Cosworth_Brochure_2008.pdf

reliability

innovation

performance

excellence

Company Overview

Cosworth leverages its successful motor

sport pedigree, performance technology

expertise and globally recognised brand

to provide high quality engineered

solutions for a growing customer base

across diverse industries.

The company’s head ofﬁ ce in

Northampton is home to leading edge

engineering, world class manufacturing

and comprehensive test facilities. Our

business is geared to deliver smart

solutions and exceptional service to

customers around the world.

Cosworth UK - Northampton, England

Over the years we have developed in-depth knowledge of engines, engine components

and engine management systems. This has been successfully used to supply engines

to some of the most successful Formula One teams and vehicle manufacturers. Our

unprecedented success in the performance market has fuelled customer demand from

diverse market sectors. In addition to the traditional markets, Cosworth is engaged in

designing and developing, engines and components for marine, rail, aerospace and

power generation applications.

Cosworth USA - Torrance, California

In North America we support our customer base from Cosworth’s sister facility in Torrance,

California.

A rigorous and comprehensive product quality assurance policy is implemented across

our business. Quality engineering is embedded in processes, procedures and team ethic;

we operate under the recognised quality management system AS9100 and environmental

management system ISO14001.

Our dedicated workforce focus on providing high quality products and solutions to meet

ever demanding customer needs.

“smart solutions and

exceptional service”

AS/EN 9100

FM 22201

ISO 14001

EMS 87074

Our broad expertise includes:

•

Software

•

Hardware

•

Electronic Systems

•

Electrical Engineering

•

Material Science

•

Mechanical Engineering

•

Manufacturing Process

Development

Systems Integration

•

Engineering

Cosworth provides cost effective, project managed, intelligent solutions for an array of

engineering assignments. Our world renowned success in top ﬂ ight racing programmes

(including Formula One, World Rally Championship, Champ Car and IRL) together with

our proven engineering capability in marine, road car and defence applications makes

Cosworth a natural choice for customers with challenging requirements.

All of our services and solutions can be customised to meet client needs and delivered

through a single point of contact, enhancing customer relationship and return on

investment.

Our Design and Application Engineers are among the most experienced and highly

skilled in the industry, utilising advanced techniques in areas such as Computer Aided

Design and Finite Element Analysis. The in-house metallurgy lab and state-of-the-art

test facilities complement our product development.

With the expertise and resources of Cosworth supporting customer investment in new

product or service development the possibilities are endless. We can improve the

performance of existing products or create innovative new solutions giving our customers

the vital competitive advantage to increase their market value and share.

Our customer focused products and services enable our clients to competitively meet the

demands of the marketplace, today and tomorrow.

“giving our customers

a competitive advantage”

Aerospace

Marine

Automotive

TOOLS

CAD/CAM

NX4, Vericut

FEA

Patran, Abaqus, Nastran

CFD

Star-CD

GT Power

Dynamic Analysis

Multi-Body Dynamics Software

& Proprietary Applications

ENGINEERING SERVICES

Design

Analysis

Simulation

Testing & Validation

Manufacturing

Product Lifecycle Management

Software Development

Electronics

Material Development

Power

Generation

Aftermarket

Rail

Racing

Medical

Design and Development

Cosworth has unrivalled experience in both normally aspirated and forced induction high

performance engine design and development. Projects range from modiﬁ ed production

engines for niche markets through to the complete design, manufacture and development

of Le Mans endurance engines.

Whilst most recognised Cosworth products are clean sheet designs, our design and

development services regularly optimise the power, durability, efﬁ ciency and weight of

clients’ existing engines, subassemblies and individual engine components, as well as

other mechanical systems. The level of analysis applied is appropriate to the scale of each

project and is complimented by the detailed knowledge of our experienced engineers.

Finite Element Analysis

Primarily used for structural analysis

of components using Patran or CAE

software with Abaqus and Nastran

solvers. FEA allows an engineer to

understand the behaviour of a component

under load, as well as the analysis of heat

transfer, for large and small components

including cylinder heads, crank cases

and pistons. Combining FEA with CFD

or 1D simulation enables very detailed

analysis to be executed.

Computer Aided Engineering

Software based analysis is a key element of Cosworth’s core skills. A variety of

computational tools and techniques are used to allow Cosworth’s engineers to solve

engineering problems for customers. Components are analysed and evaluated allowing

‘virtual’ optimisation of new designs prior to manufacturing or testing, thus reducing lead

times. Cosworth continually develops CAE methods to produce models that accurately

represent real components in a range of applications.

Programme Management

Cosworth has the expertise and infrastructure to successfully manage both large and

small scale engineering projects. Projects range from an 80cc single cylinder heavy fuel

engine for the UAV market through to complete engine development programmes for

major automotive manufacturers.

As part of our programme management work we have developed software tools for

assigning serial numbers, tracking component life and managing engine speciﬁ cations.

1D Engine Simulation

Computational Fluid Dynamics

Cosworth is a world leader in the

creation, veriﬁ cation and development

of engine simulation models to predict

engine performance (including power

output, efﬁ ciency, cylinder pressures and

heat transfer coefﬁ cients). The resulting

output also delivers accurate predictions

on ﬂ ow, pressure and wave tuning

effects in engine intake and exhaust

systems. Our experience correlating

and conﬁ rming models allows us to

conﬁ dently perform ‘virtual’ tests in order

to reduce costly and time consuming

dynamometer tests.

State of the art computers running

STAR-CD software perform the millions

of calculations required to simulate the

interaction of ﬂ uids through complex

geometries. This allows a diverse range

of ﬂ uid ﬂ ow problems to be analysed.

Various types of ﬂ uids can be simulated

including air, coolants, fuels and oils in

a variety of situations within an engine.

CFD can be coupled with 1D engine

simulation data to allow full simulation

and optimisation of an engine intake and

exhaust system.

Dynamic Analysis

The vibration of crankshafts, camshafts

and various other valvetrain components

can all be analysed using Multi-Body

Dymamics software and proprietary

applications. The results give a thorough

understanding of the dynamic behaviour

of systems within an engine. The vital

data generated aids the elimination of

torsional vibration problems and assists

in the development of camshaft proﬁ les

by predicting the dynamic behaviour of

the valves.

Electronics

Cosworth’s considerable electronics expertise gathered over many years has seen

us manufacture many bespoke electrical products in-house. Our products are used in

numerous applications and vehicles from high performance road cars to World Rally

and Formula One. We are able to offer a range of high quality prototype, small batch

assembly, rework and test services, including:

•

Wiring looms and loom cassettes

In addition we offer on-engine ignition

system performance measurement and

fault diagnosis as well as vibration and

high temperature environmental testing.

•

Electromechanical sensors and actuators

•

Semi-rigid and ﬂ exible PCBs using through hole, surface mount and BGA

components

Engine Testing

Initial engine design is only part of

the journey to the ﬁ nished product.

Cosworth’s engine test facility

houses ten fully instrumented dyno

cells including two state of the art

regenerative dynamometers rated

to 1,000kW and a maximum rated

speed of 24,000rpm. We are

able to measure and analyse an

array of engine performance and

mechanical behaviour and can carry

out performance, calibration and

endurance testing on a wide range of

engines.

We can test many engine systems

in isolation using bespoke test rigs

including valvetrain, oil, water, fuel

and ignition systems.

We also offer a vibration measurement

service which specialises in

the measurement, analysis and

management of engine, vehicle and

dyno torsional vibration.

Almost any type of naturally aspirated or forced induction engine can be tested for road,

race and marine applications running on diesel, petrol or alcohol based fuels. To reduce

the need for extensive ﬁ eld testing the air presented to the engine can be altered for

varying levels of temperature and humidity to simulate different operating conditions.

Engines can be put through their paces under any type of endurance, calibration and

performance testing.

A wide range of data can be captured and analysed, providing the complete service

necessary to optimise performance and meet design targets.

The cells are highly conﬁ gurable and our capability extends to testing complete engine

and transmission powertrains as required.

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