Chevrolet Volt
Image Credit: General Motors
GM manufactured its first advanced lithium-ion battery for a mass-marketed electric vehicle at GM's Brownstown Battery Pack Assembly Plant this month. Regular production at Brownstown and Detroit-Hamtramck is set to begin in the fourth quarter.
“This is an important milestone for GM – and a critical step in bringing the Chevrolet Volt to market,” said GM Chairman and CEO Ed Whitacre.
GM announced in August 2009 a $43-million investment to prepare the 160,000-square-foot, landfill-free facility for production of lithium-ion battery packs for the Volt and other electric vehicles with extended-range capabilities. The plant is part of a wholly-owned subsidiary of General Motors called GM Subsystems Manufacturing LLC.
In just five months, the Brownstown plant was converted from an empty facility to a production-ready battery manufacturing site. New machinery and specialized equipment have been installed and three primary assembly areas have been completed: battery module pre-assembly, final assembly and the battery pack main line.
The Volt’s battery pack is made up of multiple linked battery modules and more than 200 battery cells. The initial assembly area is where the prismatic-shaped cells are processed and installed by state-of-the-art flexible automated equipment into modules, which are then delivered to the battery pack main line.
The battery pack main line area features an Automated Guided Cart (ACG) system that includes operations for thermal and electrical assembly, along with quality and dimensional checks. The main line is also where battery pack final testing, verification and packaging for shipment take place.
Initial battery production at Brownstown will be used to validate the plant’s equipment and processes, and batteries will be sent to GM’s Global Battery Systems lab in Warren, Mich., for testing. This spring, GM will begin shipping batteries to GM’s Detroit-Hamtramck plant, the assembly location for the Volt, for use in production validation vehicles.
GM is investing $700 million in eight Michigan facilities for Volt-related production, including $336 million in the Detroit-Hamtramck plant, which will benefit from battery research conducted at the battery lab in Warren; receive batteries from Brownstown; use tooling from Grand Blanc; take delivery of camshafts and connecting rods from Bay City; and dies, stampings and the Volt’s 1.4L engine-generator from three plants in Flint.
“The development of electric vehicles like the Chevy Volt is creating entire new sectors in the auto industry – an ‘ecosystem’ of battery developers and recyclers, builders of home and commercial charging stations, electric motor suppliers and much more,” Whitacre said. “These companies and universities are creating new jobs in Michigan and across the U.S. – green jobs – and they’re doing it by developing new technology, establishing new manufacturing capability, and strengthening America's long-term competitiveness.”
In August, the U.S. Dept. of Energy selected 45 companies, universities and organizations, including GM, in 28 states for more than $2 billion in awards for electric drive and battery manufacturing and transportation electrification. Nearly half of that total is designated for cell, battery and materials manufacturing facilities in Michigan.
The Volt is an electric vehicle with extended-range capability. It is designed to drive up to 40 miles on electricity without using gasoline or producing tailpipe emissions. When the Volt’s lithium-ion battery is depleted of energy, a flex-fuel engine-generator seamlessly operates to extend the total driving range to about 300 miles before refueling or stopping to recharge the battery. Pricing has not been announced.
As the Chevrolet Volt moves closer to launch, an electric car of a different sort is making its debut at the 2010 Delhi Auto Expo. Indian blog Bikencar provides a first look at the eSpark, an electric city car they say will be India’s first four-door electric vehicle.
The “e-Spark” is GM India's bold move into the Battery Powered Electric Vehicles and will be India's first 4 door Passenger Electric Vehicle! The e-Spark is a local initiative of GM India in collaboration with Reva Electric Car Company. This is a path breaking initiative that has the ability to re-define how automotive companies in India plan for future mobility solutions keeping the carbon footprints and environmental issues in mind. The e-Spark will be one of the leading platforms of GM India in its Drive to Green initiative.
The e-Spark is a true Battery Electric Vehicle (BEV). It is going to be based on the existing Chevrolet Spark architecture and will be powered by the RECC EV powertrain. The vehicle will be equipped with a host of smart consumer friendly features.
This car will boast of smart and comfortable seating for four. The 4 doors will allow for ease of entry and exit. The e-Spark will be an "automatic drive" car owing to its unique propulsion system and will be extremely easy to drive without the hassles of using a clutch in the dense city traffic conditions. The easy drive system will be coupled with an equally informative and intelligent Driver Display System that will provide all necessary and vital signals on the dashboard, easily visible to the driver.
The Electric Drive AC Motor provides 100% torque on tap as soon as the accelerator pedal is pressed down. This leads to fantastic acceleration performance. The e-Spark will have a Regular Drive Mode and a Boost Mode that will provide power to the vehicle through a high torque AC electric motor. The Boost Mode will provide additional torque to the driver for a short duration to manage driving style and during those critical moments on the go! The e-Spark will be launched end of this year.
Information on the full range of vehicles at the show can be found on the Chevrolet India media site.
General Motors can be found at www.gm.com.
