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Home , Chevrolet Volt

Chevrolet Development Story of the Pioneering Electrified Vehicle

Edited by Lindsay Brooke

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iii Preface 71 High Voltage Hybrid Battery GM on the Critical Path Tray Design Optimization. Lead author Four years of Volt development Kristel Coronado; SAE Technical Paper 2011-01-0671. 01 Chapter 1 Why Volt? 83 High Voltage Connect Feature. Lead After 48 months’ development, the 2011 author Trista Schieffer; SAE Technical Volt has entered series production. Paper 2011-01-1266. The pioneering “E-REV” is as important to 87 Chapter 3 the mobility industry as it is to GM. Engineering with a Maniacal Focus 09 The Electrification of the Automobile: A dedicated, cohesive team and a From Conventional Hybrid, to Plug- conservative engineering approach put this in Hybrids, to Extended-Range Electric innovative vehicle into production at Vehicles. Lead author E.D. Tate; SAE moon-shot speed. Technical Paper 2008-01-0458. 90 Development Timeline 21 The CO2 Benefits of OnStar deployed as a tool Electrification – E-REVs, PHEVs, and 92 for Volt engineers Charging Scenarios. Lead author E.D. Tate; SAE Technical Paper 93 Chapter 4 2009-01-1311. A Unique Electrified Transaxle 32 2011 Chevrolet Volt Specifications Hybrid or not? Definitions aside, what really matters is GM wisely leveraged its next- 35 Chapter 2 generation Two Mode propulsion technology Creating the Heart of Volt to give Volt greater overall efficiency. GM’s battery requirements meant creating Q&A: Mahendra Muli, dSPACE a new state-of-the-art in-vehicle energy Q&A: Dr. Uwe Krueger, Behr America storage—and doing it in less than four years. The Voltec 4ET50 Electric Drive Top GM and supplier engineers reveal how 99 System. Lead author Khwaja Rahman; they did it. SAE Technical Paper 2011-01-0355. Q&A: Prabhakar Patil, Compact Power Inc. 115 The GM “Voltec” 4ET50 Multi-Mode 41 Voltec Battery Design and Electric Transaxle. Lead author Manufacturing. Lead author Robert Michael A. Miller; SAE Technical Paper Parrish; SAE Technical Paper 2011-01-0887. 2011-01-1360. 129 High Voltage Power Allocation 51 Voltec Battery System for Electric Management of Hybrid/ with Extended Range. Lead Vehicles. Lead author James D. author Roland Matthe; SAE Technical Marus; SAE Technical Paper Paper 2011-01-1373. 2011-01-1022.

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135 Chapter 5 193 Chapter 9 Codifying the Car Flogging a Mule Model-based design was one of the key The first drive of a Volt prototype in charge- enablers to Volt’s rapid development sustaining mode revealed a lot about the car’s development pace 11 months before 141 Chapter 6 production. Sweating the Body Details Extensive wind-tunnel work gave Volt a 197 Chapter 10 shape that’s slicker than it looks. Charging and Connectivity But engineers aren’t happy with GM engineers designed in maximum the curb weight. flexibility for keeping the Volt juiced up and Q&A: Paul Haelterman, IHS Automotive connected—to the grid and to the Internet. Q&A: Chris Preuss, OnStar 147 Aerodynamic Development of the 2011 Chevrolet Volt. Lead author Nina 202 Chevy Volt debuts GM’s Global A Tortosa; SAE Technical Paper electrical architecture 2011-01-0168. 206 Voltec Charging System 153 Chapter 7 EMC Requirements and Test A Chassis that Cruzes Methodologies. Lead author Vipul M. To speed development and minimize cost, Patel; SAE Technical Paper Volt shares key underpinnings with its 2011-01-0742. high-volume cousin. Q&A: Dan Milot, TRW Automotive 211 Development of the Chevrolet Volt Portable EVSA. Lead author Tony 159 Co-development of Chevy Volt Tire Argote; SAE Technical Paper Properties to balance performance 2011-01-0878. and Electric Vehicle Range. Lead author Dean C. Degazio; SAE 219 About the Author Technical Paper 2011-01-0096. 169 Chapter 8 A New Role for the ICE Volt’s modified Family Zero inline four is along for the ride—until it’s needed. 173 Optimizing 12 Volt Start - Stop for Conventional Powertrains. Lead author Darrell Robinette; SAE Technical Paper 2011-01-0699. 187 Optimizing ICEs for hybridization. Automotive Engineering International, January 2010.

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