1. Developing and delivering electric cars
Seminar: Design & Motion – Automotive and Advanced Engineering
Neil Cheeseman, Engineering Programme Manager
20th June 2013, Birmingham Made Me Design Expo
11/04/2017

2. Introduction to Zytek Group
Overview
A high technology engineering company formed 30 years ago to develop racing engine controllers.
Employs 190 people on 2 UK sites, plus an office in Detroit.
Zytek Group comprises 3 companies:-
Zytek Automotive
Roadcar activities
Electric & hybrid electric component & vehicle engineering
Engine management development, application & calibration
Zytek Engineering
Motorsport activities
Engine & chassis supply
Zytek Inc
System applications & support for US customers
Product development and durability testing activities
Zytek Group 50% investment by
Neil Cheeseman
11/04/2017

3. EMS I EMSII EMSIII EMS IV EMS V VENOM
Introduction to Zytek Group
Engine management
EMS I EMSII EMSIII EMS IV EMS V VENOM
Neil Cheeseman
11/04/2017

4. Hybrid and electric vehicles
Introduction to Zytek Group
Hybrid and electric vehicles
Neil Cheeseman
11/04/2017

5. What makes an electric drive system for a vehicle
Introduction to Zytek Group
What makes an electric drive system for a vehicle
Inverter
3 phase IGBT
MOSFET
Integrated, remote
Battery
Li-ion
NiMH
Others
Motor
Type (PMSM, ASM, SR, others)
Axial/radial/transverse flux
Speed (up to 20,000rpm)
Torque (up to 1000Nm+)
UK perceived as a leader in the development of automotive systems for EV/HEV
Neil Cheeseman
11/04/2017

6. Electric machines Electric machine 3 phase Inner rotor
Introduction to Zytek Group
Electric machines
Electric machine
3 phase
Inner rotor
Active rotor cooling
Fluid cooled stator
Embedded magnets
Neil Cheeseman
11/04/2017

7. Inverters Inverter 3 phase IGBT DC capacitor Micro board
Introduction to Zytek Group
Inverters
Inverter
3 phase IGBT
DC capacitor
Micro board
Gate drive board
Fluid cooling
DCDC converter?
Neil Cheeseman
11/04/2017

8. Batteries Battery Assembly of Li-ion cells Battery management system
Introduction to Zytek Group
Batteries
Battery
Assembly of Li-ion cells
Battery management system
Cooling
Contactors, fuses etc
Neil Cheeseman
11/04/2017

9. System – motorsport application
Introduction to Zytek Group
System – motorsport application
Neil Cheeseman
11/04/2017

10. Example vehicle development program – smart ed
Introduction to Zytek Group
Example vehicle development program – smart ed
Phase 0
Internally funded R&D, 5 demonstration vehicles
Phase 1
In 2007, Zytek were commissioned by Daimler UK to engineer and convert 100 smart for two vehicles for use in a 3 year UK field trial.
Phase 2
In 2009, Zytek were commissioned by Daimler AG to engineer & line build 2500 smart fortwo vehicles for EU/USA use as an unlimited field trial
Phase 3
High volume worldwide Daimler programme (including Japan), launch 2012
Neil Cheeseman
11/04/2017

11. Example vehicle development program – smart ed
Introduction to Zytek Group
Example vehicle development program – smart ed
Neil Cheeseman
11/04/2017

12. Example vehicle development program – smart ed
Introduction to Zytek Group
Example vehicle development program – smart ed
Neil Cheeseman
11/04/2017

13. Example vehicle development program – Gordon Murray T27
Introduction to Zytek Group
Example vehicle development program – Gordon Murray T27
In 2009, Zytek were awarded UK government supported funding to design and manufacture a brand new drivetrain for a small city electric vehicle
Motor
Inverter (with integrated DCDC converter, charger & PDU)
Gearbox
Battery
Project target was to produce highly efficient, lightweight electric powertrain for use in a lightweight vehicle
Following 18 months development, total electric powertrain system weight < 50% of that developed for use in previous electric vehicle programmes
Neil Cheeseman
11/04/2017

14. Example vehicle development program –T27 enhancements
Introduction to Zytek Group
Example vehicle development program –T27 enhancements
In order to enhance the application of the powertrain into higher temperature environments and/or higher duty cycles, a water cooled version has been developed.
Motor 12.8kg
Inverter 7.5kg
Greater degrees of installation flexibility, system does not require complex airflow management.
Cost reduction due to adoption of production inverter
Powertrain suitable for use in lightweight, urban vehicles < 1000kg, eg quadricycles
Neil Cheeseman
11/04/2017

15. Example vehicle development program – power electronics
Introduction to Zytek Group
Example vehicle development program – power electronics
Prototype vehicle to demonstrate best in class hybrid technology and vehicle efficiency whilst maintaining performance
CO2 reduction >70%
Range 680 miles
0-100kph < 6.5 secs
Zytek’s role was the development of fully custom power electronics, used to boost performance of existing HEV components
69kW motor
Total powertrain output 334PS
Engineered to fit in existing vehicle package space under boot floor
Neil Cheeseman
11/04/2017

16. Example vehicle development program – KERS
Introduction to Zytek Group
Example vehicle development program – KERS
2007
Zytek contracted to develop KERS system for leading Formula 1 team
2008
Intensive design, manufacture and test of high innovative, lightweight & powerful KERS systems
2009
Full season of use in Formula 1, zero failures, 1st win for hybrid F1 car, 2 wins in total (more than any other system). 100% reliability over 18 races.
2010
Design, manufacture & test of cost capped version for use in other motorsport series
2011
Use of Zytek KERS in 3 series, 2 of which take place in Japan
2012
Partnership announced with Honda for motorsport ERS systems
Zytek ERS upgraded to 50kW
2013
Ongoing ERS development
Neil Cheeseman
11/04/2017

17. Introduction to Zytek Group
Conclusions
Zytek have 20+ years experience in the engineering and development of EV & HEV
Skills span the whole project lifecycle, from initial specification through to product manufacture
Zytek can offer product & associated engineering for small to medium vehicle fleets, roadcar and motorsport applications
Strong European and US presence enables volumes to be maximised via access to all global OEMs
Neil Cheeseman
11/04/2017