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BMW’s battery pack technology reduces replacement costs

When people started buying hybrids and electric vehicles, the issue of battery pack costs was not so apparent. Perhaps it was due to having used batteries in conventional cars which could last a few years and replaced periodically at a relatively low cost. However, the battery pack in an electrified vehicle (hybrid/EV) is different from the typical 12V battery in millions of vehicles. While the small battery in the engine bay provides electricity to start the engine primarily, the battery pack in an electrified vehicle actually powers the vehicle.

Due to the need to store large amounts of electrical energy, the battery packs have to be bigger and use more advanced technologies and materials. Conventional 12V batteries have typically used a lead-acid combination and though improved over the years, their process of generating electricity through chemical reaction has not changed.

*Unlike the conventional 12V battery (left) that has been used for decades in millions of vehicles, battery packs in hybrids and EVs are much larger and cost a great deal more.*

Because battery pack technology is still evolving as storage capacity increases, the cost of the new technology is still high, not to mention the economies of scale are still lower than for conventional lead-acid batteries. This means they cost much more and for the early owners of electrified vehicles, there was the sudden shock of discovering that the cost of replacement was very high.

In Malaysia, depending on the model, the price was RM7,000 upwards. This led to reduced appeal for electrified vehicles and in order to provide peace of mind, the companies selling such vehicles began to offer a separate warranty on the battery pack which was longer than the factory warranty for the vehicle.

The prices have come down a bit and the battery pack for some Honda models sold in Malaysia is around RM5,500. Like those 12V batteries, the battery pack can last a while though there is no specific service life promised. Extreme operating conditions or rare system problems can shorten the life which is why the warranty is useful. But this does have an effect on resale value since the next owner would have to consider the added cost of replacement at some point in time.

BMW battery — *Battery pack in a BMW 530e M Sport (one section exposed to show the cell module inside).*

To address this key concern for electrified vehicle ownership, BMW’s high-voltage battery presents solutions to concerns around repair and maintenance by developing their batteries where single modules are replaceable. In the case of a lithium-ion battery pack (increasingly used) that houses multiple modules, there are multiple cells.

In most cases, if a battery pack starts to have problems or has reached the end of its service life, the whole unit has to be replaced – at considerable cost. However, the high-voltage battery pack used in BMWs does not necessarily require this expensive approach.

In the 530e M Sport, for example, the battery pack gas up to 6 cell modules. Should one of the modules be faulty, it does not mean the whole battery pack needs to be replace. Just that module can be changed and the cost is RM5,000 per cell. Although built to last the lifetime of the vehicle, BMW Group Malaysia still offers a comprehensive warranty coverage of 6 years/100,000 kms for the battery packs in its vehicles which should give peace of mind to owners.

The lightweight battery pack is capable of storing a great deal of energy, giving the 530e M Sport a maximum output of 83 kW which can get it to a maximum speed of 120 km/h in full electric driving. Recharging time is dependent on the type of system used but said to be under 3 hours with the BMW i Wallbox, with a fully charged battery pack giving an all-electric range of up to 40 kms.

BMW Battery technology — *BMW Group’s high-voltage battery technology is available in the plug-in hybrid variants of both BMW and MINI models.*

BMW’s high-voltage battery technology is available in the plug-in hybrid variants of the 5-Series, 7-Series, as well as the all-electric i3s and the MINI Plug-In Hybrid.

Production of High-Voltage Batteries for BMW Hybrid Vehicles underway in Thailand

30 years ago, Mercedes-Benz already had a practical EV based on the 190 model

For the past few years, Mercedes-Benz has begun its transition towards electrifications, creating the EQ range for a new line of electric vehicles (EVs). While R&D relating to EVs has accelerated in the past 10 years, the carmaker was already exploring electric propulsion 30 years ago.

In May 1990, it exhibited a 190 (W 201) model that had been converted to electric drive in the innovation market section at the Hanover Fair. “In this way, the Mercedes 190, which in terms of length and weight comes closest to the requirements of an electric vehicle, is an ideal battery test vehicle. The main objective is to assess the functional suitability of all the components in realistic situations with all the vibrations, accelerations and temperature fluctuations experienced in everyday operation,” explained the brochure issued at the time.

A mobile laboratory
The company made a fleet of electric 190s which were used to test different drive configurations and battery systems. The energy storage devices tested were mainly sodium-nickel chloride or sodium-sulphur high-energy batteries which had a significantly higher energy density than conventional classic lead-acid batteries. However, the working temperature of both systems was around 300 degrees C. which wasn’t so good.

The following year, Mercedes-Benz displayed a more advanced car at the Geneva Motor Show. This prototype with electric drive had an individual 16 kw/22 hp electric motor to drive each wheel. Total power output was 32 kW/44 hp and the energy came from a sodium-nickel chloride battery. Regenerative braking – a feature in many of today’s EVs and hybrids – returned energy to the power pack during braking actions.

A particular advantage of the concept was the elimination of weight-intensive mechanical components, so the additional weight compared to a production model with a combustion engine was only 200 kgs. It was still a substantial amount of extra weight, largely due to the battery pack.

From 1992 onwards, there was a large-scale field trial which ran for 4 years, funded by the German government. The aim of the exercise was to test EVs and energy systems, including batteries, in everyday practice. A total of 60 passenger cars and vans from several brands were involved.

100,000 kms in 1 year
The pioneering 190s were driven by various participants in the trials and these included taxi drivers who used them in daily life. There were hardly any problems and one of the Mercedes prototypes achieved a peak usage rate of around 100,000 kms in 1 year.

The results provided the engineers with new insights into battery service life, the number of possible discharge and charge cycles, range, energy consumption and reliability. In the following years Mercedes-Benz would apply the electric drive concept to other passenger models.

Mercedes-Benz EQC — *The first fully-electric Mercedes-Benz production model – the EQC. Its powertrain (below) was developed with the data gained from R&D activities since 1990.*

All the knowledge gained by the R&D teams in the 1990s contributed to the comprehensive knowledge pool of vehicle development on which engineers draw in developing today’s vehicles. In fact, some of the engineers who worked on the electric W 201 prototypes are still active in the company’s EV development and are involved in the latest projects.

Mercedes-Benz EQ Range unveiled in Malaysia

Electric Ford Mustang Cobra Jet 1400 to sizzle at the dragstrip

Electric powertrains used to have a poor image, considered suitable only for buggies around golf courses. That was when the technology was still in its infancy (though electrically-powered cars were already on roads in the 1930s) and performance as well as range were poor.

But since the beginning of the 21^st century, R&D for electric vehicles (EVs) has accelerated, partly prompted by increasingly strict emission regulations that make it very hard for the internal combustion engine (ICE) to meet. Many of today’s EVs operate with performance levels that are comparable to ICE cars and will continue to advance as they enter the mainstream.

As has happened almost since the beginning of the automobile, extending performance is a challenge for the engineers and the same is happening in the EV field. Here’s the latest example: the Mustang Cobra Jet 1400 by Ford Performance.

This is a one-off project to create a factory drag racer with all-electric propulsion. It’s projected to cross the quarter-mile (about 400 metres) in the low 8 second range at more than 270 km/h.

The powertrain is a prototype purpose-built and projected to deliver over 1,400 ps, with over 1,491 Nm of instant torque to demonstrate the capabilities of an electric powertrain in one of the most demanding race environments.

“Ford has always used motorsport to demonstrate innovation,” said Dave Pericak, Global Director, Ford Icons. “Electric powertrains give us a completely new kind of performance and the all-electric Cobra Jet 1400 is one example of pushing new technology to the absolute limit. We’re excited to showcase what’s possible in an exciting year when we also have the all-electric Mustang Mach-E joining the Mustang family.”

Ford Mustang Cobra Jet 1400 — *Uner the bonnet*

Following the debut of the all-electric Ford Mustang Mach-E SUV – the first-ever, all-electric Mustang – the Mustang Cobra Jet 1400 prototype represents another opportunity to advance the Mustang’s heritage and performance while simultaneously incorporating some of the most advanced technology coming to Ford’s future powertrains.

The name used for the prototype also honours the original Cobra Jet that first dominated dragstrips in the late 1960s and still is a major force in sportsman drag racing today. Ford Performance continues to test the Cobra Jet 1400 ahead of its world debut later this year at a drag racing event.

“This project was a challenge for all of us at Ford Performance, but a challenge we loved jumping into,” said Mark Rushbrook, Global Director, Ford Performance Motorsports. “We saw the Cobra Jet 1400 project as an opportunity to start developing electric powertrains in a race car package that we already had a lot of experience with, so we had performance benchmarks we wanted to match and beat right now. This has been a fantastic project to work on, and we hope the first of many coming from our team at Ford Performance Motorsports.”

All-electric Ford Mustang Mach-E debuts in Los Angeles, priced from around RM183,000

Honda aims to find a ‘second life’ for hybrid/EV battery packs

The lead-acid batteries in motor vehicles have been around for many decades and because they are made from elements that can be recycled, there is an established ‘business’ in collecting and recycling batteries. Even the guy who collects old newspapers will take them as the lead, plastics and even the sulphuric acid can also be recycled.

Lead-acid batteries are therefore considered as ‘closed-loop’ products which means that when their ‘first life’ is over, they can be recycled into other products. It is estimated that globally, 98% of such batteries are being recycled.

With the advent of hybrid and electric vehicles since the late 1990s, more powerful battery packs have appeared. These are needed to store electricity in large amounts and to power the electric motors. These have not continued with the lead-acid approach which would make the battery packs very heavy as they would have to be very big to store sufficient electricity.

Instead, the battery packs for battery-powered electric and hybrid vehicles use nickel-cadmium (NiCd), nickel–metal hydride (Ni-Mh), and more recently, lithium-ion or lithium-ion polymer. The technology is constantly advancing, and the battery packs are getting more compact while their storage capacity keeps growing, making possible longer travel ranges.

Honda Accord Hybrid battery pack — *Battery pack used in an Accord Hybrid.*

End-of-life disposal
The manufacturers have been mindful of the fact that the battery packs have an end-of-life and unlike lead-acid batteries, their disposal is not so straightforward. Various solutions have been explored to keep them in service and Honda Motor Europe, together with SNAM (Societe Nouvelle d’Affinage des Metaux), is investigating the possibility of using batteries in a ’second life’ for the storage of renewable energy in industrial applications.

SNAM is a battery recycling company and is increasing its role in partnership with the carmaker to advance the sustainable usability of its end-of-life battery packs. The pan-European arrangement will see SNAM collect and recycle batteries from Honda’s increasing number of hybrid and electric vehicles and either potentially prepare them for ‘second-life’ renewable energy storage uses or extract valuable materials for recycling if they are not suitable for that purpose.

Honda battery pack recycling — *End-of-life battery packs can be divided in two types – those that can be reconditioned and continue to function as energy storage units or broken apart and their materials recycled (below).*

Honda and SNAM have worked together since 2013 to ensure the traceability of end-of-life batterie packs and dispose of them in accordance with European Union environmental standards. The expansion of this agreement will see SNAM collect lithium-ion and NiMH batteries from Honda’s dealer network and Authorised Treatment Facilities in 22 countries, before analysing how suitable they are for recycling and processing them accordingly.

Second life applications
“As demand for Honda’s expanding range of hybrid and electric cars continues to grow, so does the requirement to manage batteries in the most environmentally-friendly way possible. Recent market developments may allow us to make use of these batteries in a second life application for powering businesses or by using recent improved recycling techniques to recover useful raw materials which can be used as feedstock into the production of new batteries,” said Tom Gardner, Senior Vice-President at Honda Motor Europe.

Safe and low carbon transport is utilised for the collection of used batterie packs. On arrival, SNAM assesses which battery packs are valid for inclusion in a new energy storage device. These are then repurposed and made available by SNAM for domestic and industrial applications.

When battery cells are damaged and unsuitable for ‘second life’ applications, materials such as cobalt and lithium can be extracted using hydrometallurgy techniques involving the use of aqueous chemistry. These can be reused in the production of new batteries, colour pigments or as useful additives for mortar. Other commonly used materials including copper, metal and plastics are recycled and offered to the market for use in the production of a variety of applications.

Honda e starts Honda’s electrification strategy in Europe

General Motors and Honda to jointly develop two all-new electric vehicles

General Motors and Honda have agreed to jointly develop two all-new electric vehicles for Honda, based on GM’s highly flexible global EV platform powered by proprietary Ultium batteries. The EVs will be manufactured at GM plants in North America with sales expected to begin in the 2024 model year in North America.

Production of these Honda electric vehicles will combine the development expertise of both companies. The exteriors and interiors of the new EVs will be exclusively designed by Honda, and the platform will be engineered to support Honda’s driving character.

Joint pursuit of electrification
GM and Honda already have an ongoing relationship around electrification, which both companies are pursuing in this decade. This includes work on fuel cells and the Cruise Origin, an electric, self-driving and shared vehicle, which was revealed in San Francisco earlier this year. Honda also joined GM’s battery module development efforts in 2018.

2020 Honda e — *Honda e is a new EV which the company developed primarily for the European market.*

“This collaboration will put together the strength of both companies, while combined scale and manufacturing efficiencies will ultimately provide greater value to customers,” said Rick Schostek, Executive Vice-President of American Honda Motor Co. “This expanded partnership will unlock economies of scale to accelerate our electrification roadmap and advance our industry-leading efforts to reduce greenhouse gas emissions.”

According to Doug Parks, GM Executive Vice-President of Global Product Development, Purchasing and Supply Chain, the agreement builds on a proven relationship with Honda, and further validates the technical advancements and capabilities of our Ultium batteries and our all-new EV platform.

“Importantly, it is another step on our journey to an all-electric future and delivering a profitable EV business through increased scale and capacity utilization. We have a terrific history of working closely with Honda, and this new collaboration builds on our relationship and like-minded objectives,” he said.

As part of the agreement to jointly develop electric vehicles, Honda will incorporate GM’s OnStar safety and security services into the two EVs, seamlessly integrating them with HondaLink. Additionally, Honda plans to make GM’s hands-free advanced driver-assist technology available.

Mazda CX-30 and MX-30 receive Red Dot: Product Design 2020 awards

The ‘Red Dot’ Award, which originated in Germany, has become established internationally as one of the most sought-after seals of quality for good design. Initiated in 1955, it is one of the world’s largest design competitions.

This year, two Mazda models received Red Dot: Product Design 2020 awards – the CX-30 and MX-30. Reflecting Mazda’s excellence in vehicle design, these are the eighth and ninth Red Dot awards won by Mazda’s models incorporating KODO design to date. Prior to this were the Mazda3 (2019), MX-5 RF (2017), MX-5 soft top, CX-3 and Mazda2 (all 2015), Mazda3 (2014) and Mazda6 (2013).

Mazda CX-30
The CX-30 is the second production model created with the latest evolution of the KODO design philosophy – artful design, rooted in traditional Japanese aesthetics. The honing of every element according to the ‘less is more’ principle has resulted in clean, beautiful surfaces on the CX-30 and brought an entirely original look to the compact crossover SUV segment.

“The Japanese master craftsmen have always prized simplicity of form, of being beautifully pure,” said Jo Stenuit, Mazda’s European Design Director. “This inspired our designers to trim back elements and create something dynamic yet elegant, restrained yet vital. This is how we perceive Japanese aesthetics – a sensibility that has created emotionally moving cars.”

Mazda MX-30
Though retaining the beautiful, handcrafted forms of KODO design, the styling of the Mazda MX-30 represents an exploration of a more modern aesthetic which focuses on the futuristic values and lifestyles that are beginning to emerge.

“This new approach has resulted in an original design that embodies the expansion of KODO’s expressive range,” explained MX-30 Chief Designer, Youichi Matsuda. “The exterior is uncompromisingly simple to emphasise its beauty as a solid mass, and the cabin design – with its framed top and freestyle doors – embodies an image of lightness while proactively incorporating sustainability as an element for the interior materials. As we begin an era of great change, we want the Mazda MX-30 to show people that our cars can still deliver pure joy of driving.”

The MX-30 is currently only available for the European market. It is equipped with e-SKACTIV, Mazda’s new electric drive technology, which uses a 35.5 kWh lithium-ion battery pack that gives a claimed range of approximately 200 kms. The driving range far exceeds the 48-km average daily drive of European customers, Mazda believes.

The Mazda CX-30 is available in Malaysia and to find out more about it, visit www.mazda.com.my.

First driving impressions: All-New Mazda CX-30

Volkswagen’s 1966 Classic transformed into a 21st century zero emissions vehicle

In due course, it will be possible for owners of the original Volkswagen T1 to make a conversion of the powertrain to a zero emissions electric drive system. Volkswagen Commercia Vehicles (VWCV), collaborating with eClassics, has developed a conversion package which is demonstrated in the e-BULLI all-electric concept vehicle.

VWCV engineers and designers formed a team along with drive system experts from Volkswagen Group Components and eClassics (a company which specialises in electric car conversions) to develop the e-BULLI. For the concept model, they chose a T1 Samba Bus produced in 1966 which, prior to its conversion, spent half a century on the roads of California.

New electric drive system components
The original 44 ps 4-cylinder boxer engine is replaced by a silent Volkswagen electric motor generating 61 kW (83 ps) and 212 Nm, the torque being more than double that from the engine before. The comparison of the engines’ power output alone makes it very evident that the concept vehicle will have completely new drive characteristics with performance unattainable using the original combustion engine.

Power transmission is by means of a 1-speed gearbox. The automatic transmission has 5 positions (P, R, N, D, B) and in position B, the driver can vary the degree of recuperation, ie of energy recovery when braking. The e-BULLI is claimed to have top speed of 130 km/h (electronically limited), 25 km/h more than the original T1.

1966 VW T1 — *The original T1 Samba Bus*

Just like the powertrain of the 1966 T1, the combination of gearbox and electric motor integrated in the back of the 2020 e-BULLI drives the rear axle. A 45 kWh lithium-ion battery pack provides energy for the electric motor while a DC/DC converter provides 12V power for on-board electronics.

As in the new ID.3 and future ID.BUZZ, the battery pack is housed centrally in the vehicle floor. This layout lowers the e-BULLI’s centre of gravity and thus improves its driving characteristics.

80% recharge in 40 minutes
The battery pack is charged via a combined charging system (CCS) socket. It enables charging with AC or DC electrical supply. Thanks to the CCS charging socket, the battery pack can also be charged at DC fast-charging points with up to 50 kW of charging power. In this case, recharging up to 80% energy levels can be done within 40 minutes. The range with a fully charged battery packs is claimed to be more than 200 kms.

Redesigned chassis
Compared to the T1, riding in the e-BULLI will feel completely different. This is due to the redesigned chassis which consists of multi-link front and rear axles with adjustable shock absorbers and coil-over struts. There is also a new rack-and-pinion steering system and 4 internally-ventilated disc brakes.

Click here to know more about the Volkswagen models available in Malaysia

New looks
In parallel with the new electric drive system, an interior concept has been created for the e-BULLI that is both stylish and avant-garde. The new look and corresponding technical solutions were developed by the VCVW design centre together with a team from VWCV Vintage Vehicles and the Communications department.

The designers modernised the exterior of the iconic vehicle with great sensitivity and finesse, including giving it a two-tone paintwork finish in Energetic Orange Metallic and Golden Sand Metallic MATTE.

Details such as the new round LED headlamps with daytime running lights modernise the looks. On the outside at the rear, there are also LED charge indicators. They signal to a driver walking up to the e-BULLI how much charge the lithium-ion battery still has.

Original interior concept modernised
The 8-seat interior has a few things not expected to be in a T1. While the designers have re-imagined a lot of the interior, they did not forget the original concept and the seating is one of the new features. In keeping with the external paintwork, it is also in two colours. Solid wood looking like that of a ship’s deck is used for the floor throughout and, with the nice bright leather tones, the electrified Samba Bus takes on a maritime feel. This impression is strengthened by the large panoramic folding roof.

The new speedometer is based on the original while a two-digit display within it creates a link to the modern era. There is a small detail in the centre of the speedometer: a stylised Bulli symbol. A multitude of further information is shown via a tablet integrated into the roof console.

Music on board comes from an authentic-looking retro-style radio which is equipped with cutting edge technology such as DAB+, Bluetooth and USB. The radio is linked to a sound system with high quality components, including an active subwoofer.

The e-BULLI will be available at prices starting from 64,900 euros (about RM307,000) for the T1 conversion (complete with redesigned front and rear axles), with T2 and T3 conversions also being offered by eClassics in Europe.

Volkswagen’s electric vehicles will use a 1-speed gearbox!

Battista Anniversario – the world’s first luxury pure-electric hyper GT

Automobili Pininfarina aims to offer what it describes as ‘the ultimate expression of the world’s first luxury pure-electric hyper GT’. Known as the Battista Anniversario, it celebrates 90 years since Battista ‘Pinin’ Farina started the Pininfarina coachbuilder and design house.

Laying claim to being the most powerful sportscar ever to be designed and built in Italy, 5 Battista Anniversario cars (there will be another 150 Battista hypercars made) will be hand-crafted in Turin, where Pininfarina has established its design centre and headquarters. Each is priced from 2.6 million euros (about RM12.4 million) and will be delivered to customers by the end of this year. Of course, with Italy now having a crisis and lockdown, production will be affected.

“For 90 years, the Pininfarina name has been at the forefront of automotive design and performance, and the Battista perfectly encapsulates these values. This ultimate expression of Battista, the Anniversario, is the distillation of everything that the brand has stood for in the past and which we now strive for in the future, creating a new pinnacle of desirability for sustainable and luxurious electric cars,” said Michael Perschke, CEO of Automobili Pininfarina.

“My grandfather always had the vision that one day, there would be a stand-alone range of Pininfarina-branded cars. The Battista Anniversario, named in his honour to mark 90 years of the carrozzeria that he started, is a glorious way to link our past with the future of motoring,” added Paolo Pininfarina, Chairman of Pininfarina SpA.

The Battista Anniversario delivers an added level of dynamic ability and a bespoke heritage-inspired anniversary livery. Each of the five cars is finished in a combination of three signature colours: Bianco Sestriere, the never-seen-before Grigio Antonelliano, and Automobili Pininfarina’s signature Iconica Blu.

The Battista Anniversario will have one of the most complex paint finishes in the world, with the process of creating akin to a great artist completing an Old Master painting. Skilled artisans will take several weeks to paint each car, building up the finish layer-by-layer and colour-by-colour – all by hand. The body is disassembled and reassembled three times so pinstripes in the three separate colours can be hand-painted directly onto the body.

The Battista Anniversario is also equipped with the ‘Furiosa’ package, comprising a revised carbonfibre front splitter, side blades and rear diffuser. Exclusively on the Anniversario, these parts are finished in a two-tone combination of exposed signature carbonfibre and carbonfibre tinted in Iconica Blu with pin stripes in Bianco Sestriere.

Besides the exclusive livery, a bespoke rear wing, rear aero fins and other bespoke details are unique to the Battista Anniversario. The aerodynamic enhancements enabled by the Furiosa exterior changes deliver increased downforce and greater stability at higher cornering speeds and a more dynamic balance to the car.

Four electric motors generating 1,900 bhp/2,300 Nm torque, apportioned to each wheel by the most advanced torque vectoring system, will take the car to a claimed top speed of 350 km/h. And faster than a current Formula 1 car in the sub-two second 0-100 km/h sprint, the Battista can also accelerate from 0 to 300 km/h in less than 12 seconds. This level of performance is unachievable today in any road-legal sportscar with an internal combustion engine.

“I have piloted the quickest road and race cars in the world and I’ve never driven anything as powerful as the Battista,” said Nick Heidfeld, Test and Development Driver at Automobili Pininfarina. “The Battista is faster than many race cars, but it is not a pure racing machine. Drivability in all situations is its primary focus. We will now concentrate our time testing and developing Battista to deliver a car that’s at the forefront of technological possibilities and innovation.”

GM looking forward to all-electric future with Ultium batteries

Like many carmakers, General Motors is heading for an all-electric future and putting considerable resources into building a multi-brand, multi-segment EV strategy with economies of scale that can rival its full-size truck business. By right, the company should be way ahead in the EV field today, having come out with the first mass-produced all-electric car, the EV-1, in 1996.

However, advanced as it was, the car was expensive to produce, and GM saw the EV segment then as being unprofitable, so it stopped making the car. Developing EVs then was not a priority (engineers who were assigned to such projects considered them ‘dead-end jobs’) and so GM didn’t advance its EV technology the way Toyota had done so with its hybrid technology after it introduced the Prius in the late 1990s.

GM EV-1 — *In 1996, GM launched the first mass-produced EV known as the EV-1. But it saw the EV segment as unprofitable and did not carry on development and marketing.*

Now GM is accelerating its R&D into EV technology and the heart of its strategy is a modular propulsion system and a highly flexible, third-generation global EV platform powered by proprietary Ultium batteries.

“Thousands of GM scientists, engineers and designers are working to execute a historic reinvention of the company,” said GM President Mark Reuss. “They are on the cusp of delivering a profitable EV business that can satisfy millions of customers.”

The Ultium batteries and Propulsion System
GM’s new Ultium batteries are unique in the industry because the large-format, pouch-style cells can be stacked vertically or horizontally inside the battery pack. This allows engineers to optimize battery energy storage and layout for each vehicle design.

Ultium energy options range from 50 to 200 kWh, which could enable a GM-estimated range up to 640 kms or more on a full charge with 0 to 100 km/h acceleration as low as around 3 seconds. Motors designed in-house will support front-wheel drive, rear-wheel drive, all-wheel drive and even performance all-wheel drive applications.

Ultium-powered EVs are designed for Level 2 and DC fast charging. Most will have 400-volt battery packs and up to 200 kW fast-charging capability while the truck platform will have 800-volt battery packs and 350 kW fast-charging capability.

Driving costs downwards
The flexible, modular approach to EV development is expected to drive significant economies of scale for lower production costs and create new revenue opportunities. The cells use a proprietary low cobalt chemistry and ongoing technological and manufacturing breakthroughs will drive costs even lower. Together with LG Chem, its joint venture partner, GM sees continuous improvement in battery costs as they are driven down to US$100/kWh.

GM’s all-new global platform will be flexible enough to build a wide range of trucks, SUVs, crossovers, cars and commercial vehicles. To build them with capital efficiency, GM will leverage on existing properties, including land, buildings, tools and production equipment such as body shops and paint shops.

The vehicle and propulsion systems are designed together to minimize complexity and part counts beyond today’s EVs, which are less complex than conventional vehicles powered by internal combustion engines. For example, GM plans 19 different battery and drive unit configurations initially, compared with 550 internal combustion powertrain combinations available today.

Third-party forecasters expect EV volumes in the US market to more than double from 2025 to 2030 to about 3 million units on average. But GM believes the numbers could be materially higher as more EVs are launched in popular segments, charging networks grow and the total cost of ownership to consumers continues to fall.

The Hummer is returning but you’ll hardly hear it coming… (w/VIDEO)

Second all-electric Volkswagen ID model will be the ID.4

What was presented as the ID. CROZZ showcar by Volkswagen earlier will become a production model known as the ID.4. The two letters, ‘ID’, indicate it as being part of the ID family that will use all-electric powertrains.

The ID range is part of the carmaker’s electric mobility strategy and following in the tracks of the ID.3, the countdown has already begun for this second model based on the new modular electric drive matrix (MEB). The new ID.4 will also be launched this year, possibly after the ID.3 which is scheduled to be in showrooms from mid-2020.

Volkswagen ID.CROZZ concept — *The ID.CROZZ concept displayed in 2017.*

“Just like the ID.3, the ID.4 will also come onto the market as a carbon-neutral vehicle,” said Ralf Brandstätter, Chief Operating Officer of the Volkswagen brand. “We will produce and sell the ID.4 in Europe, China and the U.S.”

The design of this zero-emission SUV is particularly aerodynamic. This is especially necessary for EVs that need every advantage to maximise energy use. More efficient aerodynamics will reduce drag and the electric motor won’t have to work so hard to achieve a desired speed. This can help boost the ID.4’s range to up to 500 kilometres, depending on the drive package.

The ID.4 will initially be launched with rear-wheel drive, while an electric all-wheel drive version will be added at a later date. The high-voltage battery is positioned near the centre of the underbody to create a low centre of gravity and optimise driving dynamics, along with an extremely well-balanced axle load distribution.

Related story: Volkswagen’s electric vehicles will use a 1-speed gearbox!

Just like all other MEB models, the ID.4 will offer plenty of interior space as its electric drive technology is compactly packaged. The fully digital cockpit of the SUV has been clearly structured and is operated primarily using touch surfaces and intelligent, intuitive voice control.

For Volkswagen, the ID.4 and ID.3 represent important milestones in the brand’s bid to become entirely carbon-neutral by 2050 – in line with the Paris climate agreement. Plans have been put in place to reduce the Volkswagen fleet’s CO²-emissions by a third by as early as 2025.

Volkswagen ID — *Prototypes of the initial ID family*

Volkswagen is currently investing one billion euros to electrify its model range while also offering an increasing number of hybrid vehicles. This is based on the fact that, just like electric powertrains, new mild and plug-in hybrid drives in high-volume product lines such as the Golf will significantly help to reduce fleet exhaust emissions in the future.