Gibson Technology

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Zytek Group Ltd is a British automotive and motorsport company founded in 1981 and based in Fradley and Repton, United Kingdom. Zytek Group is currently divided into two divisions, Zytek Automotive Ltd based at Fradley, Staffordshire, and Zytek Engineering Ltd based at Repton, Derbyshire.

Zytek Automotive

http://www.zytekautomotive.co.uk

Zytek Automotive is a specialist powertrain and vehicle engineering enterprise dedicated to delivering exceptional value to its clients with innovative engineering solutions. From its genesis of engine-management control systems, Zytek’s focus has developed to cover the Electric and Hybrid-vehicle sector where it has demonstrable experience and a proven track record in solving complex engineering challenges for production vehicle projects. Zytek’s success can be attributed to its highly skilled and committed workforce, its comprehensive in-house test & development facilities, and its electronics & electric traction-motor production facilities – a feature unique to Zytek amongst automotive design consultancies.

Zytek is one of the very best automotive engineering consultancies across the world but, crucially, it differentiates itself from the others in several key areas:

• By delivering comprehensive and exceptional resolutions to engineering challenges, and not just “meeting the customer’s specification”.

• By consideration of both the whole life-cycle and the context in which the engineering is to be carried out as this often reveals other associated opportunities for adding value for the client.

• By working sensitively and harmoniously with the client’s own departments and workforce to ensure the optimum integration of Zytek’s work into the product and client organisation.

• By keeping project teams small and flexible so that overheads are minimised, communications are optimised, and maximum focus is retained on the client’s project targets.

Through the application of these principles, Zytek has built up an enviable reputation for the quality and value of its engineering within its OEM and Tier-1 client base across the world, and this customer satisfaction is evidenced by the large amount of repeat business that Zytek enjoys.

Zytek’s outstanding engineering capability is primarily attributable to its engineering staff. They are a group of experienced, highly qualified, and industry-respected individuals who are well integrated into functional and specialist disciplines. This ensures good peer review of work whilst combining stimulating environment for the engineers to create new ideas and solve the challenges of bringing tomorrow’s low-carbon, high-performance vehicles to market.

Electric Engines

Zytek are answering the environmental challenges associated with the automotive industry by offering full turnkey solutions to design, develop and integrate electric engines into a range of cars and commercial vehicles, and offering low volume production facilities to complete the process.

The current family of electric engines ranges up to 70kW, with the next generation of drivetrains being developed to meet the needs of the advancing electric vehicle market.

Zytek has designed and integrated electric drive systems for a wide range of European and US vehicle manufacturers and is currently building high performance electric drivetrains up to 70kW and 300Nm for cars, buses and light commercial vehicles. The UK facility can accommodate up to 6,000 E-Drive integrations a year in batches as low as 100, providing vehicle manufacturers and large fleets with a highly flexible specialist production resource for their low carbon programmes. Zytek can also manufacture up to around 18,000 high efficiency electric traction motors each year, with the option of integrated control systems to further improve overall system weight and packaging.

Along with its current portfolio of electric drivetrains, Zytek can offer customers bespoke, custom-designed solutions to suit their needs.

Smart Electric Drive

Zytek converted an initial 100 smart fortwos to fully electric versions at their production facilities in Fradley, Staffordshire. These vehicles took part in a market trial by selected British customers as lease vehicles from 2007 to 2009.

The drivetrain installed in the smart electric drive utilizes state of the art 55kW brushless DC motor technology that is designed and manufactured in house by Zytek. The award winning innovative drivetrain design integrates the electric motor, power and control electronics, into one compact assembly with only three connections: water, High voltage(300V) and low voltage (12v).

The success of the UK trials has led to the next generation smart 451 electric drive rolling off the production line from October 2009 at a dedicated Zytek facility at the smart fortwo assembly plant in Hambach, France.

Modec Delivery Vehicle

The 70kW integrated drivetrain installed in the Modec electric vehicle t is designed and manufactured in house by Zytek.

The 70kW electric engine drives the 5.5 tonne suburban delivery vehicle, which has been developed as an alternative to the transit van for urban areas. Quiet and pollution free, Modec vans can carry two tonnes up to 100 miles at 50mph, with zero emissions – all from a single charge.

The Production of the E drive is completed at Zytek’s production facility in Fradley, Staffordshire.

Vito E Taxi

Zytek's 70kW flexible drivetrain is integrated in the E Vito Taxi., incorporating integrated motor/gearbox and remote inverter. The prototype was developed by a consortium of automotive engineering and technology specialists, part funded by a grant from regional development agency Advantage West Midlands.

The vehicle is capable of up to 75 mph, powered by the innovative 70kW Zytek electric drive system, driving the front wheels through a custom designed Vocis/Graziano transmission. The vehicle not only generates zero tailpipe emissions but also very low noise pollution.

Gordon Murray Design T.27

Gordon Murray Design and Zytek Automotive are developing an all-electric three-seater city car, the T.27, made possible through a £4.5m investment from the government-backed Technology Strategy Board. With a total cost of £9m, the research and development project will allow the consortium to develop up to four prototypes by April 2011.

The T.27 has been designed to be the world’s most efficient electric car due to its low weight and ‘clean sheet of paper design’. This ambitious target cannot be achieved by applying a conventional stamped steel construction design, nor with a drivetrain using existing gearboxes, motors or batteries. Instead, an entirely fresh approach is proposed; accepting no compromise in safety, performance, range, space, weight, rolling resistance and ride quality. By applying iStream® methodology, a new manufacturing process developed by Gordon Murray Design, to the T.27 and fully integrating it with a custom-designed lightweight, highly efficient drivetrain from Zytek, every aspect of the vehicle can be optimised.

As powertrain partner for the project, Zytek Automotive are developing a brand new, innovative, lightweight and fully integrated 25kW electric motor, control system and battery to ensure that maximum efficiency is achieved. The turn-key drivetrain package is extremely compact and in air-cooled configuration is up to 45% lighter than today’s production EV powertrains.

At the heart of the powertrain is Zytek’s new, high efficiency permanent magnet synchronous motor. The high maximum machine speed of 14,000 rpm has enabled generated torque and hence machine size to be reduced considerably, bringing further reductions in cost and weight. When used in conjunction with the Zytek Electric Vehicle Control Module, torque delivery is scheduled in a way that further improves overall efficiency, whilst also eliminating the harshness that can occur during changes in torque demand.

The 16 month project has several aims; to position the consortium positively to further explore the possibility of scaling up and building a manufacturing facility in the UK, with the ultimate goal of producing the T.27 in this country; keeping the new technology and IPR within the UK and making this affordable, fun and environmentally friendly car widely available on the open market. The project outcomes will help justify the required follow-on commercial investment to take the vehicle into manufacture by providing a body of evidence that the concept is a viable design for production.

KERS

Zytek’s extensive experience in the design, development and integration of road going pure electric and hybrid systems provided the platform for the high performance Zytek F1 KERS system in the 2009 season. Derivatives of this highly successful product are now being supplied to several other high profile formulae.

Zytek Engineering

www.zytekmotorsport.co.uk

Zytek Motorsport is the brand name used for the Zytek Groups motorsport product range and applications.

In 1987, Zytek bought the British Alan Smith Racing outfit in order to expand its motorsports involvement. The team initially supported the Jordan Grand Prix team in Formula 3000 before the team eventually chose to concentrate on engine development. Zytek would return to running a motorsports team in 2004 when the company entered the Le Mans Endurance Series with their first sports car, the Zytek 04S, which was able to finish second in the team championship in 2005 due to two overall victories. Zytek Engineering continues to campaign in the Le Mans Series as well as in the American Le Mans Series and 24 Hours of Le Mans.

Engine Technology

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Expanding from their development of electronic management systems, Zytek created an engine development division in the early 1990s. From experienced gained in running a Formula 3000 team, Zytek was chosen by Judd to further develop and maintain the KV V8s they had initially built for use in the series. This program would eventually lead to Zytek being chosen as the sole engine supplier for the series from 1996 until 2004, although the engines would continue to be used in later Formula 3000-based series. Zytek built 90 units of the KVF3000 V8.

In late 2000, Panoz Motor Sports and Élan Motorsport Technologies worked together on the development of the new V8 motor for the Panoz LMP07 Le Mans Prototype. Although this project did not last long due to difficulties with the LMP07, Zytek continued developing a V8 prototype engine of their own for the DBA4 03S prototype. This engine later formed the basis for the eventual Zytek 04S prototype. The engine, based on the Formula 3000 units, was developed into 4.5-Litre 4.0-Litre and 3.4-Litre variants. Although these engines were used exclusively in the 04S, some engines were also sold to customers.

A further development of these engines was announced in 2005, when Zytek was once again chosen as the sole engine supplier for a new series, A1 Grand Prix. Although larger than the initial F3000 engines, the A1GP engines are based on the same architecture. A boost option was also included, allowing for 50 extra horsepower for a small duration of time. In 2008 Ferrari replaced Zytek as the sole engine supplier in A1GP. Zytek continued to power Euroseries3000 until 2009 when it was replaced by AutoGP, which also utilises Zytek power in the form of the ZA348 3.4-Litre engine.

Vehicle Technology

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09SB as campaigned by customer team Quifel-ASM

In 2002, Zytek bought some of the remains of the defunct Reynard Motorsport from International Racing Management (IRM). These assets included the rights to the Reynard 02S Le Mans Prototype, of which only one had been completed since the company's demise. Zytek already supplied an engine to the existing chassis, and would therefore built further copies under the name Zytek 04S, offering both the chassis and engine as a complete package.

Due to changes in the prototype regulations in 2006, Zytek upgraded one of their existing 04S chassis while building a third all-new car, named the 06S. Further regulation changes in 2007 required the team to build an entirely new car, the Zytek-07s, which campaigned in both the LMP1 and LMP2 classes of the Le Mans Series.

Zytek's 09S proved an immediate success in 2009, taking the LMP2 Le Mans Series Team Championship with Quifel-ASM and the Driver's Championship with Miguel Amaral and Olivier Pla.

Hybrid Technology

Q10

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In 2009 Zytek Engineering became the first manufacturer to score a podium with a hybrid LMP. The car, run by Corsa Motorsports, finished on the podium on its debut at Lime Rock.

The Zytek Q10 Hybrid is a non-invasive parallel hybrid system, consisting of a motor-generator, battery and inverter. Its purpose is to recover energy normally wasted during deceleration and subsequently use this energy to assist the internal combustion engine during acceleration.

Whilst assisting, the motor-generator can be used to provide supplementary power or to reduce the power required from the internal combustion engine, in order to save fuel. It is important to note that the hybrid system itself doesn’t necessarily save fuel, it is by reducing the power output of the internal combustion engine that fuel is saved. The hybrid system can then be used to correct the deficit, facilitating the same power output whilst using less fuel.

ZPH

ZPH will use the lessons learnt during the Q10 Sportscar project but will use bespoke motor racing parts in contrast to the heavily road-based Q10 system. This will enable the new generation hybrid to be considerably more efficient, with double the power density of the Q10 system.

Once the system has been developed and proven it will then be offered as a “bolt-on” system which can be fitted to a wide variety of motorsport platforms. The system will be ideally suited for one-make formulas, GT and Touring Car championships, or any other series or manufacturer looking to utilise hybrid power in a cost-effective manner. ZPH will weigh c.50kg and produce c.40kW of power.

See also

• Gordon Murray

References

External links

• Zytek Engineering Limited
• Zytek Group Limited
• Zytek Automotive Limited