New powertrain simplifies EV development

Building on the knowledge gained from more than 15 years of niche EV design, manufacture and operation, this new third generation unit is a clean-sheet-of-paper design that will significantly simplify the introduction of next-generation electric vehicles, from niche models to high-volume global programmes. "The steps required to move from today's low-volume trials to tomorrow's fully-homologated production vehicles are very substantial and must not be under estimated," says Zytek Automotive's managing director Neil Heslington. "Everything has to be re-evaluated, from development processes to dealer training. This new powertrain, combined with our substantial experience of EV and hybrid vehicle production programmes, will take time and cost out of this activity while helping to deliver the quality, refinement and driving experience that discerning customers demand." The turnkey package is extremely compact and in air-cooled configuration is up to 45% lighter than today's production EV powertrains. Even the water cooled version, suitable for demanding drive cycles, is up to 30% lighter. Available in sizes from 25kW, the highly integrated modular system can be configured for a wide range of vehicle sizes, applications and architectures. 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.