

Formula 1 teams may not have to use the controversial Gill Sensors fuel flow meter for the whole of the 2014 season. It has been revealed that an alternative solution is in the final stages of development and could be homologated by the end of the year.

Most of the original team behind the development of the ultrasonic fuel flow control technology introduced to the FIA Formula 1 World Championship and the FIA World Endurance Championship this season have reunited in a new company, SentronicsTM Limited, to produce a range of second-generation ultrasonic fuel flow sensors, branded FlowSonic, for motorsport and other markets around the world.

Sentronics is a partnership of three British companies, sensor producer Reventec, precision machining firm Mikina Engineering, and electronics specialists Polyhedrus Electronics, plus US-based Hyspeed LLC.

Hyspeed originated the concept of using an ultrasonic flow sensor in motorsport to limit fuel consumption, control peak power, and balance performance in 2009, initially pursuing its development in collaboration with Gill Sensors. The termination of that relationship in early 2013 left Hyspeed seeking other ways to achieve its objectives, eventually leading to formation of the new venture in late 2013.

The new consortium is headed by Managing Director Neville Meech, for 13 years Gill Sensors’ lead motorsport engineer. “Hyspeed approached me after I started Reventec with funding for a new sensor project. Being based at Mikina made it easy to bring them on board to handle manufacturing, and the final piece of the technical puzzle was put in place when we teamed up with Polyhedrus, who brought a cutting-edge approach to the electronics element.”

“We remain convinced that the ultrasonic time-of-flight principle is the best way of measuring fuel flow on board a race car, and with our second-generation sensor we’ve let the demands of the motorsport application have a greater influence over the design. As a result, the FlowSonic is a compact and robust unit with the minimum of materials and parts, and hence less to go wrong,” says Meech. The FlowSonic weighs in at around 250g, half the maximum permitted by the FIA, and the fuel and electrical connectors are also to FIA specification, making it a potential drop-in replacement for the sensor presently used in F1 and WEC.

If homologated by the FIA, Sentronics plans to offer the sensor for F1 and WEC use on very competitive terms and it is thought to be significantly lower cost that the rival product.

The FlowSonic will also be available to other series looking to implement fuel flow control, with capabilities tailored to their requirements and priced accordingly. “Our top-of-the-line sensor will meet the current FIA standard, while our mid-range product targets series like IndyCar, DTM, and Japanese Super GT. Our basic unit is designed for GTs, touring cars, and even one-make categories. We have also approached Calibra Technology, the FIA-homologated calibration service, about adjusting the level and cost of calibration to match the needs of individual championships,” says Meech.

“Reduced design and manufacturing costs, our three-tier product strategy, and accepting a longer-term return on our investment will allow us to expand into more motorsport markets,” says Daniel Partel, Chairman of SentronicsTM. “Neither V8 Supercars nor IMSA can justify F1-type prices for a fuel flow sensor, but they both face the challenge of balancing performance across a large number of engine suppliers. If we can deliver a performance balancing solution that promotes efficiency for less than it costs to decrease efficiency by adding air restrictors, ballast, or drag, then we will be able to serve markets down to F3 and GT3, even Formula 4.”

“We are confident that we have produced a next-generation ultrasonic fuel flow sensor that represents a major improvement in both performance and value. We are also committed to providing the kind of warranty, service, and support that motorsport customers expect. As racers ourselves, we know exactly what that involves,” says Partel. “Now that we are into the final development phase, which includes bench and track testing with OEMs, we will be presenting the FlowSonic to major sanctioning bodies and other stakeholders worldwide over the next few months with a view to adoption for 2015 and beyond.”

Read the full story of the design and development of the new fuel meter in the latest edition of Racecar Engineering.

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