Category: Hybrid

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Cadillac ELR Goes Ultrasonic in Pursuit of High Quality

Ultrasonic welding, a high-tech manufacturing process used in the aerospace and medical industries, is helping ensure high quality for the new Cadillac ELR extended-range electric luxury coupe that goes on sale in North America in early 2014.

Ultrasonic welding’s key advantage is exceptional and predictable quality and performance from one battery pack to the next. Every ELR battery, for example, has close to 200 ultrasonic welds. Each is required to meet stringent quality requirements, enabling Cadillac to offer an eight-year/100,000-mile battery system warranty.

Short cycle times, low capital costs and manufacturing flexibility through the use of automation are other advantages of ultrasonic welding.

“Ultrasonic welding is a far superior joining technology in applications where it can be deployed,” said Jay Baron, president and CEO of the Center for Automotive Research in Ann Arbor, Mich. “Cadillac’s innovative process will produce batteries with superior quality compared with traditional methods – and do it more efficiently. This is one example of technology development that is becoming pervasive in today’s world class vehicles.”

General Motors’ Brownstown Battery Assembly plant near Detroit, uses ultrasonic welding to join metal electrode tabs on ELR’s advanced 16.5-kWh lithium-ion battery system, and does it with a proprietary quality monitoring process. Brownstown uses an automated system to execute millions of these welds each year.

Ultrasonic welding uses specialized tools called an anvil and horn to apply rapid mechanical vibrations to the battery’s copper and aluminum electrodes. This creates heat through friction, resulting in a weld that does not require melting-point temperatures or joining material such as adhesives, soldering or fasteners.

An integrated camera vision system is used to shoot a reference image of the weld area prior to the operation to achieve pinpoint accuracy. Quality operators check electrode tabs before and after welding, and the system monitors dozens of signal processing features during each weld.

The battery-specific welding process is a result of collaboration among General Motors’ Manufacturing Systems Research Lab and Advanced Propulsion Center and the Brownstown plant. GM first applied the process on the award-winning Chevrolet Volt – its groundbreaking extended-range electric vehicle – and further refined it for ELR.

“This effort is an outstanding example of teamwork between research and manufacturing engineering,” said Catherine Clegg, GM vice president of Global Manufacturing Engineering. “It has helped integrate the use of highly technical, complex technology into a sustainable manufacturing process, which means we can consistently deliver high-quality batteries to our customers for the Cadillac ELR.”

The ELR’s T-shaped battery pack is located along the centerline of the vehicle, between the front and rear wheels for optimal weight distribution. The 5.5-foot-long (1.6 m), 435-pound (198 kg) pack supplies energy to an advanced electric drive unit capable of 295 lb-ft of instant torque (400 Nm) to propel the vehicle. Using only the energy stored in the battery, the ELR will deliver a GM-estimated range of about 35 miles (56 km) of pure electric driving, depending on terrain, driving techniques and temperature.

Charging the ELR’s battery can be done with a 120V electrical outlet or a dedicated 240V charging station. The vehicle can be completely recharged in about 4.5 hours using a 240V outlet, depending on the outside temperature.

The Cadillac ELR is built at GM’s Detroit-Hamtramck Assembly Plant, one of the few high-volume electric vehicle manufacturing facilities based in the U.S. Its battery pack is built from cell to pack at Brownstown and shipped to Detroit-Hamtramck for assembly into the vehicle.

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Toyota Hybrid Racing outlines plans for 2013 season

Toyota Racing can confirm its plans for the remainder of the FIA World Endurance Championship season.

The team will split its efforts between the ongoing 2013 WEC season and the development of its 2014 car in order to make best use of the available resources.

As a consequence, the #8 of Anthony Davidson, Sébastien Buemi and Stéphane Sarrazin, which is the lead TS030 HYBRID in the championship, will compete in Sao Paulo (1 September) and Austin (22 September).

Alex Wurz and Nicolas Lapierre will focus on 2014 development with testing and simulation sessions while Kazuki Nakajima will continue the defence of his Super Formula title whilst also racing in Super GT.

A decision regarding the team’s line-up at the remaining WEC rounds will be announced in due course.

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Acura NSX Prototype to Lap Mid-Ohio Prior to Honda Indy 200

Acura today released an image of a prototype NSX supercar, announcing that the running prototype will take to the racetrack just prior to the Honda Indy 200 IndyCar Series race at Mid-Ohio Sports Car Course in Lexington, Ohio. The NSX prototype with custom graphics will lap the road course in advance of the race on August 4, 2013. The race will be broadcast live by NBC Sports Network starting at 3 p.m. EDT.

Global development of the NSX, slated for launch in 2015, is being led by engineers at Honda R&D Americas, Inc. in Raymond, Ohio. Additionally, it was announced in May that the next-generation Acura supercar will be produced at the newly established Performance Manufacturing Center in nearby Marysville, Ohio.

The prototype model maintains the styling and proportions of the NSX Concept that debuted at the 2012 North American International Auto Show in Detroit, while packaging the production vehicle's mid-mounted V-6 engine mated to Acura's innovative new three-motor Sport Hybrid SH-AWD (Super Handling All Wheel Drive) system.

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Next Mitsubishi Evo to be 500 hp hybrid Nissan GT-R rival

The next-gen Mitsubishi Evo will allegedly feature a hybrid setup good enough for about 500 bhp (373 kW).

The standard Lancer will be globally launched sometime next year, while a plug-in hybrid model is already in the works. In addition, Autocar says Mitsubishi executives are also analyzing the prospects of a high-performance gasoline-electric variant with technology derived from the MiEV Evolution II Pikes Peak.

Although it's in an early development stage, the new Evo is expected to offer better all-wheel drive performance than its predecessor, as well lower CO2 emissions and the possibility of running on electric power. If green-lighted for production, the car's styling could be influenced from the 2008 Concept-RA.

Before a new Evo is out, Mitsubishi is planning a Lancer PHEV with a 2.0-liter gasoline engine working together with two 80 bhp (60 kW) electric motors. The setup should enable the car to return at least 150 mpg UK (125 mpg US or 1.8 liters / 100 km) with CO2 emissions of 50 g/km and a 40-mile (64 km) electric range.

Source: autocar.co.uk

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SIX Porsche 918 Hybrid Spyder On the Road in Monaco [VIDEO]

While cruising around Monaco, Youtuber Marchettino stumbled upon a convoy of several Porsche 918 Spyders!

Technical data - 2014 Porsche 918 Spyder

  • Engine: two electric engines and a 4.6L petrol V6 with a total of 875hp / 750nm
  • Performance: 0-100 kph (0-60 mph) sprint in 2.8s and a top speed of 340kph (211 mph)
  • Curb Weight: 1675kg
  • Price: 781.000€ and limited to 918 units
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    Volkswagen XL1 achieves ‘only’ 160 MPG not 314 MPG [VIDEO]

    Volkswagen made big claims about the efficiency of their purpose-built XL1 diesel-hybrid. They claimed the car was good for 314 mpg, which equates to 0.9 l/100km in the Metric system. However, at a recent test drive event organized by VW, a handful of journalists were given the chance to drive the mid-engined XL1.

    The Automobile Magazine representative at the event averaged "only" around 160 mpg or 1.47 l/100km, which is still a hugely impressive figure but not the EU-certified314 mpg originally promised.

    It's not all bad news. Autocar were also at the event and report that on an early test drive, which including crossing a mountain range, the most economical drivers achieved a real 188 mpg and conclude there’s surely potential for 200 mpg on a long motorway run.

    The upshot is that the plug-in hybrid XL1 is probably still the most economical and most aerodynamically efficient production car of all time.

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    Volkswagen XL1 and e-up! to run @ Silvretta E-Car Rally

    Volkswagen will be lining up at the start of this year’s Silvretta E-Car Rally with two innovative vehicles: one is the XL1, the most efficient production car in the world, which is equipped with a plug-in diesel hybrid engine. The other is the e-up!, the first electric vehicle from Volkswagen to be produced in high volume. Volkswagen is showing in this way that these alternative drive systems are capable of excellent performance on Alpine roads as well.

    The new e-up! is taking part in the Silvretta E-Car Rally in the Austrian Montafon region for the first time. With its Alpine route profile, the rally is both a test of reliability and highly demanding, as the challenge is to recover large amounts of the power used on the long uphill climbs through battery regeneration on the subsequent downhill sections.

    With a totally electric drive system the e-up! provides an entry point to a new pioneering Volkswagen vehicle concept and with four seats guarantees scope for full utilisation. It is a car for everyday use, with impressively high torque of 210 Nm. Practically silent and with no loss of traction during gearshifts, the e-up! is powered by an electric motor that delivers a maximum output of 60 kW / 82 PS. It thus accelerates from 0 to 100 km/h in 12.4 seconds and achieves a top speed of 130 km/h. With its 18.7 kWh lithium-ion battery it has a reach according to NEDC of up to 160 kilometres. This means impressively low energy costs of less than €3 per 100 kilometres.

    The e-up! can be charged with 2.3 kW plugged into any standard 230V socket, with 3.6 kW via a home-installed wall box or with up to 40 kW plugged into a DC fast-charging station via the optional CSS (combined charging system). In the latter case, the battery is 80 per cent charged in under 30 minutes. The power connection point for charging the battery is concealed as usual under the fuel cap. In the ideal scenario the e-up! will be charged using electricity from regenerative sources and will then be running 100% CO2 neutral.

    The e-up! differentiates itself from the basic up! model through a high-quality, aerodynamically optimised design. One striking identifying feature externally is the curved arrangement of the LED daytime running lights in the bumper. The front section, sills and underbody have also been aerodynamically enhanced. Burnished 15-inch alloy wheels with low rolling resistance tyres, Volkswagen emblems on a blue background and e-up! lettering on the hatch and the front doors make the fully electric four-seater instantly unmistakable.

    Only a premium level of trim is being offered for the e-up! In addition to the high up! specification it includes ‘maps+more’ navigation, Climatronic climate control and multi-function display, heated windscreen, heated seats and tinted rear windows. The mobile online ‘Car Net’ services, which can be controlled via smartphone, appear in the e-up! for the first time in the New Small Family and also form part of the car’s standard specification.

    The interior is characterised by light grey seat covers with blue fell seams, a design specific to the e-up! The purposeful use of leather and chrome trim conveys a purist overall impression – in keeping with a fully-fledged, urbane electric car’s vehicle concept.

    The entry-level price of the e-up! in Germany as an already well-equipped base model inclusive of battery is €26,900. This autumn at the IAA (International Motor Show) in Frankfurt, Volkswagen will announce further details on how the vehicle is to be marketed, including, for example, leasing and flexible car hire packages.