Formula 1 stands as the pinnacle of motorsport, a thrilling arena where cutting-edge technology and exceptional driver prowess collide. For years, the sport has navigated the delicate balance between these two critical elements. There was a time when advanced systems risked overshadowing driver skill, but regulations have evolved to ensure a captivating spectacle that truly tests both machine and human.
To address escalating costs for teams and maintain a level playing field, the Fédération Internationale de l’Automobile (FIA), the governing body of Formula 1, initiated a tender in 2006 for a standardized electronics package. This move aimed to make the sport more sustainable and technically balanced. The result? Every Formula 1 car, along with IndyCars and NASCAR vehicles in the US, relies on engine control units (ECUs) designed and manufactured by McLaren Applied Technologies, based in Surrey, UK. Interestingly, McLaren’s expertise extends beyond motorsport, with their electronics also finding applications in trains and aircraft.
McLaren, a name synonymous with Formula 1 racing, secured this prestigious contract due to their long-standing experience in the field. Since 1993, they have been a trusted supplier of complete control systems to F1 teams. McLaren was also a pioneer in adopting model-based software development at the dawn of the 21st century, a forward-thinking approach that proved crucial to the success and reliability of the standard ECU system, predating its wider adoption in the automotive industry.
The electronic control and data acquisition systems within a Formula 1 car are incredibly intricate. They must manage high-revving engines, seamless-shift gearboxes, and sophisticated drive-by-wire controls, all while operating in the most demanding conditions imaginable. The challenge was amplified by the need for a single ECU hardware and software platform to be compatible with different engine and gearbox configurations across various teams. Furthermore, the system had to seamlessly integrate with diverse telemetry setups for car-to-garage communication and support varied data analysis systems used by different teams in their garages.
According to a McLaren engineer, each Formula 1 ECU requires approximately 24 hours of meticulous manual assembly. This highlights the complexity of packing sophisticated electronics into the compact and lightweight form factor demanded in F1. McLaren successfully won the tender for the ECU supply for the 2013-2015 seasons and beyond. This system was designed to initially support the V8 engines of 2013 and then, through software adaptation, transition to the new generation of Gasoline Direct Injection (GDI) turbocharged parallel hybrid power units introduced in 2014.
Telemetry is another critical application of electronics in Formula 1. In fact, the electronics on an F1 car are primarily dedicated to control and telemetry – with very few exceptions. A staggering number of sensors, typically between 120 and 130, are embedded within a Formula 1 car. While around a quarter of these are dedicated to control functions, the vast majority are for telemetry, constantly monitoring the car’s performance, position, temperatures, and movements. These specialized sensors are developed and manufactured in-house at McLaren’s Woking facility, alongside the ECUs. They are not only used in McLaren’s own racing endeavors but also supplied to other motorsport series. During a Formula 1 race, a single car generates around 1.5 Gigabytes of data from these sensors. This wealth of information is logged onboard and simultaneously transmitted back to the team’s trackside headquarters via microwave telemetry, enabling real-time analysis and strategic decision-making.
