Slide 1

Developing and delivering electric cars Neil Cheeseman, Engineering Programme Manager 20 th June 2013, Birmingham Made Me Design Expo 13/04/2015 Seminar: Design & Motion Automotive and Advanced Engineering Slide 2 2 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Overview Slide 3 3 Zytek Group 13/04/2015 Introduction to Zytek Group Neil Cheeseman Engine management EMS I EMSII EMSIII EMS IV EMS V VENOM Slide 4 4 Zytek Group 13/04/2015 Introduction to Zytek Group Neil Cheeseman Hybrid and electric vehicles Slide 5 5 Zytek Group 13/04/2015 Introduction to Zytek Group 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 What makes an electric drive system for a vehicle Slide 6 6 Zytek Group 13/04/2015 Introduction to Zytek Group Electric machine 3 phase Inner rotor Active rotor cooling Fluid cooled stator Embedded magnets Neil Cheeseman Electric machines Slide 7 7 Zytek Group 13/04/2015 Introduction to Zytek Group Inverter 3 phase IGBT DC capacitor Micro board Gate drive board Fluid cooling DCDC converter? Neil Cheeseman Inverters Slide 8 8 Zytek Group 13/04/2015 Introduction to Zytek Group Battery Assembly of Li-ion cells Battery management system Cooling Contactors, fuses etc Neil Cheeseman Batteries Slide 9 9 Zytek Group 13/04/2015 Introduction to Zytek Group Neil Cheeseman System motorsport application Slide 10 10 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Example vehicle development program smart ed Slide 11 11 Zytek Group 13/04/2015 Introduction to Zytek Group Neil Cheeseman Example vehicle development program smart ed Slide 12 12 Zytek Group 13/04/2015 Introduction to Zytek Group Neil Cheeseman Example vehicle development program smart ed Slide 13 13 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Example vehicle development program Gordon Murray T27 Slide 14 14 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Example vehicle development program T27 enhancements Slide 15 15 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Zyteks 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 Example vehicle development program power electronics Slide 16 16 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Example vehicle development program KERS Slide 17 17 Zytek Group 13/04/2015 Introduction to Zytek Group 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 Conclusions