Zytek
Encyclopedia
Zytek Group Ltd is an automotive and motorsport company founded in 1981 and based in Fradley and Repton, United Kingdom
United Kingdom
The United Kingdom of Great Britain and Northern IrelandIn the United Kingdom and Dependencies, other languages have been officially recognised as legitimate autochthonous languages under the European Charter for Regional or Minority Languages...

. Zytek Group has two main division: Zytek Automotive, which is based at Fradley, Staffordshire; and Zytek Engineering, which is based at Repton, Derbyshire.

Zytek Automotive

Zytek Automotive is a specialist powertrain and vehicle engineering enterprise. From its genesis of engine-management control systems, Zytek’s focus has developed to cover the Electric and Hybrid-vehicle sector.

Electric Motors

Zytek offer full turnkey
Turnkey
A turn-key or a turn-key project is a type of project that is constructed by a developer and sold or turned over to a buyer in a ready-to-use condition.-Common usage:...

 solutions to design, develop and integrate electric motors into a range of cars and commercial vehicles, and offering low volume production facilities to complete the process.

The current family of electric MOTORS ranges up to 70 kW, 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 70 kW 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.

Smart Electric Drive

Zytek converted an initial 100 smart fortwo
Smart Fortwo
The Smart Fortwo is a rear-engined two-seater city car manufactured by Smart GmbH, introduced at the 1998 Paris Motor Show as the Smart City Coupé, and currently in its second generation...

s 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 55 kW 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 70 kW integrated drivetrain installed in the Modec
Modec
Modec was a Coventry, UK electric vehicle manufacturer, specialising in Commercial vehicles in the N2 category. It unveiled its first model in April 2006 and announced its intention to commence series production in March 2007, with the first production vehicles destined for Tesco...

 electric vehicle t is designed and manufactured in house by Zytek.

The 70 kW electric motor 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 50 mph, 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 70 kW 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
Advantage West Midlands
-Advantage West Midlands – Regional Development Agency:Advantage West Midlands was established in 1999 as one of nine Regional Development Agencies in England. RDAs were created by the UK Government to drive sustainable economic development and social and physical regeneration through a...

.

The vehicle is capable of up to 75 mph, powered by the innovative 70 kW Zytek electric drive system, driving the front wheels through a custom designed Vocis/Graziano
Graziano Trasmissioni
Graziano Trasmissioni is an Italian company manufacturing gearboxes, drivelines and their components.It makes the seven-speed, dual-clutch gearbox used in the McLaren MP4-12C-History:...

 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 developed an all-electric three-seater city car
City car
A city car is a small car intended for use primarily in an urban area.City cars are sold worldwide and most automotive industry manufacturers have one or two in their line-up. In North-America city cars are often referred to simply as "subcompacts" alongside the superminis. These kind of cars...

, the T.27, made possible through a million ( in June 2010) investment from the government-backed Technology Strategy Board
Technology Strategy Board
The Technology Strategy Board is a UK public body operating at arm's length from the Government reporting to the Department for Business, Innovation and Skills .- History :...

. With a total cost of £9m ( in June 2010), the research and development project allowed the consortium to develop a prototype that was unveiled at the Royal Automobile Club
Royal Automobile Club
The Royal Automobile Club is a private club and is not to be confused with RAC plc, a motorists' organisation, which it formerly owned.It has two club houses, one in London at 89-91 Pall Mall, and the other in the countryside at Woodcote Park, Surrey, next to the City of London Freemen's School...

 in June 2011. The T.27 road debut is scheduled for November 2011 at the RAC Future Car Challenge. Gordon Murray Design is negotiating with three possible manufacturers for production of the T.27.

The T.27 was designed to be the world’s most efficient electric car due to its low weight and ‘clean sheet of paper design’. According to their developers, the T.27 features lower energy consumption per mile that other electric cars: uses 29% less energy per km than the Smart ED
Smart ED
The Smart fortwo electric drive is a battery electric vehicle version of the Smart Fortwo micro car. This electric car was formerly known as Smart fortwo EV...

; 36% less energy per km than the Mitsubishi i MiEV
Mitsubishi i MiEV
The Mitsubishi i-MiEV is a five-door hatchback electric car produced by Mitsubishi Motors, and is the electric version of the Mitsubishi i. According to the manufacturer, the i-MiEV all-electric range is on the Japanese test cycle...

; and 86% less energy per km than the Mini E
Mini E
The Mini E is a demonstration electric car developed by BMW as a conversion of its Mini Cooper car. The MINI E was developed for field trials and deployed in several countries, including the United States, Germany, UK, France, Japan and China...

. The efficient energy used was achieved through an entirely fresh approach, 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 was optimised.

Zytek Automotive developed a brand new, innovative, lightweight and fully integrated 25 kW
Kw
kw or KW may refer to:* Kuwait, ISO 3166-1 country code** .kw, the country code top level domain for Kuwait* Kilowatt* Self-ionization of water Kw* Cornish language's ISO 639 code* Kitchener–Waterloo, Ontario, Canada...

 electric motor
Electric motor
An electric motor converts electrical energy into mechanical energy.Most electric motors operate through the interaction of magnetic fields and current-carrying conductors to generate force...

, control system and 12.5 kWh lithium-ion battery pack, to ensure that maximum efficiency is achieved. The car all-electric range
All-electric range
All-electric range is the driving range of a vehicle using only power from its electric battery pack to traverse a given driving cycle. In the case of a battery electric vehicle, it means the total range per charge. For a plug-in hybrid , it means the range of the vehicle in charge-depleting mode...

 is 100 mile depending on driving conditions. The total weight of the motor, inverter and gearbox configuration is up to 45% lighter than comparative current production EV powertrains. The T.27 weighs only 1500 lb (680.4 kg), and achieves a top speed of 65 mph (29.1 m/s). Its 0-62 mph
0 to 60 mph
The time it takes to accelerate from 0 to 60 mph is a commonly used performance measure for automotive acceleration in the United States and the United Kingdom. In the rest of the world 0 to 100 km/h is used...

 (0 to 100 km/h) speed is said to be under 15 seconds. In crash testing, the T.27 obtained high marks in the EuroNCAP
EuroNCAP
The European New Car Assessment Programme is a European car safety performance assessment programme based in Brussels and founded in 1997 by the Transport Research Laboratory for the UK Department for Transport and backed by several European governments.-History and activities:Euro NCAP is a...

 50 km/h (31.1 mph) impact crash test
Crash test
A crash test is a form of destructive testing usually performed in order to ensure safe design standards in crashworthiness and crash compatibility for various modes of transportation or related systems and components.- Types :...

, showing good structural integrity and design.

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, while also eliminating the harshness that can occur during changes in torque demand.

The 17 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 product are now being supplied to several other high profile formulae.

Zytek Engineering

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
Jordan Grand Prix
Jordan Grand Prix was a Formula One constructor that competed from 1991 to 2005. The team is named after Irish businessman and founder Eddie Jordan...

 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
Le Mans Series
The Le Mans Series is a European sports car racing endurance series based around the 24 Hours of Le Mans race and run by the Automobile Club de l'Ouest . The series was originally named the Le Mans Endurance Series, but changed its name prior to the 2006 season...

 with their first sports car, the Zytek 04S, which was able to finish second in the team championship in 2005
2005 Le Mans Series season
The 2005 Le Mans Series season was the 2nd season of ACO Le Mans Endurance Series. It is a series for Le Mans prototype and Grand Touring style cars broken into 4 classes: LMP1, LMP2, GT1, and GT2...

 due to two overall victories. Zytek Engineering continues to campaign in the Le Mans Series as well as in the American Le Mans Series
American Le Mans Series
The American Le Mans Series presented by Tequila Patrón is a sports car racing series based in the United States and Canada. It consists of a series of endurance and sprint races, and was created in the spirit of the 24 Hours of Le Mans. Teams compete in one of five classes: LMP1, LMP2 and LMPC...

 and 24 Hours of Le Mans
24 Hours of Le Mans
The 24 Hours of Le Mans is the world's oldest sports car race in endurance racing, held annually since near the town of Le Mans, France. Commonly known as the Grand Prix of Endurance and Efficiency, race teams have to balance speed against the cars' ability to run for 24 hours without sustaining...

.

Engine Technology

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
Judd (engine)
Judd is a name brand of engines produced by Engine Developments Ltd., a company founded in 1971 by John Judd and Jack Brabham in Rugby, Warwickshire, England...

 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
Panoz
Panoz Auto Development is an American manufacturer of high-performance automobiles founded in 1989 by Dan Panoz, son of pharmaceutical and motorsport mogul Don Panoz. The company is located in Braselton, GA. Panoz products have included the Panoz Roadster and AIV Roadster, and the Panoz Esperante...

 and Élan Motorsport Technologies
Élan Motorsport Technologies
Élan Motorsport Technologies is an umbrella company containing the race car manufacturing companies owned by the Panoz Motor Sports Group. Élan designs and builds Panoz-branded race cars, and have also acquired other manufacturers, including famous Formula Ford builders Van Diemen and IndyCar...

 worked together on the development of the new V8 motor for the Panoz LMP07
Panoz LMP07
The Panoz LMP07 was a Le Mans prototype built in late 2000 for Panoz for competition in the American Le Mans Series. The car was designed as a successor to the Panoz LMP-1 Roadster-S which had competed since 1999...

 Le Mans Prototype
Le Mans Prototype
A Le Mans Prototype is a type of sports prototype race car most notably used in the 24 Hours of Le Mans, American Le Mans Series and Le Mans Series...

. 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
Reynard 02S
The Reynard 02S was a Le Mans Prototype race car built by Reynard Motorsport in 2002. Intended to replace the failed Reynard 2KQ prototype, the 02S would end up becoming the final new design from Reynard as the company went bankrupt prior to the project's completion.International Racing Management...

 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
A1 Grand Prix
A1 Grand Prix was a 'single make' open-wheel auto racing series. It was unique in its field in that competitors solely represented their nation as opposed to themselves or a team, the usual format in most formula racing series. As such, it was often promoted as the "World Cup of Motorsport"...

. 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
Ferrari
Ferrari S.p.A. is an Italian sports car manufacturer based in Maranello, Italy. Founded by Enzo Ferrari in 1929, as Scuderia Ferrari, the company sponsored drivers and manufactured race cars before moving into production of street-legal vehicles as Ferrari S.p.A. in 1947...

 replaced Zytek as the sole engine supplier in A1GP. Zytek continued to power Euroseries 3000 until 2009 when it was replaced by Auto GP, which also utilises Zytek power in the form of the ZA348 3.4-Litre engine.

Vehicle Technology

In 2002, Zytek bought some of the remains of the defunct Reynard Motorsport
Reynard Motorsport
Reynard Motorsport was at one time the world's largest racing car manufacturer. Initially based at Bicester and latterly at Reynard Park, Brackley, England the company built successful cars in Formula Ford 1600, Formula Ford 2000, Formula Vauxhall Lotus, Formula Three, Formula 3000 and Indy...

 from International Racing Management (IRM). These assets included the rights to the Reynard 02S
Reynard 02S
The Reynard 02S was a Le Mans Prototype race car built by Reynard Motorsport in 2002. Intended to replace the failed Reynard 2KQ prototype, the 02S would end up becoming the final new design from Reynard as the company went bankrupt prior to the project's completion.International Racing Management...

 Le Mans Prototype
Le Mans Prototype
A Le Mans Prototype is a type of sports prototype race car most notably used in the 24 Hours of Le Mans, American Le Mans Series and Le Mans Series...

, 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
Le Mans Series
The Le Mans Series is a European sports car racing endurance series based around the 24 Hours of Le Mans race and run by the Automobile Club de l'Ouest . The series was originally named the Le Mans Endurance Series, but changed its name prior to the 2006 season...

.

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
Miguel Amaral
Miguel Maria de Sá Pais do Amaral, 2nd Count of Alferrarede, KHDSMOM is a Portuguese aristocrat, businessman and amateur race car driver.-Family:...

 and Olivier Pla
Olivier Pla
Olivier Pla is a race car driver from France.-French Formula Campus & Formula Three:Pla's career started in 2000 in French Formula Campus before moving on to French Formula Three Championship in 2001 with the Saulnier Racing team...

.

Q10

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.

While 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 while 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.50 kg and produce c.40 kW of power.

External links

The source of this article is wikipedia, the free encyclopedia.  The text of this article is licensed under the GFDL.
 
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