Torotrak – company profile
Torotrak is the world’s foremost
developer of full-toroidal variable
drive transmissions and the leading
exponent of the technology’s fast-
growing commercial application.
Products utilising the company’s technology
are already in volume manufacture and
Torotrak’s award-winning expertise and R&D
skills are in demand across a range of markets
including:
n Automotive – small, mainstream and
premium cars, SUVs and motorsport
n Commercial vehicles – bus, truck and
specialist vehicles
n Off-highway – tractors, construction
equipment and forklift trucks
n Outdoor power equipment – garden and
specialist equipment applications
Torotrak specialises in the design and
development of Continuously Variable
Transmissions (CVTs) and Infinitely Variable
Transmissions (IVTs) which are based around
the company’s full-toroidal traction drive
expertise. As a result of more than £60m of
investment, the company has an extensive
portfolio of patents and unrivalled know-how
relating to the development and application of
its toroidal technology.
1 Aston Way, Leyland, Lancashire PR26 7UX United Kingdom
Tel: +44 (0) 1772 900 900 Fax: +44 (0) 1772 900 929 Email: marketing@torotrak.com
www.torotrak.com
Full-toroidal traction drive technology
Torotrak – winner
of a Professional
MotorSport World
Expo Award
The company’s workforce of highly qualified
engineers develops main drive transmissions,
variable ratio transmissions for flywheel-
based mechanical hybrid systems and for
auxiliary drives.
Torotrak’s KERS CVT technology has led to
a joint MotorSport World Expo Award for the
KERS CVT
company, and also a Motorsport Industry
Association Business Excellence Award.
for flywheel-based
The company licenses its intellectual property,
patent portfolio and know-how to OEMs and
Tier 1 transmission manufacturers across a
mechanical hybrids
range of markets. Torotrak also supports its
customers with in-depth expertise, providing
engineering services on a consultancy basis
and participating in manufacturing through
joint ventures.
To take advantage of Torotrak’s engineering n High efficiency n High power-density n Compact n Lightweight n Low cost
excellence please call +44 (0) 1772 900 900,
alternatively email marketing@torotrak.com
or visit www.torotrak.com
KERS issue 1, December 2008
www.torotrak.com
KERS CVT Flywheel-based mechanical hybrid technology
Torotrak has developed its full-toroidal traction drive technology for

“
application as a variable drive in mechanical Kinetic Energy Recovery
Twice the efficiency in a package
Systems (KERS) which incorporate a CVT (Continuously Variable
that is half the size, half the
Transmission) and a compact, high-speed flywheel.
weight and a quarter of
A mechanical KERS recovers, stores and then wheels. The system can provide twice the Originally created for the cost of a typical
returns energy that is otherwise lost under efficiency of many electric hybrid systems due use in F1 and other
electric hybrid

”
deceleration. As the vehicle slows, energy is to the energy being recovered, stored and motorsport
recovered from the driveline through the CVT, reapplied in the same mechanical ‘state’. This applications, system.
stored in the flywheel and subsequently approach differs from a typical electric hybrid flywheel-based
released back into the driveline, system where energy is lost KERS technology
again through the CVT. in the six-stage has far wider
conversion process from potential. It is now
Torotrak’s KERS mechanical, through being developed
CVT is a key electrical to chemical for mainstream
element within the energy states, and back automotive and
overall flywheel- again. commercial vehicle
based system, being a applications, where it
simple, power-dense The flywheel-based promises to deliver significant
and cost-effective KERS system offers fuel economy and CO2 benefits in a
variable drive outstanding whole-life compact and low cost package. Image courtesy of Xtrac Limited
transmission. Image courtesy of Flybrid Systems LLP costs and environmental
benefits compared with A number of clients and partners are already
The flywheel-based KERS system is highly electric hybrids, where battery replacement working with Torotrak, using the company’s KERS having a complete system weight of
efficient, with more than 70% of the recovered costs and disposal issues have to be taken full-toroidal technology for KERS applications. ~20kg, utilising a lightweight, high-speed
energy being returned to the vehicle’s Input driven into consideration. One such partner, Flybrid Systems LLP, is flywheel and a KERS CVT designed and
Drive
recognised as being a leader in this area. manufactured under licence from Torotrak
Step-up Flybrid Systems has designed and developed by Xtrac Limited, a motorsport transmission
Typical KERS CVT configuration Drive a high performance 60kW / 400kJ mechanical specialist.

Flywheel
Full-toroidal traction Key benefits Fuel economy improvements
drive CVT
Engine n High system efficiency n 30% – Euro (NEDC) cycle
(premium passenger car)
n No battery requirement
Transmission n High power-density n 42% – US (FTP 75) cycle
Connection to (premium passenger car)
driveline n Compact and lightweight

Differential n Cost-effective n 34% – UK bus (MLTB) cycle

Clutch
n Environmentally friendly (11 tonne city bus)
Torotrak – company profile
Torotrak is the world’s foremost
developer of full-toroidal variable
drive transmissions and the leading
exponent of the technology’s fast-
growing commercial application.
Products utilising the company’s technology
are already in volume manufacture and
Torotrak’s award-winning expertise and R&D
skills are in demand across a range of markets
including:
n Automotive – small, mainstream and
premium cars, SUVs and motorsport
n Commercial vehicles – bus, truck and
specialist vehicles
n Off-highway – tractors, construction
equipment and forklift trucks
n Outdoor power equipment – garden and
specialist equipment applications
Torotrak specialises in the design and
development of Continuously Variable
Transmissions (CVTs) and Infinitely Variable
Transmissions (IVTs) which are based around
the company’s full-toroidal traction drive
expertise. As a result of more than £60m of
investment, the company has an extensive
portfolio of patents and unrivalled know-how
relating to the development and application of
its toroidal technology.
1 Aston Way, Leyland, Lancashire PR26 7UX United Kingdom
Tel: +44 (0) 1772 900 900 Fax: +44 (0) 1772 900 929 Email: marketing@torotrak.com
www.torotrak.com
Torotrak – winner
of a Professional
MotorSport World
Expo Award
The company’s workforce of highly qualified
engineers develops main drive transmissions,
variable ratio transmissions for flywheel-
based mechanical hybrid systems and for
auxiliary drives.
Torotrak’s KERS CVT technology has led to
a joint MotorSport World Expo Award for the
company, and also a Motorsport Industry
Association Business Excellence Award.
The company licenses its intellectual property,
patent portfolio and know-how to OEMs and
Tier 1 transmission manufacturers across a
range of markets. Torotrak also supports its
customers with in-depth expertise, providing
engineering services on a consultancy basis
and participating in manufacturing through
joint ventures.
To take advantage of Torotrak’s engineering
excellence please call +44 (0) 1772 900 900,
alternatively email marketing@torotrak.com
or visit www.torotrak.com
KERS issue 1, December 2008