Environmental Commitment

GM To Be First Major U.S. Automaker to Manufacture Electric Motors

WASHINGTON (Jan. 26, 2010) – GM will expand its in-house electric vehicle development capabilities by becoming the first major U.S. automaker to design and manufacture electric motors, a core technology for hybrids and electric vehicles.

By doing so, GM will lower costs and improve performance, quality, reliability and manufacturability of electric motors by controlling design, materials selection and production processes. The first GM-designed and built electric motors are scheduled to debut in 2013 in next-generation, rear-wheel-drive Two-mode Hybrid technology.

“Electric motor innovation supported the first wave of automotive growth a century ago with the electric starter, which eliminated the need for a hand crank, and revolutionized automotive travel for the customer,” said Tom Stephens, GM vice chairman, Global Product Operations. “We think the electrification of today’s automobiles will be just as revolutionary and just as beneficial to our customers. Electric motors will play a huge role in that.”

In conventional cars and trucks, automakers design and manufacture engines to efficiently use energy provided from a gas tank to provide power to the wheels. Motors and batteries, respectively, fill that role in hybrid and electric vehicles. As the range and speed of electric-only propulsion increase, so do the importance of motors and batteries.

Electric vehicles are powered solely by electric motors, while hybrid vehicles also use an internal combustion engine for propulsion. GM’s next-generation rear-wheel-drive Two-mode Hybrid system will use two unique motor designs and an internal combustion engine to provide improved fuel efficiency compared with the current Two-mode Hybrid technology in GM’s full-size pickup trucks and sport-utility vehicles.

“In the future, electric motors might become as important to GM as engines are now,” Stephens said. “By designing and manufacturing electric motors in-house, we can more efficiently use energy from batteries as they evolve, potentially reducing cost and weight – two significant challenges facing batteries today.”

GM has been building this in-house capability for years, expanding electric motor research and development, design and validation capabilities at facilities in Michigan, Indiana and California. GM also has developed state-of-the-art math-based design and computing capacity for electric motors. The electric motors will be manufactured in the U.S. at a GM facility.

GM was selected in August by the U.S. Department of Energy for a $105-million grant for the construction of U.S. manufacturing capabilities to produce electric motors and related electric drive components. “The new GM is about speed, and we are delivering quickly on the government’s desire to grow domestic expertise in electric vehicle technologies, such as batteries and electric motors,” Stephens said.

Similar to today’s internal combustion engines, automotive electric motors require an unparalleled combination of exceptionally low noise, vibration and harshness (NVH); high reliability and affordability that is achievable only by understanding the entire value chain. In addition to growing in-house capabilities, GM will continue to purchase and co-design electric motors with suppliers.

“This is a strategy we use today with batteries,” Stephens said. “We are partnering with suppliers to create innovations faster than ever before. Our goal is simply to establish GM as a leader in automotive electric motors. We see that leadership as a key enabler – both to our long-term success and to our nation’s move away from oil dependence.”

GM announced last August a $43-million investment to prepare the 160,000-square-foot, landfill-free facility for production of lithium-ion battery packs for the Volt and other electric vehicles with extended-range capabilities. The plant is part of a wholly-owned subsidiary of General Motors called GM Subsystems Manufacturing LLC.

In just five months, the Brownstown plant was converted from an empty facility to a production-ready battery manufacturing site. New machinery and specialized equipment have been installed and three primary assembly areas have been completed: battery module pre-assembly, final assembly and the battery pack main line.

The Volt’s battery pack is made up of multiple linked battery modules and more than 200 battery cells. The initial assembly area is where the prismatic-shaped cells are processed and installed by state-of-the-art flexible automated equipment into modules, which are then delivered to the battery pack main line.

The battery pack main line area features an Automated Guided Cart (ACG) system that includes operations for thermal and electrical assembly, along with quality and dimensional checks. The main line is also where battery pack final testing, verification and packaging for shipment take place.  

Initial battery production at Brownstown will be used to validate the plant’s equipment and processes, and batteries will be sent to GM’s Global Battery Systems lab in Warren, Mich., for testing. This spring, GM will begin shipping batteries to GM’s Detroit-Hamtramck plant, the assembly location for the Volt, for use in production validation vehicles.

Regular production at Brownstown and Detroit-Hamtramck is set to begin in the fourth quarter.

GM is investing $700 million in eight Michigan facilities for Volt-related production, including $336 million in the Detroit-Hamtramck plant, which will benefit from battery research conducted at the battery lab in Warren; receive batteries from Brownstown; use tooling from Grand Blanc; take delivery of camshafts and connecting rods from Bay City; and dies, stampings and the Volt’s 1.4L engine-generator from three plants in Flint.

“The development of electric vehicles like the Chevy Volt is creating entire new sectors in the auto industry – an ‘ecosystem’ of battery developers and recyclers, builders of home and commercial charging stations, electric motor suppliers and much more,” Whitacre said. “These companies and universities are creating new jobs in Michigan and across the U.S. – green jobs – and they’re doing it by developing new technology, establishing new manufacturing capability, and strengthening America's long-term competitiveness.”

In August, the U.S. Dept. of Energy selected 45 companies, universities and organizations, including GM, in 28 states for more than $2 billion in awards for electric drive and battery manufacturing and transportation electrification. Nearly half of that total is designated for cell, battery and materials manufacturing facilities in Michigan.

The Volt is an electric vehicle with extended-range capability. It is designed to drive up to 40 miles on electricity without using gasoline or producing tailpipe emissions. When the Volt’s lithium-ion battery is depleted of energy, a flex-fuel engine-generator seamlessly operates to extend the total driving range to about 300 miles before refueling or stopping to recharge the battery. Pricing has not been announced.