Engineers at GM’s battery test facilities have developed a new computer algorithm to accelerate durability testing of the advanced lithium-ion batteries needed to power the Chevrolet Volt for up to 40 miles (64 km) of electric-only driving.
This advanced computer program duplicates real-life vehicle speed and cargo-carrying conditions, and compresses 10 years of comprehensive battery testing into the Volt’s brisk development schedule.
The battery cycling equipment is used around the clock in GM test facilities in Warren, Mich. and Mainz-Kastel, Germany. It charges and discharges power from the prototype batteries based on the Volt’s approximately 40-mile electric-only drive cycle. Results from this test data will help predict the long-term durability of the battery.
Testing the batteries in the laboratory provides a predictable environment to compare technologies under controllable situations. The batteries will soon be integrated into “mule,” or test, vehicles with other E-Flex system components for on-road tests.
Engineering an electric vehicle with a battery roughly 6 feet long (1.8 m) and weighing more than 375 pounds (170 kg) requires innovation. The T-shaped battery will be located down the center tunnel of the vehicle and under the rear seats. This integration requires the battery to be treated as part of the vehicle structure. Simulation data also indicates that the center placement provides greater protection to the battery.
Engineering innovations are also required to maximize the Volt’s 40-mile electric-only range and minimize the use of its range-extending internal combustion engine. To reduce mass, the Volt is being engineered with a relatively small fuel tank. This reduces weight, but still provides a driving range in excess of 400 miles between fill-ups.
Chevrolet Volt Lithium-Ion Battery
E-Flex Systems Design Studio the new E-flex studio was once an auditorium built for product reviews and other special events hosting famous entertainers and even several former U.S. presidents.