of contact with the ground. Control of Formula
One power plant systems is no exception in this. While
effectively transferring the limited engine power to the
tires, it must never exceed the tires limits. The control
methods used can be generally classified into two types:
one is the method for directly controlling wheel torque,
and the other is the method for controlling the amount
of tire slip. Another, indirect method for accomplishing
this is to control just the engine torque or the engine
speed. Drivetrain components have rotational inertia,
backlash, and twist. Strictly speaking, therefore, control
by wheel criteria and control by engine criteria are
different, and the various methods are employed
according to the application, the degree of ease or
otherwise of control, and the advantages or disadvantages
involved.
Figure 1 shows the history of the three systems
introduced below. Figure 2 shows a configuration
diagram of the control systems.
00
01
Engine specification
Regulation
02
03
04
05
06
07
V8 cylinder engine
TC/OC permission
TC/OC
LC
prohibition
08
Standard ECU
LC prohibition
LC permission
LC/RS
TC/OC
prohibition
Interface
(Engine & Chassis
control data)
Ignition control
Rev
PID F/B TC
Rev
Model base TC
Wheel slip
F/B TC
TC
Torque capping
Th TC
Throttle control
Rev
Blip OC
OC
LC
Rev+
Clutch position control
Fig. 1
Wheel slip
F/B OC
Rev+
Clutch torque F/B
Rev+
Clutch position control
RS
Pedal
torque
map
2stage throttle
Clutch dump
191
Pedal
torque
map
battle of wits among the teams and with the FIA since
2004. The aim of RS is to realize the best standing start
performance, with repeatability, by arranging it so that
the driver only has to follow a predetermined standing
start procedure (throttle pedal operation, clutch paddle
operation) to have the proper settings for engine and
clutch control be selected by engineers to match with the
coefficient of friction between the road surface and the
tires, as well as with the meteorological conditions.
The two challenges that LC and RS face in common
can be summarized as control of clutch transfer torque
with a high level of precision and response, and
cooperative control of the engine and clutch.
Engine controller
Chassis controller
Engine speed
Rev limit
Throttle pedal
TC controller
(rev limiter)
Target throttle
Throttle pedal
Target fuel
Throttle controller
Target IG
Wheel speed
Lateral
acceleration
Pattern IG
Throttle
Environment
TC/LC
controller
OC controller
Target throttle
00 - 01
Engine
Engine controller
Chassis controller
Engine speed
TC controller
(rev limiter)
Throttle
pedal
Rev TC torque
Driver
torque
Pedal
torque map
Rev limit
Target torque
Throttle pedal
TC controller
(rev or wheel slip)
Wheel speed
Gearbox controller
Gear position
Torque controller
Map search
Calculated torque
RS controller
IG cut/retard
torque divide
Throttle
Environment
Lateral
acceleration
OC controller
Target IG
Target throttle
07 final system
Engine
Fig. 2
192
respect to disturbance.
Figure 4 shows the actual track data for Rev TC. It
can be seen how the target tire slip is tracked by
controlling the engine speed. Rev TC has the advantages
of not being susceptible to system delays, and of fast
response. On the other hand, it does not allow
independent control using rear left or rear right tire slip,
and has disadvantages coping with curbs and the like.
In parallel with development of the Rev TC,
development of wheel slip feedback TC (W/S F/B TC)
also took place. This is a method of control that uses
the tire slip as an F/B parameter. This allows traction
control to use only favorable side of rear wheels or both
during cornering, and it increases flexibility of the
settings. It has a robustness with regard to the input of
disturbances from the road surface that was established
in advance through simulations, and it also enabled
limitation of excessive torque reductions.
Figure 5 shows the actual track data for W/S F/B
TC. The wheel torque is subject to finely tuned control
with respect to changing load on the rear tires (rear inner
and outer tire Fz), and the tire slip is retained in the TC
slip target value.
In the third era, the above two control methods (Rev
F/B TC and W/S F/B TC) were employed differently
according to the circumstances. Rev TC was mainly
employed with low speed gear (in racing starts and when
building up speed coming out of a low speed corner) or
on wet road surfaces, when the traction is large against
reaction force from road surface and the F/B system
requires high response and high resolution. W/S F/B TC,
which allows more flexible control, was employed
mainly for driving in middle and high speed gears and
under conditions when disturbances such as curbs could
have an influence.
Important points of TC F/B systems include not only
the consideration of system delay and robustness with
respect to disturbances, but also the fact that, in the
interest of drivability, it limits excessive ignition control
fluctuations that ignore the will of the driver, and that,
in the interest of fuel economy, it limits the amount of
fuel injected. Throttle TC (Th TC) implements control
Rev TC
Throttle pedal
Target
wheel speed
Lateral acceleration
Target
engine
torque
Target
engine
speed
Gear
ratio
Car speed
Rev
F/B
Controller
Engine
Chassis
Engine speed
Target
wheel speed
+
Lateral acceleration
Target
engine
torque
Target
wheel torque
Speed
F/B
Controller
Gear
ratio
Wheel speed
Fig. 3
193
Engine
Chassis
Throttle pedal
Gear ratio
Target
engine speed
Engine speed
(F/B parameter)
5.0
4.0
3.0
2.0
1.0
0.0
1.0
2.0
3.0
4.0
5.0
Overshoot area
Fig. 4
6000
Tire slip
10
5
Throttle torque demand
4
2000
6000
4000
2
0
2000
29
30
Fig. 5
31
194
33
Time: 27.870 sec
2000
1
Tire Fz [N]
10
8000
4000
Gear position
10000
TC slip target
195
10
Gear position
Tire slip
6
OC slip target
4000
4
2000
-2000
40
Fig. 6
41
196
42
Time: 39.430 sec
Gear position
6000
10
Clutch
torque target
For
race start
Fig. 7
197
For manual
operation
For full
engagement
Clutch
paddle position
Clutch
paddle position
First paddle
release
Second paddle
release
Disengagement
Engagement
Start
Fig. 8
Full engagement
Time
200
Gear position
Rear wheel speed
10000
200
284
Time: 279.550 sec
Throttle %
300
250
200.0
180.0
5
10
160.0
15
200
140.0
150
120.0
100
100.0
Tire
50
80.0
= 1.7
60.0
0
Tire
-50
= 1.0
-100
19000
18000
17000
16000
198
15000
Fig. 10
14000
13000
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
Fig. 9
283
400
10
Gear position
20000
20
25
30
35
45
55
40.0
65
20.0
75
0.0
93
Mu=1.7
Mu=1.0
Car Speed
200
Clutch actuator pressure
0
Engine speed
Gear position
10000
200
0
88
Fig. 11
89
90
200
Gear position
400
20000
91
Time: 87.623 sec
199
7. Conclusion
Throughout the third-era Formula One activities,
there was an impetus to move beyond traction control
that dealt simply with acceleration, and to incorporate
traction control for limit ranges in a variety of different
circumstances including deceleration and standing starts.
This yielded results and many new insights in connection
with (1) the adoption of torque drive system that
converts throttle pedal input to engine torque demand,
(2) the adoption of a torque interface with chassis control
systems, (3) wheel slip control that directly controls
wheel slip, (4) coordination with clutch control, and so
on.
All this brought a keen awareness that not only the
powertrain field, naturally enough, but also the chassis
field and coordination with the driver were particularly
important for traction control. It also became apparent
that alternative testing approaches, to include virtual
methods, were of importance in developing control
systems for use under limit conditions that are not
readily reproducible in the actual machine. It is to be
hoped that the experience gained on these two points will
also be put to active use in developing mass-production
models.
Reference
(1) Kishi, T., Nagatoshi, Y., Nakamura, H., Fukao, Y.:
Development of Direct Push Clutch Control during
Honda Formula One Third Era, Honda R&D Technical
Review 2009, F1 Special (The Third Era Activities),
p. 207-210
Author
Kazuharu KIDERA
200
Yoichiro FUKAO
Tatsuya ITO
Takayuki KISHI*
Hiromasa NAKAMURA*
Yoshiki NAGATOSHI*
Yoichiro FUKAO*
ABSTRACT
One main development topic for the Honda Formula One third era gearbox was the seamless gearbox (Quick Shift),
which reduced the interruption of acceleration to zero.
Gearshift control provided a way to control dog damage and excessive torque, which had been issues affecting
Quick Shift feasibility, and this enabled the team to realize first deployment of the Quick Shift in racing, ahead of
the other teams. The search for even smoother gear shifting continued after that, and led to the establishment of a
mechanism that would reduce to a minimum the torque fluctuation resulting from correlation of the torsional vibration
of the driveshaft and the inertial torque generated during gear shifts.
1. Introduction
The structure of the gearbox in the Honda Formula
One third era was the seven-gear sequential gearshift of
the constant mesh type widely used on motorcycles. This
was electronically controlled using a hydraulic pressure
actuator, and gearshift operations were carried out using
a paddle attached to the steering wheel. Given this
structure, shifting gears requires the engine torque to be
first reduced to nearly zero. Reducing this gearshift time
to the ultimate extent would contribute to increased
racing competitiveness, and development of such control
was therefore begun. The development effort sought, on
the upshift side, reduction of acceleration loss,
stabilization of wheel torque, and limitation of torque
oscillation when shifting gears. On the downshift side,
it sought reduction of minus torque when shifting gears,
and reduction of idle running time. In this way,
measures were taken to achieve a balance of hardware
evolution combined with performance enhancement and
establishment of reliability.
The Quick Shift mechanism, development of which
started in 2004, was an innovative mechanism that
enabled upshifting while still maintaining engine torque
at the maximum level. It brought about a major evolution
in performance when shifting gears. However, it was
necessary to develop new controls to take advantage of
this mechanism. Even before the introduction of the
Quick Shift, the demand for better gearshift performance
had been addressed by enhancing control equipment and
changing the controlled subjects. With the seamless
gearshift, however, there was a likelihood that significant
2. Development Goals
2.1. Establishment of Quick Shift Reliability
The Quick Shift is a mechanism that enables
upshifting without lowering the engine torque. However,
when one dog collided with another edge to edge, the
shock was significant, and sometimes the dog edge
would wear so that it could no longer provide driving
power. If the next gear provided driving power when
there was dog delta speed, an impact torque was also
generated that resulted in the gear exceeding its torque
limit so that the gear was damaged. The following two
points were therefore defined as control objectives:
(1) Zero collision of one dog with another edge to edge
(2) Zero occurrence of gear over-torque
2.2. Realization of Smooth Upshifting and Downshifting
The inertial torque that occurred in gear shifting
when shifting up or down could result in excessive wheel
slip, rear tire lock-up, deterioration in drivability due to
torque oscillation after gearshifts, and other such issues.
The following objectives were defined to address these
issues:
(1) Upshifting
Maintain wheel driving torque
Limit oscillations in engine speed and in torque after
gearshifts
(2) Downshifting
Limit minus torque after gearshifts
Limit oscillations in engine speed and in torque after
gearshifts
3. System Overview
Figure 1 shows the gearbox system configuration.
The gear position is determined by the angle of the
gearshift barrel, and the gear shifting is executed by
input on the gearshift switch attached to the steering
wheel. While shifting gears, the system controls the gear
position and simultaneously requests the clutch transfer
torque, engine speed, and engine torque.
The clutch operates according to analog input from
the clutch paddle attached to the steering wheel. In
addition to engaging and disengaging, the amount of
clutch disengagement is also controlled according to
gearshift and anti-stall requests.
The gearshift and clutch actuators are driven by 200bar hydraulic pressure controlled by a Moog valve. (The
control cycle is 1 ms.)
Dog delta
speed
Shift
request
Gear
dog
Enough in
gear depth
to drive
Paddle
request
Target position
+
Pressure
Rotary actuator
Actual position
Current
Trigger shift
Engine
Target pressure
+
F/B
controller
Current
Actual pressure
Demand
arbitration
Fig. 2
Layshaft
pulse
Clutch
Main shaft
Dog ring
Main shaft
pulse
Layshaft
Barrel delay
Pressure
Pressure voltage
15 deg
Start of in-gear
position
Engine speed
Engine torque
Target
phase
prediction
+
+
Target
phase
Offset
=
=
1 dog
(72 deg)
Engine controller
Fig. 1
Memorize
drive side
engaging
phase
Gear dog
Anti-stall
Speed, torque
request
Clutch
adaptation
Paddle
map
Barrel
Sensor voltage
Ratchet
lock/unlock
Shift
sequencer
Target phase
Moog valve
Current
F/B controller
System configuration
Fig. 3
202
Barrel
drive
enable
(trigger
signal)
60
Phase [deg]
Target
Actual
-2.61 ms -7 deg
40
20
0
Safety margin 1 ms
-20 0
100
200
300
Number of gearshifts
Fig. 4
Target
72 deg
2500
y = 1160x2 - 360x
Fig. 6
2000
Clutch torque demand
1500
1000
Dog
Safe
Dog
Wear
Fig. 5
IPS rpm
500
0.5
Engine speed
1.0
1.5
In-gear depth [mm]
Compensated clutch
torque demand
2.0
IPS rpm
203
Fig. 7
++
+
Error
+
1/Z
Gear
4th
3rd
Engine
speed
Layshaft
speed
Layshaft torque
Rear speed
Fig. 8
800
Peak torque [Nm]
Without adaptation
600
Engine
speed
400
With adaptation
200
0
10
20
30
40
50
60
Number of Gearshift
Rear
speed
Wheel slip
Front
speed
Fig. 10
Engine speed
5.1. Upshift
When shifting up with Quick Shift, as shown in Fig.
10, the inertial torque when shifting gears results in the
wheel driving torque that exceeds the tire limits and
induces excess wheel slipping as well as oscillation in
the engine speed. The torque oscillation following a gear
shift can lead to impaired drivability. Therefore, the
following two points take on importance for upshift
control:
(1) Limiting engine speed oscillation
(2) Maintaining optimal wheel driving torque
In order to quantitatively evaluate the engine speed
oscillation, therefore, the oscillation level was
represented by the deviation from a logical value for
engine speed in the next gear integrated and depicted as
an area, as shown in Fig. 11.
Figure 12 shows the summarized results of the
correlation of this oscillation level with the slope when
the engine speed is dropping. The horizontal axis of the
204
Target gear
engine speed
Fig. 11
(A)
(B)
60
40
Oscillation
Fig. 9
20
0
-200
-150
-100
-50
Fig. 12
Engine speed
(3)
Layshaft speed
Target gear engine speed
100
Oscillation
80
Engine torque
demand
60
Engine torque
40
Wheel torque
Fig. 15
20
Layshaft torque
20000
500
1000
1500
2000
18000
Engine speed
(conventional)
16000
Fig. 13
14000
4000
12000
Engine speed
Less oscillation
Driving torque
(conventional)
3000
2000
1000
Layshaft Speed
0
36.3
Fig. 14
Upshift example
Fig. 16
205
36.4
36.5
Upshift comparison
36.
(2) While being driven by the dogs, make the gear speed
lower than the dog ring speed.
In (1), the clutch is disengaged and the engine is
blipped to raise its speed. Then, the clutch is engaged,
with timing matched to when dog driving occurs. The
clutch torque raises the gear speed, and the dog delta
speeds converge. In (2), the engine speed demand is set
lower than the next gear speed to control the gear speed
so that it will be lower than the dog ring speed.
Figure 18 shows a conceptual diagram of this
control.
In the diagram, the barrel-driven timing (A) and the
clutch disengagement initiation timing (A) are
determined by the engine blip response. As noted above,
it is important that convergence of the dog delta speed
between dogs should occur gently, which is why the
engine torque and speed instruction values are defined
so as not to decrease the gear speed in (B). Also, as
shown in (C), the clutch transfer torque is controlled
appropriately so that the gear speed increases gradually,
thus relaxing the impact torque when in gear.
Figure 19 shows the results of comparison between
these controls and conventional control. Figure 19
presents the waveforms for the conventional downshift
(a) and the downshift (b) with the control described
above. Comparison of the torque behavior and the
oscillation in the engine speed after downshifting
confirmed that these are reduced when the new control
is applied.
Engine speed
Layshaft speed
Layshaft torque
(4)
Dog ring speed
(3)
(1)
(5)
(2)
Front speed
Rear speed
Gear speed
Fig. 17
Gear
(A)
Engine speed
(B)
Dog speed
(C)
Gear speed
Blip torque
0 Nm
(A)
Clutch
Fig. 18
6. Conclusion
Gear
Engine speed
200
200
100
100
Layshaft torque
-100
-100
34
35
194
Fig. 19
Author
195
Downshift comparison
Takayuki KISHI
Yoichiro FUKAO
206
Yoshiki NAGATOSHI
Hiromasa NAKAMURA
Takayuki KISHI*
Hiromasa NAKAMURA*
Yoshiki NAGATOSHI*
Yoichiro FUKAO*
ABSTRACT
One main development topic for the Formula One third era clutch was the direct push clutch (DPC), which was
developed in order to increase the accuracy of transfer torque.
Conventional pull clutch position control could not readily stabilize the amount of torque transfer during standing
starts, and therefore pressure control of the DPC was used in order to stabilize the clamp load. The non-linear
characteristics of the hardware posed some issues with the hydraulic pressure response. However, these issues were
addressed by control, and as a result response that had no issues in practical terms was able to be assured and the
method was successfully deployed in racing.
1. Introduction
In the standing start range, the main focus of
development has been to drastically curb wheel spin at
the initial stage by enhancing the accuracy of clutch
transfer torque estimation and raising the performance of
the partial clutch engagement start. For clutches with the
conventional structure, both the clamp load and the
coefficient of friction were indeterminate factors,
making it a considerable challenge to estimate torque.
The DPC with its control of clutch transfer torque by
means of hydraulic pressure was developed in 2005, but
the hardware and the control were integrated as one, so
that assuring the requisite pressure control performance
became an important subject for development as had
been experienced in the case of the gear box
development. This paper introduces the DPC pressure
control system.
2. Development Goals
In the development of DPC, the adoption of a device
that uses hydraulic pressure to determine the clamp load
increased the accuracy of estimation of transfer torque.
However, the relationship between the hydraulic pressure
and the length the piston travels in the action from the
fully disengaged state to the bite point where pressure
Development of Direct Push Clutch Control during Honda Formula One Third Era
DPC characteristic
Piston
200
Actuator pressure [bar]
Pressure plate
Pusher
Crankshaft
Layshaft
Lever
Fulcrum ring
Full engage
120
Bite point
80
(A)
40
Worn
condition
(A)
0
4
Fig. 1
Full
disengage
New
condition
160
Full disengage
Lever
208
Pressure plate
Disk
Fig. 2
Threshold of
replacing gain
Actual
pressure
Error
Press FB P-gain
Press FB LPF
Controller
output
Fig. 3
Filtered pressure
Error threshold (high)
(3)
Predicted
pressure
Error
term
(2)
(4)
Time
Integral term
Actual
pressure
Target
pressure
(1)
Dead time
Fig. 4
Fig. 6
Filter
Target pressure
Actual
pressure
Step
limiter
SMA
Pressure (raw)
Step
limiter
2nd order
IIR LPF
Predictor
2nd order
IIR
SMA
Pressure (filtered)
Filtered pressure
Step filtered
Target pressure
Controller
Pressure target
Feedforward
map
Pressure (filtered)
Predictor
Variable
P-term
Transient
state
Controller output
Constant
P-term
Steady
state
Filtered pressure
Actual pressure
Fig. 5
+
I-term
Additive
I-term
Fig. 7
209
Development of Direct Push Clutch Control during Honda Formula One Third Era
ultimately realized.
Figure 8 shows a comparison between standard PID
control and the control described above. The comparison
was carried out during step response assuming a standing
start, when accuracy and speed of hydraulic pressure
Stroke
27ms
5. Conclusion
Target pressure
Actual pressure
12ms
Stroke
105ms
Author
Target pressure
Actual pressure
(c) Standard PID (3.0 mm wear)
30ms
Takayuki KISHI
Fig. 8
Yoichiro FUKAO
210
Yoshiki NAGATOSHI
Hiromasa NAKAMURA
Kenichiro ISHII*
Masaki NEGORO*
Toshiyuki NISHIDA*
Masataka YOSHIDA*
Kohei TOSHIMA*
Yutaka MARUYAMA*
ABSTRACT
The application of electronic control systems has been rapidly increasing in Formula One cars as well as in other
vehicles. System performance is a crucial element in conducting precision control and measurement of cars.
Starting with the 2006 season, the Honda works has been working to apply original Honda systems not only in
the engine control system, as before, but in all vehicle electronic control systems.
In order to pursue higher performance at the same time as enhanced in-vehicle mountability in Formula One
electronic control systems, it is necessary to carry out optimization of these systems together with thoroughgoing
miniaturization. On-board systems have an electronic control unit (ECU) with integrated functionality linked by a highspeed network with units located in every part of the vehicle. High-speed telemetry is used to coordinate these with
the garage system in order to optimize systems.
The enhancement of unit performance by means of higher speed and greater precision contributes to heightened
controllability, and particularly to enhanced precision of driving force control and gearbox control. High-speed
communication also contributes to greater measurement performance in the pit.
1. Introduction
Formula One cars in recent years have incorporated
more than just the engine control and gearbox control
found previously. From mid-2001 to the 2007 seasons,
traction control and engine brake control have come to
be allowed in the regulations. Clutch control was not
prohibited up until 2007.
Traction control and gearbox control, in particular,
require precisely coordinated control of the engine and
chassis in real time. This has required advanced
computational capability and measurement performance.
Furthermore, Formula One cars demand aerodynamic
performance, so that there are limited on-board
installation locations for electronic control units in
Formula One cars. This means that systems require
greater compactness and lighter weight.
The functions of electronic control systems for
Formula One are generally for two purposes, for driving
and for analysis. In order to achieve compactness and
light weight, the latter functions are assigned as much
as possible to pit systems. In this way the former
functions can be optimized, and this was the basic
conceptual approach to the construction of these systems.
This article will provide an overview of Honda
2. System History
Figure 1 shows the history of electronic control
systems for the third era of Honda Formula One.
Development of third-era Formula One systems began in
1998 with a view to applying integrated engine and
chassis systems to racing.
Under the BAR-Honda system from 2000 to 2005,
engine control systems were supplied to the team. From
2006, when Honda works joined in the competition, the
Honda full system was provided as a chassis integrated
Year
Team
2000
2001
2002
2003
2004
2005
2006
2007
2008
System
Chassis Control
Data Acquisition
Telemetry
BAR System
Engine Control
(PGM-FI)
Data Acquisition
Telemetry
Power Supply
Honda System
Athena
Fig. 1
FIA
system
Data
acquisition
Right layout
Left layout
Fig. 2
Sensors
Sensor terminal (ST)
Engine
Gear Box
Differential gear
AC-DC (PBOX)
Front data acquisition
(FDA)
CAN
1 Mbps
Arcnet
10 Mbps
Sensors
CAN
1 Mbps
Ignition (CDI)
Electronic control unit
(ECU)
CAN
1 Mbps
Sensors
Steering wheel
Laser
2008system -
GPS
Camera
Logger
Tire temp/press
Video camera
Wing driver
SIO
2 Mbps
Telemetry
(HTX)
CAN
1 Mbps
CAN
1 Mbps
Ethernet
100 Mbps
Program
setting data
C
Telemetry server
Fig. 3
Server
Athena system
213
Control
Torque control
Traction control
(MIPS)
3000
Total calculation instruction
214
Engine control
Measurement control
Chassis control
Measurement control
2000
1000
2001
2003
Fig. 4
2005
2006
2007
M/Y
CDI
ECU
Fig. 5
PBOX
Battery
HTX
Fig. 6
High temp
NACA duct
Fig. 7
215
Ethernet
100 Mbps
2 ch
To PC
To
Telemetry
CPU (GCPU)
PCI
( 32 bit / 66 MHz )
20 Mbyte/s
SD
20 Mbyte/s
SD
Memory
controller
(FPGA)
Fig. 9
64
64
SDRAM
Work area
64 MB
LOGGER and
COMMUNICATION
UART
2 Mbps
2 ch
Flash ROM
Program
8 MB
32
Flash Disk
LOGGER
2 GB
CPU
SD memory controller
32
16
NVRAM
Back Up
4 MB
ARCNET
10 Mbps
1 ch
8
CAN
1 Mbps
2 ch
300 MHz
16
DPRAM
Work area
512 KB
32
SDRAM
Work area
64 MB
64
DPRAM
Work area
512 KB
16
Analog OUT
12
32
Flash ROM
Program
8 MB
NVRAM
Back Up
4 MB
To
Chassis block
To CDI, PBOX
To ST
64
CPU (DCPU)
DAC
12 bit
4 ch
MOOG driver
(2 ch)
CPU (ACPU)
32
Control
APPLICATION
16
DPRAM
Work area
512 KB
16
Digital IN
Single end
0-5 V(6 ch)
80 MHz
450 MHz
ARCNET
10 Mbps
1ch
DEVICE I/O
Analog IN
Single end
0-5 V(6 ch)
Analog OUT
ADC
16 bit
6 ch
16
12
DAC
12 bit
4 ch
CAN
1 Mbps
2 ch
MOOG driver
(2 ch)
Digital OUT
IINJECTOR
driver(10 ch)
Analog IN
To FIA
Single end
0-5 V(4)
PVRS solenoid
driver(5 ch)
DIFFERENTIAL
0-5 V(2)
Lo side
driver(10ch)
Fig. 8
Hardware architecture
216
DIFFERENTIAL
0-5 V(2 ch)
LAMBDA
Sensors(2 ch)
Thermo
Couple(2ch)
Internal
Monitor(26ch)
Device CPU
Gateway CPU
Application
layer
Driving force
Control
Device control
Measurement
communication
Middleware
layer
Arcnet
OS layer
RTOS
Data
exchange
Run header 1
Run data 1
RTOS
Run header
Lap data
Straight end data
Fail data
Warning data
Index data
Ch1
Ch6
Ch7
Ch3
Ch6
Ch2
Ch7
Ch5
Ch8
Ch7
Ch3
Ch8
Ch1
Ch5
Ch4
Ch4
Ch6
Ch4
Ch6
Ch2
Ch5
Ch8
Ch7
Ch6
Ch1
Ch1
Ch4
Ch6
Ch8
Ch7
Ch5
Ch3
Ch2
Ch8
Ch2
Ch4
Ch1
Ch3
Ch6
Ch8
Ch5
Ch1
Ch4
Ch6
Ch3
Run data 2
Run header 3
Ethernet
Arcnet
Software architecture
Run data
Run header 2
Data
exchange
RTOS
Fig. 10
Measured data
CAN
Block data
Channel
Channel ID
ID
Cannel
Cannel number
number
Next
Next channel
channel number
number
Sampling
Sampling interval
interval
Number
Number of
of data
data
Data 1
Data 2
Data 3
Data 4
Data 5
Data 6
Data 7
1 kByte
Run data 3
Fig. 11
217
Alarm lamp
Diff
+/-
+/Speed limit
Shift paddle
(down)
Driver radio
Traction control
(tire warm up)
Clutch paddle
(for right hand)
Clutch paddle
(for left hand)
A/F
Fig. 13
Launch/Overtake
Toggle switch Mode function
Measurement data
analysis
Fig. 14
Lap chart
Measured data
Client PC
Server
Feedback
5. Hardware Development
Race strategy
support
Setting data tuning
Measured data
Auto warm-up
Client PC
Fig. 12
Garage system
Configuration change
The electronic control units were given a threedimensional structure using multiple circuit boards in
order to increase the package density. Circuit boards
densely populated with electronic parts have large
numbers of wiring connections, and it was necessary to
218
Fig. 16
Al base PCB
Cu core PCB
Thermal flow
A heating element (CPU, Driver)
Fig. 15
Fig. 17
219
PCB
Copper core PCB
Frame
Performance
Refer to Fig.4
Volume
50%
Rigid-flexible
Metal-cored build-up
FBGA package
1608 chip
Build up
00
01
-02
03
-04
Fig. 18
05
0402 chip
Buried chip
2009 TDL
06
07
09
Year
ECU package
6. Telemetry
6.1. History of Telemetry Development
Telemetry is the system that takes data from the
various kinds of sensor data and the like while the
vehicle is running and uses radio to transmit it to the
pit. Telemetry was first developed for use in races by
Honda in the mid-1980s, during the second era of
participation in Formula One competition. Telemetry was
used during the second era by acquiring important data
on engine speed, engine oil and water pressure, engine
oil and water temperature, fuel consumption, and the like
while the car was passing in front of the pit, and using
that data to manage conditions in the car. In the third
era, by contrast, that system evolved to acquire and
analyze all data concerning the engine and the chassis
in real time. Figure 19 shows the history of change in
communication speed and communication protocols used
in telemetry.
In 2000 and 2001, the telemetry system developed
during the second era was carried over. Its carrier wave
frequency was in the 400 MHz band, the modulation
method was Frequency Shift Keying (FSK), and the
220
2 Mbps
Data transmission speed [kbps]
100%
2000
1500
Standard transmission
speed of 3G wireless phone
FSK
QPSK
1000
Two-way telemetry
460 kbps
500
19.2 kbps
38.4 kbps
0
2000 2001 2002 2003 2004 2005 2006 2007
year
Fig. 19
90%
80%
70%
60%
50%
40%
Packet rate
30%
20%
Coverage
10%
0%
9 10 11 12 13 14 15 16 17 18 19 20 21 22
Sector
PIT
Fig. 20
Direct wave
Frame 1
Delay wave
d: Delay time
Frame 2
Frame 1
Frame 3
Frame 2
Frame 3
Usable frame
d
Interference
(unusable)
Received signal
Delay wave
Bits/frame is
same as above
Many rates of
interference
2
Received signal
Fig. 21
Fig. 22
221
1
2
3
4
5
6
Fig. 23
7. Component Development
1.E+00
1.E-01
1.E-02
1.E-03
Good
1.E-04
Fig. 24
4
5
Number of paths
222
Wire harness
Hall IC
Magnet
Sensor case
Fig. 25
Throttle sensor
Fig. 26
223
Author
Fig. 27
Kenichiro ISHII
Toshiyuki NISHIDA
Kohei TOSHIMA
Masaki NEGORO
Masataka YOSHIDA
Yutaka MARUYAMA
Harness
8. Conclusion
In retrospect, Hondas Formula One system
development proceeded without break from the time of
the test runs at Pembrey Circuit in the United Kingdom
in 1999, one year after their development started, up to
the Brazil Grand Prix in 2007, and a wealth of findings
224
Masataka YOSHIDA*
Masato KITA*
Hirofumi ATARASHI*
ABSTRACT
In 2009, the regulations for the Formula One World Championship were amended to allow the use of kinetic energy
recovery systems (KERS). The new regulations stipulated that the KERS drive shaft be limited to the rear wheels,
that output should be no more than 60 kW, and that the amount of energy used per lap be no more than 400 kJ.
Honda had been conducting R&D in this area since the summer of 2007, and had developed a high speed, high output,
direct oil-cooled motor, a water-cooled power control unit (PCU) which integrated a motor drive inverter unit and
voltage control system, as well as a high power density lithium ion battery, all based on being small and lightweight
enough for Formula One characteristics.
This system was first used to drive on straight roads in April 2008, and in May of that year Honda beat out other
teams to conduct the worlds first driving tests in an actual vehicle at the Silverstone Circuit, where the technologys
superiority and high level of safety were proven.
1. Introduction
Honda has been developing electric vehicles, fuel cell
electric vehicles and hybrid vehicles to find alternatives
to fossil fuels, reduce emissions and mitigate the impact
of automobiles on global warming.
As for the Formula One World Championship, the
regulation amendments of 2009 allowed usage of KERS,
which recovers and utilizes braking energy as drive
power assist. To work with the new rules, Honda chose
for its energy recovery method an electrical hybrid
system and proceeded with development for use in
Formula One based on the electric drive technology it
had been developing.
Because the maximum output and the amount of
assist energy that can be used per lap are stipulated by
regulations, this development focused on making
equipment as small and lightweight as possible with high
output and high torque technology without changing the
high level of dynamic performance unique to racing cars,
and therefore Honda developed a motor, PCU and
lithium ion battery capable of installation on a racing car.
Honda additionally achieved high responsiveness to meet
the requirement for output characteristics during racing.
Development began in earnest in the summer of
2007, and in just nine months, actual driving tests were
conducted using the prototype vehicle RA1082 (a vehicle
built to check functionality), and subsequently KERS
was run at full power on a racing course for the first
time in the Formula One environment. Based on the
basic functions that had been confirmed with the
2. Development Concept
Under the 2009 regulations, KERS could only be
connected to the rear wheel, with maximum energy use
per lap of 400 kJ and maximum output of 60 kW. The
necessary performance targets set as development themes
for this project were as listed below, not only to make
the equipment compact and lightweight in order to be
installed on a Formula One vehicle, but also to create a
vehicle capable of winning races.
(1) System weight: no more than 30 kg
(i.e., no more than 60% of the vehicle ballast weight of
the 2006 vehicle)
(2) Assist performance: at least 5 continuous seconds at
output of 60 kW
(i.e., the output and assist time enabling the vehicle to
overtake others)
When setting targets for performance, weight, center
of gravity and the like for the various functional
components, these parameters were investigated from
many angles, including race strategy and the use of
vehicle dynamics simulation, but some major conceptrelated issues were encountered when doing these
investigations.
One was whether the race strategy should emphasize
Battery
PCU
Motor
Table 1
Specifications of KERS
RA1082
2008-APR
60 kW
45 Nm
800 kJ
Transmission
100 x 202
21000 rpm
7.7 kg
Transmission oil
Si-IGBT/SiC-diode
Boost copper
680 V
11.2 kg
Water
Li-ion
114
22.4 kg
Air
Vehicle code
Shake-down
KERS power
Torque
KERS energy
Location
Dimension
Max rpm
Weight
Cooling
Power module
VCU type
Operating voltage
Weight
Cooling
Type
Cell number
Weight
Cooling
RA1089
2008-NOV
60 kW
45 Nm
400 kJ
Front of engine
100 x 190
21000 rpm
6.9 kg
Engine oil
Si-IGBT/SiC-diode
Switched capacitor
560 V
8.0 kg
Water
Li-ion
108
21.2 kg
Air
RA109K
2009-JAN
60 kW
45 Nm
400 kJ
Front of engine
100 x 190
21000 rpm
6.9 kg
Engine oil
Si-IGBT/SiC-diode
Switched capacitor
580 V
7.4 kg
Water
Li-ion
106
20.8 kg
Air
Battery
Front
Front
Layout
Motor
Motor
Motor
PCU
Battery
Front
PCU
Battery
PCU
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
Mel Sep Bah Bcn Mco Mtl
Nur Bud Ist Mza Sha Int Suz Hok Spa Fuj Imo
Circuit
Fig. 1
226
3. Development of KERS
3.1.2. Development of RA1089 (race prototype)
We considered the issues of the RA1082 and began
designing the RA1089 with the aim of minimizing the
impact of KERS being on-board while maintaining a
high level of vehicle dynamic performance. This vehicle
also had an important position as the winter test vehicle
(i.e., pre-season test vehicle) in anticipation of the
coming 2009 season. The unprecedented installation
layout, offering both vehicle performance and KERS
performance, ran into troubles, and even once into
chassis production, there were numerous design changes
that put a burden on the production site. Moreover,
engine changes to install KERS that were originally
unapproved were later allowed after a request from
Honda to FIA, so the installation of functional
components was reviewed again. About that time, the
350
300
200
+ 15 km/h
Assist start
180 km/h
150
Non-KERS car
400 kJ assist
finish at 60 kW
250
30
Normal
40 kW
50 kW
60 kW
25
20
15
10
+ 20 m
5
0
Time (sec)
7
6.666 sec
Non-KERS car
10
Scale up
10
9
8
7
6
5
4
3
2
1
0 0
2 car lengths
1 car length
3
2.78 sec
4
4.22 sec
Time (sec)
Fig. 2
227
6 Non-KERS car
Table 2
Motor position
Mass
Front-weight
distribution
C.O.G
8.69 kg
-0.60%
+1.0 mm
Gearbox
10.30 kg
-1.13%
+1.4 mm
228
Battery module
(nose)
Battery module
(keel)
Fig. 3
Motor
Engine
Front
Fig. 5
Energy storage
Li-ion 106 cells
Five-gear box
Water cooling
Water cooler
J/Box
Water pump
S-ECU
M/G ECU
PCU
Engine
oil cooler
Engine
Oil tank
Oil pump
Five-gear train
Oil cooling
Motor
Front
Fig. 4
Hybrid system
229
Coil end
Three-phase terminal
Stator
Fig. 8
Fig. 6
Core assembly
in
out
Prototype
Fig. 7
Oil out
Oil seal sleeve
Developed
Direction of magnetization
Fig. 9
230
Oil in
3.5. PCU
The PCU consists of an inverter unit (PDU) to drive
the motor and a voltage control unit (VCU) that allows
the voltage to be raised or lowered freely. The PCU is
used to supply the optimal amount of voltage and current
from the battery to the motor and to recharge the battery,
and it makes a great contribution to increasing motor
efficiency while making it more compact. An intelligent
power module (IPM), installed in the PDU, used a
special design to enhance compactness and reduce
electrical loss, while an SiC diode was used on-board for
the first time to reduce flywheel diode noise.
Development of the VCU started out with a boost
chopper form, but the PCU also faced severe on-board
installation requirements and had to be made smaller and
lighter, so system operation frequency was increased and
the form was changed to switched capacitor, which
offers the potential for a smaller, lighter reactor (voltage
step-up coil) (Fig. 11). An effort was made to make the
reactor smaller and lighter, not only by increasing the
system operation frequency as previously stated, but by
forming a 3D core by using dust core materials.
60
30 90%
93% 95%
20
97%
96%
98%
10
Case
0
-10
VCU
Water jacket
-20
-30
96%
-40
87% 90%93%
-50
-60
9000
94%
95%
13000
17000
Speed [rpm]
Fig. 10
In brake
40
In boost
50
PCU
Control board
21000
Reactor
Fig. 12
Motor efficiency
PCU
VCU
PDU
P
U
V
W
N
Fig. 11
231
Side plate
6000
RA109K specifications
5000
RA1082/RA1089 specifications
4000
Original specifications
3000
2000
Ni-MH
1000
50
Fig. 13
100
150
200
Energy density (kJ/kg)
250
Battery specifications
Battery module
(nose)
Battery module
(keel)
Main switch
Fuse
Contactor
Sensor terminal unit
Fig. 14
232
Connector
PCU
Keep plate
Fig. 15
Control board
PC for KERS
support system
Management
& Battery MPU
Battery
sensor terminal
FIA standard
ECU
Voltage
control unit
Battery
Power
drive unit
Motor
Fig. 16
233
234
Battery simulator
Inverter stand
Fig. 17
Function test
Durability test
Engine
Motor
Fig. 18
Fig. 20
Motor speed
Engine speed
Assist / Regenerative
Throttle opening
500
1000
11-Start
Start-1
1500
11
1
10-11
5000
4500
10
9-10
98-9 8
4000
1-2
2000
3500
7-8
23
2-3
3-4
4-5
45
5-6
3000
7
18:24:00
18:24:05
18:24:10
18:24:15
18:24:20
18:24:25
18:24:30
18:24:35
18:24:40
18:24:45
18:24:50
18:24:55
18:25:00
18:25:05
18:25:10
Lap 83f
%r R1
nEngine
rThrottleL=
%r R1
%
nKERS
18:25:20
In Lap
%r R1
rpm
18:25:15
rpm
%r R1
MKERSMotorRequestFinal =
Nm
ATLAS 8.17.3537
ATLAS 8.17.3537
Fig. 19
235
6-7
6 2500
Mileage
238.4 km
465.4 km
611.0 km
748.8 km
1351.9 km
566.1 km
236
Fig. 21
83.2
83.1
Lap time [sec]
KE-05
83.0
82.9
0.4 sec
82.8
82.7
82.6
0
100
200
300
400
Fig. 22
500
Date
Circuit
29-Apr
Santa Pod
7-May
Silverstone
(short course)
J. Rossiter
(RA1082)
29-Jul
Silverstone
(Stow School)
M. Conway
(RA1082)
16-Sep
Jerez*
19-Sep
Jerez*
13-Nov
Kemble
28-Nov
M. Conway
(RA1082)
A. Wurz
(RA1082)
Mileage
Notes
A. Davidson
10.5 km Shake down
(RA1089)
Shake down
A. Davidson
33.5 km 25 kW assist
(RA1089)
25 kW recharge
*: Full race track
Santa Pod
5. Conclusion
Assisted by 60 kW for 5.4 sec
310
Without KERS
With KERS
290
Car speed [km/h]
Table 5
270
250
230
210
190
170
150
25
26
27
28
29
30
31
32
33
34
35
Fig. 23
Afterword
Fig. 24
237
Reference
(1) Nakamura, S., Motohashi, Y., Hayakawa, S.:
Development of Wind Simulator Equipment for Analysis
of Intake Phenomena in Formula One Engines, Honda
R&D Technical Review, 2009, F1 Special (The Third
Era Activities), P. 95-100
Author
Masataka YOSHIDA
238
Masato KITA
Hirofumi ATARASHI
Kiyoshi ITO*
Makoto ASAMI*
Hiroshi KOINUMA*
ABSTRACT
A material that combines high thermal conductivity, seizure toughness, and high strength was developed by
enhancing hardening methods and fine homogenization in the deposit phase of a Corson alloy. This material was used
as the back metal for shell bearings, it was used in parts as a high strength high thermal conductivity shell bearing,
and it achieved consecutive use in events under one-engine, two-race rules.
1. Introduction
Table 1
3-layer metal
Pb-plating
Overlay
Pb-plating
Cu-alloy
Lining
Steel
Cu-alloy
Back metal
Fig. 1
Electric conductivity
UTS
IACS (%)
MPa
BeCu50
45-50
690 - 800
BeCu25
25
>1000
65
490
CF-2 (Cr-Cu alloy)
40-45
690
NC50 (Corson alloy)
Material
0.2%YS
MPa
590
15
10
5
0
Fig. 2
BeCu25
CF-2
NC50
155
150
145
: Current material
: NC50ES
5C
140
135
130
125
Test condition
Speed
10000 rpm
Load
10 kN
Oil temp 100 C
120
200
Fig. 4
3C
300
400
500
Oil flow rate (cm3/min)
70
600
Good
Cr-Cu alloy
60
IACS (%)
20
BeCu50
Current material
NC50ES
50
BeCu50
NC50ES
: 20.0
12%
NC50
Overlay thickness ( m)
: 17.5 20.0
: 15.0 17.5
40
: 12.5 15.0
30%
: 10.0 12.5
30
: 7.5 10.0
: 5.0 7.5
BeCu25
: 2.5 5.0
20
400
600
800
1000
#1UP-side
Fig. 3
Fig. 5
241
0 2.5
#1UP-side
4. Conclusion
The new Cu alloy NC50ES was developed for use
as shell bearing back metal. Shell bearing parts were
fabricated from the material.
The reliability of the shell bearings was enhanced
with respect to the high-speed, long-distance assurance
of Formula One engine regulations. The shell bearings
achieved continuous use in events under one-engine,
two-race rules as well as straight-end 19000 rpm
performance enhancement.
References
(1) http://www.yamatogokin.co.jp, 2009/03/27
(2) JP, 3563315, B (2004)
(3) Machida, K., Takahashi, S., Ueshima, H., Fujiki, K.,
Proposal of New Bearing Simulation Rig Tester for High
Efficiency Engine Bearing Development, Honda R&D
Technical Review, Vol. 18, No. 2, p. 131-139
Acknowledgement
This occasion is taken to express the warmest
gratitude to Miyoshi Gokin Kogyo Co., Ltd., and
Yamato Gokin Co., Ltd., which cooperated generously
in the development of this material.
Author
Kiyoshi ITO
242
Makoto ASAMI
Hiroshi KOINUMA
Kiyonobu MIZOUE*
Yasushi KAWAHITO*
Ken MIZOGAWA*
ABSTRACT
A hollow crankshaft of light weight and high quality was realized through the use of friction welding. The oil
passage in the journal was made a hollow structure, and this had the effect of increasing average oil pressure by 500
kPa (reducing the pressure drop), reducing the pulsation amplitude by 400 kPa, and raising the minimum oil pressure
by 600 kPa. The connecting rod bearing clearance was also adjusted and confirmed to yield 1 kW of performance
enhancement and over 1200 km of durability as well as curbing bearing friction. Although this new crankshaft was
never used in a race, this developed technology has provided the prospect of the first hollow crankshaft of 10 kg or
less for practical use in the Honda Formula One.
1. Introduction
The durable reliability of the crankshaft is essential
in the high speed and high power development of
Formula One engines. Accordingly, this part is also
considered to require lower friction and lighter weight
in the pin and journal rotating portions as well as higher
stiffness with respect to torsion resonance. The
development of a lightweight, high stiffness hollow
crankshaft has been underway since the end of 2003 as
a horizontal deployment of the hollow structure of the
connecting rod in other parts. Meanwhile, the
International Automobile Federation (FIA) included a
provision in its regulations that no welding would be
permitted between the front and rear main bearing
journals from 2006. This would make it impossible to
use a welded hollow crankshaft in cars entered in FIA
races. Honda therefore established the structure
manufacturing technology for a hollow crankshaft in
2005, and set out to install it in a racing vehicle for use
that year.
The creation of a hollow crankshaft required joining
technology capable of providing stable strength and
precision in the junctions that are of greatest importance.
It also required manufacturing technology capable of
assuring quality by enhancing the accuracy of machining
on junctions as well as by removing burrs and the like.
Fig. 1
Fig. 4
Friction bonding
FW bonding
Fig. 2
Journal joint
Rotation
Hold
Fig. 5
After cleaning
Pre-stress
Flash
Flash
Upset
Rear
Front
Fig. 6
Nitride of FW section
Flash
Fig. 3
FW bonding
244
3. Results
A weight reduction of 0.8 kg was achieved, going
from 6.55 kg (10.3 kg with counterweight) for the solid
crankshaft to 5.75 kg (9.5 kg with counterweight) for the
hollow, and making this the first Honda Formula One
crankshaft to realize a weight of 10 kg or less. The
effects of enhanced lubrication with the hollow
crankshaft include recovery of 500 kPa in the
instantaneous minimum oil pressure, which had shown
negative pressure because of oil pressure pulsation, and
prospects for durability.
4. Conclusions
The technology was established for manufacturing a
hollow crankshaft that would satisfy the properties
required for use in a high-speed, high-power Formula
One racing engine.
The crankshaft was made hollow using a highly
reliable FW technique, and production engineering
capable of guaranteeing crankshaft accuracy as well as
the cleanliness to use the hollow portion for oil passages
was established.
It has been verified that the developed technology
reduced weight 8% relative to the conventional
crankshaft and had the effect of oil pressure pulsation
reduction that could not be obtained with the
conventional structure, yielding the prospect of durability
for practical use. Regulations prohibiting welded
crankshaft structures went into effect in 2006, and this
hollow crankshaft was never used in actual competition.
Acknowledgements
This occasion is taken to express the warmest
gratitude to Takayuki Ohnuma and Nobuki Matsuo of
Honda Engineering Co., Ltd., for their cooperation with
FW joining technology and quality assurance.
Author
Kiyonobu MIZOUE
245
Yasushi KAWAHITO
Ken MIZOGAWA
Kazuhisa ISHIZUKA*
Katsuhito KUSAKAI*
Nobuyuki IMAI*
ABSTRACT
A metal matrix composite that can be expected to have outstanding strength at elevated temperatures was applied
to reduce the piston weight. In composites, it is generally difficult to cope with both strength and toughness. To solve
this issue, a powder alloy was applied using the mechanical alloying process, and the manufacturing process and surface
treatment were optimized. This achieved a 16% weight reduction compared to the conventional material, AA2618. In
addition, this enabled the Formula One engine speed to be increased by 400 rpm.
1. Introduction
Table 1
2. Developed Technologies
2.1. MMC Materials (AMC225XE) for Pistons
Table 1 compares the physical properties of MMC
and the conventional material, AA2618(1). MMC uses
AA2124 as the base alloy, and adds SiC with a particle
size of 3 m in a 25% ratio by volume as the dispersed
ceramics. The SiC is dispersed and alloyed with the base
alloy powder for the prescribed time using a high energy
mill. Figure 1 shows a metallographic image of the
MMC, and a mapped image of the carbon from the SiC
obtained using EPMA. Here, a countless number of
submicron size particles can be observed, dispersed
uniformly between large particles with several m. These
submicron particles are thought to be the SiC crushed
by the mechanical alloying process and dispersed within
Material
AA2618
MMC
Modulus
GPa
74.6
113.0
Density
g/cm3
2.76
2.89
CTE
ppm/K
22.6
15.5
CTC
W/mK
165
129
25 m
1 m
Fig. 1
4. Conclusion
A high strength piston material was successfully
developed by optimizing the composition and
manufacturing method of MMC manufactured using the
mechanical alloying method. Application of this material
reduced the piston weight by 16% compared to the
conventional material AA2618, and achieved an increase
in the engine speed of 400 rpm.
Reference
(1) http:/www.amc-mmc.co.uk/
3. Effects on Performance
Figures 2 and 3 show the mechanical characteristics
of a test sample taken from the roof section of the piston
material. Both high fatigue strength and ductility were
achieved in the piston operating temperature range of
200 to 300 C.
Use of this material realized lightweight and high
strength pistons that were applied to races from the first
GP of 2004.
90
80
AA2618
70
MMC
60
50
40
30
20
150
Fig. 2
200
350
250
300
Temperature (C)
Elongation (%)
50
AA2618
40
MMC
Author
30
20
10
0
0
Fig. 3
50
300
350
Kazuhisa ISHIZUKA
247
Katsuhito KUSAKAI
Nobuyuki IMAI
Sadami MINATO*
Yasunori ONAHA*
ABSTRACT
An intermetallic titanium aluminide material displaying increased fracture toughness and fatigue strength, and a
process enabling the formation of the material into components, have been developed. Exploiting the materials low
specific gravity and high modulus of elasticity, it was employed to manufacture a piston pin, enabling the achievement
of a 17% reduction in weight and a 28% increase in rigidity against a conventional nitriding steel piston pin. The
developed piston pin has contributed to increased speed, power and long-distance reliability in V10 engines, which
have been required to complete two race distances since 2005.
1. Introduction
In addition to possessing high specific stiffness at the
upper limit of Formula One material regulations and
excellent high-temperature strength, titanium aluminide
(TiAl) also displays excellent fatigue strength at ambient
(or room) temperatures. For these reasons, manufacturers
have been attempting to extend the use of the material
to the main reciprocating components, which are the
subject of a constant quest for weight savings. However,
there have been concerns over the low fracture toughness
and the quality of the European materials employed in
engine valves(1), and other significant issues have arisen,
including insufficient resources for development due to
oligopolistic supply.
The aim of the project discussed in this paper was
to develop an original high-quality TiAl material by
balancing fracture toughness with strength, and to
contribute to the achievement of increased engine speed
by reducing reciprocating mass through the application
of the material in piston pins.
2. Developed Technology
2.1. Material Design
In order to increase the strength and fracture
toughness of TiAl, the first important step is to use an
extrusion process to refine the coarse lamellar
microstructure produced by ingot casting. The piston pin
3. Component Specifications
CAE and stress measurements were conducted to
determine the piston pin design in view of the strength
of the piston pin itself and the effect to the piston, and
the component design was changed from the
conventional tube type used with nitriding steel to a solid
type. The solid design increased rigidity in the collapsing
direction by 28% and reduced stress on the piston pin
boss, which had previously represented a reliability issue,
by 6%, while the application of the new material enabled
the achievement of a 17% weight saving. Figure 3
shows comparison results of deformation in CAE
analysis.
In addition, given the decline in hardness of the base
material with the use of TiAl, a high-hardness diamondlike carbon (DLC) coating with a 7 m Cr 2 N film
formed by PVD sputtering as a backup layer was
employed as the surface treatment, enabling adhesion
strength and scratch resistance to be increased.
Fig. 1
Extrusion temp.
Fig. 3
4. Performance Results
Phase volume
fraction [%]
5.0
wb
800
4.0
Elong
600
3.0
400
2.0
200
1.0
0.0
Elongation [%]
Rotating bend
fatigue wb [MPa]
1000
2 (Ti3Al)
20
(TiAl)
40
(bcc-Ti)
60
Ext. temp.
1200 C
1150 C
1150 C
Ext. ratio
58
Annealing
As ext.
As ext.
1000 C
1000 C
Fig. 2
1150 C
249
Fig. 4
DLC wear
(a) Conventional steel
(18800 rpm/1503 km)
Fig. 5
5. Conclusion
Control of microstructure by means of chemical
composition design and management of the formation
process has enabled the development of a TiAl material
that balances high fatigue strength with excellent fracture
toughness (displaying an elongation of 2% or more). The
use of this material to manufacture a piston pin has
resulted in the achievement of a 17% reduction in
weight, and has contributed to a 200 rpm increase in
engine speed, and, by means of a reduction in the level
of deformation of the pin, to reduced DLC wear and
increased reliability in the piston pin boss section.
Acknowledgments
The authors wish to take this opportunity to offer
their sincere thanks to the staff of the Titanium Metals
Division of Kobe Steel, Ltd., and the Kobelco Research
Institute, Inc., who generously assisted in the
development of the material and product discussed in
this paper.
Author
References
(1) Clemens, H., Kestler, H., Eberhardt, N., Knabl, W.:
PROCESSING OF TiAl BASED ALLOYS ON AN
INDUSTRIAL SCALE, The Minerals, Metals &
Materials Society, Gamma Titanium Aluminides 1999,
p. 209-223 (1999)
(2) http://www.thermocalc.se/, 2009/04/02
(3) JP, Patent Application No. 2000-24748
Sadami MINATO
250
Yasunori ONAHA
Sadami MINATO*
Ken MIZOGAWA*
ABSTRACT
It is necessary to reduce the reciprocating mass in order to increase the engine speed and power of Formula One
engines. The project discussed in this paper therefore set out to increase the section modulus of the shaft of the
connecting rod while maintaining its rigidity and achieving weight savings. To this end, the diffusion bonding method
was optimized, and a process of manufacturing a hollow connecting rod was developed. The developed connecting
rod is lighter in weight and higher in rigidity than a rod with a conventional I-type section produced by forging, and
has contributed to enabling engines to be increased in speed.
1. Introduction
As one of the main kinetic components enabling the
operation of high-speed and high-power Formula One
engines, connecting rods (conrods) are the subject of a
constant quest for weight reductions and increases in
strength and rigidity. For this reason, titanium alloys
displaying high specific strength were applied in their
manufacture. In 2000, weight savings were achieved
through the use of a -rich + titanium alloy, SP-700(1),
which possesses 25% higher fatigue strength than that
of the formerly used 6A14V titanium alloy. However,
responding to demands for further weight savings
exclusively by means of increasing strength was bringing
materials close to the limit of rigidity design, a situation
which necessitated a new technological breakthrough.
The potential for the use of a hollow conrod structure
as a means of achieving weight savings while
maintaining a geometrical rigidity was therefore studied.
2. Developed Technology
2.1. Study of Method for Hollowing Conrod
A variety of potential methods of realizing a hollow
conrod structure were studied. One suggested method
was to form a hollow shaft extending from the big end
by means of electrochemical or mechanical machining,
which would then be cover-welded using electron beam
welding (EBW), thus forming a hollow structure.
However, this method was unable to resolve the issue
of the strength of the joints. Issues of reduced strength
also arose in the cases of casting and wax soldering.
Diffusion bonding, as employed in the manufacture
of aircraft turbines, involves the diffusion of a solid
* Automobile R&D Center
251
Fig. 1
Developed
(hollow)
Rolled plate
(t19)
Blanking
(water Jet)
T-joint piece
1200
60
1000
50
800
40
600
30
400
20
200
10
Hot forging
0.2%YS-T
0.2%YS-L
UTS-T
UTS-L
EL-T
EL-L
RA-T
RA-L
0
DB-Rt 1.6
DB-Rt 6.3
Cut
L-joint piece
EL / RA [%]
Fig. 4
25 m
Round bar
( 50)
10
45
Base (no-DB)
Conventional
(solid)
M6
17
10
Fig. 2
2.5
0
R1
Fig. 5
Heat treatment
(STA)
Half-blank machining
(dowel at S/B end)
Machining
Acid
cleaning
Surface treatment
Diffusion bonding
(hot pressing)
Finished product
Work
Stopper plate
Fig. 3
252
3. Achieved Performance
A hollow structure in which diffusion bonding is
employed in the central section of the conrod thickness
has been developed, as shown in Fig. 6. This has
increased the modulus section of the shaft of the conrod
while enabling thickness to be minimized. Compared to
a conventional I-type section, an 8% reduction in weight,
2.5 times increase in the rigidity of the shaft, and 18%
increase in the rigidity of the circulation of the big end
have also been achieved. In addition, as a result of the
reduction in the load on the conrod bearings, the
potential for a 250 rpm increase in engine speed has
been demonstrated in durability tests in a real engine.
Diffusion
bonded area
Conventional
Fig. 6
Hollow shape
4. Conclusion
A method of manufacture of a hollow conrod using
diffusion bonding has been developed. The weight
savings achieved enabled engines to be increased in
speed and power, and the technology was introduced to
race engines in 2003.
References
(1) Ouchi, C., Minakawa, K., Takahashi, K., Ogawa, A.,
Ishikawa, M.: Development of -rich + Titanium
Alloy SP-700, NKK Technical Review, No. 65, p. 6167 (1992)
(2) Owczarski, W. A., Paulonis, D. F.: Application of
Diffusion Welding in the USA, Welding Journal, Vol.
60, No. 2, p. 22-33 (1981)
Author
Sadami MINATO
253
Ken MIZOGAWA
Masayuki TSUCHIYA*
Sakae TSUNASHIMA*
Hisashi HASHIMOTO*
ABSTRACT
Titanium aluminide intermetallic compound has a high specific stiffness close to 40 GPa/gcm3, the maximum
allowed under the regulations. The material also has high temperature strength and its use in the cylinder head valves
of Formula One engines has contributed to achieving higher engine speed. Vacuum annealing has been developed to
try to enhance fracture toughness, and a technique has been established to prevent products with micro-cracks from
being shipped if they occur during processing, by optimizing eddy current inspection technology to overcome quality
issues.
1. Introduction
Table 1
Fig. 1
Cr
Nb
Ta
Ti
2002
46.5
2.5
1.0
0.5
0.1
Bal
2003-2005
42.0
2.5
1.0
0.5
0.1
Bal
2. Development Technology
2.1. Annealing for high fracture toughness
Since 2003, materials regulations have prohibited
material with specific stiffness of greater than 40 GPa,
so Honda engineers have switched to a composition with
less Al, as shown in Table 1. Because of electrode
dripping during VAR, valves initially have a segregation
structure as shown in Fig. 2, and in 2003 valves were
sorted by quality based on observation of the structure
of all valves. Subsequently, melting rods for VAR were
shortened and a quality sorting technique was established
that used samples showing structural limits.
Broken valve
Fig. 2
2.3. Effects
In 2002, techniques to make inlet valves lighter
helped cut 6.0 g from the weight of earlier titanium
valves while raising engine speed by 600 rpm, and in
2003, valves became 2.4 g lighter and engine speed 240
rpm faster.
8.0
Ultimate tensile strength
Bending fatigue strength
Elongation
1400
1200
Stress (MPa)
7.0
6.0
1000
5.0
800
4.0
600
3.0
400
2.0
200
1.0
Elongation (%)
1600
0.0
AS Extrusion
Fig. 3
Anneal 1000 C 2 hr
Fig. 4
255
3. Conclusion
Using vacuum annealing heat treatment and eddy
current scanning, Honda developed lightweight TiAl
valves with long-distance reliability. This technology was
applied to inlet and exhaust valves to help create engines
able to produce higher engine speed.
References
(1) Publication of unexamined patent application, 200024748 (2000), Japan
(2) http://www.mwracing.eu/
Author
Masayuki TSUCHIYA
256
Sakae TSUNASHIMA
Hisashi HASHIMOTO
Taihei SANADA*
ABSTRACT
Valve specifications with the largest hollow area possible while still assuring the strength of welded areas were
established, achieving a weight reduction of 4.4 g per valve, and applied to races. In addition, a high-quality oxidation
resistant process was established for filling titanium valves with sodium-potassium, and technology that cools the high
temperature areas of the valve by 100C or more was developed. These cooling effects enabled expansion of the hollow
area, further reducing the weight by 4.8 g per intake valve and 4.6 g per exhaust valve. Engine 2-race event durability
tests were completed, but the intake valve experienced a drop in output due to the effects of sodium-potassium heat
exchange, and some issues with exhaust valve durability also remained.
1. Introduction
Formula One regulations prohibited the application of
intermetallics to engine parts from 2006. Therefore, the
titanium-aluminum (TiAl, density 4.05 g/cm3, Youngs
modulus 155 GPa) valves had to be changed to titanium
alloy valves (in case of intake valve, density 4.65 g/cm3,
Youngs modulus 114 GPa).
To reduce the weight and increase the stiffness of
titanium alloy (Ti) valves, and increase the engine
rotations, it was essential to make the valve head and
stem hollow. In addition, filling Ti valves with sodiumpotassium was investigated to further reduce the weight
by expanding the hollow space.
Hollow
Non-welded area
Plug
EBW
2. Development Contents
Fig. 1
1.2
Fatigue strength ratio
to solid valve head
EBW
1.0
0.8
0.6
0.4
1.27 mm
0.2
0.0
0.0
Fig. 2
0.5
1.0
1.5
Non-welded area thickness (mm)
2.0
Inner plug
Fig. 3
Inside of
box
Dew
point
meter
NaK
nozzle
Valve
blank
Glove box
Fig. 4
Temperature
(C)
Fatigue strength
(MPa)
Valve weight (g)
Exhaust valve
Current
NaK
Difference Current
NaK
Difference
718
544
-174
840
737
-103
227
615
+130%
126
211
+67%
35.1
30.3
-4.8
32.7
28.1
-4.6
4. Conclusion
Vacuum
gauge
Oximeter
Table 1
258
Reference
(1) Japan Society of Corrosion Engineering: Fusyoku
bousyoku handobukku, Maruzen, p. 32 (2000) (in
Japanese)
Author
Taihei SANADA
259
Naoaki ITO*
Masaomi YONEHARA*
Kazushige YAKUBO*
ABSTRACT
Among the Formula One engine valve train parts, the camshaft and rocker arm are subject to severe sliding
conditions and constant demands for higher rotating speeds, so it was necessary to increase endurance reliability.
Therefore, diamond-like carbon (DLC) coating films that strengthen the surface were developed, the film compositions
and hardness balance were optimized, and the coating films were applied. As a result, friction was reduced by a total
of approximately 5 kW, and endurance reliability was achieved that enables continuous camshaft use in 4-Race events.
1. Introduction
The camshaft and rocker arm are Formula One
engine valve train parts that are subject to severe sliding
conditions. The sliding conditions in the boundary
lubrication area reach a contact pressure of 1 GPa or
more, and a PV (contact pressure x sliding velocity)
value of 20000 MPa m/s or more. Figure 1 shows the
position of the sliding conditions on a Stribeck curve.
To secure sufficient endurance reliability under these
conditions, it was necessary to cover the parts with a
tough coating film that does not experience scuffing,
even when the oil film breaks, and does not wear under
high speed and high contact pressure sliding conditions.
For this reason, DLC coatings have been used since
2002.
Engines are becoming increasingly high power and
high speed, a pneumatic valve return system (J-VLV
2. DLC Specifications
2.1. Approach towards DLC Layer Configuration
The sliding surfaces of both the cam robe and the
rocker arm slipper were treated with DLC, and this was
confirmed to increase wear toughness and reduce friction
for both parts. Figure 2 shows the film configuration
concept. To realize uniform contact, the top layer forms
a low-hardness running-in layer. In addition, the DLC
layer that serves as the main sliding layer achieves a
balance between hardness and toughness, and the
Surface condition
Control of solid-solid contact by surface smoothing
Friction
Mixed
lubrication
Bonding layer
Multi-layer structure to reduce stress inside coating
Retention of transformation ability
Substrate surface
Rationalization of surface roughness, hardness and
cleanliness
Elastohydrodynamic
lubrication
V/P
Fig. 1
Stribeck curve
Fig. 2
Running-in layer
3. Confirmation of Effects
Main layer
35
25
20
15
10
-IDV38S (ICS)
-DF1 (KOBE)
5
0
50
150
250
350
450
550
650
750
850
950
1500
Contact pressure
PV value
1450
23000
1400
22000
1350
21000
1300
20000
+17%
+32%
19000
1250
PV (MPam/s)
Fig. 3
Hardness (GPa)
30
18000
1200
17000
1150
16000
1100
2004
Fig. 6
Fig. 4
2005
2006-
4. Conclusion
Running-in layer
: Hv1000, 0.2-0.5 m
Running in layer
: Hv1000, 0.2-0.5 m
DLC: Hv2000-2500, 2 m
Substrate
Substrate
Fig. 5
261
Acknowledgements
The authors would like to express their deep thanks
to ICS Corporation and Kobe Steel, Ltd., for their
cooperation with the production technology and quality
assurance associated with these parts.
Author
Naoaki ITO
262
Masaomi YONEHARA
Kazushige YAKUBO
Nobuyuki IMAI*
Hiroaki NISHIDA**
ABSTRACT
Laser clad welded valve seats can expand the flexibility of layout compared to conventional press fit valve seats.
The slot form, the shape and amount of the powder to be supplied, and the laser output parameters were optimized
and balanced, quality assurance requirements were established, and the valve diameter was expanded by 1 mm. This
achieved an increase in engine power of 6 kW at high water temperatures. In addition, the continuous use of one
engine over the distance for two Formula One race events was supported by enhancing the powder materials.
1. Introduction
The valve seat (hereafter, seat) pressed fit require
sufficient wall thickness around the seat press fitting area
of the cylinder head (hereafter, head), and also
stiffness of annular rigidity of the seat itself. For this
reason, the flexibility of the combustion chamber layout,
including the valve diameter, valve pitch, and port angle,
was limited. In addition, the area between the seat and
the head is crimped, so heat transfer is insufficient
Fig. 1
Thin
wall
Thin
wall
Fig. 2
Combustion chamber
Valve seat
Symmetry
Clad area
Work
Line
Obtuse angle
Non-weld
Length regularity
Port
Fig. 6
Cylinder head
Fig. 3
Dilution brittleness
Impact stress
Good
Cu alloy +
stellite 5%
800
Cu alloy
Cu alloy +
tribaloy 5%
Cu alloy+
stellite 7%
4 mm
700
600
500
Critical zone = Hv500
400
300
200
100
0
-0.4
Abrasion resistance
Fig. 4
Fig. 7
Cylinder head
Fig. 5
0.2
0.4
0.6
0.8
Seat side
-0.2
Head side
3. Results
Laser clad welded seat technology increased the
flexibility of the layout around the valve seat, enabled
expansion of the valve diameter by 1 mm, and achieved
a 6 kW increase in the engine power at a high water
temperature of 120C.
264
4. Conclusion
Laser clad welded valve seat manufacturing
technology was established and applied to Formula One
races from 2004. Hard particle powder was added and
quality standards were established, which helped achieve
the durability and reliability required to support the
continuous use of one engine over the distance for two
Formula One race events.
Acknowledgements
The authors wish to express their deep thanks to
Tosei Electrobeam Co., Ltd., for cooperation in
establishing the powder supply conditions.
Author
Nobuyuki IMAI
265
Hiroaki NISHIDA
Takeshi MUNEMURA*
Hiroshi YAMADA*
Takayuki OHNUMA**
ABSTRACT
This paper discusses the use of titanium exhaust pipes for Formula One race cars in weight reduction. Newly
developed processes for titanium material including heat treatment providing an acicular structure, oxidation
resistant coating, sandwich press forming, and investment casting manufacturing have achieved a 20% weight
reduction. This specification was not applied to race cars but provides technology for lightweight titanium exhaust
pipes.
2. Technology Developed
Front
Rear
Collector
50
Tail pipe
Primary pipe
Ti-9 acicular
30
20
10
0
550
Fig. 1
Inco625
40
600
Fig. 2
650
700
750
800
Temperature (C)
850
900
950
Welding
Chemical
milling
Annealing
Heat treatment
for diffusion
Fig. 3
3D data
Removing RP model
burning shell
Fig. 6
Aluminum
plating
Casting
Molding
HIP
Chemical
milling
Process of casting
Heat treatment
providing acicular
structure
3. Results
Ti base metal
20 m
Fig. 4
SUS t1.0
Ti-9 t1.0
SUS t1.0
Die (FCD)
Fig. 5
Die (FCD)
Rear
Front
SUS t1.0
Ti-9 t1.0
SUS t1.0
Die (FCD)
Process of press forming
Fig. 8
267
4. Conclusion
The exhaust pipe for the 2007 specification had a
unique layout: the exhaust pipe extending toward the
engine in the forward direction, then loops back toward
the rear. The loop-back area was broken during a track
test and so this was not used for the race. However, in
the 2006 specification (normal type; straight toward the
rear of vehicle), the exhaust system based on this
technology was used for 1200 km, confirming the
durability of the technology.
This has shown that weight reduction is feasible by
converting the exhaust pipe to titanium and optimizing
the component shape.
Author
Takeshi MUNEMURA
268
Hiroshi YAMADA
Takayuki OHNUMA
Yu MURAI*
Masayuki TSUCHIYA*
ABSTRACT
The total weight of the scavenge and feed oil pump rotors fitted in Formula One V10 engines was previously
more than 1 kg, leading to demands for weight savings and friction reductions. A polyethyl ethyl ketone material and
a polyimide material have been used to manufacture the scavenge pump outer rotor in a two-stage injection molding
process, and a polyethyl ethyl ketone extrusion material has been used to manufacture the feed pump outer rotor.
This has resulted in a weight saving of 465 g and a friction reduction of 1.8 kW.
2. Product Development
160
= 0 B50 (MPa)
Fatigue strength
1. Introduction
PEEK+CF30%
injection
Working temperature
140
120
PI +CF30%
injection
100
80
Phenol+GF40%
injection
60
40
PEEK+CF30%
extrusion
20
0
0
Fig. 1
50
100
150
Temperature (C)
200
Development of Lightweight and Low-friction Resin Materials for Oil Pump Rotor
1.2
Friction torque (Nm)
1.0
0.8
0.4
Developed rotor
0.2
Outer: PEEK-PI
Inner: WE54
0
3000
Fig. 3
4000
5000
6000
7000
Pump speed (rpm)
8000
9000
4. Conclusion
Resin oil pump rotors were developed, with the
following outcomes.
(1) Scav pump rotor
The outer rotor is manufactured from PEEK and PI in a
two-stage injection process, and the inner rotor is
manufactured from WE54 magnesium alloy, resulting
in a weight saving of 420 g and a friction reduction of
1.8 kW. The new rotor has been employed in races since
the first race of 2004.
(2) Feed pump rotor
The outer rotor is manufactured from a PEEK extrusion
material and the inner rotor is manufactured from the
conventional Al sintered metal, resulting in a weight
saving of 45 g. The new rotor has been employed in races
since the 16th race of 2004.
Fig. 2
10% DOWN
0.6
Acknowledgments
The authors wish to take this opportunity to thank all
the members of staff at Nichiei Co., Ltd., who made
helpful proposals concerning the molding of the parts
discussed in this paper, and who cooperated in the
development of the manufacturing method for the parts.
270
Author
Yu MURAI
Masayuki TSUCHIYA
Yu MURAI*
ABSTRACT
Research was done on coolants with the objective of increasing automobile radiator cooling efficiency and
contributing to aerodynamics by enhancing the thermophysical properties of engine coolants.
The research confirmed the effectiveness of adding nano additives to enhance heat conductance, as well as using
heavy water in solvent to increase specific heat of the coolant. Because evaluations of cooling performance in actual
engines have not shown a clear difference from conventional coolants using water, a precise heat transfer measurement
technology was established to clarify the factors affecting heat transfer, and from this, directions were established for
the development of engine coolants.
1. Introduction
2. Materials Development
The heat transport capacity of coolants is generally
calculated from the specific heat per unit volume and
from the heat transfer coefficient, as shown in Eq. (1).
From Eq. (3), which is found by substituting Eq. (2) into
Eq. (1), it is supposed that raising thermal conductivity,
raising specific heat and lowering viscosity will cause
heat transport capacity to increase.
(1)
(2)
Substituting (2) into (1),
Heat transport capacity =
[Cp ] [ 1/6 (Cp )1/3 U1/2 2/3]
(3)
Material
Additive
Table 1
J/(cm3K)
mm2/sec
g/cm3
H2O (Base)
0.61
4.2
0.7
1.00
DW178
CNT 10%
ROSO3-Na
0.74
4.0
1.4
1.06
H2O+Al2O3
Al2O3 30%
0.73
4.0
1.5
1.27
D 2O
0.60
4.6
0.9
1.11
D2O+Al2O3
Al2O3 30%
0.79
(+30% )
4.5
2.5
(+7.7%) (+270%)
1.41
16000
Conduction
14000
12000
10000
H 2O
H2O+Al2O3
D 2O
D2O+Al2O3
Convection
H 2O
8000
6000
4000
D2O+Al2O3
2000
0
0
0.5
1.0
1.5
2.0
2.5
3.0
Fig. 2
4. Conclusion
The newly developed nano fluid increases thermal
conductivity, but at the same time causes an increase in
viscosity because of the effect of interactions between
additive particles, indicating that cooling efficiency
would decline at the flow velocities at which Formula
One engine coolants are used. Therefore, engine coolants
need to be formulated to strike a good balance between
increasing thermal conductivity and controlling increases
in viscosity.
References
(1) JP, P2008-201834, A (2008)
(2) Nakamura, S., Motohashi, Y., Hayakawa, S.:
Development of Wind Simulator Equipment for Analysis
of Intake Phenomena in Formula One Engines, Honda
R&D Technical Review, F1 Special (The Third Era
Activities), p. 95-100
Hot coolant; 80 C
Thermo
couple
Stainless steel
Thermo
couple
Author
Channel 9x50x1-3 mm
Aluminum or Stainless
2-10 mm
Channel 9x50x1-3 mm
Thermo
couple
Stainless steel
Thermo
couple
Cold coolant; 7 C
Fig. 1
Yu MURAI
272
Daiki KONAGAYA*
Tsutomu TANAHASHI*
Takashi TANAKA*
ABSTRACT
Two types of steel, a high pitting-toughness material displaying excellent performance in relation to the gear tooth
fatigue characteristic and a high yield strength material displaying excellent tooth bending toughness, were developed
for use in Formula One gearboxes. Optimization of the alloy composition increased pitting toughness, contributing to
the achievement of a 740 g weight saving by enabling the thickness of the gear teeth to be reduced. The high yield
strength gear material displayed a yield strength in excess of 1900 MPa, and was developed to ameliorate the issue
of tooth root fatigue damage originating in bending of the gear teeth under the excessive input forces characteristic of
Formula One racing. From 2008, regulations were changed to stipulate the use of a single gearbox for four race events,
and the new material contributed to the achievement of increased long-distance reliability.
1. Introduction
Table 1
Chemical composition
(mass%)
C
Conventional steel
SNCM815VA
Developed steel
LBHD-2E
Si
Mn
Ni
Cr
Mo
0.12- 0.15- 0.30- 4.00- 0.70- 0.150.18 0.35 0.60 4.50 1.00 0.30
0.30
1.50
0.35
2.00
1.50
0.75
800
Chemical composition
Hardness (HmV)
Conventional steel
(mass%)
Developed steel
700
LBHD-2E
Conventional steel
LBHD-2E
600
Developed steel
250STF5
500
400
0.0
Si
Mn
Ni
Cr
Mo
0.30
1.50
0.35
2.00
1.50
0.75
0.52
2.50
0.70
1.80
0.80
0.40
SNCM815VA
Table 3
0.5
1.0
1.5
2.0
3600
3400
3200
3000
2800
2600
2400
SNCM815VA
2200
2000
1800
1600
1400
1200
1000
1.E+04
1.E+05
EL
%
Core
hardness
42 HRC
SNCM815VA
1029
1308
18.6
LBHD-2E
1332
1795
15.9
52 HRC
Developed steel
250STF5
2137
2493
6.5
59 HRC
14
LBHD-2E
12
LBHD-2E
250STF5
10
8
6
4
+19%
1.E+06
1.E+07
0
0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15
Impact load (ton)
1.E+08
Number of failures
Fig. 2
TS
MPa
Conventional
steel
Deformation ( m)
Fig. 1
0.2% YS
MPa
Fig. 3
4. Conclusion
A high pitting-toughness material was developed, and
was employed for ratio gears in races from 2004. This
helped to enable the thickness of the gear teeth to be
reduced by 20%, contributing to the realization of a
weight saving of 740 g in the gearbox as a whole. The
material was later also employed for the final gears and
the dog rings, contributing to the achievement of
increased reliability against gear tooth pitting.
A high yield strength gear material was developed
that exceeded development targets, achieving a yield
strength of 2137 MPa, 60% greater than that of the
previous steel. When the developed steel was employed
in a gearbox, the load at which the teeth commenced
bending was increased by 24.8%. This material was used
for the 1st gears and shaft from the opening race of 2008,
and contributed to the achievement of increased
reliability over long distances, as necessitated by the
274
Acknowledgments
The authors wish to take this opportunity to thank the
staff of Daido Steel Co., Ltd., for their generous
assistance in materials development and gear tooth
bending tests during the course of the projects discussed
in this paper.
References
(1) Hanyuda, T., Nakamura, S.: Properties of Newlydeveloped Pitting Resistance Steel for Gears,DPG1,
Electric Furnace Steel, Vol. 71, No. 1, p. 59-64 (2000)
(2) Kurebayashi, Y., Hatano, A.: Influence of Silicon and
Vanadium Contents on Fatigue Properties of Carburizing
Steels, Electric Furnace Steel, Vol. 67, No. 1, p. 34-43
(1996)
Author
Daiki KONAGAYA
275
Tsutomu TANAHASHI
Takashi TANAKA
Tsutomu TANAHASHI*
Yasunori ONAHA*
ABSTRACT
A diamond-like carbon (DLC) coating has been developed for the transmission gears to increase their transmission
efficiency. Using the carbon sputter method increased topcoat hardness and suppressed the formation of interfaces
within the coating film, which enhanced durability under high surface pressures. This DLC was applied to the shift
gear, final gear and bevel gear, and contributed to reducing friction. In addition, it secured the reliability needed to
enable continuous use in the 4-Race events that Formula One regulations prescribe.
1. Introduction
3. Developed Technology
2. Development Concept
Engine valve trains that use a DLC coating perform
reciprocal motion, so there is an oil film break point with
a sliding speed of 0 m/s. This means that a hard bonding
layer is required below the coating film to enhance scuff
resistance.
On the other hand, the gear sliding environment has
a high maximum surface pressure of 2.2 GPa, but the
sliding speed does not go to 0 m/s, and there is no oil
film break such as in a valve train. For this reason it was
thought that a bonding layer is not required for the gear
DLC, so efforts focused on developing a topcoat and
coating film composition with an emphasis on wear
resistance.
* Automobile R&D Center
276
DLC
WC-C
Substrate
Fig. 1
DLC
(topcoat)
Cr
WC-C
(interlayer)
Cr (adhesion)
1 m
0.6 m
Substrate
Developed DLC
100
Conventional DLC
(%)
80
60
Tip side
40
Flank center
20
Root side
Fig. 2
Flank center
Root side
4. Confirmation of Effects
Pin on disk seizing limit tests and actual transmission
tests were performed. In the pin on disk seizing limit
tests, oil was applied, wiped off, and then the load at
which the friction coefficient rose due to seizing
measured. As shown in Fig. 3, the seizing load increased
by 40%. This is thought to be due to an increase in the
300
Friction
Shift gear
Bevel gear
Final gear
0.8 kW
1.3 kW
1.2 kW
350
5. Conclusion
0
Tip side
Table 1
Acknowledgements
The authors wish to express their deep thanks to ICS
Corporation for their cooperation with the hard DLC
condition settings and gear coating production process.
Reference
Lubrication: semi-wet
Velocity: 0.2 m/s
250
+40%
200
150
100
Conventional DLC
Fig. 3
Developed DLC
Author
Fig. 4
Tsutomu TANAHASHI
277
Yasunori ONAHA
Yu MURAI*
Masatoshi OKUMURA*
ABSTRACT
The DC-DC converter is key to developing small, lightweight power control units for Formula One hybrid systems.
A new material consisting of a silver-impregnated diamond powder compact, was developed in order to enhance the
heat dissipation performance of the DC-DC converter. The coefficient of thermal conductivity of the developed material
is three times that of a conventional aluminum material. The use of the silver-diamond composite material in a
heatspreader has reduced the temperature increase of the switching elements by 33%, offering a good prospect for the
extension of continuous boost from 1.4 to 6.6 seconds, the maximum regulation figure.
Table 1
Material
Coefficient of
thermal expansion
10-6/K
200
630
23.4
5.5
A6063
Ag-CD
g/cm3
Volume fraction
of diamond
%
2.7
6.0
62
Density
2. Developed Technology
Chip
Solder
Chip
AlN
Brazing
Al buffer for heat stress relief
Al 6063
Solder
AlN
Solder
Heatspreader
Ag-CD
Pin fin
Former spec.
Fig. 1
Developed spec.
4. Results
Heat dissipation performance was evaluated in
thermal resistance tests of prototype power modules
using heatspreaders manufactured from Al6063 and the
Ag-CD material.
In a comparison using the same finless shape, the
temperature increase of the switching elements was 35%
lower in the power module using the Ag-CD
heatspreader than in the module using the conventional
Al6063 heatspreader. As Fig.4 shows, when the
developed material was applied in the manufacture of a
heatspreader that also incorporated a change in shape, the
temperature increase of the switching elements was
reduced by 33%. This indicates a solid potential for the
extension of continuous boost time from 1.4 to 6.6
seconds per lap (full boost) at a cooling water
temperature of 80 C or below, as assumed for an entire
racing season.
180
170
160
150
120
Ag-CD plane
110
6.6 sec
100
Regulation limit
90
800
80
CTE
Good
700
Potting resin
10 ppm <
TC
Good
500
Ag
400
Fig. 4
Go
Cu
AlN4.5
Former
6063
SiC
10
15
20
25
Fig. 2
0.1 mm
Diamond powder
Author
Ag matrix
Fig. 3
5. Conclusion
Other materials
for heatspreader
Si3N4
Al
Si AlN
100
od
300
200
Developed
Ag-CD
600
33%
140
130
Yu MURAI
279
Masatoshi OKUMURA
Takehiro MIYOSHI*
ABSTRACT
Stator core iron loss was reduced by 60% by optimizing the thickness and microstructure of iron-cobalt alloy,
which shows a high induction, and by developing a new adhesive and surface treatment technology. A manufacturing
process was developed that satisfies the required magnetic characteristics and dimensional accuracy, and a new
production system was constructed for laminated parts. The newly developed stator enabled a 20% reduction in the
motor size.
2. Developed Technologies
2.1. Material Development
Figure 1 shows the target material property values.
Compared to Fe-Si (Base), existing FeCo materials
(original) have high iron loss, so the target was set at
an iron loss equal to or less than that of Fe-Si. Iron loss
is classified into the two types of eddy current loss and
hysteresis loss, and eddy current loss is proportional to
the square of the thickness, so eddy current loss can be
reduced by reducing the thickness(1). However, reducing
the thickness raises the issues of a lower lamination
factor, lower rolling and pressing quality, and lower
productivity due to an increased number of layers. The
iron loss values of cold rolled materials with a thickness
of 10 m to 150 m were measured under conditions
of 1.0 T and 400 Hz. The magnetic characteristics were
measured using a toroidal-shaped laminated ring with an
2.4
Induction (T)
1. Introduction
FeCo
(original)
Target
2.0
Base
1.6
1.2 Amorphous
0.8
Fig. 1
Thin
Fe-Si
Low loss
Fe-Si
High TS
Fe-Si
Fedust
10
15
20
Iron loss (W/kg)
Target properties
25
30
3. Effects on Performance
Copper wire was wrapped around a core yoke, and
the DC BH characteristics and iron loss value were
measured to confirm the magnetic characteristics of an
actual stator core. Figure 5 shows an exterior view of
the test sample. The induction B50 was 2.0 T or more,
and iron loss was 12 W/kg or less at W10/400, which
met the targets. A motor using the newly developed
materials achieved 15% higher torque with a size 20%
smaller than that of a motor using Fe-Si materials.
Fig. 5
BH measurement sample
4. Conclusion
t = 150 m
t = 10 m
50 m
50 m
Fig. 2
Acknowledgments
25
Iron loss (W/kg)
Microstructure
Total loss
20
15
Hysteresis
10
Reference
5
Eddy current
0
0
50
100
150
Thickness ( m)
Fig. 3
Author
2 m
FeCo
Oxide layer
Adhesive
FeCo
Fig. 4
Takehiro MIYOSHI
281
Yasuhiro YAMADA*
ABSTRACT
This paper describes the research conducted on Carbon Fiber Reinforced Plastic (CFRP) for the side panel of a
Formula One monocoque.
The elongation ratio of a matrix resin was increased, thus increasing intrusion load 30% by load distribution. This
enabled weight reduction by 1.1 kg for only a segment of the side panel.
In addition, weight reduction research was further conducted on single-sheet side panel, an alternative option to
aluminum-honeycomb sandwich side panel, and the resulting technical issues were clarified.
1. Introduction
A several-mm-thick material called CFRP is used for
the Formula One monocoque. CFRP is made by laying
up multiple 100 m-thick prepreg sheets, which is a
carbon fiber fabric impregnated with matrix resin, and
hardening the layered sheets. In addition, sandwich
structures in which an aluminum honeycomb is
sandwiched between CFRP increased strength and
rigidity, and weight reduction is further required.
The Federation Internationale de lAutomobile (FIA)
sets regulations for intrusion resistance in side impacts
to help ensure side panel safety(1).
The FIA updates side panel regulations every few
years in order to enhance safety, and each time the
monocoque weight is increased.
Weight increases are expected to continue in the
future following regulation updates, so the mechanism
of intrusion resistance was studied, a matrix resin for
side panels was developed, and weight reduction research
using optimized panel structures was initiated.
Fig. 1
Fig. 2
Destructive
Maximum load; Energy absorption;
morphology;
first 100 mm of first 100 mm of
after 150 mm
displacement (kN) displacement (kJ)
displacement
Year
2001-2004
150
2005-2006
No destruction
to frame
Additional extra
secondary panel
250
2007-
Others
3. Technology Elements
The impact of carbon fiber-type, panel structure,
aluminum honeycomb density, matrix resin of CFRP was
confirmed.
3.1. Carbon Fibers
Intrusion tests were conducted on CFRP made from
commercial carbon fibers. The carbon fiber series
T1000G manufactured by Toray Industries, Inc. was
confirmed as offering the highest tensile strength and
best intrusion resistance among available carbon fibers.
3.2. Panel Structures (Sandwich Panel and Single
Sheet)
Formula One monocoque is designed to receive the
highest intrusion load when the inner wall of the panel
is penetrated. Figure 3 shows intrusion test results for
the sandwich panel and single sheet. For the sandwich
panel, the top panel that corresponds to the outer wall
panel of the monocoque was penetrated with 142 kN of
load. Then, the bottom panel that corresponds to the
inner wall panel of the monocoque was penetrated with
261 kN of load. Also, the single sheet was penetrated
with 200 kN of load, 61 kN less than the bottom panel
of the sandwich panel, despite being 1.3 mm thicker than
Jig
Top panel
Bottom panel
Stress distribution area
300
Bottom panel
10 mm
(honeycomb)
Fig. 4
250
4 mm
Single panel
300
61 kN
250
Top panel
150
Load (kN)
Load (kN)
200
Sandwich panel
(Top 1.3 mm / Al honeycomb 10 mm
/ Bottom 2.7 mm)
100
200
150
100
50
50
50
100
Displacement (mm)
150
Fig. 5
Fig. 3
283
20
40
60
80
100
Displacement (mm)
120
140
Commercial grade
(estimated)
50
40
30
20
2
Elongation (%)
Fig. 6
Section
55
300
Bend.,
compression
Tension
Cycom2020 panel
Fig. 7
250
RH421 panel
200
150
100
Fig. 9
Bending
modulus
Compression
modulus
Bending
strength
Fig. 8
45
3.5
Compression
strength
0
Tensile
modulus
Shear
strength
Intrusion load
50
Tensile
strength
Shear
modulus
50
Final specification
RH421
70
60
4.0
4.5
5.0
5.5
Panel thickness (mm)
6.0
Center
Outer
RH421/T1000G (developed)
Cycom2020/T1000G
(conventional ; Cytec)
Fig. 10
284
280
260
Weight reduction
Good
240
ne
d li
loa RP
n
o
CF
usi
Intr single
of
220
200
180
5500
Fig. 11
6000
6500
7000
Panel weight (g/m2)
7500
6. Conclusion
10000
8000
6000
4000
0
30
Fig. 12
No delamination
to frame
35
8000
2000
Delamination
to frame
40
45
Intrusion displacement (mm)
50
55
References
Author
Delamination
Low modulus layer
CFRP
Iron frame
Fig. 13
Yasuhiro YAMADA
285
Akihiro YANASE*
Hiroshi YAMADA*
ABSTRACT
A production process was developed that uses high-strength Al-Li materials to reduce the brake caliper weight.
Anisotropy of material strength due to metal flow was eliminated with 3-axis multi forging, and an 8% increase in
fatigue strength was achieved by T6 heat treatment with 3-stage aging. This is expected to increase the service life to
4 times that of current calipers.
1. Introduction
Regulation
2090
79
8090
2099
77
75
2618
73
2.5
2. Developed Technology
2.6
2.7
2.8
2.9
Density []
Fig. 1
380
Maximum stress L [MPa]
2099
ext. bar
360
340
8090
forged
320
300
Target
2090
forged
280
260
2618
240
240 260 280 300 320 340 360 380
Maximum stress T [MPa]
Fig. 2
Fatigue property
Fig. 5
Sampling regions
380
2099-T83 ext. bar
z
Heat
treatment
y
x
Die forging
Rotation y
1st upset
Rotation z
2nd upset
3rd upset
Target
340
320
300
8090 forged
T6 (2006)
2099 extrusion
T83 (2007)
2099 multi-forged
3 stage T6
(110)
3. Conclusion
(Al3Li)
T1 (Al2CuLi)
Fig. 4
8% UP
360
Fig. 6
(100)
280
287
Development of Brake Caliper Production Process with High Strength Al-Li Material
Reference
(1) Romios, M., Tiraschi, R., Parrish, C., Babel, H. W.,
Oqren, J. R., Es-Said, O. S.: Design of Multistep Aging
Treatment of 2099 (C458) Al-Li Alloy, Journal of
Materials Engineering and Performance, p. 641(2005)
Author
Akihiro YANASE
288
Hiroshi YAMADA
Hidetada TANIGUCHI*
Shigeo MIYAJIMA*
Katsunori TAGUCHI*
Osamu WATANABE**
Masataka NODA*
ABSTRACT
In racing operations, parts development and supply must be constantly reviewed in a short time with regards to
changing circumstances in order to simultaneously promote upgrading and supplying of parts with the aim of
maintaining competitiveness relative to other teams. For this reason, a part lifecycle management system was constructed
to increase development speed and effectively utilize resources. This system aimed for centralized management of
part plans and results data for all stages, from investigation of part design specifications to drawing issue, production
plans, arrangement and purchasing, procurement and manufacturing, receiving inspection, inventory control, assembly,
usage history, and disposal. Centralized data management enabled instant sharing of information across the Racing
Division, and provided prospects for creating an environment that enables accurate and prompt decision making even
at racing sites.
1. Introduction
The Racing Division of Hondas Automobile R&D
Center (Tochigi) developed, assembled and supplied
engines, developed advanced chassis technologies, and
also developed and supplied internal gears and gear
shifting parts for the gear box to the Honda Racing
Formula One Team (HRF1). Engines were also
assembled and supplied by Honda Racing Development
Ltd. (HRD) in England, and in addition to parts
development and supply to race sites from Tochigi,
locally procured parts were supplied from HRD.
In racing operations, development speed is demanded
to maintain competitiveness, and this assumes a unique
operations flow (F i g . 1 ). Parts with multiple
specifications are constantly designed, arranged and
tested, then just before assembly the test results are
reviewed to select the optimum specifications from
among the current inventory and parts scheduled for
delivery, and the selected parts are assembled into
products and supplied. In addition, arrangements must be
made concurrently for development parts and racing
supply parts, and assembly specifications also change
frequently. This means that a diverse and large volume
of inventory is essential in securing a constant stock of
parts that might be used.
Assembly specifications and inventory conditions
change constantly, including support for races that are
held every other week, and it is also necessary to
accurately record part assembly results and usage
Drawing
Drawing
Purchasing
Purchasing
Purchasing
Assembly
planning
Manufacturing
Manufacturing
Manufacturing
Assembly
Test
Assembly
planning
Inventory
Assembly
Re-assembly
planning
Inventory
Assembly
planning
Inventory
Assembly
Re-assembly
Test
Race
Assembly
planning
Drawing
Work flow
Assembly
Race
Decision
Purchasing
Availability Information
Fig. 1
Assembly
planning
Drawing
Purchasing
Fig. 2
Manufacturing
Inventory
Racing operations
Manufacturing
Inventory
Assembly
Test
2. Development Policy
The newly developed system aimed to share accurate
parts management information to enable the timely and
accurate decisions needed for racing operations. In
addition, construction of an environment enabling the
maximum utilization of development resources was also
expected as a result.
To achieve this, the target was set as centralized
management of constantly up-to-date plans and results
for all stages, from the investigation of part design
specifications to drawing issue, production plans,
arrangement and purchasing, procurement and
manufacturing, receiving inspection, inventory control,
assembly, usage history, and disposal.
The specific development indexes were determined as
follows.
(1) Faster verification of assembly plan feasibility
(2) Increased purchase order speed
(3) Enhanced parts management information
Construction of the new system required that the
operations flow be restructured, so members selected
from all related departments thoroughly verified the work
flow, and reviewed operational roles to achieve the
optimum overall balance.
Due to the nature of racing operations, speed and
flexibility are demanded, so the division between
contents that should be decided by humans and areas that
can be left to the system was thoroughly discussed, and
291
Inventory
Assembly
A
Model
event
unit number
B
Assembly plan
Test team
Assembly
F
Part issue
G
Mileage
record
Assembly
result
Designer
C
Drawing issue
Part registration
Specification application
Arrangement and
purchasing order
D
Arrangement and
purchasing order
Assembly plan feasibility monitor
Fig. 3
Quantity
Common
L1
N5
Round1
Region
Bench
R001
R002
Performance
Piston
L1
10
N5
20
Funnel
E1
10
E2
10
F1
memo
F2
Quantity
Part
Assembly
date
2007
06/01
2007
06/02
2007
06/10
Performance
Unit No.
R001
R002
Quantity
Piston
L1
Piston
N5
Quantity
10
14
20
22
Common
Common
20
28
10
14
10
14
20
28
E1
Funnel
E2
Funnel
F1
F2
Common
Common
Fig. 4
292
Planned parts
selection & issue
Future inventory
(arranged but not yet ordered
+
ordered but not yet received)
Free inventory
Current inventory
Reserved inventory
(reserved for immediate
assembly work, shipping, etc.)
Fig. 5
Free inventory
X=(B+A)-C-D
(1)
X: Free inventory
B: Current inventory in parts warehouse
A: Future inventory (Sum of quantity arranged but not
yet ordered and quantity ordered but not yet received)
C: Reserved inventory (Quantity ready and awaiting
issue from inventory)
D: Allocation for planned unit numbers not yet reserved
(Quantity required by unit number plans but not yet
reserved for issue from inventory)
The final arranged quantity can be determined by
experienced personnel by taking into account irregular
factors such as the feasibility of reusing old parts based
on the shared part management information described
hereafter, and the number of race events remaining in
the season, and then adjusting the quantity with respect
to the free inventory obtained in the manner described
above. This enabled more accurate arrangements.
3.5. Inventory Sorting
Labels noting the unit number information based on
the assembly plan at the time of purchasing order
placement were formerly affixed to parts, but this was
not useful for racing part management in which assembly
plans undergo frequent changes. Therefore, an inventory
sorting function was developed to increase the sorting
speed and accuracy.
This function automatically creates prioritized sorting
proposals for available inventory based on the latest
assembly parts configuration sheets, assembly dates, unit
number purposes, applied specifications, and quality
rank. Humans then make a comprehensive decision to
determine the final sorting destination. This enabled
highly flexible operation.
293
Drawing
Drawing issue
Concurrent operation
Drawing
Purchase
order
Increased purchase
order speed (2 days)
Drawing issue
Arrangement
preparation
Purchasing
preparation
Fig. 6
Arrangement
Purchase
order
294
Unit number Z
Assembly X
Assembly Y
Fig. 7
Alert
Launch button
Arrangement status
for each part
Fig. 8
295
Basic information
Fig. 9
Parts list
Fig. 10
Receiving confirmation
Common functions
Explanation
Usage pattern
a. Display
Table column
customization
Structure expansion
Memo
b. Multi
location
Multi language
Multi location
c. External
interface
Excel input
Excel output
d. Security
Menu privilege
Data privilege
Arrangement
Unit001
Unit002
Unit003
May/20/2009
Jun/10/2009
Jun/20/2009
Part A
Part B
Part C
1
2
Part A
Part A
Part A
May/10/2009
Part B
May/30/2009
Part C
Jun/10/2009
Purchase order
E0002
Part C
Unit003
Part B
Part C
Jun/10/2009
Jun/10/2009
Part A
Unit003
0030
Unit001
Part B
Jun/1/2009
Part C
Unit003
May/10/2009
May/30/2009
E0003
E0001
Part C
May/10/2009
0020
Part A
Part B
Part B
0010
50
Unit001
Unit002
Part A
50
E0002
Quantity
Unit002
Agreed
delivery date
E0001
Serial
No.
Part A
Requested
delivery date
Part
Part
Unit002
Ordered
quantity
Mileage
Order
No.
Unit No.
Unit001
Arranged
date
Part A
Test
Serial
No.
Arranged
quantity
Part
Part
2
E0003
E0010
1
1
2
E0011
E0012
Serial
No.
E0001
May/10/2009
0010
E0002
May/10/2009
0010
Part A
E0003
May/10/2009
0010
Part B
E0010
Jun/1/2009
0020
Part B
E0011
Jun/1/2009
0020
Part B
E0012
Jun/1/2009
0020
Jun/10/2009
0030
Data model
296
Order
No.
Part A
Fig. 11
Received
date
Part A
Part C
Quantity
8. Conclusion
Author
Hidetada TANIGUCHI
Katsunori TAGUCHI
Shigeo MIYAJIMA
Osamu WATANABE
297
Masataka NODA
Activity Reports
Tsuyoshi ISHIHARA*
Atsushi NORIHARA*
Naoto SUNAKO*
Motoaki ISHIZAKA*
ABSTRACT
Numerous technologies were developed and put to use in races during Hondas third-era Formula One activities.
This paper introduces assembly activities from development tests to the racetrack.
1. Introduction
Hondas third-era Formula One assembly activities
began with several goals: no dropping out of a race
because of human error; no supply delays; reflect
development issues in blueprints; and pass down
technological skills. Based on Hondas second-era
experience, these four elements were essential for race
management, and activities were always pursued with a
consciousness of these targets as the path to victory.
This article introduces these activities by dividing
them into those that are in the factory domain, taking
place at Tochigi R&D Center (HGT), which oversaw
development of new technical items and the assembly
and supply of race and test vehicles, and at Honda
Racing Development (HRD); and those in the circuit
domain, which supported race and running test sites.
2. Factory domain
2.1. Startup of Honda Formula One Third Era
The third era started in 1999 by organizing the team
strength so that primarily those members who had
supported the golden era of Honda Formula One in the
second era could pass down their technical skills to new
members, increase development speed and pursue supply
of equipment for races. Passing on everything to the new
members involved a lot more than just writing a manual
and making them read it; it was a lot of work!
This section first gives a simple explanation of how
technological skills relating to the work of the assembly
crew were handed down.
At the development stage, one repeatedly assembles
and dismantles previously developed single-cylinder
engines, demonstration bench engines, durability engines
and running test engines, after which one checks the new
1000
Q R
1engine
1GP
1engine
2GP 1engine
1170
1141
981
124
229
1033
996
120
847
256
174
134
924
276
305
941
37
65
295
206
118
500
628
250
1003
547
514
246
312
351
04
05
06
457
583
289
03
315
437
657
424
383
304
07
08 - 12/5
00
01
02
2 teams supplied
Fig. 1
2 teams supplied
301
Fig. 2
Try 1
302
303
3. Mechanical Domain
3.1. Supplying Equipment to Two Teams
From the start of Hondas third-era Formula One
activities until Honda began supplying more engines to
two teams in 2001, the number of staff members
increased and, as a result, Honda started supplying two
teams with a staff consisting of 13% experienced persons
and the rest not experienced. For the mechanics, of
course, inexperienced personnel had to be used, but
under the guidance of experienced staff from Hondas
second-era Formula One activities, these people received
practical training in on-site trouble-analysis techniques.
Experience taught us that the ability to evaluate
sudden troubles cannot be learned in a very short time,
so all sorts of means were considered and put into effect
to help the inexperienced staff make up the gap between
themselves and the experienced staff. An attempt was
made to enhance their knowledge by, for example,
reading up on past troubles, conducting simulations of
trouble with an actual vehicle in front of them, and
having groups of young mechanics practicing FMEA
amongst themselves. Sometimes, however, they became
overwhelmed by the atmosphere of the site and the sense
of urgency and were unable to act.
We felt that the ability to judge and act at a
moments notice in extreme circumstances could not be
acquired unless we always had an engine in front of us
and could put our hands on it.
Even as their knowledge and competency increased,
it did not help at the racetrack unless they had tools,
spare parts (including, for example, proven replacement
components, in cases where a malfunction occurred with
a newly introduced component) and so on.
The veterans often said, Preparation occupies 90%
of work.
The most essential thing needed was the practice of
keeping the tools, equipment and components needed at
the site in a neat and orderly way so that they could
quickly be found when in a hurry and nothing would be
missing. This is all very basic. But for the young
mechanics, this was where the work began.
The following relates what happened at one event.
An engine that had been running smoothly suddenly
blew out without warning. The blown engine hurriedly
underwent emergency dismantling by two of us, a
veteran and myself (Ishihara); when we did primary
analysis of the cause, the veteran asked me to pass him
a battery-powered impact wrench, but when I picked it
up, the battery was dead.
This led to a severe scolding from the veteran. I
realized that my negligence in preparation had come to
light in that instant. After that incident, the first thing
we did at the site was to keep a battery charger ready.
The engines supplied to the race track are supposed
to have undergone a very strenuous final check at HGT
or HRD, but all engines underwent another enginespecification check at the hands of the mechanics, with
each bolt checked for torque, harness wiring checked,
etc., time and time again.
Oil-pressure adjustments and air-intake trumpetlength adjustments were made in keeping with the usage
environment at the site.
From time to time, components were replaced to deal
with troubles in time for an event and the crews
constantly tried to extract the maximum performance,
durability and reliability in each race.
On the starting grid of the final round, a number of
final quality checks on the hardware side of the engine
were performed right up to the start of the formation lap,
including checks of whether oil, water, fuel and air
pressure, air and oil consumption and oil and water
temperature were acceptable, whether there were any
leaks, whether all cylinders were firing and whether the
air/fuel ratio was correct.
This is very hard work, as malfunctions have to be
responded to immediately when found.
Sometimes the members were so nervous that their
stomachs hurt and they could not eat until the signal
changed and the vehicle got off to a trouble-free start.
More than actual race results, the mission of the
assembly crew was to make sure the vehicle finished
without trouble: for example, during the race, members
read data from the telemetry system and prepared for an
emergency pit stop if any abnormalities occurred.
3.2. Kitching
On the job at the racetrack, it was necessary to make
sure that all mechanics were correctly producing the
same output. This is referred to as kintaroame, which
is a kind of candy formed with an image in it. The
association implies that it was vital, no matter who cuts
it open and where they cut it, that the result will be the
same.
The two race engines provided for the two drivers
were lined up and arranged in detail right down to the
thickness, position, direction and binding force of the
wire harness and the tie-wrap that anchors the auxiliary
components (Fig. 3).
Deciding on assembly work procedures and
specifications when there are no blueprint instructions is,
in large part, dependent on the experience of the
mechanics.
This is because the heat, vibration and stress on
304
Fig. 3
Completed engine
305
306
307
Fig. 4
308
309
Fig. 5
310
4. Afterword
Looking back on nine years of activities, Hondas
third era of Formula One started with the development
and supply of engines. The effort subsequently responded
to diverse needs, from meeting development
requirements to developing a gearbox, conducting
vehicle running tests, developing KERS and, moreover,
launching a private team. Although Hondas withdrawal
from Formula One ended an era and we were never able
to ascertain the competitive strength of the 2009 vehicle,
we believe that the racing spirit cultivated here will one
day shine again in a new age of racing.
While we did not unfortunately leave a great record
of race success, the guidance given by our veterans
helped to pass down their mindset. We are moreover
thankful for the cooperation of all departments concerned
with development that helped us to carry out our duties.
Author
Tsuyoshi ISHIHARA
Motoaki ISHIZAKA
311
Naoto SUNAKO
Atsushi NORIHARA
Yusuke HASEGAWA*
Shiro HISATSUNE**
Tatsuya KODAMA**
ABSTRACT
In conjunction with the launch of our Formula One project in 1998, Honda Racing Development (HRD) was
established as the British base for administering the Honda Formula One team. Subsequently, plans were modified to
supply engines and joint development efforts with the BAR Team, and HRD came to assume the role of Hondas
frontline European base for timely project and decision-making. This article describes the roles and accomplishments
of HRD.
2. Location
As shown in Fig. 1, HRD is located in Bracknell,
almost in the center of Berkshire, about one hour west
of London by car. This location is 80 km from the
Formula One teams base in Northamptonshire and 20
km from Heathrow Airport, making it a convenient
location for Formula One-related activities, which require
a lot of travel.
The layout of HRD, comprising an office building
and a factory, is shown in Fig. 2.
In addition to local British employees, half the staff
was made up of Japanese employees on long-term or
temporary assignments, which made HRDs employeemix somewhat different from that of other overseas
locations. Many Japanese employees are there on shortterm assignments, and in addition to working on projects,
HRD also played a major role in managing housing,
hotels, and travel arrangements for the Japanese
employees.
M40
Oxford
M25
London
M4
HRD
Fig. 1
Heathrow Airport
Fig. 2
3. Factory Management
Figure 3 is a chronology of activities at HRD. The
Formula One team was BAR at the beginnings, and then
became BAR-Honda, with a 45% investment by Honda.
During the transition to all-Honda-owned HRF1, HRDs
functions also evolved one after another. The division of
labor between HRF1 and HRD can be essentially
described as vehicle body on one hand, and engines on
the other.
Initially, HRDs function was to serve as a contact
point for BAR, FIA and other Formula One associations,
and as a logistics and supply base. However, as BAR
HONDA shifted to Honda Racing Formula One (HRF1),
contact point for BAR became no longer necessary and
the contact point for FIA and other organizations was
also shifted to HRF1.
313
Year
99
00
F1 project
History
01
02
03
BAR
04
05
BAR HONDA
JORDAN
06
07
08
HRF1
Super AGURI F1
HRD function
Engine parts supply base
Engine maintenance
Reinforcement
Engine assembly
Logistics
F1 project
Troubleshooting
Powertrain setting
EU technical research
Engine quality enhancement
Local purchase control
#2Dyno
#3Dyno
ONO
ONO
AVL
HRD facility
Fig. 3
HRD history
314
100
High-speed circuit
90
Grainger Worral
80
Torque (%)
70
IST
60
50
Ilmor
40
30
20
Cosworth
Low-speed circuit
10
0
0
Fig. 4
10 20 30 40 50 60 70 80 90 100
Pedal (%)
CD-Adapco
Pedal-to-torque characteristics
Fig. 5
315
Development item
EU concept
cylinder head assy
Inlet valve (Ti3Al)
(high stiffness / light weight)
High-lift + narrow-duration
cam profile
IST
EU concept
cylinder block assy
Light-weight piston
( 5-axis machine)
Twin oil circuit system
(piston jet - crank)
EU concept air box
8-cylinder LAF sensor
+Real-time mapping
Ilmor
Grainger Worrall
F1 casting parts
manufacturer
CD-Adapco
Cosworth
6. Conclusion
At HRD, which functioned as a frontline base far
away from Japan, both short-term and long-term
personnel encountered difficulties due to the overseas
working environment and unique strictures of racing. As
we struggled on the front lines in direct contact with
races and teams, we learned a great deal and were able
to grow.
We would like to take this opportunity to thank
everyone inside and outside Honda who constantly gave
priority to local programs and supported and cooperated
with us.
Author
Yusuke HASEGAWA
316
Shiro HISATSUNE
Tatsuya KODAMA
Katsuhiko SUZUKI*
318
Race Records
Honda
Test Driver
Chassis ; RA099
Engine ; RA099E
Jos Verstappen (Netherland)
320
RA000E
Engine specifications (RA000E)
Engine Type
88 V10
2995.6
Displacement (cm3)
Cylinder diameter (mm)
94.4
Stroke (mm)
42.8
Compression ratio
13.4
Weight (kg)
112
Maximum power (kW)
567 Over
Maximum Ne (rpm)
17000 Over
Mileage (km)
400
Engine electronic control system
Honda
Chassis ; BAR002
Engine ; RA000E
CARNo.22 Jacques Villeneuve (Canada)
CARNo.23 Ricardo Zonta (Brazil)
321
Ranking
5th
7th
14th
EJ11
RA001E
Engine specifications (RA001E)
Engine Type
80 V10
2994.1
Displacement (cm3)
Cylinder diameter (mm)
95
Stroke (mm)
42.24
Compression ratio
13.4
Weight (kg)
108
Maximum power (kW)
588 Over
Maximum Ne (rpm)
17300 Over
Mileage (km)
400
Engine electronic control system
Honda
Chassis ; BAR003
Engine ; RA001E
CAR No. 9 Olivier Panis (France)
CAR No. 10 Jacques Villeneuve (Canada)
Darren Manning (United Kingdom)
Chassis ; EJ11
Engine ; RA001E
CAR No. 11 Heinz-Harald Frentzen (Germany)
CAR No. 12 Jarno Trulli (Italy)
CAR No. 12 Jean Alesi (France)
CAR No. 11 Ricardo Zonta (Brazil)
322
Ranking
6th
14th
7th
Ranking
5th
13th
9th
15th
19th
EJ12
RA002E
Engine specifications (RA002E)
Engine Type
94 V10
2994.4
Displacement (cm3)
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
12.2
Weight (kg)
111
Maximum power (kW)
640 Over
Maximum Ne (rpm)
18000 Over
Mileage (km)
400
Engine electronic control system
Honda
Chassis ; BAR004
Engine ; RA002E
CAR No. 11 Jacques Villeneuve (Canada)
CAR No. 12 Olivier Panis (France)
Anthony Davidson (United Kingdom)
Chassis ; EJ12
Engine ; RA002E
CAR No. 9 Giancarlo Fisichella (Italy)
CAR No. 10 Takuma Sato (Japan)
323
Ranking
8th
12th
14th
Ranking
6th
11th
15th
RA003E
Engine specifications (RA003E)
Engine Type
90 V10
Displacement (cm3)
2994.4
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
12.4
Weight (kg)
99
Maximum power (kW)
662 Over
Maximum Ne (rpm)
18800 Over
Mileage (km)
400
Engine electronic control system
Honda
Chassis ; BAR005
Engine ; RA003E
CAR No. 16 Jacques Villeneuve (Canada)
CAR No. 17 Jenson Button (United Kingdom)
CAR No. 16 Takuma Sato (Japan)
Anthony Davidson (United Kingdom)
324
Ranking
5th
16th
9th
18th
RA004E
Engine specifications (RA004E)
90 V10
Engine Type
2994.4
Displacement (cm3)
97
Cylinder diameter (mm)
40.52
Stroke (mm)
12.8
Compression ratio
91
Weight (kg)
662 Over
Maximum power (kW)
19000 Over
Maximum Ne (rpm)
800
Mileage (km)
Engine electronic control system
Honda
Chassis ; BAR006
Engine ; RA004E
CAR No. 9 Jenson Button (United Kingdom)
CAR No. 10 Takuma Sato (Japan)
Anthony Daivdson (United Kingdom)
325
Ranking
2nd
3rd
8th
RA005E
Engine specifications (RA005E)
Engine Type
90 V10
Displacement (cm3)
2994.4
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
12.8
Weight (kg)
89
Maximum power (kW)
662 Over
Maximum Ne (rpm)
19200 Over
Mileage (km)
1400
Engine electronic control system
Honda
Chassis ; BAR007
Engine ; RA005E
CAR No. 3 Jenson Button (United Kingdom)
CAR No. 4 Takuma Sato (Japan)
CAR No. 4 Anthony Davidson (United Kingdom)
326
Ranking
6th
9th
23rd
SA05 (Rd.1-Rd.11)
SA06 (Rd.15-Rd.18)
RA806E
Engine specifications (RA806E)
Engine Type
90 V8
Displacement (cm3)
2395.5
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
12.8
Weight (kg)
95
Maximum power (kW)
537 Over
Maximum Ne (rpm)
19600 Over
Mileage (km)
1400
Engine electronic control system
Honda
Chassis ; RA106
Engine ; RA806E
CAR No. 11 Jenson Button (United Kingdom)
CAR No. 12 Rubens Barrichello (Brazil)
Anthony Davidson (United Kingdom)
Chassis ; SA06
Engine ; RA806E
CAR No. 22 Takuma Sato (Japan)
CAR No. 23 Yuji Ide (Japan)
CAR No. 23 Sakon Yamamoto (Japan)
CAR No. 23 Franck Montagny (France)
327
Ranking
4th
6th
7th
Ranking
11th
23rd
25th
26th
27th
SA07
RA807E
Engine specifications (RA807E)
Engine Type
90 V8
2395.5
Displacement (cm3)
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
13
Weight (kg)
95
Maximum power (kW)
544 Over
Maximum Ne (rpm)
19000 Limit
Mileage (km)
1400
Engine electronic control system
Honda
Chassis ; RA107
Engine ; RA807E
CAR No. 7 Jenson Button (United Kingdom)
CAR No. 8 Rubens Barrichello (Brazil)
Christian Klien (Austria)
Chassis ; SA07
Engine ; RA807E
CAR No. 12 Takuma Sato (Japan)
CAR No. 14 Anthony Davidson (United Kingdom)
James Rossiter (United Kingdom)
328
Ranking
8th
15th
20th
Ranking
9th
17th
23rd
SA08
RA808E
Engine specifications (RA808E)
Engine type
90 V8
2395.5
Displacement (cm3)
Cylinder diameter (mm)
97
Stroke (mm)
40.52
Compression ratio
13
Weight (kg)
95
Maximum power (kW)
548 Over
Maximum Ne (rpm)
19000 Limit
Mileage (km)
1400
Engine electronic control system
Microsoft MES
Chassis ; RA108
Engine ; RA808E
CAR No. 7 Jenson Button (United Kingdom)
CAR No. 8 Rubens Barrichello (Brazil)
Alex Wurz (Austria)
Chassis ; SA08
Engine ; RA808E
CAR No. 12 Takuma Sato (Japan)
CAR No. 14 Anthony Davidson (United Kingdom)
James Rossiter (United Kingdom)
329
Ranking
9th
18th
14th
Ranking
11th
21st
22nd
QUALIFYING
Melbourne
RACE
5.302km58Laps=307.574km
(DELAY)
ROUND 2 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.325km71Laps=305.909km
(DELAY)
QUALIFYING
Imola
RACE
4.693km62Laps=305.609km
(DELAY)
#22 J. VILLENEUVE
#23 R. ZONTA
8th (1'31.968)
16th (1'33.117)
4th
6th
(44.447)
(46.468)
10th (1'15.515)
8th (1'15.484)
R (16LAPS)
9th
(2LAPS)
9th (1'26.124)
14th (1'26.814)
5th
12th
(1LAP)
(1LAP)
10th (1'27.025)
16th (1'27.772)
16th
R (36LAPS)
(DNF)
QUALIFYING
Silverstone
RACE
5.141km60Laps=308.356km
(DELAY)
ROUND 5 SPAIN GP
QUALIFYING
6th (1'21.963)
16th (1'22.882)1
Barcelona
RACE
R (21LAPS)
8th
4.727km65Laps=307.323km
(DELAY)
(1LAP)
ROUND 6 EUROPE GP
QUALIFYING
9th (1'18.742)
18th (1'19.766)2
Nurburgring
RACE
R (46LAPS)
R (51LAPS)
4.556km67Laps=305.235km
(DELAY)
ROUND 7 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.367km78Laps=262.860km
(DELAY)
ROUND 8 CANADA GP
QUALIFYING
Montreal
RACE
4.421km69Laps=305.049km
(DELAY)
ROUND 9 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.250km72Laps=305.886km
(DELAY)
ROUND 10 AUSTRIA GP
QUALIFYING
Spielberg
RACE
4.319km71Laps=307.146km
(DELAY)
ROUND 11 GERMANY GP
QUALIFYING
Hockenheim
RACE
6.823km45Laps=307.125km
(DELAY)
ROUND 12 HUNGARY GP
QUALIFYING
Budapest
RACE
3.971km77Laps=306.075km
(DELAY)
ROUND 13 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
6.968km44Laps=306.592km
(DELAY)
ROUND 14 ITALY GP
QUALIFYING
Monza
RACE
5.770km53Laps=306.764km
(DELAY)
RACE
4.192km73Laps=305.999km
(DELAY)
ROUND 16 JAPAN GP
QUALIFYING
Suzuka
RACE
5.864km53Laps=310.596km
(DELAY)
ROUND 17 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.542km56Laps=310.408km
(DELAY)
POLE
PODIUM
POSITION
(FIRST 3)
#1 M. HAKKINEN
1'30.556
#3 M. SCHUMACHER
#4 R. BARRICHELLO
#9 R. SCHUMACHER
#1 M. HAKKINEN
1'14.111
#3 M. SCHUMACHER
#11 G. FISICHELLA
#5 H. FRENTZEN
#1 M. HAKKINEN
1'24.714
#3 M. SCHUMACHER
#1 M. HAKKINEN
#2 D. COULTHARD
#4 R. BARRICHELLO
1'25.703
#2 D. COULTHARD
#1 M. HAKKINEN
#3 M. SCHUMACHER
#3 M. SCHUMACHER
1'20.974
#1 M. HAKKINEN
#2 D. COULTHARD
#4 R. BARRICHELLO
#2 D. COULTHARD
1'17.529
#3 M. SCHUMACHER
#1 M. HAKKINEN
#2 D. COULTHARD
17th (1'21.848)
20th (1'22.324)
#2 D. COULTHARD
7th
R (48LAPS)
(1LAP)
6th (1'19.544)
8th (1'19.742)
15th
8th
(DNF)
7th (1'16.653)
19th (1'17.668)
4th
R (16LAPS)
(61.322)
7th (1'11.649)
6th (1'11.647)
4th
R (58LAPS)
(1LAP)
9th (1'48.121)
12th (1'48.665)
8th
R (37LAPS)
(47.537)
16th (1'19.937)
18th (1'20.272)
12th
14th
(2LAPS)
(2LAPS)
7th (1'51.799)
13th (1'53.002)
7th
12th
(72.380)
(1LAP)
4th (1'24.238)
17th (1'25.337)
R (14LAPS)
6th
(69.292)
8th (1'15.317)
12th (1'15.784)
4th
6th
(17.935)
(51.694)
9th (1'37.267)
18th (1'38.269)
6th
9th
(1LAP)
(1LAP)
6th (1'38.653)
11th (1'39.158)
5th
R (46LAPS)
(70.692)
#3 M. SCHUMACHER
1'19.475
#4 R. BARRICHELLO
#11 G. FISICHELLA
#3 M. SCHUMACHER
1'18.439
#3 M. SCHUMACHER
#4 R. BARRICHELLO
#11 G. FISICHELLA
#3 M. SCHUMACHER
1'15.632
#2 D. COULTHARD
#1 M. HAKKINEN
#4 R. BARRICHELLO
#1 M. HAKKINEN
1'10.410
#1 M. HAKKINEN
#2 D. COULTHARD
#4 R. BARRICHELLO
#2 D. COULTHARD
1'45.697
#4 R. BARRICHELLO
#1 M. HAKKINEN
#2 D. COULTHARD
#3 M. SCHUMACHER
1'17.514
#1 M. HAKKINEN
#3 M. SCHUMACHER
#2 D. COULTHARD
#1 M. HAKKINEN
1'50.646
#1 M. HAKKINEN
#3 M. SCHUMACHER
#9 R. SCHUMACHER
#3 M. SCHUMACHER
1'23.770
#3 M. SCHUMACHER
#1 M. HAKKINEN
#9 R. SCHUMACHER
#3 M. SCHUMACHER
1'14.266
#3 M. SCHUMACHER
#4 R. BARRICHELLO
#5 H. FRENTZEN
#3 M. SCHUMACHER
1'35.825
#3 M. SCHUMACHER
#1 M. HAKKINEN
#2 D. COULTHARD
#3 M. SCHUMACHER
1'37.397
#3 M. SCHUMACHER
#2 D. COULTHARD
#4 R. BARRICHELLO
1 Raised from 17th to 16th position after a fuel infringement by P. de la Rosa in 9th position caused his qualifying times to be deleted.
2 Raised from 19th to 18th position after a minimum weight infringement by N. Heidfeld in 13th position resulted in his disqualification.
330
TOTAL
AUS
BRA
SMR
GBR
SPA
EUR
MON
CAN
FRA
AUT
GER
HUN
BEL
ITA
USA
JPN
MAL
170
16
10
13
13
16
10
10
16
13
14
152
10
16
16
10
11
16
10
14
13
10
36
3
6
20
20
17
Arrows
Jaguar Racing
10
11
2
7
1
1
2
1
4
3
No.
TOTAL
AUS
BRA
SMR
GBR
SPA
EUR
M. SCHUMACHER (GER)
108
10
10
10
10
M. HAKKINEN (FIN)
89
10
D. COULTHARD (GBR)
73
10
10
R. BARRICHELLO (BRA)
62
R. SCHUMACHER (GER)
24
11
G. FISICHELLA (ITA)
18
22
J. VILLENEUVE (CAN)
17
10
J. BUTTON (GBR)
12
DRIVER (NAT)
3
3
MON
CAN
3
6
H. FRENTZEN (GER)
11
J. TRULLI (ITA)
11
17
M. SALO (FIN)
12
19
J. VERSTAPPEN (NED)
13
E. IRVINE (GBR)
14
23
R. ZONTA (BRA)
15
12
A. WURZ (AUT)
16
18
P. DE LA ROSA (ESP)
17
J. HERBERT (GBR)
18
16
P. DINIZ (BRA)
19
20
M. GENE (ESP)
20
15
N. HEIDFELD (GER)
21
21
G. MAZZACANE (ARG)
22
14
J. ALESI (FRA)
23
L. BURTI (BRA)
AUT
GER
HUN
BEL
ITA
USA
JPN
MAL
10
10
10
10
10
10
10
10
10
3
2
3
3
2
1
3
2
10
FRA
10
1
1
1
2
1
331
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km55Laps=304.865km
(DELAY)
ROUND 3 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
RACE
4.933km62Laps=305.609km
(DELAY)
ROUND 5 SPAIN GP
QUALIFYING
Barcelona
RACE
4.730km65Laps=307.323km
(DELAY)
ROUND 6 AUSTRIA GP
QUALIFYING
Spielberg
RACE
4.326km71Laps=307.146km
(DELAY)
#12 J. TRULLI
POLE
PODIUM
POSITION
(FIRST 3)
9th (1'28.518)
8th (1'28.435)
4th (1'27.658)
7th (1'28.377)
7th1
R (4LAPS)
5th2
R (38LAPS)
(62.050)
(72.807)
#2 R. BARRICHELLO
10th (1'36.681)
7th (1'36.397)
9th (1'36.578)
5th (1'36.180)
#1 M. SCHUMACHER
R (1LAP)
R (3LAPS)
4th
8th
(46.543)
(1LAP)
11th (1'15.046)
12th (1'15.182)
8th (1'14.633)
7th (1'14.630)
4th
7th
11th
5th
(1LAP)
(1LAP)
(DNF)
(1LAP)
8th (1'24.213)
11th (1'24.769)
9th (1'24.436)
5th (1'23.658)
8th
R (30LAPS)
6th
5th
(1LAP)
(1LAP)
(85.558)
11th (1'19.479)
7th (1'19.122)
8th (1'19.150)
6th (1'19.093)
7th
3th
R (5LAPS)
4th
(64.977)
(49.626)
(51.253)
10th (1'10.435)
12th (1'11.058)
11th (1'10.923)
5th (1'10.202)
5th
8th
R (0LAP)
(53.776)
(1LAP)
12th (1'19.294)
9th (1'19.086)
13th (1'19.316)
8th (1'18.921)
R (13LAPS)
4th
R (49LAPS)
R (30LAPS)
(32.454)
ROUND 7 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.370km78Laps=262.860km
(DELAY)
ROUND 8 CANADA GP
QUALIFYING
6th (1'16.771)
9th (1'17.035)
12th (1'17.328)
4th (1'16.459)
Montreal
RACE
R (38LAPS)
R (34LAPS)
7th
11th
4.421km69Laps=305.049km
(DELAY)
(1LAP)
(DNF)
ROUND 9 EUROPE GP
QUALIFYING
13th (1'16.872)
11th (1'16.439)
8th (1'16.376)
7th (1'16.138)
Nurburgring
RACE
R (23LAPS)
9th
R (48LAPS)
R (44LAPS)
#1 M. SCHUMACHER
1'26.892
#1 M. SCHUMACHER
1'35.220
#1 M. SCHUMACHER
#4 D. COULTHARD
#2 R. BARRICHELLO
#4 D. COULTHARD
#1 M. SCHUMACHER
1'13.780
#4 D. COULTHARD
#1 M. SCHUMACHER
#16 N. HEIDFELD
#4 D. COULTHARD
1'23.054
#5 R. SCHUMACHER
#4 D. COULTHARD
#2 R. BARRICHELLO
#1 M. SCHUMACHER
1'18.201
#1 M. SCHUMACHER
#6 J. MONTOYA
#10 J. VILLENEUVE
#1 M. SCHUMACHER
1'09.562
#4 D. COULTHARD
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#4 D. COULTHARD
1'17.430
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#18 E. IRVINE
#11 R. ZONTA
#1 M. SCHUMACHER
1'15.782
#5 R. SCHUMACHER
#1 M. SCHUMACHER
#3 M. HAKKINEN
#11 H. FRENTZEN
4.556km67Laps=305.235km
(DELAY)
ROUND 10 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.251km72Laps=305.886km
(DELAY)
RACE
5.141km60Laps=308.356km
(DELAY)
(1LAP)
11th (1'14.181)
10th (1'14.096)
7th (1'13.815)
5th (1'13.310)
9th
R (5LAPS)
8th
5th
(1LAP)
(1LAP)
(68.285)
11th (1'22.316)
12th (1'22.916)
5th (1'21.217)
4th (1'20.930)
R (0LAP)
8th
7th
R (0LAP)
(1LAP)
(1LAP)
#1 M. SCHUMACHER
1'14.960
#1 M. SCHUMACHER
#6 J. MONTOYA
#4 D. COULTHARD
#5 R. SCHUMACHER
1'12.989
#1 M. SCHUMACHER
#5 R. SCHUMACHER
#2 R. BARRICHELLO
#1 M. SCHUMACHER
1'20.447
#3 M. HAKKINEN
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#11 R. ZONTA
ROUND 12 GERMANY GP
QUALIFYING
Hockenheim
RACE
6.825km45Laps=307.125km
(DELAY)
ROUND 13 HUNGARY GP
QUALIFYING
Budapest
RACE
3.975km77Laps=306.075km
(DELAY)
ROUND 14 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
6.968km36Laps=250.831km
(DELAY)
ROUND 15 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.749km
(DELAY)
RACE
4.192km73Laps=306.016km
(DELAY)
ROUND 17 JAPAN GP
QUALIFYING
Suzuka
RACE
5.859km53Laps=310.331km
(DELAY)
13th (1'40.610)
12th (1'40.437)
15th (1'41.174)
10th (1'40.322)
7th
3th
R (7LAPS)
R (34LAPS)
(77.527)
(62.806)
#11 J. TRULLI
#12 J. ALESI
11th (1'16.382)
10th (1'16.212)
5th (1'15.394)
12th (1'16.471)
R (58LAPS)
9th
R (63LAPS)
10th
(2LAPS)
(2LAPS)
11th (1'58.838)
6th (1'57.038)
16th (1'59.647)
13th (1'59.128)
11th
8th
R (31LAPS)
6th
(1LAP)
(64.970)
(59.684)
17th (1'24.677)
15th (1'24.164)
5th (1'23.126)
16th (1'24.198)
9th
6th
R (0LAP)
8th
(1LAP)
(82.469)
(1LAP)
13th (1'13.122)
18th (1'14.012)
8th (1'12.605)
9th (1'12.607)
11th
R (45LAPS)
4th
7th
(1LAP)
(57.423)
(1LAP)
17th (1'35.766)
14th (1'35.109)
8th (1'34.002)
11th (1'34.420)
13th
10th
8th
R (5LAPS)
(2LAPS)
(1LAP)
(1LAP)
#6 J. MONTOYA
1'38.117
#5 R. SCHUMACHER
#2 R. BARRICHELLO
#10 J. VILLENEUVE
#1 M. SCHUMACHER
1'14.059
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#4 D. COULTHARD
#6 J. MONTOYA
1'52.072
#1 M. SCHUMACHER
#4 D. COULTHARD
#7 G. FISICHELLA
#6 J. MONTOYA
1'22.216
#6 J. MONTOYA
#2 R. BARRICHELLO
#5 R. SCHUMACHER
#1 M. SCHUMACHER
1'11.708
#3 M. HAKKINEN
#1 M. SCHUMACHER
#4 D. COULTHARD
#1 M. SCHUMACHER
1'32.484
#1 M. SCHUMACHER
#6 J. MONTOYA
#4 D. COULTHARD
1 O. Panis finished in 4th position, but 25 seconds was added to his racing time for overtaking under a yellow flag, and he was demoted to 7th position.
2 H. Frentzen finished in 6th position, but was raised to 5th position after 25 seconds was added to O. Panis racing time for overtaking under a yellow flag.
332
TOTAL
AUS
MAL
BRA
SMR
ESP
AUT
MON
CAN
EUR
FRA
GBR
GER
HUN
BEL
ITA
USA
JPN
179
14
16
10
10
16
12
14
10
16
12
12
102
10
10
10
14
80
10
10
21
19
17
3
1
2
4
3
1
3
3
4
10
3
1
2
2
14
1
10
Jaguar Racing
Prost Acer
10
11
European Minardi F1
7
1
3
4
2
No.
TOTAL
AUS
MAL
BRA
DRIVER (NAT)
M. SCHUMACHER (GER)
123
10
10
D. COULTHARD (GBR)
65
10
R. BARRICHELLO (BRA)
56
R. SCHUMACHER (GER)
49
10
M. HAKKINEN (FIN)
37
J. MONTOYA (COL)
31
10
J. VILLENEUVE (CAN)
12
16
N. HEIDFELD (GER)
12
11
J. TRULLI (ITA)
12
10
17
K. RAIKKONEN (FIN)
11
G. FISICHELLA (ITA)
12
18
E. IRVINE (GBR)
13
22
H. FRENTZEN (GER)
14
O. PANIS (FRA)
15
12
J. ALESI (FRA)
16
19
17
J. BUTTON (GBR)
18
14
J. VERSTAPPEN (NED)
19
11
R. ZONTA (BRA)
20
19
L. BURTI (BRA)
21
15
E. BERNOLDI (BRA)
22
20
T. MARQUES (BRA)
23
21
F. ALONSO (ESP)
24
23
T. ENGE (CZE)
25
23
G. MAZZACANE (ARG)
26
20
A. YOONG (MAS)
SMR
6
4
2
ESP
AUT
MON
CAN
EUR
FRA
GBR
10
10
10
10
10
10
10
HUN
BEL
ITA
USA
JPN
10
10
10
10
3
2
2
3
10
10
1
3
GER
1
3
2
3
4
2
1
3
2
1
333
1
2
2
1
1
1
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
ROUND 3 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
RACE
4.933km62Laps=305.609km
(DELAY)
ROUND 5 SPAIN GP
QUALIFYING
Barcelona
RACE
4.730km65Laps=307.327km
(DELAY)
ROUND 6 AUSTRIA GP
QUALIFYING
Spielberg
RACE
4.326km71Laps=307.146km
(DELAY)
ROUND 7 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.370km78Laps=262.860km
(DELAY)
ROUND 8 CANADA GP
QUALIFYING
Montreal
RACE
4.361km70Laps=305.270km
(DELAY)
ROUND 9 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.146km60Laps=308.743km
(DELAY)
RACE
5.141km60Laps=308.356km
(DELAY)
ROUND 11 FRANCE GP
QUALIFYING
#10 T. SATO
#11 J. VILLENEUVE
#12 O. PANIS
8th (1'27.869)
(1'53.351)
13th (1'28.657)
12th (1'28.381)
R (0LAP)
R (12LAPS)
R (27LAPS)
R (0LAP)
9th (1'37.536)
15th (1'38.141)
13th (1'38.039)
18th (1'38.390)
POLE
PODIUM
POSITION
(FIRST 3)
#2 R. BARRICHELLO
1'25.843
#1 M. SCHUMACHER
#6 J. MONTOYA
#4 K. RAIKKONEN
#1 M. SCHUMACHER
1'35.266
#5 R. SCHUMACHER
13th
9th
8th
R (9LAPS)
(3LAPS)
(2LAPS)
(1LAP)
14th (1'14.748)
19th (1'15.296)
15th (1'14.760)
17th (1'14.996)
R (6LAPS)
9th
10th
R (25LAPS)
(2LAPS)
(DNF)
15th (1'24.253)
14th (1'24.050)
10th (1'23.116)
12th (1'23.821)
R (19LAPS)
R (5LAPS)
7th
R (44LAPS)
(1LAP)
12th (1'18.291)
18th (1'19.002)1
15th (1'18.847)
13th (1'18.472)
R (5LAPS)
R (10LAPS)
7th
R (43LAPS)
(1LAP)
15th (1'09.901)
18th (1'10.058)
17th (1'10.051)
9th (1'09.561)
5th
R (26LAPS)
10th
R (22LAPS)
(49.965)
(1LAP)
11th (1'18.342)
16th (1'19.461)
14th (1'19.252)
18th (1'19.569)
5th
R (22LAPS )
R (44LAPS)
R (51LAPS)
(1LAP)
#5 R. SCHUMACHER
6th (1'14.132)
15th (1'14.940)
9th (1'14.564)
11th (1'14.713)
#1 M. SCHUMACHER
5th
10th
R (8LAPS)
8th
(42.812)
(1LAP)
(1LAP)
18th (1'32.591)
14th (1'31.999)
19th (1'32.968)
12th (1'31.906)
R (26LAPS)
16th
12th
9th
(2LAPS)
(1LAP)
(1LAP)
17th (1'21.636)
14th (1'21.337)
9th (1'21.130)
13th (1'21.274)
7th
R (50LAPS)
4th
5th
(1LAP)
(1LAP)
(1LAP)
DNQ
14th (1'13.542)
13th (1'13.506)
11th (1'13.457)
#6 J. MONTOYA
#1 M. SCHUMACHER
#6 J. MONTOYA
1'13.114
#1 M. SCHUMACHER
#5 R. SCHUMACHER
#3 D. COULTHARD
#1 M. SCHUMACHER
1'21.091
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#5 R. SCHUMACHER
#1 M. SCHUMACHER
1'16.364
#1 M. SCHUMACHER
#6 J. MONTOYA
#3 D. COULTHARD
#2 R. BARRICHELLO
1'08.082
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#6 J. MONTOYA
#6 J. MONTOYA
1'16.676
#6 J. MONTOYA
1'12.836
#3 D. COULTHARD
#1 M. SCHUMACHER
#3 D. COULTHARD
#2 R. BARRICHELLO
#6 J. MONTOYA
1'29.906
#2 R. BARRICHELLO
#1 M. SCHUMACHER
#4 K. RAIKKONEN
#6 J. MONTOYA
1'18.998
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#6 J. MONTOYA
#6 J. MONTOYA
1'11.985
#1 M. SCHUMACHER
Magny Cours
RACE
R (23LAPS)
R (35LAPS)
R (29LAPS)
4.251km72Laps=305.886km
(DELAY)
ROUND 12 GERMANY GP
QUALIFYING
6th (1'15.690)
12th (1'16.072)
11th (1'16.070)
7th (1'15.851)
Hockenheim
RACE
R (59LAPS)
8th
R (27LAPS)
R (39LAPS)
4.574km67Laps=306.458km
(DELAY)
(1LAP)
#5 R. SCHUMACHER
ROUND 13 HUNGARY GP
QUALIFYING
5th (1'14.880)
14th (1'15.804)
13th (1'15.583)
12th (1'15.556)
#2 R. BARRICHELLO
Budapest
RACE
6th
10th
R (20LAPS)
12th
3.975km77Laps=306.069km
(DELAY)
(68.804)
(1LAP)
(1LAP)
ROUND 14 BELGIUM GP
QUALIFYING
14th (1'46.508)
16th (1'46.875)
12th (1'46.403)
15th (1'46.553)
Spa Francorchamps
RACE
R (38LAPS)
11th
8th
12th
6.963km44Laps=306.355km
(DELAY)
(1LAP)
(79.855)
(DNF)
12th (1'22.515)
18th (1'23.166)
9th (1'22.126)
16th (1'22.645)
8th
12th
9th
6th
(70.891)
(1LAP)
(81.068)
(68.491)
9th (1'11.902)
15th (1'12.647)
7th (1'11.738)
12th (1'12.161)
7th
11th
6th
12th
(1LAP)
(1LAP)
(58.211)
(1LAP)
8th (1'33.276)
7th (1'33.090)
9th (1'33.349)
16th (1'34.192)
R (37LAPS)
5th
R (27LAPS)
R (8LAPS)
(82.694)
ROUND 15 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.719km
(DELAY)
RACE
4.192km73Laps=306.016km
(DELAY)
ROUND 17 JAPAN GP
QUALIFYING
Suzuka
RACE
5.821km53Laps=308.317km
(DELAY)
#3 D. COULTHARD
#1 M. SCHUMACHER
1'14.389
#2 R. BARRICHELLO
1'13.333
#1 M. SCHUMACHER
#6 J. MONTOYA
#1 M. SCHUMACHER
#5 R. SCHUMACHER
#1 M. SCHUMACHER
1'43.726
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#6 J. MONTOYA
#6 J. MONTOYA
1'20.264
#2 R. BARRICHELLO
#1 M. SCHUMACHER
#16 E. IRVINE
#1 M. SCHUMACHER
1'10.790
#2 R. BARRICHELLO
#1 M. SCHUMACHER
#3 D. COULTHARD
#1 M. SCHUMACHER
1'31.317
1 Raised from 19th to 18th position after a fuel infringement by E. Irvine resulted in his disqualification.
334
#4 K. RAIKKONEN
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#4 K. RAIKKONEN
TOTAL
AUS
MAL
BRA
SMR
ESP
AUT
MON
CAN
EUR
GBR
FRA
GER
HUN
BEL
ITA
USA
JPN
221
10
10
16
10
16
14
16
16
10
13
16
16
16
16
16
92
16
10
65
10
10
23
Sauber Petronas
11
Jaguar Racing
4
2
1
1
1
5
1
2
1
KL Minardi Asiatech
10
11
Orange Arrows
4
1
1
1
No.
TOTAL
AUS
MAL
BRA
SMR
ESP
AUT
MON
CAN
EUR
GBR
FRA
GER
HUN
BEL
ITA
USA
JPN
DRIVER (NAT)
M. SCHUMACHER (GER)
144
10
10
10
10
10
10
10
10
10
10
10
R. BARRICHELLO (BRA)
77
10
10
10
10
J. MONTOYA (COL)
50
R. SCHUMACHER (GER)
42
D. COULTHARD (GBR)
41
K. RAIKKONEN (FIN)
24
15
J. BUTTON (GBR)
14
14
J. TRULLI (ITA)
16
E. IRVINE (GBR)
10
N. HEIDFELD (GER)
6
6
6
10
6
6
10
3
6
3
2
3
11
G. FISICHELLA (ITA)
12
11
J. VILLENEUVE (CAN)
13
F. MASSA (BRA)
14
12
O. PANIS (FRA)
15
10
T. SATO (JPN)
16
23
M. WEBBER (AUS)
17
24
M. SALO (FIN)
18
20
H. FRENTZEN (GER)
19
25
A. McNISH (GBR)
20
22
A. YOONG (MAS)
21
17
P. DE LA ROSA (ESP)
22
21
E. BERNOLDI (BRA)
23
22
A. DAVIDSON (GBR)
3
1
1
2
1
1
3
1
3
2
1
2
1
2
1
1
335
#17 J. BUTTON
6th (1'28.420)
8th (1'28.682)
9th
10th
(65.536)
(65.974)
12th (1'38.289)
9th (1'38.073)
R (0LAP)
7th
(1LAP)
13th (1'14.668)
11th (1'14.504)
POLE
PODIUM
POSITION
(FIRST 3)
#5 D. COULTHARD
ROUND 1 AUSTRALIA GP
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
ROUND 3 BRAZIL GP
QUALIFYING
Interlagos
RACE1
6th
R (32LAPS)
4.309km54Laps=232.656km
(DELAY)
(17.910)
QUALIFYING
7th (1'23.160)
9th (1'23.381)
Imola
RACE
R (19LAPS)
8th
4.993km62Laps=305.609km
(DELAY)
(1LAP)
#2 R. BARRICHELLO
ROUND 5 SPAIN GP
QUALIFYING
11th (1'19.563)
5th (1'18.704)
#1 M. SCHUMACHER
Barcelona
RACE
R (12LAPS)
9th
4.730km65Laps=307.324km
(DELAY)
(2LAPS)
12th (1'10.618)
7th (1'09.935)
12th
4th
(1LAP)
(42.243)
11th (1'16.755)
- 2
R (63LAPS)
#1 M. SCHUMACHER
14th (1'17.347)
17th (1'18.205)
#1 M. SCHUMACHER
R (14LAPS)
R (51LAPS)
17th (1'34.596)
12th (1'33.395)
ROUND 6 AUSTRIA GP
QUALIFYING
Spielberg
RACE
4.326km69Laps=298.494km
(DELAY)
ROUND 7 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.340km78Laps=260.520km
(DELAY)
ROUND 8 CANADA GP
QUALIFYING
Montreal
RACE
4.361km70Laps=305.270km
(DELAY)
ROUND 9 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.148km60Laps=308.863km
(DELAY)
ROUND 10 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
RACE
5.141km60Laps=308.355km
(DELAY)
ROUND 12 GERMANY GP
QUALIFYING
Hockenheim
RACE
4.574km67Laps=306.458km
(DELAY)
ROUND 13 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.663km
(DELAY)
ROUND 14 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.720km
(DELAY)
RACE
4.192km73Laps=306.016km
(DELAY)
#8 F. ALONSO
1'37.044
#6 K. RAIKKONEN
#2 R. BARRICHELLO
#8 F. ALONSO
#2 R. BARRICHELLO
1'13.807
#11 G. FISICHELLA1
#6 K. RAIKKONEN
#8 F. ALONSO
#1 M. SCHUMACHER
1'22.327
#1 M. SCHUMACHER
1'17.762
#1 M. SCHUMACHER
#6 K. RAIKKONEN
#8 F. ALONSO
#2 R. BARRICHELLO
#1 M. SCHUMACHER
1'09.150
#1 M. SCHUMACHER
#6 K. RAIKKONEN
#2 R. BARRICHELLO
#4 R. SCHUMACHER
1'15.259
#4 R. SCHUMACHER
1'15.529
#3.J. MONTOYA
#6 K. RAIKKONEN
#4 R. SCHUMACHER
#3. J. MONTOYA
7th
(1LAP)
12th (1'16.990)
14th (1'17.077)
9th
R (21LAPS)
(1LAP)
20th (
#3 J. MONTOYA
#6 K. RAIKKONEN
R (51LAPS)
9th (1'22.591)
#1 M. SCHUMACHER
1'27.173
#6 K. RAIKKONEN
1'31.523
#4 R. SCHUMACHER
#3 J. MONTOYA
#2 R. BARRICHELLO
#4 R. SCHUMACHER
1'15.019
#4 R. SCHUMACHER
#3. J. MONTOYA
#1 M. SCHUMACHER
#2 R. BARRICHELLO
1'21.209
#2 R. BARRICHELLO
10th
8th
(63.569)
(45.478)
#3 J. MONTOYA
13th (1'17.090)
17th (1'18.085)
9th
8th
(2LAPS)
(1LAP)
16th (1'24.100)
14th (1'23.847)
R (14LAPS)
10th
(1LAPS)
10th (1'22.717)
7th (1'22.301)
6th
R (24LAPS)
(1LAP)
#2 R. BARRICHELLO
12th (1'13.050)
11th (1'12.695)
#1 M. SCHUMACHER
R (63LAPS)
R (41LAPS)
#6 K. RAIKKONEN
#3 J. MONTOYA
1'15.167
#3 J. MONTOYA
#5 D. COULTHARD
#7 J. TRULLI
#8 F. ALONSO
1'21.688
#8 F. ALONSO
#6 K. RAIKKONEN
#3 J. MONTOYA
#1 M. SCHUMACHER
1'20.963
#6 K. RAIKKONEN
1'11.670
#1 M. SCHUMACHER
#3 J. MONTOYA
#6 K. RAIKKONEN
#10 H. FRENTZEN
#16 T. SATO
ROUND 16 JAPAN GP
QUALIFYING
Suzuka
RACE
5.807km53Laps=307.573km
(DELAY)
13th (1'33.924)
9th (1'33.474)
6th
4th
(51.692)
(33.106)
#2 R. BARRICHELLO
1'31.713
#2 R. BARRICHELLO
#6 K. RAIKKONEN
#5 D. COULTHARD
1 The red flag was displayed during lap 56, and the race was ended. Because more than 75% of the race had been completed, times at
lap 54, two laps before the red flag was displayed, were used as the official times.
2 J. Button was involved in an accident during the Saturday morning free practice session, and was ordered not to participate in the race
by a doctor.
336
TOTAL
AUS
MAL
158
11
144
142
16
88
26
Sauber Petronas
19
Jaguar Racing
18
16
Jordan Ford
13
10
BRA
RSM
ESP
AUT
MON
CAN
EUR
FRA
GBR
GER
HUN
ITA
USA
JPN
16
16
16
14
10
15
16
10
11
15
14
18
18
10
11
12
10
13
12
12
10
10
10
12
11
12
10
14
4
8
10
3
1
3
2
No.
TOTAL
AUS
MAL
M. SCHUMACHER (GER)
DRIVER (NAT)
93
K. RAIKKONEN (FIN)
91
10
J. MONTOYA (COL)
82
R. BARRICHELLO (BRA)
65
R. SCHUMACHER (GER)
58
5
6
F. ALONSO (ESP)
55
D. COULTHARD (GBR)
51
10
J. TRULLI (ITA)
33
17
J. BUTTON (GBR)
17
10
14
M. WEBBER (AUS)
17
10
H. FRENTZEN (GER)
13
12
11
G. FISICHELLA (ITA)
12
13
21
C. DA MATTA (BRA)
10
14
N. HEIDFELD (GER)
15
20
O. PANIS (FRA)
16
16
J. VILLENEUVE (CAN)
17
M. GENE (ESP)
18
16
T.SATO (JPN)
19
12
R. FIRMAN (IRL)
20
15
J. WILSON (GBR)
21
15
A. PIZZONIA (BRA)
22
19
J. VERSTAPPEN (NED)
23
18
N. KIESA (DEN)
24
12
Z. BAUMGARTNER (HUN)
RSM
ESP
AUT
MON
CAN
EUR
FRA
GBR
GER
HUN
ITA
USA
10
10
10
10
10
10
8
2
10
10
10
10
11
BRA
5
2
2
2
10
10
5
5
10
1
6
5
2
6
2
3
1
1
3
4
5
10
1
JPN
4
1
4
3
4
3
1
1
337
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
ROUND 3 BAHRAIN GP
QUALIFYING
Bahrain
RACE
5.417km57Laps=308.523km
(DELAY)
#9 J. BUTTON
#10 T. SATO
4th (1'24.998)
7th (1'25.851)
6th
9th
(70.598)
(1LAP)
6th (1'34.221)
20th ( - )
3th
15th
(11.568)
(DNF)
6th (1'30.856)
5th (1'30.827)
POLE
PODIUM
POSITION
(FIRST 3)
#1 M. SCHUMACHER
1'24.408
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#8 F. ALONSO
#1 M. SCHUMACHER
1'33.074
#1 M. SCHUMACHER
#3 J. MONTOYA
#9 J. BUTTON
#1 M. SCHUMACHER
1'30.139
#1 M. SCHUMACHER
3th
5th
(26.687)
(52.460)
PP (1'19.753)
7th (1'20.913)
2th
16th
(9.702)
(DNF)
14th (1'17.575)
3th (1'15.809)
8th
5th
(1LAP)
(42.327)
3th (1'14.396)1
8th (1'14.827)1
2th
R (2LAPS)
(0.497)
#2 R. BARRICHELLO
5th (1'29.245)
2th (1'28.986)
#1 M. SCHUMACHER
3th
R (47LAPS)
(22.533)
2th (1'12.341)
17th (1'17.004)
3th2
R (48LAPS)
(20.409)
4th (1'10.820)
3th (1'10.601)
Indianapolis
RACE
R (26LAPS)
3th
4.192km73Laps=306.016km
(DELAY)
(22.036)
4th (1'13.995)
7th (1'14.240)
5th
R (15LAPS)
(32.484)
3th (1'18.580)
9th (1'19.688)3
4th
11th
RACE
4.933km62Laps=305.609km
(DELAY)
ROUND 5 SPAIN GP
QUALIFYING
Barcelona
RACE
4.627km66Laps=305.256km
(DELAY)
ROUND 6 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.340km77Laps=257.180km
(DELAY)
ROUND 7 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.148km60Laps=308.863km
(DELAY)
ROUND 8 CANADA GP
QUALIFYING
Montreal
RACE
4.361km70Laps=305.270km
(DELAY)
ROUND 10 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
RACE
5.141km60Laps=308.355km
(DELAY)
ROUND 12 GERMANY GP
QUALIFYING
Hockenheim
RACE
4.574km66Laps=301.884km
(DELAY)
ROUND 13 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.663km
(DELAY)
ROUND 14 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
6.976km44Laps=306.927km
(DELAY)
ROUND 15 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.720km
(DELAY)
ROUND 16 CHINA GP
QUALIFYING
Shanghai
RACE
5.451km56Laps=305.066km
(DELAY)
ROUND 17 JAPAN GP
QUALIFYING
Suzuka
RACE
5.807km53Laps=307.573km
(DELAY)
ROUND 18 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
#2 R. BARRICHELLO
#9 J. BUTTON
#9 J. BUTTON
1'19.753
#1 M. SCHUMACHER
#9 J. BUTTON
#3 J. MONTOYA
#1 M. SCHUMACHER
1'15.022
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#7 J. TRULLI
#7 J. TRULLI
1'13.985
#1 M. SCHUMACHER
1'28.351
#7 J. TRULLI
#9 J. BUTTON
#2 R. BARRICHELLO
#9 J. BUTTON
#4 R. SCHUMACHER
1'12.275
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#9 J. BUTTON2
#2 R. BARRICHELLO
1'10.223
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#10 T. SATO
#8. F. ALONSO
1'13.698
#1 M. SCHUMACHER
#8. F. ALONSO
#2 R. BARRICHELLO
#6 K.RAIKKONEN
1'18.233
#1 M. SCHUMACHER
#6 K.RAIKKONEN
#2 R. BARRICHELLO
(10.683)
(33.736)
3th (1'13.674)4
9th (1'14.287)4
2th
8th
(8.388)
(46.842)
4th (1'19.700)
3th (1'19.693)
5th
6th
(67.439)
(1LAP)
12th (2'00.237)
15th (2'01.813)
R (29LAPS)
R (0LAP)
#2 R. BARRICHELLO
6th (1'20.786)
5th (1'20.715)
#2 R. BARRICHELLO
3th
4th
(10.197)
(15.370)
3th (1'34.295)
9th (1'34.993)
2th
6th
(1.035)
(54.791)
5th (1'35.157)
4th (1'34.897)
3th
4th
(19.662)
(31.781)
5th (1'11'092)
6th (1'11.120)
R (3LAPS)
6th
(50.248)
#1 M. SCHUMACHER
1'13.306
#1 M. SCHUMACHER
#9 J. BUTTON
#8 F. ALONSO
#1 M. SCHUMACHER
1'19.146
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#8 F. ALONSO
#7 J. TRULLI
1'56.232
#2 R. BARRICHELLO
1'20.089
#6 K.RAIKKONEN
#1 M. SCHUMACHER
#1 M. SCHUMACHER
#9 J. BUTTON
#2 R. BARRICHELLO
1'34.012
#2 R. BARRICHELLO
#9 J. BUTTON
#6 K.RAIKKONEN
#1 M. SCHUMACHER
1'33.542
#1 M. SCHUMACHER
#4 R. SCHUMACHER
#9 J. BUTTON
#2 R. BARRICHELLO
1'10.646
#3. J. MONTOYA
#6 K. RAIKKONEN
#2 R. BARRICHELLO
1 As a result of an engine replacement penalty, R. Schumacher, who qualified in 2nd position, was demoted 10 grid positions, and J.
Button and T. Sato took the 2nd and 7th positions on the grid, respectively.
2 J. Button was raised from 4th to 3rd position as a result of R. Schumachers disqualification due to a brake duct size infringement.
3 Due to an engine replacement, F. Alonso, who qualified in 6th position, was demoted 10 grid positions; as a result T. Sato moved from 9th
to 8th position on the grid.
4 J. Button qualified 3rd, but was demoted 10 grid positions due to an engine replacement. He started the race in 13th position on the grid,
while T. Sato was raised from 9th to 8th position on the grid.
338
CAN
USA
FRA
GBR
18
15
18
13
18
18
18
18
16
16
10
18
119
10
105
11
10
13
88
69
Sauber Petronas
34
ESP
MON EUR
Jaguar Racing
10
1
4
Jordan Ford
10
Minardi Cosworth
GER HUN
10
1
3
BEL
ITA
CHN
JPN
14
18
10
10
11
11
11
BRA
10
14
12
CHN
JPN
BRA
10
3
1
No.
DRIVER (NAT)
M. SCHUMACHER (GER)
10
10
10
10
10
R. BARRICHELLO (BRA)
114
J. BUTTON (GBR)
85
F. ALONSO (ESP)
59
J. MONTOYA (COL)
58
J. TRULLI (ITA)
46
K. RAIKKONEN (FIN)
45
10
T. SATO (JPN)
34
R. SCHUMACHER (GER)
24
10
D. COULTHARD (GBR)
24
11
11
G. FISICHELLA (ITA)
22
12
12
F. MASSA (BRA)
12
13
14
M. WEBBER (AUS)
ESP
MON EUR
CAN
USA
FRA
GBR
10
10
10
10
10
10
6
5
1
4
2
4
4
GER HUN
10
BEL
ITA
10
10
10
8
5
10
10
5
3
2
14
17
O. PANIS (FRA)
15
A. PIZZONIA (BRA)
16
15
C. KLIEN (AUT)
17
16
C. DA MATTA (BRA)
18
18
N. HEIDFELD (GER)
19
19
T. GLOCK (GER)
20
21
Z. BAUMGARTNER (HUN)
21
J. VILLENEUVE (CAN)
22
17
R. ZONTA (BRA)
23
M. GENE (ESP)
24
19
G. PANTANO (ITA)
25
20
G. BRUNI (ITA)
5
2
1
2
2
3
1
2
1
339
2
1
6
6
1
1
QUALIFYING
Melbourne
RACE
5.303km57Laps=302.271km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
#4 T. SATO
8th (3'12.128)1
- 1
11th
14th
(DNF)
(DNF)
POLE
PODIUM
POSITION
(FIRST 3)
#6 G. FISICHELLA
3'01.4601
#6 G. FISICHELLA
#2 R. BARRICHELLO
#5 F. ALONSO
#4 A. DAVIDSON
9th (3'09.832)1
15th (3'11.890)1
R (2LAPS)
R (2LAPS)
#5 F. ALONSO
3'07.6721
#5 F. ALONSO
#16 J. TRULLI
#8 N. HEIDFELD
#4 T. SATO
ROUND 3 BAHRAIN GP
QUALIFYING
Bahrain
RACE
5.412km57Laps=308.238km
(DELAY)
RACE
4.933km62Laps=305.609km
(DELAY)
ROUND 5 SPAIN GP
QUALIFYING
Barcelona
RACE
4.627km66Laps=305.256km
(DELAY)
ROUND 6 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.340km78Laps=260.520km
(DELAY)
ROUND 7 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.148km59Laps=303.715km
(DELAY)
11th (3'04.348)1
13th (3'05.563)1
R (46LAPS)
R (27LAPS)
3th (2'44.105)1
6th (2'44.658)1
D 2
D 2
- 3
- 3
#5 F. ALONSO
#5 F. ALONSO
3'01.9021
#16 J. TRULLI
#9 K. RAIKKONEN
#9 K. RAIKKONEN
2'42.8801
#5 F. ALONSO
#1 M. SCHUMACHER
#10 A. WURZ
#9 K. RAIKKONEN
2'31.4211
#9 K. RAIKKONEN
#5 F. ALONSO
#16 J. TRULLI
- 3
- 3
#9 K. RAIKKONEN
2'30.3231
#9 K. RAIKKONEN
#8 N. HEIDFELD
#7 M. WEBBER
4
13th (1'32.594)
16th (1'32.926)
10th
12th
(95.786)
(1LAPS)
#8 N. HEIDFELD
1'30.081
#5 F. ALONSO
#8 N. HEIDFELD
#2 R. BARRICHELLO
ROUND 8 CANADA GP
QUALIFYING
PP (1'15.217)
6th (1'15.729)
Montreal
RACE
R (46LAPS)
R (40LAPS)
4.361km70Laps=305.270km
(DELAY)
#2 R. BARRICHELLO
3th (1'11.277)
8th (1'11.497)
#1 M. SCHUMACHER
R (0LAPS)
R (0LAPS)
8th ( 1'15.051)
5th (1'14.655)
RACE
4.192km73Laps=306.016km
(DELAY)
ROUND 10 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
RACE
5.141km60Laps=308.355km
(DELAY)
ROUND 12 GERMANY GP
QUALIFYING
Hockenheim
RACE
4.574km67Laps=306.458km
(DELAY)
ROUND 13 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.663km
(DELAY)
ROUND 14 TURKEY GP
QUALIFYING
Istanbul
RACE
5.338km58Laps=309.396km
(DELAY)
ROUND 15 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.720km
(DELAY)
ROUND 16 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
6.976km44Laps=306.927km
(DELAY)
ROUND 17 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
ROUND 18 JAPAN GP
QUALIFYING
Suzuka
RACE
5.807km53Laps=307.573km
(DELAY)
ROUND 19 CHINA GP
QUALIFYING
Shanghai
RACE
5.451km56Laps=305.066km
(DELAY)
4th
11th
(1LAP)
(1LAP)
3th (1'20.207)5
8th (1'21.114)5
5th
16th
(40.264)
(2LAPS)
2th (1'14.759)
8th (1'15.501)
3th
12th
(24.422)
(1LAP)
8th (1'21.302)
10th (1'21.787)
5th
8th
(58.832)
(1LAP)
13th (1'30.063)
- 6
5th
9th
(39.304)
(109.987)
4th (1'21.369)
5th (1'21.477)
8th
16th
(63.635)
(1LAP)
9th (1'47.978)
11th (1'48.353)
3th
R (13LAPS)
(32.077)
4th (1'12.696)
7th
10th
(1LAP)
(1LAP)
2th (1'46.141)
5th (1'46.841)
5th
- 7
(29.507)
4th (1'34.801)
17th (1'37.083)
8th
R (34LAPS)
(41.249)
1
2
3
4
5
#3 J. BUTTON
1'15.217
#16 J. TRULLI
1'10.625
#9 K. RAIKKONEN
#1 M. SCHUMACHER
#2 R. BARRICHELLO
#18 T. MONTEIRO
#5 F. ALONSO
1'14.412
#5 F. ALONSO
#9 K. RAIKKONEN
#1 M. SCHUMACHER
#5 F. ALONSO
1'19.905
#10 J. MONTOYA
#5 F. ALONSO
#9 K. RAIKKONEN
#9 K. RAIKKONEN
1'14.320
#5 F. ALONSO
#10 J. MONTOYA
#3 J. BUTTON
#1 M. SCHUMACHER
1'19.882
#9 K. RAIKKONEN
#1 M. SCHUMACHER
#17 R. SCHUMACHER
#9 K. RAIKKONEN
1'26.797
#9 K. RAIKKONEN
#5 F. ALONSO
#10 J. MONTOYA
#9 K. RAIKKONEN
1'20.878
#10 J. MONTOYA
#5 F. ALONSO
#6 G. FISICHELLA
#10 J. MONTOYA
1'46.391
#9 K. RAIKKONEN
#5 F. ALONSO
#3 J. BUTTON
#5 F. ALONSO
1'11.988
#10 J. MONTOYA
#9 K. RAIKKONEN
#5 F. ALONSO
#17 R. SCHUMACHER
1'46.106
#9 K. RAIKKONEN
#6 G. FISICHELLA
#5 F. ALONSO
#5 F. ALONSO
1'34.080
#5 F. ALONSO
#9 K. RAIKKONEN
#17 R. SCHUMACHER
From the opening round to Round 6 (Monaco), the aggregate of QF1 and QF2 times was used as the qualifying time.
Disqualified due to vehicle weight infringement.
Suspended from racing due to vehicle weight infringement at San Marino GP.
From Round 7, rule changes specified a single Saturday qualifying run.
K. Rikknen, who was qualified in 2nd position, was demoted 10 grid positions due to an engine replacement penalty, raising J. Button
from 3rd to 2nd grid position and T. Sato from 8th to 7th grid position.
6 Qualifying times were deleted as a result of impeding another vehicle.
7 Eliminated from results due to contact with another vehicle.
340
16
10
10
10
12
13
182
10
12
14
10
100
10
14
88
66
38
ESP MON EUR CAN USA FRA GBR GER HUN TUR
12
13
11
14
18
13
13
15
16
10
11
CHN
14
10
14
15
16
15
10
18
10
5
5
JPN
13
34
Sauber Petronas
20
12
11
10
Minardi F1 Team
ITA
BEL BRA
4
3
F. ALONSO (ESP)
133
K. RAIKKONEN (FIN)
112
M. SCHUMACHER (GER)
62
10
J. MONTOYA (COL)
60
G. FISICHELLA (ITA)
58
10
17
R. SCHUMACHER (GER)
45
16
J. TRULLI (ITA)
43
R. BARRICHELLO (BRA)
38
J. BUTTON (GBR)
37
10
M. WEBBER (AUS)
36
11
N. HEIDFELD (GER)
28
12
14
D. COULTHARD (GBR)
24
12
F. MASSA (BRA)
11
14
11
J. VILLENEUVE (CAN)
15
16
17
T. MONTEIRO (POR)
10
10
6
2
13
10
ESP MON EUR CAN USA FRA GBR GER HUN TUR
8
10
10
2
2
4
4
5
4
10
4
10
3
1
3
6
3
1
6
8
2
2
T. SATO (JPN)
24
25
R. DOORNBOS (NED)
10
10
10
10
10
2
4
3
3
3
4
1
4
3
2
1
341
10
BEL BRA
23
A. PIZZONIA (BRA)
10
C. ALBERS (NED)
CHN
21
22
ITA
19
JPN
P. FRIESACHER (AUT)
10
N. KARTHIKEYAN (IND)
20
19
10
4
6
18
20
21
10
2
3
10
QUALIFYING
Bahrain
RACE
5.412km57Laps=308.238km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
ROUND 3 AUSTRALIA GP
QUALIFYING
Melbourne
RACE
5.303km57Laps=302.271km
(DELAY)
RACE
4.959km62Laps=307.221km
(DELAY)
#23 Y. IDE
6th (1'32.579)
3th (1'31.549)
20th (1'37.411)
21th (1'40.270)
15th
4th
18th
R (35LAPS)
(1LAP)
(19.992)
(4LAPS)
12th (1'34.683)
2th (1'33.986)
21th (1'39.011)
22th (1'40.720)
10th
3th
14th
R (33LAPS)
(1LAP)
(9.631)
(3LAPS)
17th (1'29.943)
PP (1'25.229)
21th (1'32.279)
22th (1'36.164)
7th
10th
12th
13th
(51.904)
DNF
(2LAPS)
(3LAPS)
3th (1'23.242)
2th (1'22.988)
21th (1'27.609)
22th (1'29.282)
10th
7th
R (44LAPS)
R (23LAPS)
(77.851)
(39.635)
Super Aguri F1
#22 T. SATO
POLE
QF FASTEST
PODIUM
POSITION
LAP TIME
(FIRST 3)
#1 F. ALONSO
#5 M. SCHUMACHER #5 M. SCHUMACHER
#5 M. SCHUMACHER
1'31.431
1'31.431
#3 K. RAIKKONEN
#2 G. FISICHELLA
1'33.840
#12 J. BUTTON
1'33.527
#2 G. FISICHELLA
#1 F. ALONSO
#12 J. BUTTON
#12 J. BUTTON
1'25.229
#12 J. BUTTON
1'25.229
#1 F. ALONSO
#3 K. RAIKKONEN
#7 R. SCHUMACHER
#5 M. SCHUMACHER
#5 M. SCHUMACHER #5 M. SCHUMACHER
#1 F. ALONSO
1'22.795
1'22.579
#4 J. MONTOYA
#23 F. MONTAGNY
ROUND 5 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.148km60Laps=308.863km
(DELAY)
ROUND 6 SPAIN GP
QUALIFYING
Barcelona
RACE
4.627km66Laps=305.256km
(DELAY)
ROUND 7 MONACO GP
QUALIFYING
Monte Carlo
RACE
3.340km78Laps=260.520km
(DELAY)
QUALIFYING
Silverstone
RACE
5.141km60Laps=308.355km
(DELAY)
ROUND 9 CANADA GP
4th (1'30.754)
6th (1'30.940)
21th (1'35.239)
22th (1'46.505)
5th
R (28LAPS)
R (45LAPS)
R (29LAPS)
(72.586)
5th (1'15.885)
8th (1'16.008)
20th (1'18.920)
21th (1'20.763)
7th
6th
17th
R (10LAPS)
(1LAP)
(58.347)
(4LAPS)
- 1
4th
11th
R (46LAPS)
16th
(53.337)
(1LAP)
(3LAPS)
6th (1'20.943)
19th (1'23.247)
20th (1'26.158)
21th (1'26.316)
10th
R (8LAPS)
17th
18th
(1LAP)
(3LAPS)
(3LAPS)
QUALIFYING
9th (1'16.912)
8th (1'16.608)
21th (1'19.088)
22th (1'19.152)
Montreal
RACE
R (11LAPS)
9th
15th
R (2LAPS)
4.361km70Laps=305.270km
(DELAY)
(1LAP)
(DNF)
4th (1'12.109)
7th (1'12.523)
18th (1'13.496)
21th (1'16.036)
R (6LAPS)
R (0LAP)
RACE
4.192km73Laps=306.016km
(DELAY)
ROUND 11 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
6th
R (3LAPS)
(36.516)
14th (1'17.027)
19th (1'17.495)
22th (1'18.845)
21th (1'18.637)
R (18LAPS)
R (61LAPS)
R (0LAP)
16th
(3LAPS)
#1 F. ALONSO
1'29.819
#1 F. ALONSO
1'29.819
#5 M. SCHUMACHER
#1 F. ALONSO
#6 F. MASSA
#1 F. ALONSO
1'14.648
#5 M. SCHUMACHER #1 F. ALONSO
1'14.637
#5 M. SCHUMACHER
#2 G. FISICHELLA
#1 F. ALONSO
1'13.9622
#3 K. RAIKKONEN #1 F. ALONSO
1'13.532
#4 J. MONTOYA
#14 D. COULTHARD
#1 F. ALONSO
1'20.253
#1 F. ALONSO
1'20.253
#1 F. ALONSO
#5 M. SCHUMACHER
#3 K. RAIKKONEN
#1 F. ALONSO
1'14.942
#1 F. ALONSO
1'14.726
#1 F. ALONSO
#5 M. SCHUMACHER
#3 K. RAIKKONEN
#5 M. SCHUMACHER
1'10.832
#5 M. SCHUMACHER #5 M. SCHUMACHER
1'10.636
#6 F. MASSA
#2 G. FISICHELLA
#5 M. SCHUMACHER
1'15.493
#5 M. SCHUMACHER #5 M. SCHUMACHER
1'15.111
#1 F. ALONSO
#6 F. MASSA
#23 S. YAMAMOTO
ROUND 12 GERMANY GP
QUALIFYING
Hockenheim
RACE
4.574km67Laps=306.458km
(DELAY)
ROUND 13 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.663km
(DELAY)
ROUND 14 TURKEY GP
QUALIFYING
Istanbul
RACE
5.338km58Laps=309.396km
(DELAY)
ROUND 15 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.720km
(DELAY)
ROUND 16 CHINA GP
QUALIFYING
Shanghai
RACE
5.451km56Laps=305.066km
(DELAY)
ROUND 17 JAPAN GP
QUALIFYING
Suzuka
RACE
5.807km53Laps=307.573km
(DELAY)
ROUND 18 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
6th (1'14.934)
4th (1'14.862)
19th (1'17.185)
21th (1'20.444)
R (18LAPS)
4th
R (38LAPS)
R (1LAP)
(18.898)
3th (1'20.085)
4th (1'20.092)3
19th (1'22.967)
22th (1'24.016)
4th
WIN
13th
R (0LAP)
(45.205)
(5LAPS)
14th (1'28.257)
7th (1'27.790)
22th (1'30.850)
21th (1'30.607)
8th
4th
R (41LAPS)
R (23LAPS)
(60.034)
(12.334)
8th (1'22.787)4
5th (1'22.011)4
21th (1'24.289)
22th (1'26.001)
6th
5th
16th
R (18LAPS)
(42.409)
(32.685)
(2LAPS)
3th (1'45.503)
4th (1'45.503)
6th
4th
- 6
16th7
(79.131)
(72.056)
(4LAPS)
8th (1'31.478)
7th (1'30.992)
20th (1'33.666)
#5 M. SCHUMACHER #5 M. SCHUMACHER
1'13.778
#6 F. MASSA
#3 K. RAIKKONEN
#3 K. RAIKKONEN
1'19.599
#6 F. MASSA
1'19.504
#12 J. BUTTON
#4 P. DE LA ROSA
#16 N. HEIDFELD
12th
4th
15th
17th
(1LAP)
(34.101)
(1LAP)
(3LAPS)
5th (1'11.619)
14th (1'11.742)
20th (1'13.269)
21th (1'13.357)
7th
3th
10th
16th
(40.294)
(19.394)
(1LAP)
(2LAPS)
1
2
3
4
#3 K. RAIKKONEN
1'14.070
#6 F. MASSA
1'26.907
#5 M. SCHUMACHER #6 F. MASSA
1'25.850
#1 F. ALONSO
#5 M. SCHUMACHER
#3 K. RAIKKONEN
1'21.484
#6 F. MASSA
1'21.225
#5 M. SCHUMACHER
#3 K. RAIKKONEN
#17 R. KUBICA
#1 F. ALONSO
1'44.360
#1 F. ALONSO
1'43.951
#5 M. SCHUMACHER
#1 F. ALONSO
#2 G. FISICHELLA
#6 F. MASSA
1'29.599
#5 M. SCHUMACHER #1 F. ALONSO
1'28.954
#6 F. MASSA
#2 G. FISICHELLA
#6 F. MASSA
1'10.680
#5 M. SCHUMACHER #6 F. MASSA
1'10.313
#1 F. ALONSO
#12 J. BUTTON
342
10
18
201
110
10
86
36
35
16
Williams F1 Team
11
10
Spyker M F1 Team
11
SMR
EUR
ESP
USA
FRA
11
16
13
15
15
10
11
15
16
13
12
12
18
16
18
10
14
6
3
ITA
CHN
JPN
11
14
16
11
16
10
10
15
15
6
2
BRA
5
1
F. ALONSO (ESP)
134
10
M.SCHUMACHER (GER)
121
F. MASSA (BRA)
80
G. FISICHELLA (ITA)
72
10
K. RAIKKONEN (FIN)
65
6
5
12
J. BUTTON (GBR)
56
11
R. BARRICHELLO (BRA)
30
J. MONTOYA (COL)
26
16
N. HEIDFELD (GER)
23
10
R. SCHUMACHER (GER)
20
11
P. DE LA ROSA (ESP)
19
12
J. TRULLI (ITA)
15
13
14
D. COULTHARD (GBR)
14
14
M. WEBBER (AUS)
15
17
J. VILLENEUVE (CAN)
16
EUR
ESP
USA
FRA
10
10
10
10
10
10
10
10
10
10
5
1
15
C. KLIEN (AUT)
19
20
V. LIUZZI (ITA)
20
21
S. SPEED (USA)
21
18
T. MONTEIRO (POL)
22
19
C. ALBERS (NED)
23
22
T. SATO (JPN)
CHN
JPN
10
10
10
8
10
Y. IDE (JPN)
343
8
10
6
2
1
2
4
2
1
3
BRA
5
1
1
23/41 F. MONTAGNY
ITA
18
27
5
5
6
2
23
3
2
N. ROSBERG (GER)
26
3
4
10
25
SMR
17
24
10
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
5.543km56Laps=310.408km
(DELAY)
ROUND 3 BAHRAIN GP
QUALIFYING
Bahrain
RACE
5.412km57Laps=308.238km
(DELAY)
ROUND 4 SPAIN GP
QUALIFYING
Barcelona
RACE
4.655km65Laps=302.449km
(DELAY)
#8 R. BARRICHELLO
#12 T. SATO
#14 A. DAVIDSON
14th (1'27.264)
17th (1'27.679)
10th (1'28.871)
11th (1'26.909)
15th
11th
12th
16th
(1LAP)
(1LAP)
(1LAP)
(2LAPS)
15th (1'36.088)
19th (1'36.827)
14th (1'35.945)
18th (1'36.816)
12th
11th
13th
16th
(1LAP)
(1LAP)
(1LAP)
(1LAP)
16th (1'33.731)
15th (1'33.624)
17th (1'33.984)
13th (1'33.082)
R (0LAP)
13th
R (34LAPS)
16th
(1LAP)
(DNF)
14th (1'22.120)
12th (1'22.097)
13th (1'22.115)
15th (DNF)
12th
10th
8th
11th
(1LAP)
(1LAP)
(1LAP)
(1LAP)
9th (1'17.498)1
21th (1'18.554)
17th (1'18.250)
11th
10th
17th
18th
(1LAP)
(1LAP)
(2LAPS)
(2LAPS)
15th (1'17.541)
13th (1'17.116)
11th (1'16.743)
17th (1'17.542)
R (0LAP)
12th
6th
11th
ROUND 5 MONACO GP
Monte Carlo
RACE
3.340km78Laps=260.520km
(DELAY)
ROUND 6 CANADA GP
QUALIFYING
Montreal
RACE
4.361km70Laps=305.270km
(DELAY)
RACE
4.192km73Laps=306.016km
(DELAY)
ROUND 8 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
RACE
5.141km59Laps=303.214km
(DELAY)
ROUND 10 EUROPE GP
QUALIFYING
Nurburgring
RACE
5.148km60Laps=308.863km
(DELAY)
ROUND 11 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.663km
(DELAY)
ROUND 12 TURKEY GP
QUALIFYING
Istanbul
RACE
5.338km58Laps=309.396km
(DELAY)
ROUND 13 ITALY GP
QUALIFYING
Monza
RACE
5.793km53Laps=306.720km
(DELAY)
ROUND 14 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
7.004km44Laps=308.053km
(DELAY)
ROUND 15 JAPAN GP
QUALIFYING
Fuji
RACE
4.563km67Laps=305.416km
(DELAY)
ROUND 16 CHINA GP
QUALIFYING
Shanghai
RACE
5.451km56Laps=305.066km
(DELAY)
ROUND 17 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
#7 J. BUTTON
30.439
16.698
24.318
13th (1'12.998)
15th (1'13.201)
18th (1'13.477)
16th (1'13.259)
12th
R (0LAP)
R (13LAPS)
11th
(1LAP)
(1LAP)
12th (1'15.584)
13th (1'15.761)
19th (1'16.244)2
20th (1'16.366)
8th
11th
16th
R (1LAP)
58.885
(1LAP)
(2LAPS)
18th (1'21.335)
14th (1'20.364)
21th (1'22.045)
19th (1'21.448)
10th
9th
14th
R (35LAPS)
(1LAP)
(1LAP)
(2LAP)
17th (1'32.983)
14th (1'32.221)
16th (1'32.838)
15th (1'32.451)
R (2LAPS)
11th
R (19LAPS)
12th
(1LAP)
(1LAP)
17th (1'21.737)
18th (1'21.877)
19th (1'22.143)
15th (1'21.127)
R (35LAPS)
18th
15th
R (41LAPS)
(2LAPS)
(1LAP)
15th (1'28.220)
14th (1'28.188)
19th (1'28.953)
11th (1'28.002)
13th
17th
18th
14th
(1LAP)
(1LAP)
(1LAP)
(1LAP)
10th (1'25.165)
12th (1'23.176)
17th (1'23.749)
14th (1'23.274)
8th
10th
16th
14th
POLE
QF FASTEST
PODIUM
POSITION
LAP TIME
(FIRST 3)
#6 K. RAIKKONEN
1'26.072
#1 F. ALONSO
1'25.326
#6 K. RAIKKONEN
#1 F. ALONSO
#2 L. HAMILTON
#1 F. ALONSO
#5 F. MASSA
1'35.043
#1 F. ALONSO
1'34.057
#2 L. HAMILTON
#6 K. RAIKKONEN
#5 F. MASSA
#5 F. MASSA
1'32.652
#5 F. MASSA
1'31.359
#2 L. HAMILTON
#6 K. RAIKKONEN
#5 F. MASSA
#5 F. MASSA
1'21.421
#5 F. MASSA
1'20.597
#2 L. HAMILTON
#1 F. ALONSO
#1 F. ALONSO
#1 F. ALONSO
1'15.726
#1 F. ALONSO
1'15.431
#2 L. HAMILTON
#5 F. MASSA
#2 L. HAMILTON
#2 L. HAMILTON
1'15.707
#2 L. HAMILTON
1'15.486
#9 N. HEIDFELD
#17 A. WURZ
#2 L. HAMILTON
#2 L. HAMILTON
1'12.331
#1 F. ALONSO
1'11.926
#1 F. ALONSO
#5 F. MASSA
#6 K. RAIKKONEN
#5 F. MASSA
1'15.034
#2 L. HAMILTON
1'14.795
#5 F. MASSA
#2 L. HAMILTON
#6 K. RAIKKONEN
#2 L. HAMILTON
1'19.997
#1 F. ALONSO
1'19.152
#1 F. ALONSO
#2 L. HAMILTON
#1 F. ALONSO
#6 K. RAIKKONEN
1'31.450
#5 F. MASSA
1'30.912
#5 F. MASSA
#15 M. WEBBER
#1 F. ALONSO3
1'19.674
#2 L. HAMILTON
#2 L. HAMILTON
1'19.301
#6 K. RAIKKONEN
#9 N. HEIDFELD
#5 F. MASSA
#5 F. MASSA
1'27.329
#1 F. ALONSO
1'26.841
#6 K. RAIKKONEN
#1 F. ALONSO
#1 F. ALONSO
#1 F. ALONSO
1'21.997
#1 F. ALONSO
1'21.356
#2 L. HAMILTON
72.168
76.958
(1LAP)
(1LAP)
#6 K. RAIKKONEN
14th (1'46.955)
18th (1'47.954)
19th (1'47.980)
21th (1'48.199)
#6 K. RAIKKONEN
#6 K. RAIKKONEN
1'45.994
#6 K. RAIKKONEN
#5 F. MASSA
1'45.070
#1 F. ALONSO
R (36LAPS)
13th
15th
16th
(1LAP)
(1LAP)
(1LAP)
7th (1'26.913)
17th (1'27.323)
21th (1'28.792)
19th (1'27.564)
11th
10th
15th
R (54LAPS)
(DNF)
88.342
(DNF)
#6 K. RAIKKONEN
10th (1'39.285)
17th (1'37.251)
20th (1'38.218)
15th (1'37.247)
#6 K. RAIKKONEN
5th
15th
14th
R (11LAPS)
68.666
(1LAP)
(1LAP)
16th (1'13.469)
11th (1'12.932)
18th (1'14.098)
20th (1'14.596)
R (20LAPS)
R (40LAPS)
12th
14th
(2LAPS)
(3LAPS)
#2 L. HAMILTON
#2 L. HAMILTON
1'25.368
#2 L. HAMILTON
1'35.908
#2 L. HAMILTON
1'24.753
#4 H. KOVALAINEN
#6 K. RAIKKONEN
#1 F. ALONSO
1'35.381
#5 F. MASSA
#6 K. RAIKKONEN
#5 F. MASSA
1'11.931
#5 F. MASSA
1'11.931
#5 F. MASSA
#1 F. ALONSO
1 D. Coulthard was not allowed to start in Q3 and was penalized two positions for impeding another vehicle in Q2. As a result, J. Button
was raised from 11th to 10th position, and R. Barrichello from 10th to 9th position.
2 T. Sato was penalized 10 grid positions for overtaking under a yellow flag during the previous US Grand Prix, and started the race at
the back of the grid.
3 F. Alonso was demoted five grid positions as a result of impeding another vehicle in the qualifying session.
344
TOTAL
AUS
MAL
BRN
ESP
USA
FRA
GBR
EUR
HUN
TUR
ITA
BEL
JPN
CHN
BRA
204
13
10
16
10
MON CAN
7
11
18
14
18
18
16
18
101
10
51
12
AT&T Williams
33
24
13
10
11
4
1
10
5
5
1
8
1
1
3
1
No.
TOTAL
AUS
MAL
BRN
K. RAIKKONEN (FIN)
DRIVER (NAT)
110
10
L. HAMILTON (GBR)
109
F. ALONSO (ESP)
109
10
F. MASSA (BRA)
94
N. HEIDFELD (GER)
61
10
R. KUBICA (POL)
39
USA
FRA
GBR
HUN
TUR
ITA
BEL
JPN
CHN
BRA
10
10
10
10
10
10
10
10
10
10
10
10
10
10
H. KOVALAINEN (FIN)
30
G. FISICHELLA (ITA)
21
16
N. ROSBERG (GER)
20
10
14
D. COULTHARD (GBR)
14
11
17
A. WURZ (AUT)
13
12
15
M. WEBBER (AUS)
10
13
12
J. TRULLI (ITA)
14
19
S. VETTEL (GER)
15
J. BUTTON (GBR)
16
11
R. SCHUMACHER (GER)
17
22
T. SATO (JPN)
18
18
V. LIUZZI (ITA)
19
20
A. SUTIL (GER)
20
R. BARRICHELLO (BRA)
21
19
S. SPEED (USA)
22
17/38
K. NAKAJIMA (JPN)
23
23
A. DAVIDSON (GBR)
24
21
S. YAMAMOTO (JPN)
25
21
C. ALBERS (NED)
3
1
3
ESP
MON CAN
3
5
2
1
8
5
EUR
2
2
8
4
5
5
5
1
1
1
3
3
1
345
3
4
5
2
4
2
3
4
10
2
8
QUALIFYING
Melbourne
RACE
5.303km58Laps=307.574km
(DELAY)
ROUND 2 MALAYSIA GP
QUALIFYING
Kuala Lumpur
RACE
#14 A. DAVIDSON
13th (1'26.259)
11th (1'26.173)
20th (1'28.208)
22th (1'29.059)
R (0LAP)
- 1
R (32LAPS)
R (0LAP)
11th (1'35.208)
14th (1'35.622)
20th (1'37.087)
22th (1'37.481)
10th
13th
16th
15th
5.543km56Laps=310.408km
(DELAY)
86.214
(1LAP)
(2LAPS)
(1LAP)
ROUND 3 BAHRAIN GP
QUALIFYING
9th (1'35.057)
12th (1'32.508)
22th (1'35.725)
21th (1'34.140)
Bahrain
RACE
R (19LAPS)
11th
17th
16th
5.412km57Laps=308.238km
(DELAY)
77.862
(1LAP)
(1LAP)
13th (1'21.211)
11th (1'21.049)
22th (1'23.496)
21th (1'23.318)
6th
R (34LAPS)
13th
R (8LAPS)
53.010
(1LAP)
13th (1'27.298)
12th (1'27.219)
11th
14th
ROUND 4 SPAIN GP
QUALIFYING
Barcelona
RACE
4.655km66Laps=307.104km
(DELAY)
ROUND 5 TURKEY GP
QUALIFYING
Istanbul
RACE
5.338km58Laps=309.396km
(DELAY)
ROUND 6 MONACO GP
Monte Carlo
RACE
3.340km76Laps=253.840km
(DELAY)
ROUND 7 CANADA GP
QUALIFYING
Montreal
RACE
4.361km70Laps=305.270km
(DELAY)
ROUND 8 FRANCE GP
QUALIFYING
Magny Cours
RACE
4.411km70Laps=308.586km
(DELAY)
QUALIFYING
Silverstone
RACE
5.141km60Laps=308.355km
(DELAY)
ROUND 10 GERMANY GP
QUALIFYING
Hockenheim
RACE
4.574km67Laps=306.458km
(DELAY)
ROUND 11 HUNGARY GP
QUALIFYING
Budapest
RACE
4.381km70Laps=306.630km
(DELAY)
ROUND 12 EUROPE GP
QUALIFYING
Valencia
RACE
5.419km57Laps=308.883km
(DELAY)
ROUND 13 BELGIUM GP
QUALIFYING
Spa Francorchamps
RACE
7.004km44Laps=308.052km
(DELAY)
ROUND 14 ITALY GP
QUALIFYING
Monza
RACE
RA
5.793km53Laps=306.720km
(DELAY)
ROUND 15 SINGAPORE GP
QUALIFYING
Singapore
RACE
5.067km61Laps=308.950km
(DELAY)
ROUND 16 JAPAN GP
QUALIFYING
Fuji
RACE
4.563km67Laps=305.416km
(DELAY)
ROUND 17 CHINA GP
QUALIFYING
Shanghai
RACE
5.451km56Laps=305.066km
(DELAY)
ROUND 18 BRAZIL GP
QUALIFYING
Interlagos
RACE
4.309km71Laps=305.909km
(DELAY)
(1LAP)
POLE
QF FASTEST
PODIUM
POSITION
LAP TIME
(FIRST 3)
#22 L. HAMILTON
1'26.714
#2 F. MASSA
1'35.748
#4 R. KUBICA
1'33.096
#22 L. HAMILTON
#22 L. HAMILTON
#3 N. HEIDFELD
1'25.187
#7 N. ROSBERG
#1 K. RAIKKONEN
#1 K. RAIKKONEN
#4 R. KUBICA
1'34.188
#23 H. KOVALAINEN
#2 F. MASSA
1'31.188
#1 K. RAIKKONEN
1'21.813
#2 F. MASSA
1'20.584
(1LAP)
(28.408)
19th (1'23.565)
9th (1'20.848)
11th
7th
(67.540)
(53.597)
17th (1'16.306)
18th (1'16.330)
R (16LAPS)
14th
(1LAP)
17th (1'21.631)
16th (1'21.512)
R (38LAPS)
3th
(82.273)
14th (1'15.701)
18th (1'16.246)
17th
R (50LAPS)
#1 K. RAIKKONEN
#2 F. MASSA
#22 L. HAMILTON
#2 F. MASSA
1'25.994
(1LAP)
6th
#1 K. RAIKKONEN
#4 R. KUBICA
#2 F. MASSA
1'27.617
#2 F. MASSA
#22 L. HAMILTON
#1 K. RAIKKONEN
15th (1'16.537)2
11th
#2 F. MASSA
#2 F. MASSA
1'15.787
#2 F. MASSA
1'15.110
#22 L. HAMILTON
#4 R. KUBICA
#2 F. MASSA
#22 L. HAMILTON
1'17.886
#1 K. RAIKKONEN
1'16.449
#4 R. KUBICA
#22 L. HAMILTON
#3 N. HEIDFELD
1'16.909
#9 D. COULTHARD
#2 F. MASSA
1'15.024
#2 F. MASSA
#1 K. RAIKKONEN
#11 J. TRULLI
#22 L. HAMILTON
#23 H. KOVALAINEN #22 L. HAMILTON
#3 N. HEIDFELD
1'21.049
1'19.537
#17 R. BARRICHELLO
#22 L. HAMILTON
1'15.666
#22 L. HAMILTON
#22 L. HAMILTON
#6 N. PIQUET
1'14.603
#2 F. MASSA
(1LAP)
12th (1'20.332)
18th (1'21.332)3
12th
16th
(1LAP)
(2LAPS)
16th (1'38.880)
19th (1'39.811)4
13th
16th
(1LAP)
(1LAP)
#4 R. KUBICA
17th (1'48.211)
16th (1'48.153)
#2 F. MASSA
15th
R (19LAPS)
(1LAP)
19th (1'37.006)
16th (1'36.510)
15th
17th
(73.370)
(1LAP)
12th (1'45.133)
18th (1'46.583)
9th
R (14LAPS)
(19.885)
18th (1'19.100)
17th (1'18.882)
14th
13th
#22 L. HAMILTON
1'20.899
#2 F. MASSA
1'19.068
#23 H. KOVALAINEN
#12 T. GLOCK
#1 K. RAIKKONEN
#2 F. MASSA
1'38.989
#22 L. HAMILTON
1'47.338
#15 S. VETTEL
1'37.555
#2 F. MASSA
1'44.801
#15 S. VETTEL
1'37.842
#2 F. MASSA
#22 L. HAMILTON
#23 H. KOVALAINEN
#3 N. HEIDFELD
1'46.037
#22 L. HAMILTON5
#15 S. VETTEL
#23 H. KOVALAINEN
#23 H. KOVALAINEN
1'35.214
#4 R. KUBICA
#2 F. MASSA
1'44.014
#5 F. ALONSO
#7 N. ROSBERG
#22 L. HAMILTON
#22 L. HAMILTON
1'18.404
#2 F. MASSA
1'17.287
#5 F. ALONSO
#4 R. KUBICA
(1LAP)
(1LAP)
#1 K. RAIKKONEN
18th (1'37.053)
14th (1'36.079)6
#22 L. HAMILTON
16th
11th
(1LAP)
(85.061)
17th (1'12.810)
15th (1'13.139)
13th
15th
(1LAP)
(1LAP)
#22 L. HAMILTON
1'36.303
#2 F. MASSA
1'12.368
#22 L. HAMILTON
#2 F. MASSA
1'34.947
#1 K. RAIKKONEN
#2 F. MASSA
#23 H. KOVALAINEN
#5 F. ALONSO
1'11.768
#1 K. RAIKKONEN
1 Eliminated from the race for ignoring a red signal at the pit lane exit.
2 D. Coulthard was demoted five grid positions as a result of a gearbox change. As a result, J. Button was raised from 12th to 11th position,
and R. Barrichello from 15th to 14th position on the grid.
3 S. Bourdais was demoted five grid positions for impeding another vehicle in the qualifying session. As a result, R. Barrichello was raised
from 18th to 17th position on the grid.
4 Because a change was made to the vehicle in parc ferme, R. Barrichello was required to make a pit start in the race.
5 25 seconds were added to L. Hamiltons racing time for cutting a chicane, demoting him from 1st to 3rd position.
6 M. Webber was demoted 10 grid positions for an engine change, raising R. Barrichello from 14th to 13th position on the grid.
346
ESP
P.
172
10
18
18
16
151
14
10
11
135
11
11
80
56
39
29
AT&T Williams
26
14
10
11
GBR
BEL
ITA
18
10
10
14
14
14
13
10
18
11
10
10
15
2
9
FRA
8
10
ESP
SIN
JPN
8
10
CHN BRA
14
16
10
P.
No.
DRIVER (NAT)
22
L. HAMILTON (GBR)
98
F. MASSA (BRA)
97
K. RAIKKONEN (FIN)
75
R. KUBICA (POL)
75
F. ALONSO (ESP)
61
N. HEIDFELD (GER)
60
23
H. KOVALAINEN (FIN)
53
15
S. VETTEL (GER)
35
11
J. TRULLI (ITA)
31
10
12
T. GLOCK (GER)
25
11
10
M. WEBBER (AUS)
21
12
N. PIQUET (BRA)
19
13
N. ROSBERG (GER)
17
14
17
R. BARRICHELLO (BRA)
11
15
K. NAKAJIMA (JPN)
16
D. COULTHARD (GBR)
17
14
S. BOURDAIS (FRA)
18
16
J. BUTTON (GBR)
19
21
G. FISICHELLA (ITA)
20
20
A. SUTIL (GER)
21
18
T. SATO (JPN)
22
19
A. DAVIDSON (GBR)
10
1
10
10
10
10
10
10
10
8
1
1
3
10
1
2
10
10
10
10
10
5
3
347
10
10
5
1
2
1
5
8
6
1
4
2
1
2
2
10
6
2
CHN BRA
1
2
JPN
1
8
1
3
SIN
3
2
ITA
1
6
BEL
5
2
3
8
4
1
GBR
10
4
5
FRA
A.L.M.T. Corp.
AEROSPACE METAL
COMPOSITES Ltd
HINODE-SEISAKUSHO CO,LTD
HIRAI CO.,LTD.
DALLARA AUTOMOBILI
DASSAULT SYSTEMES
Hitachi, Ltd.
Hitachi Metals,Ltd.
DOME CO.,LTD.
Ebara Corporation
EMZLAB Inc.
ENAX,INC.
HONDA PERFORMANCE
DEVELOPMENT INC
AJACOM CO.,LTD.
Akashi Communication CO.,LTD
ALCOA
ALTIMA Corp.
AN motorsport LTD
Arai Seisakusho Co.,Ltd.
Arisawa Manufacturing Co., Ltd.
ARTFAST
ASANO Co.,Ltd.
ASIA NETSUSYORI (in Japanese)
ASPECT Inc.
ATIA, Inc.
ENKEI CORPORATION
automax co.,ltd
ERAMET INTERNATIONAL
TOKYO BRANCH
AutoTechnicJapan co.,LTD
Ichikawa.co.,ltd.
FUJI FURUKAWA
ENGINEERING &
CONSTRUCTION CO.,Ltd
Bodycote
IHI Corporation
Bridgestone Corporation
Busak+Shamban K.K.
FujiStaff, Inc.
IMV CORPORATION
FUJITSU LIMITED
INCS INC.
CEROBEAR GmbH
FUJIWARA CO.,LTD.
CHIRIKA.Co.,ltd.
IPEC co.ltd
Ishihara Precision,Inc.
CMK CORPORATION
GIKENSEIKI CO.,LTD
COMATSU
GS Yuasa Corporation
CorporationYamazaki Setsubi.
Cosworth Electronics Ltd.
Cranfield University
CYAN Co.,Ltd.
JEFTEC CO.,LTD.
350
Hoshino Corporation
ICS Corporation
MITSUBISHI RESEARCH
INSTITUTE, INC.
MITSUBISHI STEEL MFG.
Co.,Ltd.
MIYAMA CORPORATION
PHIARO CORPORATION
KDDI CORPORATION
Keihin Corporation
MIYASAKA RUBBER.,CO.LTD.
PLANSEE SE
PSG
MORIKAWA INDUSTRIES
CORPORATION
Morimura Bros.,Inc.
RDS CO.,LTD.
MORIYA CORPORATION.
M-TEC Co.Ltd
MW RACING GMBH
Saint-Gobain K.K.
KOUKEN CO.,LTD
NDK,Incorporated
Kowa ss CO.,LTD.
NEC TOHOKU.LTD.
ktel.co
KYOWA ELECTRONIC
INSTRUMENTS CO., LTD.
QUALICA Inc.
Nihon Unisys,Ltd.
SHIBAURA ELECTRONICS
CO.,LTD.
NISSIN MANUFACTURING
CO.,LTD.
SHINRYO CORPORATION
351
Sumitomo Corporation
TOSEI ELECTROBEAM
COMPANY LIMITED
TOSHIBA CORPORATION
TOYAMA PREFECTURAL
UNIVERSITY Department of
Intelligent Systems Design
Engineering
TOYO Corporation
TOYO DENSO CO.,LTD.
TOYO iTEC Co., Ltd.
TOYO KOKU DENSHI Co.,Ltd.
T.RAD Co.,Ltd.
Taikisha Ltd.
TAISEI CORPORATION
TAKASAGO LTD.
UCHIDA Co.,LTD
TAKATA CORPORATION
TAMAGAWA SEIKI CO.,LTD.
TANAKA SEIMITSU KOGYO
Co.,Ltd
TDK Corporation
Techno-Core Corporation
TECHNOPRO Engineering, Inc.
TEIKOKU PISTON RING Co.,Ltd
Tigers Polymer Corporation
TIMET
TNO-Automotive Japan K.K.
TOAMEC Inc.
TODA CORPORATION
Tohoku Steel Co., Ltd.
TOKAI SEIKI CO,Ltd.
TOKIWA CO.,LTD.
UESAWA WORKS,INC.
Vector & Scalar Products Limited
(VSPL)
Wave Front Co.,Ltd
Westmoreland Mechanical Testing
& Research, Ltd
Watanabe Architects & Engineers
co., Ltd
YACHIYO-SEIKI Ltd.
YAGISHITA GIKEN CO.,LTD.
Yamada Manufacturing Co., Ltd.
Yamaguchi University Graduate
School of Science and Engineering
Yamaguchi University Faculty of
Agriculture
YAMASAN CO., LTD
YAMASHITA RUBBER CO.,LTD.
YAMATO GOKIN
TOKOROZAWA ALLOY
FOUNDRY CO.,LTD.
352
354
355
356
357
358
359
360
Engine
Gearbox
Throttle
Cylinder Head
Exhaust Pipe
Know-How
Jacques Villeneuve
Motor Sports Division
HONDA Racing F1 Team
home base
Facility Control Section expert
Parts Control Division
Honda Engineering Co., Ltd.
361
Afterword
Almost a year has passed since Honda suddenly announced its withdrawal from Formula One, and we
commenced planning this special issue of the Technical Review. An older colleague once told me that being
guaranteed a position in the company and being able to participate in race development was great good
fortune for an engineer; for me, being involved in race development and being able to bring together the
outcomes of those projects as an editor has been an even more precious experience.
Today, the gulf between race technologies and mass-production technologies is pointed out to be great
in comparison to Hondas first and second Formula One eras. While their applications and effects may not
immediately be apparent, the technologies that we produce by reaching for the ultimate will be useful and
valuable in some way to the future, and I will be happy if their recording here in this form can show this
to be the case.
On the final note, I would like to take this space to remember our friends and colleagues who, to our
sadness, passed away during the time that they participated in Hondas Formula One project: Tomohiro
Kumagai, who was involved in the development of both hardware and software for vehicle bodies and gear
boxes; Tadasu Takahashi, who was involved in engine research based on track running and carried out
research on gear boxes; Kenji Nakashima, who was involved in engine research; and Masanori Wakasa,
who was involved in the development of control systems. This volume is dedicated to their memory.
(Hiromasa Tanaka)
Published by:
Honda Motor Co., Ltd.
2-1-1, Minami-Aoyama, Minato-ku,
Tokyo 107-8556, Japan
Edited by:
Honda R&D Co., Ltd.
Honda R&D Technical Paper Committee
Printed:
Dec. 1, 2009
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