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Cosworth to work with Speedworks in BTCC hybrid development

Cosworth has announced that leading British Touring Car Championship team Speedworks Motorsport will be its official testing partner during development of the new-for-2022 hybrid system.

Cheshire-based Speedworks was chosen after a ‘competitive tender process’ and the team, which runs Tom Ingram in a Toyota Corolla, will work closely with Cosworth over the coming months.

Cosworth had last July been announced as the hybrid partner for the BTCC, with deployment of the new system being developed in time for the 2022 season.

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Active development has taken place since August 2019, with the system now in its final design phase. Cosworth will now carry out bench testing of each element before running the system on a custom-designed rig before it hits the track for further testing later this year.

The first on-track appearance is expected to be at the Snetterton tyre test in July, although this date remains fluid due to the ongoing COVID-19 coronavirus situation.

“Speedworks demonstrated a clear understanding for our requirements on this project and we are delighted to be working with them,” said Cosworth Electronics Motorsport Director Rob Kirk.

“We are delivering an innovative hybrid solution for the BTCC, which will herald a new and exciting era for the series.

“In Speedworks, we have a partner with proven capabilities and credentials to help us accelerate the development of our hybrid offering.

“Testing will give us the real-time data and feedback that we need to validate the system and to understand precisely how it will be deployed in racing.

“Although we are currently experiencing uncertain times with Coronavirus, we are still working towards our initial plan and are firmly on track to prepare the system for testing.”

Speedworks will carry out initial integration and validation of the complete hybrid system, with tests carried out to ascertain the deployment and regeneration strategies along with fine-tuning, reliability and endurance.

Upon its deployment in 2022, the system will allow drivers to boost to either overtake or defend their position, after the first lap of the race.

The exact nature of the boost system will be determined during the development process.

“We have been a huge supporter of the BTCC’s planned hybrid era,” said Speedworks Team Principal Christian Dick. “I am excited and proud that we have secured the development car contract.

“To have been selected for this by Cosworth, a company with a rich heritage in this industry, is a great testament to the engineering expertise that we have here at Speedworks.

“It is obviously a very tough time for everyone right now and the global pandemic will undoubtedly throw us some curveballs and change the way we execute this project, but ultimately it’s great news that there is still progress being made behind the scenes.”

2022 BTCC – Cosworth hybrid system: Technical Overview

‘P2 off-axis’ hybrid system

  • 60v high power – low volt system
  • Electric motor integrates within modified current BTCC Xtrac gearbox
  • Separate custom hybrid motor cooling unit
  • Utilising the best power-to-weight hybrid motor currently available
  • Compact size and weight: 7.5 kg
  • Little disruption to current NGTC specification
  • Calibrated and driver-adjustable regeneration

Bespoke Delta Motorsport 60v battery pack

  • Battery weight: 20 kg – housed within IP67 rated isolated composite safety cell
  • Incorporated battery coolant system
  • Quick release connectors
  • Easy removal and replacement – less than 10 minutes
  • Charging via 240v wall socket – one-hour full charge time
  • Replaces current ballast box

Modifications required to current car

  • Updated gearbox case (not all internals) to incorporate electric motor
  • Additional electronic connections
  • Changes to some intercooler locations and pipes
  • Upgraded Cosworth ‘Antares’ electronics suite
  • Total fully installed system weight approx. 64 kg – including electric motor, battery, controllers, looms, pumps, pipes, cables, fluids etc.

Hybrid Performance

  • Push to pass or defend – power gain of approx. 40+ bhp
  • Maximum of 15 seconds per lap – available after first lap
  • No limit on number of uses per lap – can only be used when full traction
  • Alternative calibrations for wet track conditions
  • Cars will drive the length of the pit lane on full electric power
  • Configurable percentages of hybrid output/regeneration rate – this will replace the use of success ballast weights
  • On-car LED light system to display hybrid deployment
  • Hybrid power is additional to the current BTCC 2 litre turbo engine power, with no reduction to the exhaust note.
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