The powertrain of Hayden Paddon’s electric Hyundai Kona rally car is based on the “fully flexible” kit used in the Projekt E rallycross series but with unique adaptations.
STARD’s REVelution powertrain will be incorporated into Paddon Rallysport’s rally car, which is set to be completed in the coming months for a full race program in New Zealand next year.
The electric kit from Austrian company STARD is the same platform used in Projekt E, the electric support series to the FIA World Rallycross Championship that will debut in May.
Paddon says he’s cooperated with STARD to make adaptations to the package, but praises the flexibility of the design, which can incorporate between one and four 150 kW motors.
“We’ve worked with STARD to adapt the package a little bit for us,” Paddon told e-racing365.
“The whole package, in terms of motors and power output, is fully flexible. You can run one motor, two motors, three motors or four. It’s going to depend on the application.
“If we’re doing it in rallies, we’re not going to need massive amounts of power because it’s everything you need to factor in.
“If we do short hill climbs, or Pikes Peak, or those type of events, it’s a matter of simply changing the motor configuration and software, and then you’ve got a different power package.
“We’ll adapt that accordingly to the events that we’re doing.”
A key quality of the REVelution powertrain is its flexibility, which allows it to be used in a number of environments instead of just for rallycross in Projekt E.
STARD’s layout has no physical connection between the two axles and a separate transmission on each, with space for up to two motors on each axle.
“We can run with up to 18,000 rpm input speed from the motors and we can mount two motors on one transmission and a huge range of ratios to cover different motors and different speed ranges in different racing categories,” STARD’s CEO Michael Sakowicz explained to e-racing365.
In Paddon’s project, his team is building everything around STARD’s motors and control system itself, allowing for “a lot of unique designs” and some new EV technology.
“Because of the different weight distribution and the way EVs work with torque curves, we’ve designed some of the geometry in this car quite differently to our current cars,” the New Zealander said.
“On top of that, we’ve got a lot of unique designs that we’re incorporating into this car as well, and some new products on the EV side that are unique to us, that we’ll hopefully launch out to the world as products that could be almost like bolt-on kits for any type of EV motorsport.”
Enough Range to Avoid Daytime Charging During Rallies
Paddon is still keeping details on charging infrastructure and range capacities under wraps but he’s confident the car won’t need recharging during a day of competition.
The difficulty with using electric cars in rallies is the remoteness and large footprint of such events, making charging more difficult than on a standard race track.
“We’re trying to stay away from the charging side during events, so we’ve got some other systems in place, a little bit through regeneration and a little bit through other batteries,” Paddon explained.
“There are a few design things that will become apparent when the car is up and running later this year.
“Obviously we’d charge it overnight but we’re not interested in charging during a day of competition.”