Design Optimization, Development and Manufacturing of General Motors New Battery Electric Vehicle Drive Unit (1ET35)

Hawkins, Shawn; Holmes, Alan; Ames, David; Rahman, K.M.; Malone, Rodney

doi:10.4271/2014-01-1806

Cited by 25 publications

(6 citation statements)

References 2 publications

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“…A survey of mostly light-duty EMs and ETDUs that are in production, near production, or high probability production prototypes dating from early 2000s to the present, 2023, [7][8][9][13][14][15][16]23,[26][27][28][29][30][61][62][63][64][65][66][67][68][69] are summarized in Figures 6-9 and focus on various attributes and trends related to EV propulsion system integration. Numerical data contained in Figures 6-9 can be found in the supplementary material.…”

Section: Review Of Electric Motors and Electric Traction Drive Unitsmentioning

confidence: 99%

“…These articles also provide a means to extract trends in EM technology that migrate to the production of EVs. Research studies by [11][12][13][14][15][16][17][18][19] have focused on advanced new EM design, construction, and control strategies, enabling higher torque density, minimal to zero use of rare earth materials, and reduced torque ripple and/or improved torque delivery for drivability, respectively. The direction of magnetic flux, which is traditionally radial in PMSMs, has been shown analytically [18,20,21], experimentally [7], and in the production of EMs [22,23] to provide benefits in torque and packaging.…”

Section: Introductionmentioning

confidence: 99%

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Electric Motor and Transmission Integration for Light-Duty Electric Vehicles: A 2023 Benchmarking Perspective and Component Sizing for a Fleet Approach

Robinette

2023

Vehicles

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A review of past, current, and emerging electric vehicle (EV) propulsion system technologies and their integration is the focus of this paper, namely, the matching of electric motor (EM) and transmission (TRM) to meet basic requirements and performance targets. The fundaments of EM and TRM matching from a tractive effort and a vehicle dynamics perspective are provided as an introductory context to available or near-production propulsion system products available from OEM and Tier 1 suppliers. Engineering data and details regarding EM and TRM combinations are detailed with a specific focus on volumetric and mass density. Evolutionary trends in EM and TRM technologies have been highlighted and summarized through current and emerging products. The paper includes an overview of the initial EV propulsion system’s sizing and selection for a set of simple requirements that are provided through an examination of three light-duty EV applications. An enterprise approach to developing electrified propulsion modules with suitable applicability to a range of light-duty EVs from compact cars to full-size trucks concludes the paper.

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Section: Review Of Electric Motors and Electric Traction Drive Unitsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Electric Motor and Transmission Integration for Light-Duty Electric Vehicles: A 2023 Benchmarking Perspective and Component Sizing for a Fleet Approach

Robinette

2023

Vehicles

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“…Significant strides have been made to improve the range, cost, and fueling times of electric vehicles through the improvement of the design and control of cells, and several automobile manufacturers are releasing battery powered vehicles with price points that target the general public. [1][2][3][4][5][6][7][8][9][10] New chemistries, such as lithium ion, have also been examined in order to increase the energy densities of these batteries in order to increase the range of battery powered vehicles, and decrease the volume displacement of these batteries in the vehicle powertrain. However, because these new chemistries result in more energy in a smaller volume, safety problems may arise.…”

mentioning

confidence: 99%

“…[1][2][3][4][5][6][7][8][9][10] New chemistries, such as lithium ion, have also been examined in order to increase the energy densities of these batteries in order to increase the range of battery powered vehicles, and decrease the volume displacement of these batteries in the vehicle powertrain. However, because these new chemistries result in more energy in a smaller volume, safety problems may arise.…”

mentioning

confidence: 99%

Modeling Volume Change in Dual Insertion Electrodes

Garrick

Huang

Srinivasan

et al. 2017

J. Electrochem. Soc.

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A mathematical model is presented that incorporates the dimensional and porosity changes in porous electrodes caused by volume changes in the active material during intercalation. Porosity and dimensional changes in an electrode can significantly affect the resistance of the battery during cycling. In addition, volume changes generate stresses in the electrode, which can lead to premature failure of the battery. Here, material conservation equations are coupled with the mechanical properties of porous electrodes to link dimensional and porosity changes to stresses and the resulting resistances that occur during the intercalation processes. Several different battery casings are examined in order to generate summary figures to aid in battery design. The associated stress, strain, porosity and resistance is predicted and discussed in relation to battery performance. Significant strides have been made to improve the range, cost, and fueling times of electric vehicles through the improvement of the design and control of cells, and several automobile manufacturers are releasing battery powered vehicles with price points that target the general public.1-10 New chemistries, such as lithium ion, have also been examined in order to increase the energy densities of these batteries in order to increase the range of battery powered vehicles, and decrease the volume displacement of these batteries in the vehicle powertrain. However, because these new chemistries result in more energy in a smaller volume, safety problems may arise.11 Therefore, it is critical to be able to predict the performance of new battery systems in order to improve safety and reliability, while also continuing to increase the energy density, which in turn decreases the weight and volume requirement of battery systems in alternative energy passenger vehicles.Due to the recent commercial and government sector success of high energy density batteries, high performance electrode materials, separators, electrolytes, and new cell and stack designs are being actively developed to further improve cell capacity, charging and discharge rates, safety, cycle life, and shelf life. The most widely used anode material (graphite) in Lithium-ion batteries undergoes a volume change (10%) during lithiation and delithiation cycles.12 However, high capacity anode materials, such as silicon and its alloys, undergo even higher volume changes ranging from 100% to 270%.12-15 Other battery chemistries, such as Li-Sn alloy intercalation cathodes, have seen volume changes as high as 350% as observed by Yang et al. 16The volume changes seen in these new battery electrode materials induce a significant amount of stress in the electrodes during battery operation.12,17-19 These volume changes and high stresses may result in the fracturing of active particles within the electrodes, and induces bulk stresses at the cell and stack level. A moderate amount of bulk stress in lithium-ion cells may be beneficial to cell operation, however, excessive stresses cause reduced cell performance an...

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“…There is an increased focus on improving the range, cost, and fueling times of electric vehicles through the improvement of the design and control of cells. [1][2][3][4][5][6][7][8][9][10] New chemistries, such as lithium ion, have also been examined in order to increase the energy densities of these batteries in order to increase the range of battery powered vehicles, and decrease the volume displacement of these batteries in the vehicle powertrain. However, safety problems have arisen in the past several years.…”

mentioning

confidence: 99%

Modeling Battery Performance Due to Intercalation Driven Volume Change in Porous Electrodes

Garrick

Higa

et al. 2017

J. Electrochem. Soc.

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Simulations are presented that result from incorporating dimensional and porosity changes in porous electrodes caused by volume changes in the active material during intercalation into a detailed lithium-ion battery model. Porosity and dimensional changes in an electrode can significantly affect the resistance of the battery during cycling, which in turn alters the reaction distributions in the porous electrodes. In addition, volume changes generate stresses in the electrode which can lead to premature failure of the battery. Here, material conservation equations are coupled with the mechanical properties of porous electrodes to link dimensional and porosity changes to stresses and the resulting resistances that occur during the intercalation processes. Through the use of porous rock mechanics, porosity and strain gradients can be predicted based on state of discharge and discharge rate. Several different battery casings and discharge rates are examined and operating curves are predicted.

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Design Optimization, Development and Manufacturing of General Motors New Battery Electric Vehicle Drive Unit (1ET35)

Cited by 25 publications

References 2 publications

Electric Motor and Transmission Integration for Light-Duty Electric Vehicles: A 2023 Benchmarking Perspective and Component Sizing for a Fleet Approach

Electric Motor and Transmission Integration for Light-Duty Electric Vehicles: A 2023 Benchmarking Perspective and Component Sizing for a Fleet Approach

Modeling Volume Change in Dual Insertion Electrodes

Modeling Battery Performance Due to Intercalation Driven Volume Change in Porous Electrodes

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