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Powering innovation
World’s first major touring
car championship
goes hybrid
The solution Talk to us about your design

Innovating 60 years of tradition

Innovating 60 years of tradition

The annual British Touring Car Championship attracts the world's highest performance vehicles and drivers. In 2022, for the first time, a new hybrid engine developed by Cosworth Electronics will be added to the cars and used as a “tactical boost” by the drivers when rapid acceleration is required. The new hybrid engine features an innovative, ultra-lightweight, 48V lithium-ion-based battery pack and intelligent power management system designed by Delta Motorsport, who were subcontracted by Cosworth Electronics.

Customer challenge

Power delivery network challenges

Compact and lightweight

Compact and lightweight

Reliable

Reliable

Fast transient response

Fast transient response

Delivering 48V of compact power

Delivering 48V of compact power

The new 48V lithium-ion-based battery pack has an innovative intelligent power management and a high-power-density DC-DC converter and regulation system. The battery pack powers the inverter-motor combination and also accepts regenerated power from it, while the high-power-density converter solution powers all the car’s electrical circuits and devices. The level of power density and power management achieved by this architecture allows the alternator system to be removed, further improving weight, performance and reliability.

Why Vicor

Why Vicor

High-power density

High-power density

Modular

Modular

Reliable

Reliable

The solution

The DC-DC converter power system uses four Vicor DCM3623 isolated, regulated DC-DC converter ChiP power modules to deliver a regulated 13.8V output from the battery pack with current levels up to 85 amps. Due to their low profile and small footprint, they are mounted in direct thermal contact with the micro-bore cooling plates that extend between the battery cells. This allows a reduced footprint without sacrificing power. Vicor modular power components excelled during initial battery pack tests, with no de-rating necessary and no voltage sags. Delta also uses the Vicor PI3105, a small 60W isolated converter for an uninterruptable power supply (UPS), which supplies power to the battery pack electronics in order to maintain the safety systems when isolated from the vehicle power supply.

 

The power delivery network

Power Delivery Network for Delta Motorsports
DCM DC-DC converter

DCM3623T75H17C2T00 DC-DC converter

Input: 48V (36 – 75V)

Output: 15V (9.0 – 16.5V)

Power: Up to 320W

38.72 x 22.8 x 7.21mm

PI3105 DC-DC converter

PI3105-00-HVIZ DC-DC converter

Input: 48V (36 – 75V)

Output: 12V (9.6 – 13.2V)

Current: Up to 5A

16.5 x 22.0 x 6.31mm

Related products

Family of DCM DC-DC converter modules

DCM DC-DC converters

Input: 9 – 420V

Output: 3.3, 5, 12, 13.8, 15, 24, 28, 36, 48V

Power: Up to 1300W

Efficiency: Up to 96%

PI31xx DC-DC converters

PI31xx DC-DC converters

Input: 24, 28, 48V

Output: 3.3, 5, 12, 15, 18V

Power: Up to 60W

Efficiency: Up to 89%

Buck-boost regulators

ZVS buck-boost regulators

Input: 8 – 60V

Output: 10 – 54V

Power: Up to 200W continuous

Efficiency: Over 98%

ZVS buck regulators

ZVS buck regulators

Input: 8 – 60V

Output: 1 – 16V

Current: Up to 22A

Efficiency: Up to 98%

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