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2015 Chevy Spark will have lighter, smaller battery

As General Motors gets ready to release the 2015 Chevy Spark EV, it is retooling the Brownstown Battery Assembly to build a new battery system for the chirpy little electric car. The new Spark will lose a few pounds and kWh from its lithium-ion pack, but it will keep all of it's performance specs. The current Spark EV uses a 21-kWh lithium-ion battery pack with bits made by A123 Systems (known as B456 Systems during bankruptcy). For the 2015 model, GM is going to build a 19-kWh battery system in-house that will use 192 LG Chem cells. Losing a bit of energy capacity means that the battery system for the 2015 Spark EV will be 86 pounds lighter but it will keep the EPA-rated 82-mile range and 119 MPGe. The 2015 Spark EV also keeps its $26,685 (plus destination) starting price from the 2014 model. The car will once again qualify for a federal tax credit of up to $7,500. LG Chem also supplies the cells for GM's other plug-in vehicles from its facility in Western Michigan. The Brownstown production line currently builds the battery packs for the Chevy Volt, the Opel Ampera and the Cadillac ELR. You can read our first drive of the 2014 Chevy Spark here. Brownstown Battery Assembly Expands Capabilities Will build battery system for 2015 Chevrolet Spark EV 2014-05-14 DETROIT – General Motors will bring all its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at its battery assembly plant in Brownstown, Mich. "Using our in-house engineering and manufacturing expertise enabled us to deliver a battery system that is more efficient and lighter than the 2014 Spark EV without sacrificing range," said Larry Nitz, executive director of GM global transmission and electrification engineering. "Our successful working relationship with LG Chem has allowed us to deliver a new battery system for the Spark EV that helps us to better leverage our economies of scale." A newly designed battery system features an overall storage capacity of 19 kWh and uses 192 lithium ion cells. The cells are produced at LG Chem's plant in Holland, Mich. The battery system weight of 474 lbs. is 86 pounds lighter than the system in the 2014 Spark EV. The Spark EV battery is built on a dedicated production line at Brownstown, which also manufactures complete battery packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR.

Weekly Recap: GM plans massive new paint shop at Chevy Corvette factory

General Motors is laying out some serious green to maintain the Chevy Corvette's expansive color palette. The automaker is breaking ground on a new paint shop this summer that's part of a $439-million investment to upgrade the 34-year-old Bowling Green, KY, factory that builds the Stingray. The massive new structure will total 450,000 square feet, nearly half the size of the current 1-million square-foot facility. Construction is expected to take two years and won't impact Corvette production. The upgrades include new robots that save paint and create a better finish, longer, more efficient ovens to bake in the finish, and LED lighting. There's also a dry scrubbing booth technology with a limestone handling system that eliminates waste. GM has invested $135 million in the factory in last four years for the changeover to build the C7 and to relocate its Performance Build Center to Bowling Green. The improvements continue to modernize the Kentucky factory, which has become a tourist attraction in its own right, as more than 56,000 enthusiasts visited it last year. The upgrades are part of a $5.4-billion investment GM confirmed in April that will remake its US footprint in the next three years. The Bowling Green expansion underscores GM's continued commitment to the Corvette, which sold nearly 38,000 copies around the world last year, an eight-year high. "With this major technology investment, we can continue to exceed the expectations of sports car buyers for years to come," North American manufacturing manager Arvin Jones said in a statement. OTHER NEWS & NOTES Takata recall hits 34 million vehicles The National Highway Traffic Safety Administration expanded the Takata airbag recall to an almost unthinkable 34 million vehicles on Tuesday. The recall is part of an agreement reached by the two sides where Takata admitted some of its airbag inflators have a defect, and the deal compels the company to comply with all future regulatory actions and investigations. Takata's airbag inflators were produced with "a propellant that can degrade over time" and lead to ruptures, NHTSA said. Six deaths have been attributed to the flaw worldwide. Investigations conducted by Takata, automakers, and others have not determined the exact cause of the inflator problem, but NHTSA said moisture appears to alter the propellant's chemical structure. It then ignites too rapidly, creates too much pressure that ruptures the inflator, and blasts shards of metal at passengers.

Recharge Wrap-up: Volt makes up third of Quebec Chevy dealerships sales, Tesla seeks Aussie talent

A Chevrolet dealership in Quebec has had the Volt make up 35 percent of its sales so far this year. Bourgeois Chevrolet in Rawdon, Quebec received recognition for the feat at the 2014 Electric Vehicle Conference, where it won the award for Leading Plug-in Hybrid Electric Vehicle Dealership. To sell that many, Bourgeois Chevrolet had to import used Volts from the US, and keeps about 50 units on the lot in various configurations. The conference also saw Park Avenue Nissan of Brossard, Quebec win the Leading Battery Electric Vehicle Dealership Award, and Loch Lomond Mitsubishi of Saint John, New Brunswick receive the award for Electric Vehicle Dealership Inspiration. Read more at Green Car Reports. Tesla Motors has begun scouting Australian engineers as other automakers shutter operations there. Ford, General Motors and Toyota have announced that they will shut down their Australian factories, leaving behind a lot of unused talent. Tesla recently held a "Recruiting Open House" in Melbourne for engineers to fill positions at its plant in Fremont, CA, where they will be paired with other Aussie engineers already on staff. Read more at Green Car Reports, or at Motoring. Electric turbochargers may come to play a key role in making internal combustion engines more efficient. Valeo recently showed an electric turbo it plans to supply to an unnamed automaker at a fuel economy showcase event at the EPA's National Vehicle Emissions and Fuel Lab. Electric turbochargers have the advantage of greatly reduced lag when compared to exhaust-driven turbos. They also work well when paired with cylinder deactivation, providing a much-needed boost when driving on a grade, which can help reduce the need for cylinders to reactivate. Independence from the exhaust system also makes it easier to package the turbocharger wherever there is room. Read more from Navigant Research. US crude oil futures have dropped to their lowest in more than two years. Saudi Arabia cut oil costs for the US and raised them for Europe and Asia as the US has increased output. On November 3, US crude futures fell as much as 2.2 percent in New York. West Texas Intermediate closed at $78.78, the lowest since June 2012. Brent crude slipped $1.08 to $84.78 a barrel. Read more at Bloomberg.