GM-VOLT : Chevy Volt Electric Car Site

With all of GMs recent trouble coming from the crashing SUV market, they must be looking forward to the launching of their fuel efficient smaller SUVs. The Saturn VUE is on the verge of morphing into first a strong 2-mode hybrid form launching later this year, and after that a lithium-ion plug-in 2-mode hybrid version. The latter has the potential to be the first mass-produced plug-in hybrid to hit the U.S. market.

The 2-mode VUE is expected to get greater than 50% combined improved fuel efficiency .  The plug-in version has the potential for 70 mpg although I have no official figure from GM.  The plug-in VUE is a parallel rather than series design, and although capable of going up to 10 miles pure EV, on-board controllers will choose from the ICE, or a low speed or high speed electric motor, depending on what is best for the driving conditions of that moment.

I had the chance recently to ask GM’s director of hybrid integration, Mick Bly, some questions about these programs.

How is the 2-mode plug-in VUE program coming along?
We have developmental mules up and running on the plug-in VUE. As we announced we have joined in to two developmental contracts with two suppliers, one being JCS and the other being Cobasys/A123 and we are continuing to work with them. We have a lot of good data over the last year. Bench, lab, supplier, and vehicle data and we’re going to continue to work and decide which path we’re going to take in that particular vehicle program.

Are you pitting the two suppliers against one another with the idea that one will be chosen in the end?
No, what we’ve said is that we are going to develop with two suppliers, and we are probably going to look at others also, and we will make a selection on the best solution for the vehicle and then have one put forward into production, very similar to what were doing for the Volt.

Is that program further along than the Volt at this point?
Yes and no. Its further along in the sense that its getting all the benefits of a vehicle that exists, the VUE. Its further along because the 2-mode front wheel drive program is getting very close to production. That takes a lot of stress off my organization to really focus in on converting over to the lithium-ion plug-in system, the charger, the electronics, and the software unique to that. So yes its much farther in that sense but it still has a lot of integration activity left around the battery itself.

When is the target production for the VUE 2-mode?
The VUE 2-mode will be later this year, 2008. The plug-in as early as 2010.

Besides the fact that its not soon enough, the closest date I can get as to this year’s 2-mode VUE release is “a few months down the road” per a GM spokesperson involved in the launch.

GM has had to recall 9000 NiMh battery packs, made by Cobasys, which are being used in the mild hybrid versions of the VUE, Aura, and Malibu.

This represents one third of the entire fleet. The reports of battery failures apparently began surfacing in December, when drivers became aware of them via dashboard indicators displaying low voltage. The packs apparently had internal electrolyte leaks that led to the loss of voltage.

This story alone speaks of the importance of assuring the Volts packs are robust before going to widespread roll-out. The mild hybrids can still drive, but offer no hybrid benefit.

Now GM is apparently looking into the possibility of acquiring Cobasys, and may even “imminently ” do so.

Cobasys, co-owned by Chevron and Energy Conversion Devices, has been experiencing financial difficulties and internal feuding. The venture is reportedly at the point of “fold or be sold”.

Since all of GMs current major hybrids, and thus their current green turnaround, are based on Cobasys’ batteries, a collapse of the firm could spell big trouble to the already beleaguered automaker. Although GM has recently indicated they have no interest in making batteries, they may have no choice but to buy the firm.

Of course there is plenty of irony (or should we say nickelry) in this story, as GM actually co-founded Cobasys in a joint venture with Ovonics in 1994, later selling their stake with Texaco, who merged with Chevron.

Source (Automotive News)

In following GMs development of the Volt, one cant help but notice the automaker has been developing other higher-fuel economy vehicles.

One effort thats hard to miss is the production of 2-mode hybrid versions of the large SUV Chevy Tahoes and GMC Yukons. These massive trucks have remarkably advanced 2-mode hybrid systems that allow electric-only propulsion at both slow and high velocities. For engineering details, read my test drive here. These are the largest production hybrid vehicles available anywhere.

The SUVs were first introduced in late 2007, and get a 50% mpg improvement over the standard models achieving 21/22 city/hwy mpg, extremely impressive for trucks of this size. There is no plug, or lithium-ion battery, and the price tops $50,000.

GM’s initial analysis was for U.S. sales of 10,000 – 15,000 combined units annually.

The first trucks trickled out in February, and March was the first full month of sales. So far they have sold a combined 1000 units in March and April. This is compared to 13,000 combined sales of standard Tahoes and Yukons in April alone.

So with gas and oil prices rising as they are is it too little too late to save trucks, do people still not know about them yet, or is it just a matter of availability?

Only time will tell.

Source (MSNBC)

In the past Honda president Takeo Fukui has said lithium-ion batteries weren’t ready for cars yet, and that an E-REV like the Volt didn’t make sense (see post). His company also despite beating Toyota to the starting gate with its now defunct Insight, has been markedly losing the race to the Prius.

Amidst all the recent fuel efficiency and oil price headlines, Honda has now joined the crowd with its own hybrid announcements.

The automaker will be coming out with a low-cost hybrid based on the FCX clarity exterior design. They also intend to make a hybrid version of the Fit in 2010, the current ICE model of which is already the most fuel-efficient in its class.

However Honda is holding to its guns, and has no plans to compete in the plug-in hybrid arena. The most recent quote from Mr. Fukui, “We don’t necessarily think the plug-in hybrid is a very great idea,”

I beg to differ Sir.

Source (Businessweek)

GM currently builds cars using two different hybrid powertrains, the 2-mode hybrid, and the belt-alternator-hybrid system (BAS). The latter is found in current Malibus, Auras, and VUEs and gives a 10 to 15% efficiency improvement. This relatively low cost system replaces the belt and alternator with a small electric motor and a 36 volt NiMh battery. The system works by shutting down the engine while idling, recapturing kinetic energy from braking, and applying a power boost during certain portions of the driving cycle.

Today GM CEO Rick Wagoner has announced in Geneva that this system will be upgraded for 2010.

The new system will use a lithium-ion battery pack that will allow more power output, increased regenerative storage capacity, and low speed electric-only driving.

This system should allow for 15-20% increased fuel economy over standard combustion versions of the vehicles. GM is expected to deploy these on a wide scale with initial production numbers of greater than 100,000 units.

One significant point of this news is that its yet a another sign of GMs commitment to the lithium-ion battery pack, a much larger version of which will power the Volt.

Press Release:

GM Announces Next-generation GM Hybrid System

· Plans to roll out, across our brands and regions, starting in North America in 2010, and we expect high volumes, far exceeding 100,000 units annually
· This technology will use a lithium-ion battery and deliver nearly three times more power than the system it replaces.
· Increased power will allow the next-generation GM Hybrid System to be used in a wide range of global powertrains, including naturally aspirated engines, new high-efficiency turbocharged engines, bio-fuel engines and diesels.
· The next-generation GM Hybrid System will build upon the current technology available on the Saturn Vue Green Line, Saturn Aura Green Line and Chevrolet Malibu Hybrid.
· By building on a proven system design, GM will be able to reduce engineering costs and ease vehicle integration, helping to make the next-generation GM Hybrid System more cost-effective and expand its application in GM’s global vehicle portfolio
· Estimated overall fuel economy improvements for vehicles using the system of 15 to 20 percent, depending on engine and vehicle application
· Help optimize fuel efficiency and reduce emissions by:

· Turning the engine off at idle
· Offering brief electric-only propulsion
· Using a more powerful electric motor to enhance engine efficiency
· Extending fuel cutoff during deceleration
· Extending regenerative braking to recapture more energy
· Performing intelligent hybrid battery charging
· This new system is a key part of GM’s comprehensive strategy to reduce vehicle fuel consumption and emissions

GM has announced it is making progress on the Saturn VUE plug-in 2-mode hybrid, and that they expect production in calenday year 2010.

The vehicle is expected to have 10 mile all-electric driving range and will use a lithium-ion battery pack. I had a chance to speak with Bob Reuter who is the chief engineer. Bob advised that packs from several companies were being evaluated for the vehicle but in the end only one will be chosen for production.

He also mentioned that early test mules are indeed already in operation.

The plug-in VUE will have a 2-mode hybrid drivetrain, and can function in charge sustaining as well as charge depleting modes. After the 1st 10 miles of charge is depleted, the battery can be restored by regeneration to be able to run the car again if possible in charge depleting mode.

Read full release below.

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