BTCC organiser TOCA has awarded a vital contract to Cosworth Electronics for the design, supply and servicing of the BTCC Hybrid System, which will be introduced for the 2022 British Touring Car Championship.



The BTCC was the first major touring car championship in the world to announce the move to hybrid (in August 2018) – and now the first to specify the exact timing, pathway and technical details of their hybrid power. Although it could have been introduced from 2021, it was decided to stay with the original 2022 introduction date in order to allow ample preparation.



The contract was awarded to Cosworth Electronics after a successful round of tenders that met with the very challenging specifications – particularly those regarding packaging, performance and low-cost – that TOCA had outlined. All major TOCA technical partners worked very closely together in order to define the specification, technical integration and performance parameters of the hybrid system.



The additional hybrid power will be used by each driver for either passing or defending and will introduce new competitive strategies and opportunities during each BTCC race.



Performance simulations undertaken by Cosworth show that the most significant gains will be achieved at the low engine RPM ranges; the hybrid power burst will bring the engine up into the turbo ‘window’ more quickly. This will provide drivers deploying the system the chance to pull alongside or gain ground on the opposition.

In a simulation using Silverstone Circuit, with two cars accelerating out of Copse Corner, the car with the hybrid power deployed should gain around 8m before the next braking zone.



After lap one, drivers will have control over the amount of their hybrid energy they use or regenerate – and when – during the course of each race. The driver will have a steering wheel mounted button to engage the hybrid once full traction has been achieved. The hybrid deactivates ona second button press, the use of brakes, on reaching the time or energy limit, a reduced throttle pressure or sudden acceleration/deceleration.

Prior to introduction, rigorous testing and simulations will refine the more exact nature of the driver-selectable hybrid power delivery (i.e. how many seconds per lap, when/how it can be used etc.) as well as configuring the varying amounts of regeneration and hybrid power that will be used to replace the current success ballast system.



The total weight of the hybrid system is well within the current operating window of all NGTC cars and their components; the total system weight will be some 10kg less than the maximum success ballast weight (75 kg) previously used.



A technical and performance overview of the system follows….



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 – there is no reduction to either its power output…. or exhaust note



Comprehensive annual lease scheme;



The BTCC – Cosworth Hybrid System annual lease fee of £20,500 (i.e. £2,050 per event) includes:



Complete electric hybrid motor

Complete bespoke battery pack

Hybrid cooling hardware

Hybrid power and control looms

Car installation sign-off and systems check

At-event Cosworth hybrid engineer support

Full annual service/maintenance/refurbishment

Systems and safety training

Warranty



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BTCC Technical Stability and Asset Protection;



Now in place is a 5-year extension of the current NGTC regulations – through to the end of 2026.



This provides our teams with both technical stability and crucial long-term asset protection of their investment.



By the end of 2026 the hugely successful BTCC-NGTC regulations will then have been in place for 15 years, with just two updates in that time; i.e. the upgraded RML components and Hybrid.