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Chevrolet Volt Owners Surpass Half a Billion Electric Miles

June 17, 2014 in Electric Vehicles, EV enthusiast, EV News, GM, Volt

After 30 months of use, a sampling of Volts shows consistent all-electric range

Infographic courtesy of GM

Infographic courtesy of GM

DETROIT Since its launch in late 2010, Chevrolet Volt owners have accumulated more than half a billion all-electric miles.

Additionally, based on a General Motors’ study of more than 300 Volts in service in California for more than 30 months, many owners are exceeding the EPA-rated label of 35 miles of EV range per full charge, with about 15 percent surpassing 40 miles of range.

“The fact that most of the folks who purchased the Volt at launch are still enjoying EV range performance on target with when they took delivery is testament to the attention to detail our team paid to delivering on our promise of most people driving all electrically most of the time,” said Pam Fletcher, Chevrolet Volt executive chief engineer.

Volt owners are doing more than 63 percent of their overall driving in EV mode. While the driving range in EV mode can be greatly impacted by temperature, driving technique and terrain, the ease with which Volt drivers are avoiding gasoline use further shows the Volt’s suitability for almost any lifestyle.

Volt owners who charge regularly typically drive more than 970 miles between fill-ups and visit the gas station less than once a month. The 2014 Volt provides owners with fuel economy of EPA estimated 98 MPGe (electric) and 35 city/40 highway on gasoline power, saving $1,450 in annual fuel costs with no change in daily driving habits.

In an independent study conducted between July and December 2013, Volt drivers who participated in the Department of Energy’s EV Project managed by Idaho National Labs totaled 1,198,114 vehicle trips of which 974,692, or 81.4 percent, were completed without the gasoline-powered generator being used.

Since the Volt was launched in 2010, owners have helped to reduce gasoline consumption by more than 25 million gallons, the equivalent of no gasoline being used in Washington D.C. for 2½ months.

The Volt continues to attract new buyers to Chevrolet with 69 percent of Volt buyers new to GM. The Toyota Prius is the most frequently traded-in vehicle for a Volt.

About Chevrolet

Founded in 1911 in Detroit, Chevrolet is now one of the world’s largest car brands, doing business in more than 140 countries and selling more than 4.9 million cars and trucks a year. Chevrolet provides customers with fuel-efficient vehicles that feature spirited performance, expressive design, and high quality. More information on Chevrolet models can be found at www.chevrolet.com.

About General Motors

General Motors Co. (NYSE:GM, TSX: GMM) and its partners produce vehicles in 30 countries, and the company has leadership positions in the world’s largest and fastest-growing automotive markets. GM, its subsidiaries and joint venture entities sell vehicles under the Chevrolet, Cadillac, Baojun, Buick, GMC, Holden, Jiefang, Opel, Vauxhall and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety, security and information services, can be found at http://www.gm.com

This article is a repost, credit: GM.

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GM Outlines Efforts to Transform Transportation

May 19, 2014 in Electric Vehicles, EV News, GM

Sustainability report shares progress toward a more enduring industry

A Chevrolet Volt hooked up to one of TimberRock’s solar charging stations. Photo courtesy of GM

A Chevrolet Volt hooked up to one of TimberRock’s solar charging stations.
Photo courtesy of GM

DETROIT – Facing an automotive industry that is unsustainable in its current form, General Motors is restructuring its global vehicle portfolio, rethinking manufacturing and collaborating with unlikely partners to advance the industry.

The company is working to transform transportation and describes its efforts in its latest sustainability report.

“Our customer focus underscores why sustainability is and will continue to be a core strategy for GM,” said CEO Mary Barra. “People care about more than the cars. They care how we build them, and how we engage with the world around us. This knowledge, and the discipline that flows from it, is transforming our approach to product design, manufacturing, safety, quality, the environment, customer care and a host of other areas at a remarkable pace.”

From smaller and cleaner high-performing engines to mass reduction and improved aerodynamics, vehicle efficiency efforts will reduce carbon emissions and increase fuel economy while meeting a variety of customer needs. The company now has five models achieving more than 40 miles per gallon. GM progressed in all four of its product commitments in fuel economy, electrification and emissions reduction, and added another to tackle its biggest market. It has committed to reducing the average carbon emissions of its China fleet by 28 percent by 2020, which could result in an annual reduction of 2 million metric tons of CO2 and avoid the use of 1 billion liters of gasoline.

GM had 153,034 electrified vehicles on the road as of 2013, moving along its path to reach 500,000 by 2017. Last year the company launched two new electrified vehicles, the Chevrolet Spark EV and the Cadillac ELR extended-range electric vehicle. They join the Opel Ampera in Europe, the Chevrolet Volt, the best-selling U.S. plug-in electric vehicle of 2012 and 2013, and the Chevrolet Springo EV in China.

“Climate change, energy security, and congestion challenge our environment and our industry, but we see value in the disruption,” said Mike Robinson, vice president, GM Sustainability and Global Regulatory Affairs. “We are reimagining transportation using a long-term, customer-centric approach.”

As more people expect their cars to have the technology they use everywhere else in their lives, GM satisfies connectivity demands while enabling a more sustainable transportation future. Customers can use OnStar route optimization to find ways around congestion and receive real-time feedback on how to drive more efficiently. GM also is working toward a vision for connected vehicles that share information with each other and their infrastructure to help anticipate and avoid crashes.

“This innovation helps our products stay relevant and broadens the positive impact of a connected world,” Robinson said.

GM also is changing how cars are made to reduce the industry’s environmental footprint. The company completed a lifecycle analysis to better understand the greenhouse gas impacts of its products throughout the supply chain so it can make broader improvements.

GM remains the only automaker signatory of the Climate Declaration, which asserts there is economic opportunity in addressing climate change.  The company ranked among the top 10 percent of organizations that reported in the CDP Global 500 Climate Change Report 2013, demonstrating transparency in emissions and energy measurement and climate change strategy.

Last year, GM met the voluntary ENERGY STAR® Challenge for Industry criteria at nine additional plants for an industry-leading total of 63 facilities worldwide, saving $162 million in combined energy costs. From removing coal-fired boilers at its Detroit-Hamtramck assembly plant to saving $10 million in annual energy costs by using more landfill gasat its Fort Wayne and Orion assembly plants, GM is reducing its global carbon footprint, plant by plant.

GM and its communities continue to benefit from ongoing energy, water and waste reduction. Seven years ahead of schedule, the company met its commitments to reduce total waste and volatile organic compound emissions by 10 percent each and to establish 25 non-manufacturing landfill-free facilities. It will now set new targets.

Progress against other 2020 global manufacturing commitments with a 2010 baseline includes:

  • Expanding renewable energy use to 66.2 megawatts, toward a goal of 125 megawatts
  • Increasing the number of landfill-free manufacturing sites to 83, toward a goal of 100
  • Reducing water intensity by 9 percent, with a goal of 15 percent
  • Reducing energy intensity by 10 percent, with a goal of 20 percent
  • Reducing carbon intensity by 7 percent, with a goal of 20 percent

“We like the results we are seeing, but we fully recognize we have a tremendous amount of work to do,” Barra said. “We must innovate more, seize opportunities faster and work harder to achieve true leadership – a claim that only matters if our customers, employees, communities and other stakeholders agree.”

Industry transformation will not come from one company’s actions alone. GM collaborates with unlikely partners, including competitors such as Honda to develop fuel cell systems and technology, and such non-governmental organizations as the BlueGreen Alliance, Union of Concerned Scientists, World Wildlife Fund and Ceres to create a greener economy and conserve the resources vital to the industry.

For more information, visit www.gmsustainability.com.

About General Motors Co.

General Motors Co. (NYSE:GM, TSX: GMM) and its partners produce vehicles in 30 countries, and the company has leadership positions in the world’s largest and fastest-growing automotive markets.  GM, its subsidiaries and joint venture entities sell vehicles under the Chevrolet, Cadillac,  Baojun, Buick, GMC, Holden, Jiefang, Opel, Vauxhall and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety, security and information services, can be found at http://www.gm.com.

This article is a repost, credit: GM.

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Brownstown Battery Assembly Expands Capabilities

May 14, 2014 in Electric Vehicles, EV News, GM

Will build battery system for 2015 Chevrolet Spark EV

General Motors Brownstown Battery Assembly Plant worker Tina Oaks attaches wiring harnesses on a Spark EV battery pack Tuesday, May 13, 2014 in Brownstown, Michigan. GM is bringing all of its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at Brownstown. The plant already manufactures complete packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR. (Photo by John F. Martin for General Motors) Courtesy of GM

General Motors Brownstown Battery Assembly Plant worker Tina Oaks attaches wiring harnesses on a Spark EV battery pack Tuesday, May 13, 2014 in Brownstown, Michigan. GM is bringing all of its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at Brownstown. The plant already manufactures complete packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR. (Photo by John F. Martin for General Motors)
Courtesy of GM

DETROIT – General Motors will bring all its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at its battery assembly plant in Brownstown, Mich.

“Using our in-house engineering and manufacturing expertise enabled us to deliver a battery system that is more efficient and lighter than the 2014 Spark EV without sacrificing range,” said Larry Nitz, executive director of GM global transmission and electrification engineering. “Our successful working relationship with LG Chem has allowed us to deliver a new battery system for the Spark EV that helps us to better leverage our economies of scale.”

A newly designed battery system features an overall storage capacity of 19 kWh and uses 192 lithium ion cells. The cells are produced at LG Chem’s plant in Holland, Mich. The battery system weight of 474 lbs. is 86 pounds lighter than the system in the 2014 Spark EV. The Spark EV battery is built on a dedicated production line at Brownstown, which also manufactures complete battery packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR.

Changes in battery design will not affect the Spark’s MPGe, or gasoline equivalent, performance compared to the 2014 model. Range will remain at an EPA-rated 82 miles and MPGe will remain at 119.

Priced at $19,995 with full federal incentives, The Spark EV is one of the most efficient – and affordable – all-electric vehicles available. Currently on sale in California and Oregon, the 2015 Spark EV features segment-leading technology including Siri Eyes Free, 4G LTE and DC Fast Charging.

Brownstown Battery Assembly’s 479,000-square-foot, landfill-free facility south of Detroit produces the lithium-ion battery packs for GM’s extended-range electric vehicles. It started mass production in October 2010 and is the first high-volume manufacturing site in the U.S. operated by a major automaker for automotive lithium-ion battery production. The site was made possible with the help of American Recovery and Reinvestment Act funding through the U.S. Department of Energy.

About General Motors Co.

General Motors Co. (NYSE:GM, TSX: GMM) and its partners produce vehicles in 30 countries, and the company has leadership positions in the world’s largest and fastest-growing automotive markets.  GM, its subsidiaries and joint venture entities sell vehicles under the Chevrolet, Cadillac,  Baojun, Buick, GMC, Holden, Jiefang, Opel, Vauxhall and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety, security and information services, can be found at http://www.gm.com.

This article is a repost, credit: GM.

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GM Invests $449 Million for Next Generation Electrification

April 10, 2014 in Electric Vehicles, EV News, GM, Volt

General Motors announced that it will invest $449 to upgrade manufacturing processes at Detroit-Hamtramck Assembly and Brownstown Battery Assembly plants in preparation for the next generation of electric vehicles and advanced battery technologies. The announcement was made Tuesday, April 8, 2014 by Gerald Johnson, GM North America Manufacturing vice-president. Infographic courtesy of GM

General Motors announced that it will invest $449 to upgrade manufacturing processes at Detroit-Hamtramck Assembly and Brownstown Battery Assembly plants in preparation for the next generation of electric vehicles and advanced battery technologies. The announcement was made Tuesday, April 8, 2014 by Gerald Johnson, GM North America Manufacturing vice-president.
Infographic courtesy of GM

DETROIT – In preparation for the next generation of electric vehicles and advanced battery technologies, General Motors will invest $449 million to upgrade manufacturing processes at Detroit-Hamtramck Assembly and Brownstown Battery Assembly plants.

“General Motors is committed to building award-winning products and developing technologies in America, which helps to grow our economy from a resurgent auto industry,” said Gerald Johnson, GM North America Manufacturing vice president. “These investments will help the next-generation Chevrolet Volt build on its position as the leader in electrified propulsion.”

The investment, announced at the Automotive Press Association, is the largest to date at both facilities and includes $384 million at Detroit-Hamtramck for new Body Shop tooling, equipment, and additional plant upgrades to build the next generation Chevrolet Volt and two future products. This brings GM’s total investment at Detroit-Hamtramck to more than $1 billion over the last five years.

GM’s $65 million investment at its Brownstown Battery Assembly will support the next generation of lithium-ion battery production and future battery systems.

“Michigan is poised for even greater global leadership in automotive innovation,” Michigan Gov. Rick Snyder said. “This significant investment by GM will harness the power of our state’s unparalleled assets, such as its talent, world-class universities, and research and development capabilities.

“While challenges remain throughout the auto industry, this announcement shows that it is looking to the future, and the resulting technological advancements will strengthen our economy and benefit our environment,” Snyder said. “This is great news for Detroit, the region and all of Michigan.”

Since 2009, GM has announced more than $5.4 billion in U.S. facility investment for vehicle technologies that benefit customers. This includes more than $2.8 billion invested in Michigan-based facilities alone.

The Detroit-Hamtramck Assembly Plant is the world’s only automotive plant that mass-produces extended-range electric vehicles – including the Volt, Cadillac ELR and Opel Ampera – for markets in 33 countries. Detroit-Hamtramck also builds the Chevrolet Malibu and Impala sedans and is home to a 264,000-square-foot photovoltaic solar array that can generate up to 516 kilowatts of electricity, or enough to charge 150 electric vehicles per day.

“This is a significant investment by General Motors and it helps to further position Detroit as a leader in the innovative technologies of tomorrow,” said Detroit Mayor Mike Duggan. “We anticipate that the upgrading of the Detroit-Hamtramck Assembly Plant and the production of GM’s next-generation electric vehicles will create well-paying jobs for Detroiters. As we continue to bring real change to our city, we need partners like GM who are committed to investing in our future.”

Brownstown Battery Assembly’s 479,000-square-foot, landfill-free facility south of Detroit produces the lithium-ion battery packs for GM’s extended-range electric vehicles. It started mass production in October 2010 and is the first high-volume manufacturing site in the U.S. operated by a major automaker for automotive lithium-ion battery production. The site was made possible with the help of American Recovery and Reinvestment Act funding through the U.S. Department of Energy.

General Motors Co. (NYSE:GM, TSX: GMM) and its partners produce vehicles in 30 countries, and the company has leadership positions in the world’s largest and fastest-growing automotive markets. GM, its subsidiaries and joint venture entities sell vehicles under the Chevrolet, Cadillac, Baojun, Buick, GMC, Holden, Jiefang, Opel, Vauxhall and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety, security and information services, can be found at http://www.gm.com.

This article is a repost, credit: GM. Video courtesy of GM.

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General Motors Increases Battery Development Expertise

September 16, 2013 in Battery Energy Storage, Electric Vehicles, EV News, GM, Volt

Nearly triples size of Global Battery Systems Lab since opening in 2009

General Motors announces Monday, September 16, 2013, it has expanded its Global Battery Systems Laboratory in Warren, Michigan, where it tests and validates both battery cells and packs for all of GM's vehicle electrification systems, including the battery systems for the Chevrolet Volt, Cadillac ELR, Chevrolet Spark EV and GM's eAssist light electrification system. The expanded lab features dedicated equipment for future vehicle battery system development, building of prototype battery packs for vehicle development programs, and a hub for validation and testing of all future battery systems designed for use in GM vehicles. The facility is the largest battery lab in North America owned and operated by a major auto manufacturer.  (Photo by John F. Martin for General Motors) Courtesy of GM

General Motors announces Monday, September 16, 2013, it has expanded its Global Battery Systems Laboratory in Warren, Michigan, where it tests and validates both battery cells and packs for all of GM’s vehicle electrification systems, including the battery systems for the Chevrolet Volt, Cadillac ELR, Chevrolet Spark EV and GM’s eAssist light electrification system. The expanded lab features dedicated equipment for future vehicle battery system development, building of prototype battery packs for vehicle development programs, and a hub for validation and testing of all future battery systems designed for use in GM vehicles. The facility is the largest battery lab in North America owned and operated by a major auto manufacturer. (Photo by John F. Martin for General Motors)
Courtesy of GM

WARREN, Mich. – General Motors has nearly tripled the size of its Global Battery Systems Laboratory, cementing the lab’s stature as the largest battery lab in North America owned and operated by a major auto manufacturer.

The latest addition of 50,000 square feet brings to 85,000 the total square footage of the lab. The expansion made possible the increase in the number of pack-level test channels from 64 to 112 and cell-level test channels from 96 to120.

“In the past four years, the competitive landscape in the electrification space has grown exponentially. This has required us to raise our game and draw a new line in the sand,” said Doug Parks, GM vice president, global product programs. “To maintain our battery leadership, this additional real estate is filled with new capability that will help us improve speed to market for our next generation of battery systems and help us improve the value equation to our customers around the world.”

GM’s Global Battery Systems Lab has been responsible for testing and validating both battery cells and packs for all of GM’s vehicle electrification systems, including the battery systems for the Chevrolet Volt, Cadillac ELR, Chevrolet Spark EV and GM’s eAssist light electrification system.

The additional capabilities of the lab expansion include:

  • dedicated equipment for future vehicle battery system development such as charger development and testing, cord set testing and competitive benchmarking;
  • building prototype battery packs for vehicle development programs; and,
  • the ability to act as the hub for validation and testing of all battery systems designed for use in future GM vehicles around the world.

The lab will also play a critical role in assuring GM’s current generation of electric vehicles maintain their battery leadership position. Teams will validate and test updates to existing chemistries and system designs to make the most of performance and reduce cost. For example, updates were made to the battery system in 2013 Chevrolet Volt that added three miles of EV range.

GM Battery Lab Photo courtesy of GM

GM Battery Lab
Photo courtesy of GM

“GM is committed to vehicle electrification and our products in this area must continue to excite customers. A critical part of this plan is to deliver safe, reliable and affordable energy storage systems,” said Larry Nitz, GM’s executive director of global electrification engineering. “The new capabilities of this lab will enhance our engineers’ ability to design, develop, process and validate class-leading products to meet the needs of our growing customer base.”
In addition to the lab in Michigan, GM also operates battery labs in Shanghai, China, and Mainz-Kastel, Germany, which are tasked with testing and validation of battery cells, packs, and advanced battery system development. Teams at the China, Germany and Michigan labs work collectively to test battery systems around the clock to reduce validation time.

Facts: Global Battery Systems Battery Lab

Alternative Energy Center, GM Technical Center, Warren, Mich.

History:

  • Lab completed: May 2009
  • Expansion completed: July 2013

Size:

Expansion total floor space: 50,000 sq.-ft.

Lab total floor space: 85,000 sq.-ft.

  • 16,500 sq. ft. – Pack testing, Support
  • 18,500 sq. ft. – Cell / Module testing, Vibration #1, Safety and Abuse #1, Support
  • 30,000 sq. ft. – Safety and Abuse #2, Manufacturing Support, Pack Build, Test, Storage
  • 20,000 sq. ft. – Software / Dev. Test, Vibration #2, Modal test, Software / Dev. Support

Benefits:

  • Increased pack testing
  • New cell and module testing
  • Additional capabilities
    • New Vibration testing area with added Modal testing capability
    • Charger testing
    • Immersion testing (pack seals)
    • Hardware in the Loop / Software in the Loop testing and development
    • Manufacturing Engineering area for support of assembly plants (equipment partially funded by the U.S. Department of Energy)

Enhanced capability

  • Welding of battery systems: Development of new ultrasonic and laser weld capabilities.
  • Battery system mock-up capabilities: Tooling to hand-build modules, sections and validate parts.
  • Prototype pack build area

About General Motors Co.

General Motors Co. (NYSE:GM, TSX: GMM) and its partners produce vehicles in 30 countries, and the company has leadership positions in the world’s largest and fastest-growing automotive markets.  GM, its subsidiaries and joint venture entities sell vehicles under the Chevrolet, Cadillac,  Baojun, Buick, GMC, Holden, Isuzu, Jiefang, Opel, Vauxhall and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety, security and information services, can be found at http://www.gm.com.

This article is a repost, credit: General Motors, http://www.gm.com.

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2014 Chevrolet Volt Now Offers Even Greater Value

August 6, 2013 in Electric Vehicles, EV News, GM, Volt

Pricing for the 2014 model will start at $34,995

2014 Chevrolet Volt  Photo courtesy of GM

2014 Chevrolet Volt
Photo courtesy of GM

DETROIT – The Chevrolet Volt, already recognized for having the most satisfied owners will soon come with another people pleaser: a lower price. The 2014 model will start at $34,995, including an $810 destination fee (excluding tax, title, license and dealer fees).

If consumers include federal tax credits ranging from $0-$7,500 (depending on individual tax liability), pricing could start at $27,495. Individual tax situations differ, so consult a tax professional prior to claiming any credits to confirm eligibility for vehicle tax benefits.

“The lower price and cost savings from driving on electricity provide Volt owners an unmatched balance of technology, capability and cost of ownership,” said Don Johnson, U.S. vice president, Chevrolet sales and service. “The 2014 Volt will offer the same impressive list of features, but for $5,000 less.

“We have made great strides in reducing costs as we gain experience with electric vehicles and their components,” Johnson said. “In fact, the Volt has seen an increase in battery range and the addition of creature comforts, such as a leather-wrapped steering wheel and MyLink, since its launch in 2010.”

Volt owners who charge regularly typically drive 900 miles between fill-ups and visit the gas station about once a month. The 2014 Volt will continue to provide owners with impressive fuel economy of 98 MPGe (electric) and 35 city/40 highway on gasoline power without any need to change their daily driving habits while saving $900 in annual fuel costs. Today’s Volt owners have logged 364 million miles, including 225 million electric miles.

The Volt’s lower price also changes the comparative set of vehicles on popular auto information sites like kbb.com, Edmunds.com and cars.com, where visitors to these sites can search for a new vehicle by type and/or prices. The Volt’s lower price will broaden its exposure to price-sensitive prospective buyers using these sites to search for a plug-in electric vehicle or a gas-powered alternative sedan.

The Volt continues to be the best selling plug-in vehicle in America and is attracting new buyers to the Chevrolet brand. More than 70 percent of Volt buyers are new to General Motors. Not surprisingly, the Toyota Prius is the most frequently traded-in vehicle for a Volt.

California continues to be Volt’s largest market. The 2014 Volt will continue to offer a low emissions package that earns the Volt a coveted “sticker” for single-occupancy HOV lane access in California and New York.

The Chevrolet Volt allows gas-free driving for an EPA-estimated 38 miles (61 km), depending on terrain, driving techniques and temperature. The range-extending engine gives the Volt up to 380 total miles (615 km) of total driving range. The 2014 Volt will start to be available in dealer showrooms late this summer.  Chevrolet will introduce two new colors – Ashen Gray Metallic and Brownstowne Metallic for the 2014 model year – and a leather-wrapped steering wheel.

This article is a repost, credit: General Motors, http://media.gm.com/content/media/us/en/gm/news.html.

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Cadillac ELR Goes Ultrasonic in Pursuit of High Quality

August 2, 2013 in Electric Vehicles, EV News, GM

Welding and monitoring process supports eight-year/100,000-mile warranty

Cadillac executives gather with influencers in the design and luxury communities to discuss the Cadillac ELR luxury coupe on display Saturday, July 20, 2013 at the Montauk Beach House in Montauk, NY. Cadillac honored builder Frank Dalene of Telemark and architect Richard Stott of Steelbone, for their work in sustainable building. Cadillac Executive Director Global Design Mark Adams spoke about how the concept of Art & Science is the design philosophy behind his team's work.  Photo courtesy of GM

Cadillac executives gather with influencers in the design and luxury communities to discuss the Cadillac ELR luxury coupe on display Saturday, July 20, 2013 at the Montauk Beach House in Montauk, NY. Cadillac honored builder Frank Dalene of Telemark and architect Richard Stott of Steelbone, for their work in sustainable building. Cadillac Executive Director Global Design Mark Adams spoke about how the concept of Art & Science is the design philosophy behind his team’s work.
Photo courtesy of GM

DETROIT – Ultrasonic welding, a high-tech manufacturing process used in the aerospace and medical industries, is helping ensure high quality for the new Cadillac ELR extended-range electric luxury coupe that goes on sale in North America in early 2014.

Ultrasonic welding’s key advantage is exceptional and predictable quality and performance from one battery pack to the next. Every ELR battery, for example, has close to 200 ultrasonic welds. Each is required to meet stringent quality requirements, enabling Cadillac to offer an eight-year/100,000-mile battery system warranty.

Short cycle times, low capital costs and manufacturing flexibility through the use of automation are other advantages of ultrasonic welding.

“Ultrasonic welding is a far superior joining technology in applications where it can be deployed,” said Jay Baron, president and CEO of the Center for Automotive Research in Ann Arbor, Mich. “Cadillac’s innovative process will produce batteries with superior quality compared with traditional methods – and do it more efficiently. This is one example of technology development that is becoming pervasive in today’s world class vehicles.”

General Motors’ Brownstown Battery Assembly plant near Detroit, uses ultrasonic welding to join metal electrode tabs on ELR’s advanced 16.5-kWh lithium-ion battery system, and does it with a proprietary quality monitoring process. Brownstown uses an automated system to execute millions of these welds each year.

Ultrasonic welding uses specialized tools called an anvil and horn to apply rapid mechanical vibrations to the battery’s copper and aluminum electrodes. This creates heat through friction, resulting in a weld that does not require melting-point temperatures or joining material such as adhesives, soldering or fasteners.

An integrated camera vision system is used to shoot a reference image of the weld area prior to the operation to achieve pinpoint accuracy. Quality operators check electrode tabs before and after welding, and the system monitors dozens of signal processing features during each weld.

The battery-specific welding process is a result of collaboration among General Motors’ Manufacturing Systems Research Lab and Advanced Propulsion Center and the Brownstown plant. GM first applied the process on the award-winning Chevrolet Volt – its groundbreaking extended-range electric vehicle – and further refined it for ELR.

“This effort is an outstanding example of teamwork between research and manufacturing engineering,” said Catherine Clegg, GM vice president of Global Manufacturing Engineering. “It has helped integrate the use of highly technical, complex technology into a sustainable manufacturing process, which means we can consistently deliver high-quality batteries to our customers for the Cadillac ELR.”

The ELR’s T-shaped battery pack is located along the centerline of the vehicle, between the front and rear wheels for optimal weight distribution. The 5.5-foot-long (1.6 m), 435-pound (198 kg) pack supplies energy to an advanced electric drive unit capable of 295 lb-ft of instant torque (400 Nm) to propel the vehicle. Using only the energy stored in the battery, the ELR will deliver a GM-estimated range of about 35 miles (56 km) of pure electric driving, depending on terrain, driving techniques and temperature.

Charging the ELR’s battery can be done with a 120V electrical outlet or a dedicated 240V charging station. The vehicle can be completely recharged in about 4.5 hours using a 240V outlet, depending on the outside temperature.

The Cadillac ELR is built at GM’s Detroit-Hamtramck Assembly Plant, one of the few high-volume electric vehicle manufacturing facilities based in the U.S.  Its battery pack is built from cell to pack at Brownstown and shipped to Detroit-Hamtramck for assembly into the vehicle.

About Cadillac

Cadillac has been a leading luxury auto brand since 1902. Today Cadillac is growing globally, driven by an expanding product portfolio featuring dramatic design and technology. More information on Cadillac appears at www.cadillac.com. Cadillac’s media website with information, images and video can be found at media.cadillac.com.

This article is a repost, credit: General Motors, http://media.gm.com/content/media/us/en/gm/news.html.