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GM executive chief EV engineer says reducing cost of plug-in vehicles is 'huge priority'

As we know, another major automaker investing heavily in electrified vehicles is General Motors, and it's doing things much differently than rivals BMW, Ford or Nissan. The Chevrolet Volt extended-range EV is a modest seller at its $35,000 sticker price but a huge hit with owners. The Chevy Spark BEV, still in limited availability, puts smiley faces on its owners and drivers. The just-introduced Cadillac ELR, a sharp-looking, fun-driving $76,000 luxocoupe take on the Volt's EREV mechanicals, has admittedly low sales expectations. With this interesting trio in showrooms and much more in the works, the third vehicle electrification leader I collared for an interview at Detroit's North American International Auto Show (see #1 and #2) was Pam Fletcher, GM's executive chief engineer, Electrified Vehicles. ABG: Why do your EREVs need four-cylinder power to extend their range when BMW's i3 makes do with an optional 650 cc two-banger? "We designed [the Volt and the ELR] to go anywhere, any time" - Pam Fletcher PF: I get that question all the time: why not something smaller? You don't really need that much. You use the electric to its ability, then you just need to limp. But we designed those cars to go anywhere, any time, and we don't want their performance to be compromised. If you're driving through the mountains, we don't want you to be crawling up grades, or to be limited on any terrain. So it's optimized to be able to travel literally the biggest grades and mountain roads around the globe at posted speeds. Because what if you can't? Another good reason: when the engine is on, you have to run it wide open throttle, max speed, most of the time. And while we can do a lot with acoustics, and the ELR has active noise cancelation, a small-displacement, low cylinder-count engine at high speed, high load all the time isn't something you want to live with. That's how we came up with the balance we did among the key factors of performance, NVH [noise, vibration and harshness] and range. ABG: Where you go from here? Is the range-extender engine due for an update? PF: We know and love the current Volt, and there is still a lot of acclaim about it, so we think it's a good recipe. But we are heavily in the midst of engineering the next-generation car, which I think everyone will love and be excited about.

GM will likely build PHEV batteries in China soon

It's a big week for batteries. Friday, Tesla will hold a big event at its Gigafactory in Reno, NV. But even in Michigan, there are things happening on the electrified automotive front. This was proven when GM invited journalists to its Brownstown Battery Assembly Plant today, highlighting the six different battery packs it makes for nine vehicles around the world (plus a tenth, coming to Asia, that has not yet been announced). During our tour, we learned a few interesting tidbits that we thought readers would like to hear: The Cadillac CT6 plug-in hybrid launches in China this fall before coming to the US next year. GM builds the battery packs in Michigan and ships them to China for final assembly in the PHEV. For now, this is all fine for GM to qualify for China's incentives for building green cars in the country. But, as Bill Wallace, GM's director of global battery systems, told AutoblogGreen, this could change thanks to the country's 'Made in China 2025' plan. The situation is "evolving," he said, and it's a safe assumption that GM will need to build packs in China some day. For the CT6 PHEVs that will be sold in the US, the batteries will make a round trip, since GM will only build the plug-in version in China. As for the range of the CT6 PHEV, that hasn't been announced, but since China offers incentives for vehicles that get at least 50 kilometers (31 miles), that's a likely target (the US range (UPDATE: GM did announce an expected range for the CT6 PHEV in the US at the LA Auto Show last fall, saying it would "travel approximately 30 miles on a full electric charge"). The battery pack in the CT6 is also a clunky box-type thing, totally unlike the near-elegant T-shape used in the Volt. This despite the fact that the guts of the two packs are similar. Both have 192 li-ion cells and weigh almost the same, but GM tuned the CT6 pack for acceleration instead of range, the way it did with the Volt's pack. Still, the main reason the packs are different is because the CT6 is a rear-wheel drive vehicle, and the tunnel that the Volt's pack uses is occupied by the driveshaft. Despite the highly touted second-gen Chevy Volt going on sale last year, GM still has the capacity to build battery packs for the old, first-gen model. This is because the company is legally required to be able to provide replacement packs for warrantied vehicles (for up to 10 years), and the second-gen packs don't fit into the first-gen vehicles.

GM shows off 'digital vehicle platform' enabling more in-car tech and OTA updates

It appears to have dropped the sobriquet "Global B," but General Motors' new electrical architecture has bowed in drawings and video. This is the "digital vehicle platform" GM president Mark Reuss spoke to Reuters about in 2015, saying it would move a great deal of a vehicle's computer work to the cloud and enable over-the-air updates. Reuss took the microphone for the debut, too, saying, "Our new digital vehicle platform and its eventual successors will underpin all our future innovations across a wide range of technological advancements, including EVs and expanded automated driving." The system will go into production later this year, appearing in dealerships first either on the 2020 Cadillac CT5 or the mid-engined 2020 Chevrolet Corvette. Yes, these are the same electronics cited for delaying the launch of the C8 Corvette over excessive draw, security and getting the more-than-100 computer modules to communicate seamlessly. When Car and Driver asked about that, GM replied with "No comment." Volkswagen's having the same issues with the Mk8 Golf right now, though, so GM isn't alone, and this will be the new normal among OEMs for a while. What's certifiable is that the new architecture is robust enough to handle 4.5 terabytes of data per hour, which is five times what GM's current wiring can handle. And thanks to Ethernet connections of 100 Mbps, 1 Gbs and 10 Gbs, communication within and without the vehicle happens much faster. The advances mean better screen resolutions, better battery management for hybrids and electric vehicles, the capability for over-the-air updates and "functionality upgrades throughout the lifespan of the vehicle." Cadillac's Super Cruise has already been lined up as a leading candidate for constant improvements in the driving assistance suite, a key part of GM's "vision for a world with zero crashes, zero emissions and zero congestion." And whenever GM decides to take the plunge, it will mean a 48-volt electrical system. More than 300 specialists worked on the digital platform, and security was a huge part of the task. We've already heard that GM consulted with Boeing and military contractors on how to prevent hacking. The carmaker has an internal Product Cybersecurity group that reached out to the research community, and created a "bug bounty" program to crowdsource uncovering any flaws.