Automotive Design and Production

DEC 2015

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If this is an "efciency story," then one might think that the way to eke out more from the "range extender," a.k.a., the internal combustion engine, would be to have a smaller engine under the hood. Yet that's precisely what they didn't deploy. Whereas the frst generation vehicle has a 1.4-liter DOHC I4 that produces 84 hp, the 2016 Volt has an Ecotec 1.5-liter DOHC I4 that produces 101 hp. As previously noted, the 1.5-liter engine provides 42 mpg; the 1.4- liter provides 37 mpg. The electric portion of what's called the second-generation "Voltec electric drive system" ofers more— as in a 12% efciency improvement— and less—as in being 100 lb lighter than the frst-generation system. It is a two-motor drive unit that has been engineered so that there is motor power (the two combine for 111 kW) that is best suited for the application. For example, there can be a single motor used for low-speed driving, a split between two motors during moderate operation, and both when high speeds are required. Fletcher says that the Volt customers were interested in more spirited driving. And the drive unit responds, by improving the 0 to 30 mph acceleration to 2.6 seconds (a 19% improvement) and the 0 to 60 mph to 8.4 seconds (a 7% improvement). (The previously mentioned Model X: 0 to 60 in 3.2 seconds.) One concern that some had expressed as regards the electrifcation of vehicles was the demands for rare earth elements for the motors which are, well, rare (or not readily available or expensive or both). For the 2016 Volt, one of the motors uses little and the other uses none. One important simplifcation that they did in developing the new system is integrating the Traction Power Inverter Module, which manages the power fow between the battery and the drive motor, into the drive unit. Through the integration, they were able to eliminate the large orange wires under the hood. And another thing they wanted was fresh, contemporary styling 32 AD&P; > December 2015 > FEATURE > The 2016 Volt: Achieving Efciency > Gary S. Vasilash

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