GM Gets Serious About Electric Car Production

Engineers for Chevrolet Bolt EV partner with LG Electronics for critical components.

Even with all the hype, electric cars are not the spectacle they used to be.

I see one on my commute almost every day. Even if you include the Tesla, Chevy Volt and Nissan Leaf, no one really notices the presence of electric vehicles on our streets anymore.

The reality is that electric vehicles are a fraction of total vehicle sales and with continuing concerns about cost and anxiety about range limits, the EV market has been slower to grow than many anticipated.

Crude oil prices are currently low and for now the American love affair for large SUVs and pickup trucks works against widespread electric vehicle manufacturing.

However, this doesn’t mean that mainstream manufacturers aren’t hoping to spread electric car popularity with lower-cost, longer-range technology. General Motors’ Chevrolet Bolt EV, not to be confused with the Chevrolet Volt, is an example. The way GM is engineering the vehicle shows how serious they are. 

General Motors rejected their traditional in-house vehicle development process and instead selected LG Electronics as its partner in developing the new Bolt EV.

What’s the goal? An affordable, usable electric vehicle that has a 200 mile range, eliminating the need for away-from-home recharging for the majority of motorists.

The 200 mile range at a moderate cost is a challenging specification. When combined with consumer demand for very sophisticated infotainment systems in the cabin, however, it makes the partnership sensible.

LG Electronics offers expertise in infotainment, battery systems and component development, while GM possesses proven in-house capabilities in electric motor design, battery control, system validation and vehicle body/system integration.

All engineers know that making something good is relatively easy, but to make it both good and affordable is exponentially more difficult; the Chevrolet Bolt EV is no exception.

The Bolt EV concept was shown at the North American International Auto Show in January this year and Chevrolet has announced that the Bolt EV will go into production at GM’s Orion Township, Michigan (USA) assembly plant in late 2016.

GM & LG Blend Expertise

Engineers considered different vehicle architectures, electric driving ranges and performance options for the Bolt EV before deciding the vehicle must be affordable and deliver 200-plus miles of all-electric driving while retaining spirited performance.

LG supplied an array of new components and systems for the Chevrolet Bolt EV, including:

  • Electric Drive Motor (built from GM design)
  • Power Inverter Module (converts DC power to AC for the drive unit)
  • On Board Charger
  • Electric Climate Control System Compressor
  • Battery Cells and Pack
  • High Power Distribution Module (manages the flow of high voltage to various components)
  • Battery Heater
  • Accessory Power Module (maintains low-voltage power delivery to accessories)
  • Power Line Communication Module (manages communication between vehicle and a DC charging station)
  • Instrument Cluster
  • Infotainment System

LG Electronics’ Vehicle Components is leading a team of LG companies including LG Chem, LG Innotek and LG Display to help develop the Bolt EV.

LG Electronics has invested more than $250 million in an engineering and manufacturing facility in Incheon, Korea, to support the component development and manufacturing for Bolt EV components.

GM’s relationship with LG began in 2007, when LG Electronics supplied the vehicle communications module for OnStar, GM’s telematics system.

Another LG-owned company, LG Chem, was chosen as the sole supplier of battery cells for the first-generation Chevrolet Volt, which launched in 2010.

LG delivered more than 23 million battery cells with less than two problems per million cells produced for the first-generation Chevrolet Volt; better than six sigma quality assurance for this critical component.

So why does this matter? Mainly because electric cars, although interesting and suggestive of low-cost green transportation, are not a disruptive technology.

They’re too expensive for the average motorist and lack useful range. The real impact awaits the introduction of true low-cost, long-range technology that compares dollar for dollar with similarly equipped gasoline or diesel powered vehicles.

It’s not clear at this point whether the Bolt EV will be that vehicle, but if the pricing can be held under $40,000, with the range meeting the 200 mile goal, it may be the vehicle that truly ignites the switch to nonpetroleum transportation.

If it works, the Bolt EV may become as iconic as Ford’s Model T, the Volkswagen Beetle or the original Austin Mini. We’ll keep an eye on it and let you know how it goes.

Written by

James Anderton

Jim Anderton is the Director of Content for ENGINEERING.com. Mr. Anderton was formerly editor of Canadian Metalworking Magazine and has contributed to a wide range of print and on-line publications, including Design Engineering, Canadian Plastics, Service Station and Garage Management, Autovision, and the National Post. He also brings prior industry experience in quality and part design for a Tier One automotive supplier.