Transcript Continental PowerPoint Template, two colored, DIN A4

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
17/07/2015
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
2 © Zytek Group
17/07/2015
Introduction to Zytek Group
Engine management
EMS I
Neil Cheeseman
3 © Zytek Group
17/07/2015
EMSII
EMSIII
EMS IV
EMS V
VENOM
Introduction to Zytek Group
Hybrid and electric vehicles
Neil Cheeseman
4 © Zytek Group
17/07/2015
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
5 © Zytek Group
17/07/2015
Introduction to Zytek Group
Electric machines
Electric machine
3 phase
Inner rotor
Active rotor cooling
Fluid cooled stator
Embedded magnets
Neil Cheeseman
6 © Zytek Group
17/07/2015
Introduction to Zytek Group
Inverters
Inverter
3 phase IGBT
DC capacitor
Micro board
Gate drive board
Fluid cooling
DCDC converter?
Neil Cheeseman
7 © Zytek Group
17/07/2015
Introduction to Zytek Group
Batteries
Battery
Assembly of Li-ion cells
Battery management system
Cooling
Contactors, fuses etc
Neil Cheeseman
8 © Zytek Group
17/07/2015
Introduction to Zytek Group
System – motorsport application
Neil Cheeseman
9 © Zytek Group
17/07/2015
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
10 © Zytek Group 17/07/2015
Introduction to Zytek Group
Example vehicle development program – smart ed
Neil Cheeseman
11 © Zytek Group 17/07/2015
Introduction to Zytek Group
Example vehicle development program – smart ed
Neil Cheeseman
12 © Zytek Group 17/07/2015
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
13 © Zytek Group 17/07/2015
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
14 © Zytek Group 17/07/2015
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
15 © Zytek Group 17/07/2015
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
16 © Zytek Group 17/07/2015
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
17 © Zytek Group 17/07/2015