Magneti Marelli has revealed itself as the supplier of multiple components and systems for the LaFerrari, the high-tech supercar which was revealed at the recent Geneva motor show.

The new model is the first Ferrari to be fitted with a hybrid-electric powertrain, which the company is branding as a ‘HY-KERS’ system, thereby linking it to Formula 1 technology.

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The HY-KERS on the LaFerrari is claimed to help generate 963hp of power. Exactly 800hp comes from a 6,262cc normally aspirated V12. Magneti Marelli provides two electric motors (one primary unit, plus another for auxiliary systems) which are said to deliver combined peak power of 163hp (120kW). The motors are controlled by two small, lightweight inverters.

The first electric motor provides drive to the vehicle and recovers kinetic energy during braking, storing such energy in the lithium batteries. This energy is used for an over-boost power function. The secondary motor, driven by the combustion engine, generates electricity used to keep the charge level of the batteries constant, in addition to providing energy for standard vehicle systems (lights, etc.).

Magneti Marelli also supplies the LaFerrari’s high-intensity bi-xenon headlights and LED rear lights and various electronics systems. The car has ten ECUs dedicated to controlling vehicles functions such as headlights, the Superlift system, an electric actuator for the intake manifolds, as well as the Dual Clutch transmission. Superlift uses hydraulic actuators to raise the vehicle for speed bumps or other irregularities in the road surface.

Main components of the Magneti Marelli operating system:

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  • EM1: Hy-Power electric motor used for drive or as a generator, coupled to the dual-clutch transmission (DCT). This motor recovers kinetic energy under braking (the KERS principle), converting it into electricity which is stored in the batteries, and generates additional power (over-boost) during acceleration. This motor also ensures the deactivation of the combustion engine once the vehicle has stopped, keeping the in-vehicle electronic systems active. The Hy-Power electric motor features a stator with what the company terms “revolutionary bar windings”.
  • EM2: Auxiliary electric motor operated by the combustion engine, used to keep the charge level of the KERS lithium ion batteries constant as well as to convert – thanks to the dedicated inverter – electricity from high to low voltage (12V), which can then be used for standard vehicle functions (lighting, air-conditioning, etc.)
  • Double inverter used to control the two electric motors. There are two compact-size DCDC converters inside the same box: one with voltage of 12V, and another one that controls the battery cooling system.

Battery control system consisting of a BSM (Battery Management System) and 8 BMCs (Battery Module Controllers), connected one to the other by means of two CAN lines. The control units constantly monitor the 120 battery cells. Each BMC monitors 15 cells, their balancing and temperatures. The BSM handles the control strategies of the entire package, including safety checks, such as, for example, any insulation losses.

EM1 (Hy-Power) electric/generator motor specifications:

  • Length                                    251mm
  • Width                                      346mm
  • Weight                                    47.5kg
  • Cooling liquid                        Oil (Tmax 90°)
  • Max torque                             > 200Nm
  • Max power                             120kW

EM2 electric generator:

  • Length                                    280mm
  • Width                                      218mm
  • Weight                                    14.95kg
  • Cooling liquid                       Water (Tmax 90°)
  • Max torque                             20Nm
  • Max power                             6kW

Inverter:

  • Power control module for both electric motors
  • Length                                    371mm
  • Width                                      218mm 
  • Weight                                   14.5kg
  • Cooling liquid                       Water (Tmax 80°)
  • DCDC LV (12V)                    Up to 3.3kW
  • DCDC HV (380V)                 Up to 7kW

Author: Glenn Brooks