SAE PT-149-2011 Chevrolet Volt Development Story of the Pioneering Electrified Vehicle (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、Chevrolet VoltDevelopment Story of thePioneering Electrified VehicleEdited byLindsay BrookeChevrolet VoltDevelopment Story of the Pioneering Electrified VehicleOther SAE books of interestHybrid-Powered Vehicles, Second EditionBy John M. German(Product Code: T-125)Electric and Hybrid-Electric Vehicle

2、s by Ronald K. Jurgen, (Product Code: PT-143.SET) Advanced Hybrid Powertrains for Commercial VehiclesBy Haoran Hu, Rudy Smaling, and Simon J. Basely(Product Code: R-396)Chevrolet VoltDevelopment Story of the Pioneering Electrified VehicleBy Lindsay BrookePublished bySAE International400 Commonwealth

3、 DriveWarrendale, PA 15096-0001 USAPhone: (724) 776-4861Fax: (724) 776-5760www.sae.orgPT-149Copyright 2011 SAE International. eISBN: 978-0-7680-5783-6 400 Commonwealth DriveWarrendale, PA 15096-0001 USA E-mail: CustomerServicesae.orgPhone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside US

4、A)Fax: 724-776-1615Copyright 2011 SAE International. All rights reserved.No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE. For permission and licens-ing requests, contact

5、SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765.ISBN 978-0-7680-4765-3Library of Congress Catalog Number 2011922124SAE Order No. PT-149Information contained in this work has been obtained by SAE International fr

6、om sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this inform

7、ation. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought.To purchas

8、e bulk quantities,please contact:SAE Customer ServiceE-mail: CustomerServicesae.orgPhone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA)Fax: 724-776-1615Visit the SAE Bookstore at http:/store.sae.orgiSAE Electrification SeriesSAE Vehicle Electrification Table of Contents ELECTRIFICAT

9、IONvehicle SERIESiii PrefaceGM on the Critical Path Four years of Volt development 01 Chapter 1Why Volt?After 48 months development, the 2011 Chevrolet Volt has entered series production. The pioneering “E-REV” is as important to the mobility industry as it is to GM.09 The Electrification of the Aut

10、omobile: From Conventional Hybrid, to Plug- in Hybrids, to Extended-Range Electric Vehicles. Lead author E.D. Tate; SAE Technical Paper 2008-01-0458.21 The CO2 Benefits of Electrification E-REVs, PHEVs, and Charging Scenarios. Lead author E.D. Tate; SAE Technical Paper 2009-01-1311.32 2011 Chevrolet

11、 Volt Specifications35 Chapter 2Creating the Heart of VoltGMs battery requirements meant creating a new state-of-the-art in-vehicle energy storageand doing it in less than four years. Top GM and supplier engineers reveal how they did it. Q SAE Technical Paper 2011-01-1360.51 Voltec Battery System fo

12、r Electric Vehicle with Extended Range. Lead author Roland Matthe; SAE Technical Paper 2011-01-1373.71 High Voltage Hybrid Battery Tray Design Optimization. Lead author Kristel Coronado; SAE Technical Paper 2011-01-0671.83 High Voltage Connect Feature. Lead author Trista Schieffer; SAE Technical Pap

13、er 2011-01-1266.87 Chapter 3Engineering with a Maniacal FocusA dedicated, cohesive team and a conservative engineering approach put this innovative vehicle into production at moon-shot speed.90 Chevrolet Volt Development Timeline92 OnStar deployed as a tool for Volt engineers93 Chapter 4A Unique Ele

14、ctrified TransaxleHybrid or not? Definitions aside, what really matters is GM wisely leveraged its next-generation Two Mode propulsion technology to give Volt greater overall efficiency.Q SAE Technical Paper 2011-01-0355.115 The GM “Voltec” 4ET50 Multi-Mode Electric Transaxle. Lead author Michael A.

15、 Miller; SAE Technical Paper 2011-01-0887.129 High Voltage Power Allocation Management of Hybrid/Electric Vehicles. Lead author James D. Marus; SAE Technical Paper 2011-01-1022.ii SAE Electrification Series SAE Vehicle Electrification 193 Chapter 9Flogging a MuleThe first drive of a Volt prototype i

16、n charge-sustaining mode revealed a lot about the cars development pace 11 months before production.197 Chapter 10Charging and ConnectivityGM engineers designed in maximum flexibility for keeping the Volt juiced up and connectedto the grid and to the Internet.Q SAE Technical Paper 2011-01-0742.211 D

17、evelopment of the Chevrolet Volt Portable EVSE. Lead author Tony Argote; SAE Technical Paper 2011-01-0878.219 About the Author135 Chapter 5Codifying the CarModel-based design was one of the key enablers to Volts rapid development141 Chapter 6Sweating the Body DetailsExtensive wind-tunnel work gave V

18、olt a shape thats slicker than it looks. But engineers arent happy with the curb weight.Q SAE Technical Paper 2011-01-0168.153 Chapter 7A Chassis that CruzesTo speed development and minimize cost, Volt shares key underpinnings with its high-volume cousin. Q SAE Technical Paper 2011-01-0096.169 Chapt

19、er 8A New Role for the ICEVolts modified Family Zero inline four is along for the rideuntil its 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 Inter

20、national, January 2010.Table of Contents ELECTRIFICATIONvehicle SERIESiiiSAE Electrification SeriesSAE Vehicle Electrification PrefaceGM on the Critical PathFour years of Volt developmentWhen veteran GM engineer Jon Lauckner sketched out his idea for a new type of electrified propulsion system for h

21、is boss, Bob Lutz, in 2007, he reckoned there were two major hurdles in the way of the idea actually reaching production.The first hurdle was simply getting the idea for an “extended range” electric vehicle approved. But Lutz, then GMs Vice Chairman for Product Development, was immediately convinced

22、 this was something the automaker had to do. The second hurdle was far more daunting. For Lauckners idea to work as conceived, it needed a high power/high energy automotive battery that did not exist.Lutz likened the program to a “moon shot,” because of the high level of invention and critical-path

23、engineering required to meet the aggressive 2010 production target. Lauckner remained confi-dent that the issue of developing a suitable battery would be solved. “We have the best technical organization in the industry,” he told me about a year into the Volts development. “Were going to execute this

24、 program and deliver an exceptional new vehicle as planned.”With volume production of the 2011 Chevrolet Volt underway at GMs Detroit-Hamtramck assem-bly plant, the development team and its strategic suppliers have delivered on Lauckners promises. Volts overall performance, battery range, NVH attenu

25、ation, driver interfaces, and build quality ex-ceeded my high expectations during recent drives. Currently the car has no peer in its approach to “green” mobility. My four years of reporting on this milestone vehicle inspired the special Volt digital magazine which launched on SAE Internationals new

26、 Ve-hicle Electrification web portal () in November 2010. In covering the programs devel-opment I filled a dozen notebooks and compiled hundreds of hours of interview recordings with the engineers who made Volt happen. This SAE techni-cal publication is the logical follow-up to the online magazine.W

27、ith GM set to publish 12 technical papers related to Volt at the 2011 SAE World Congress, it made sense to combine them with the Volt digital magazine and other Volt-related content previously published in Automotive Engineering International magazine. Taken together, the compendium pro-vides the mo

28、st comprehensive insight into Volts genesis, engineering, and development.Competitors will find many things of interest when they tear down a Volt for analysis. Its innova-tive powertrain brings a number of high-volume, industry-first technology applications. Among them are the liquid-cooled Li-ion

29、battery pack; smart-phone driver interface for remote cabin condition-ing and battery-charge control; SAE J1772 charge coupler; and the use of Behrs novel “chiller” heat exchanger that uses both A/C refrigerant and glycol-based coolant to help cool the battery in extreme operating conditions. The mo

30、re than 200 patents GM has filed related to the Volt program will prove useful as more com-petitors enter the electrified-vehicle space. Particu-larly important is the intellectual property related to power controls and the functionality of the new 4ET50 electrified transaxle. My key takeaway about

31、Volt as a product is that it represents the advent of the industrys turn toward vehicles that are primarily electronics plat-forms, rather than mechanical ones. By the time the car had entered production, it had undergone more than 20 major vehicle control software calibrations (known as VESCOMs), p

32、lus many more v.1, v.2, etc., iterations. No wonder GM is investing so heav-ily in new resources in the rapidly growing electri-cal/electronics engineering arena.But the highlight of covering Volt for me was getting to know the high-caliber people who made it happen. Its execution reflects the dedic

33、ation and focus of everyone involved.Lindsay BrookeSenior Editor, SAE International March 2011iv SAE Electrification Series SAE Vehicle Electrification 1SAE Electrification SeriesSAE Vehicle Electrification Why Volt?Engineers will debate whether Volt is technically a series-type hybrid or an extende

34、d-range EV (E-REV as GM prefers to call it). Lear Corp. helped develop the cars offboard 120-V and 240-V charging set. GM continues to evaluate charging technologies (Coulomb Technologies charging station shown).After 48 months development, the 2011 Chevrolet Volt has entered series production. The

35、pioneering “E-REV” is as important to the mobility industry as it is to GM.CHAPTER ONE:2 SAE Electrification Series SAE Vehicle Electrification A production-spec Volt undergoes aerodynamic testing by technician Nina Tortosa at GMs Warren, MI, wind tunnel in 2009.Mention the words “fuel injector” to

36、any-one whos reasonably savvy about ve-hicles, and theyll likely know some-thing about the device that controls the metering of liquid fuel into an engines cylinders and helps cause the vehicle to drive faster or slower.But mention the term “IGBT” and the response may elicit a lot of blank stares. I

37、GBTs, the acronym for insulated gate bipolar transistors, are the fuel injectors of electrically driven vehicles. They con-trol the supply of battery electrical energy into the electric motors that drive the wheels. IGBTs are valves for electrons, much like a fuel injector is a valve for liquid fuel

38、s. Comparing these two simple and essential com-ponents shows how fundamentally the auto industry is going to change, as it moves from the petroleum-based model that has sustained it for more than 100 years to the electrified model that many experts be-lieve will literally propel it for the next 100

39、 years. Vehicle electrificationthe industrys shift to hy-brids, plug-in hybrids, and electric vehicles (EVs)is bringing more than a different vocabulary. It is bringing new technologies, patents, core competencies, and skill sets for engineers. Electrification is attracting investment capital that h

40、as helped create new companies aimed at disrupt-ing the status quo. It has helped jump-start a U.S. battery industry (aided by billions in federal and state subsidies), invigorated development of more efficient electric motors, and forced traditional automakers and suppliers to rethink their own pro

41、duct-develop-ment strategies, R Im talking about everybody everywhere. Its incred-ible growth,” he said.“Combine money and brainpower and youre very likely to get results. This thing is going to hap-penits not a question of if but when. The com-panies that step out and harness money and intel-lectua

42、l commitment are the companies that are go-ing to win,” he said. And the entire auto industry will be chasing them. Experts expect a steady global march to zero-emissions laws.8 SAE Electrification Series SAE Vehicle Electrification 9SAE Electrification Series2008-01-0458Published04/14/2008doi:10.42

43、71/2008-01-0458The Electrification of the Automobile: From Conventional Hybrid, to Plug-in Hybrids, to Extended-Range Electric Vehicles E. D. Tate, Michael O. Harpster and Peter J. Savagian General Motors Corporation ABSTRACT A key element of General Motors Advanced Propulsion Technology Strategy is

44、 the electrification of the automobile. The objectives of this strategy are reduced fuel consumption, reduced emissions and increased energy security/diversification. The introduction of hybrid vehicles was one of the first steps as a result of this strategy. To determine future opportunities and di

45、rection, an extensive study was completed to better understand the ability of Plug-in Hybrid Electric Vehicles (PHEV) and Extended-Range Electric Vehicles (E-REV) to address societal challenges. The study evaluated real world representative driving datasets to understand actual vehicle usage. Vehicl

46、e simulations were conducted to evaluate the merits of PHEV and E-REV configurations. As derivatives of conventional full hybrids, PHEVs have the potential to deliver a significant reduction in petroleum usage. However, the fuel consumption benefits are limited by the underlying constraints of the b

47、ase hybrid systems and vehicles. Even with incremental electric power and speed improvements, the PHEVs lack of full-performance, all-electric capability requires engine operation under everyday speed and/or load conditions, regardless of available battery energy. This creates emissions concerns and

48、 can severely limit the actual all-electric driving range in the real world. The E-REV is principally an Electric Vehicle (EV) with full vehicle performance available as an EV. Significantly, it overcomes the historical EV re-charge time limitations by adding a fuel-powered electric generator to ext

49、end driving range. Actual all-electric driving can regularly be experienced throughout the working energy range of the vehicles battery without fear of being stranded. The E-REV offers the opportunity for petroleum independence, and a dramatic reduction in emissions for many drivers. An E-REV traction drive and battery system needs to be specifically designed for the task. The systems