http://www.engineering.com/DesignerEdge/DesignerEdgeArticles/ArticleID/11294/Inside-the-Chevrolet-Bolt-EV.aspx Inside the Chevrolet Bolt EV January 12, 2016 Kagan Pittman
[images / © General Motors http://res.cloudinary.com/engineering-com/image/upload/w_640,h_640,c_limit/Bolt_3_g0wagy.jpg (transparent/x-ray view) http://res.cloudinary.com/engineering-com/image/upload/w_640,h_640,c_limit/Bolt_2_day3am.jpg Chevrolet Bolt EV Battery System http://res.cloudinary.com/engineering-com/image/upload/w_640,h_640,c_limit/Bolt_1_omi3xk.jpg (body-less chassis view) ] GM recently released the specs on their 2017 Chevrolet Bolt Electric Vehicle (EV) not long after unveiling the completed vehicle at CES 2016. GM engineers designed the Bolt EV’s propulsion system to offer a range of more than an estimated 200 miles on a single charge. The drive system uses a single high capacity electric motor to power the car. Constructed from steel and aluminum, the front-wheel drive, five-passenger, five-door and all-electric crossover utility vehicle has a maximum speed of 91mph (145kph). The electric motor has an offset gear and shaft configuration to meet the 200mi estimate and is capable of producing up to 266lbs-ft (360Nm) of torque and 200hp (150kW). With a final drive ratio of 7.05:1, the Bolt EV can go from 0-60mph in under seven seconds. The 2017 model will control power delivery with Chevrolet’s first Electronic Precision Shift system. The shift and park-by-wire system will send electronic signals to the Bolt EV’s drive unit to manage delivery of power and torque based on drive mode selection and accelerator inputs. An additional benefit of the new shift system comes from the added interior space and layout. Bolt EV’s Battery Offers over 200 miles of Range The engineers behind the Bolt EV battery teamed up with strategic partner LG Electronics to develop the vehicle’s new cell and battery pack. Preliminary specifications detail a 60kWh lithium-ion battery pack with 288 lithium ion cells. The cells are arrayed in five sections with 10 modules and 96 cell groups (three cells per group). The battery pack weighs 906lbs (435kg) total. “You usually have a battery cell that delivers either the desired levels of energy or power, but not traditionally both,” said Gregory Smith, Bolt EV battery pack engineering group manager. “With this cell design and chemistry we were able to deliver a battery system with 160 kilowatts of peak power and 60 kilowatt hours of energy.” The Bolt EV’s battery, similar to the Chevrolet Volt’s, uses active thermal conditioning to keep the battery at optimum temperature. Cells are arranged in a “landscape” format, similar to Faraday Future’s FFZERO1. Each cell measures 3.9in (100mm) high and 13.1in (338mm) wide. Lower profile cell design allows for additional interior space. The Bolt EV’s battery system is mated to a standard equipment 7.2kW onboard charger for regular overnight charging from a 240-V wall box. A commute of 50mi can be recharged in under two hours. Alternatively, the optional DC Fast Charging system with an SAE Combo connector can charge 90mi of range in 30 minutes. However, outside temperatures may effect charging times. Bolt EV utilizes Regenerative Braking for One Pedal Driving The Bolt EV features a new regenerative braking system to allow for one pedal driving. Increased regenerative deceleration and software controls allow the vehicle to slow down and come to a complete stop without using the brake pedal in certain driving conditions. Drivers can bring the Bolt EV to a stop when driving in “Low” mode or by holding the Regen on Demand paddle located on the back of the steering wheel and lifting their foot off the accelerator. However, wise drivers won’t rely on the technology in heavy rain or during particular bad winter days. This is a technology best used cautiously – the brake pedal will not be eliminated any time soon. The Chevrolet Bolt EV is scheduled to enter production in October of 2016. An exact list price has not yet been released, but speculation puts it between USD$30,000-40,000 after government subsidies. With key competitors in the Nissan Leaf, BMW i3, Ford Focus Electric, Kia Soul EV, VW eGolf and Mercedes-Benz B-Class Electric, it’s looking certain that the big auto names are ready for a market turning electric ... For more information ... www.chevrolet.com. [© 2016 ENGINEERING.com] http://insideevs.com/chevrolet-bolt-ev-specs-revealed-60-kwh-0-60-in-less-than-7-seconds/ Chevrolet Bolt EV Specs Revealed: 60 kWh, 0-60 In “Less Than” 7 Seconds – Video [January 11, 2016] Jay Cole [images http://insideevs.com/wp-content/uploads/2016/01/Chevrolet-Bolt-EV-engine.jpg Chevrolet Bolt EV Motor – 266 lb-ft of torque/200 hp http://insideevs.com/wp-content/uploads/2016/01/2017-Bolt-EV-specs-1.jpg 2017 Chevrolet Bolt EV Specs http://insideevs.com/wp-content/uploads/2016/01/2017-Bolt-EV-specs-2b.jpg (charge times/performance) http://insideevs.com/wp-content/uploads/2016/01/2017-Bolt-EV-specs-3.jpg (chassis/suspension) http://insideevs.com/wp-content/uploads/2016/01/2017-Bolt-EV-specs-4.jpg (dimensions - exterior) http://insideevs.com/wp-content/uploads/2016/01/2017-Bolt-EV-specs-5.jpg (dimensions - exterior +capacities) video flash regen system that provides “one-pedal” driving ] ... GM states that in conjunction with a 7.05:1 final drive ratio, the Bolt EV will zip past 60 mph (98 km/h) from a standstill in “less than seven seconds“, while 0-30 mph is accomplished in 2.9 seconds. GM puts top speed of the Bolt EV at 91 mph/145 km/h ... On the 60 kWh battery itself: 60 kWh lithium-ion battery pack. 288 lithium ion cells Five sections 10 modules 96 cell groups – three cells per group 960 lbs. (435 kg) total weight GM says that the pack uses active thermal conditioning which is “similar” to the 2016 Chevrolet Volt. Still, a 8-year/100,000 mile warranty should take care of any issues owners might come across “You usually have a battery cell that delivers either the desired levels of energy or power, but not traditionally both. With this cell design and chemistry we were able to deliver a battery system with 160 kilowatts of peak power and 60 kilowatts hours of energy,” – Gregory Smith, Bolt EV battery pack engineering group manager ... The nickel-rich lithium-ion chemistry provides improved thermal operating performance over other chemistries, which requires a smaller active cooling system for more efficient packaging. The chemistry allows the Bolt EV to maintain peak performance in varying climates and driver demands. The cells are arranged in a “landscape” format and each measures in at only 3.9 ins. (100 mms) high and 13.1 ins. (338 mms) wide providing improved packaging underfloor. The lower profile cell design enabled the vehicle structure team to maximize interior space ... GM saying that a 50 mile recharge can take less than two hours via a 7.2 kW on board charger (which is standard). Full charge on L2 takes 9 hours ... DC Fast Charging is in the SAE Combo connector configuration. Here again GM says 90 miles of range can be recouped in 30 minutes ... Through a combination of increased regenerative deceleration and software controls, one pedal driving enables the vehicle to slow down and come to a complete stop without using the brake pedal in certain driving conditions. When operating the Bolt EV in “Low” mode, or by holding the Regen on Demand paddle located on the back of the steering wheel, the driver can bring the vehicle to a complete stop under most circumstances by simply lifting their foot off the accelerator, although the system does not relieve the need to use the brake pedal altogether. Operating the Bolt EV in “Drive” mode and not pulling the paddle while decelerating delivers a driving experience where usage of the brake pedal is required to stop ... 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