Le Mans Hypercar Prototype

After a three-month program, Astauto delivered:

1. Performance target estimations: Based on a fully modeled and developed LMH car simulation, incorporating initial targets for aerodynamics, vehicle dynamics, and powertrain specifications.
2. BoM creation and PERT chart: A comprehensive Bill of Materials and PERT chart for the design, development, and construction of the LMH car, informed by our experience with LMP1 design and production.
3. Budget creation: Utilizing the BoM and partner quotations, we outlined five distinct racing scenarios with corresponding budgets:
   • One-car team – 2 Races + Le Mans
   • Two-car team – 2 Races + Le Mans
   • One-car team – Full WEC Championship
   • Two-car team – Full WEC Championship
   • Two-car team + spare car – Full WEC Championship

Astauto’s strategy for this project comprised the following steps:

1. Study of LMH regulations and creation of the Specifications Book: The LMH regulations, introduced in 2021, were based on a concept proposed to the ACO by Sergio Rinland in 2010. Unlike traditional approaches, this concept focused on regulating performance outcomes—such as power output, aerodynamic drag, and downforce—rather than prescribing vehicle design details.
   • Power is measured via torque and RPM at the driveshafts, while drag and downforce are homologated through standardized wind tunnel tests. Homologated 3D designs are submitted to the FIA for verification, with random checks during scrutineering at events.
   • Although the initial downforce and drag targets seemed achievable based on our LMP1 experience, maintaining maximum efficiency (lift-to-drag ratio) across various speeds and ride heights presented a significant challenge. Our first step was launching a CFD program to evaluate these constraints.
   • For power, while achieving peak outputs appeared straightforward, the challenge lay in designing a combined rear ICE and front MGU system capable of consistently operating at maximum allowed power.
2. Initial aerodynamic design and CFD program: The project’s Specifications Book outlined ambitious aerodynamic targets. These targets guided the aerodynamic simulations to predict the vehicle’s performance across Le Mans and other WEC circuits.
3. ICE and MGU torque-power curve specifications: LMH regulations defined a power curve at the wheels with specified minimum and maximum tolerances. Our simulation model incorporated an ICE with this torque curve and a control system to adjust output when the front motors were activated.
4. Simulation program to assess target performance: Using AVL VSM simulation software, we conducted detailed simulations to establish performance targets for the vehicle’s key parameters as outlined in the Specifications Book.