ELECTRONIC AUTOMOTIVE
DESIGNERS
DESIGN SOLUTIONS

FROM ENGINE CONTROL TO
RACING GEAR SHIFT UNITS

ROAD AND RACE APPLICATIONS

Zytek are pioneers in the use of electronics in both road and race applications, claiming for example the design and manufacture of the first digital, re-programmable, microprocessor-controlled engine management system used in Formula 1 (and had the privilege of working with Ayrton Senna in its first application).

Since 1981, our company’s mission has been to design automotive electronics, and in particular engine control units, plus gearshift and clutch control units for race applications.

Used In Niche Applications Around The World

Our engine control units have been used in niche applications around the world, and this led to a business that can develop any number of low voltage electronic controllers, including hybrid control units, chassis control units, racing gearshift units, and indeed any customised, bespoke hardware platform required for a customer. 

The Latest Microprocessors

We enjoy very close working relationships with microprocessor suppliers and can benefit from the early release of the latest range of microprocessors ensuring that we can offer the very latest designs into ever more demanding applications.

Inverter Design, Assembly, Test and Application

In addition to the low voltage electronics design capability, we also offer the design, assembly, test, and application of high voltage inverter systems, tailored specifically for automotive applications. 

Inverters can be either taken “off the shelf”, be semi-customised based on an existing design, or be developed from a clean sheet of paper where necessary. This is a very fast-moving area of technology, where new developments are available on an annual (or more frequent) basis. 

We enjoy very close working relationships with high voltage IGBT suppliers and have the ability to produce the designs using the very latest (sometimes prototype) high voltage devices, maximising efficiency, minimising heat loss, and reducing both mass and footprint.

Inverter design is undertaken, whenever possible, at a system level with all component parameters in mind, as these will play a large part in determining the overall system efficiency. Advanced modelling techniques are used to determine key operating parameters, incorporating the operation of both the hardware system itself and the influence of the electric motor control system.

It is also possible to develop custom high voltage DCDC converters, where the DC link voltage is stabilised within the inverter. Finally, in systems where two variable voltage energy sources are used (such as a fuel cell), a DCDC converter can be developed in isolation to ensure all energy flows within the system can be controlled and managed.

Specification Development 

Specification development capabilities that are employed within the hardware and electronic department include:-

  • Circuit design at both micro-and power-levels
  • Schematic capture
  • Design Failure Mode and Effects Analysis (FMEA) including safety analysis
  • Electromagnetic Compatibility (EMC) and product validation programme
  • Multilayer Printed Circuit Board (PCB) design
  • High and low voltage design
  • In house manufacturing capability for prototypes, samples, and low volumes
  • Close ties with inhouse and local suppliers for higher volumes

RELATED CAPABILITIES

concept
vehicle design

We have been designing, developing, and converting prototype concept motorsport vehicles since the mid-1990s from our dedicated workshop facilities.

Mechanical Engineering

Our design team includes mechanical engineers with a wide range of skills from product design to vehicle A surface designers with all the necessary skills required for full vehicle build.

electric motor design

We specialise in the design and development of high performance 3-phase, internal rotor, PMSM electric machines for hybrid and electric vehicles.

TESTING


In-house/track testing facilities and our dedicated team creates the environment to develop highest quality solutions in the quickest time.

FREQUENTLY ASKED QUESTIONS

Since 1981, we have been developing automotive electronics, and in particular engine control units for race applications.

We have dedicated teams for the design of high voltage electronics. Whilst normally working within the FIA limit of 1000 volts, this is not necessarily a design limit if customers wish to explore higher voltage domains.

Whilst off-the-shelf components are frequently used for cost-effectiveness, if customers require advanced materials, bespoke components can be designed.

Whilst we have a range of microprocessors that have available software sets, should customers require something unique, this can also be accommodated.

A thermal network is built using raw component data to understand overall performance. Should a thermal model of an individual component not be available, a model can be generated.

Electronics will be run under representative conditions and thermal performance measured in real-time using a sophisticated thermographic camera system.

WORK WITH US