UK-based Zytek Automotive has developed a new electric vehicle (EV) powertrain. The company said that this new unit is expected to simplify the introduction of EVs, from niche models to high-volume global programs.

According to the company, the turn-key package is compact and in air-cooled configuration is up to 45% lighter than existing production EV powertrains. The water cooled version, suitable for demanding drive cycles, is up to 30% lighter. Available in sizes from 25kW, the 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, permanent magnet synchronous motor. The maximum machine speed of 14,000rpm 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 EV 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 company said.

Parallel design and integration of the major subsystems has allowed optimization. The integration of the charger within the inverter, reduces the number of separate enclosures and connectors required in the vehicle, reducing cost and increasing reliability, the company claims.

A new transmission, designed specifically for use with the new electric machine, is being developed by transmission specialist Vocis.

Mike Everitt, managing director of Vocis, said: “We are working closely with Zytek to ensure that the motor and gearbox are optimised as a single system, delivering maximum efficiency and installation flexibility with minimum cost, weight and packaging requirement.

“The width across the gearbox is just 138mm and transmission weight is only 10kg, which we have achieved without any compromise in performance. Testing has already shown that this is a very robust unit that delivers excellent durability and refinement.”

The Zytek electric vehicle control module interfaces with all standard vehicle systems such as ABS (Antilock Braking System) and ESP (Electronic Stability Programme). It also provides the complete range of expected diagnostic information as well as its own range of diagnostic codes, the company said.