Ultium Explained

Ultium is an electric vehicle battery and motor architecture developed by General Motors.[1] It is being deployed for battery electric vehicles from General Motors portfolio brands along with vehicles from Honda[2] and Acura.[3]

Ultium is characterized by a modular layout, using an Ultium battery to supply power to one or two Ultium Drive unit(s) using a common set of power electronics (charging, battery management system, and inverter). The high-voltage battery is composed of pouch cells that can be stacked horizontally or vertically, depending on the form factor appropriate for each vehicle, generally carried between the axles and under the floor. The traction motor(s), reduction gear, and power electronics are combined into a single Ultium Drive unit that drives the front, rear, or both axles. Three electric motor designs, sharing a common stator, are used across all planned vehicles.[4] [5] Ultium is used by GM's BEV3 and BT1 platforms.[6]

History

General Motors revealed the Ultium battery and platform technologies during a week-long March 2020 event held at the General Motors Technical Center in Warren, Michigan;[7] GM chairwoman and CEO Mary Barra called it "a multi-brand, multi-segment EV strategy with economies of scale that rival our full-size truck business with much less complexity and even more flexibility".[8] The Ultium Drive branding was applied six months later in September 2020, referring to electric vehicle drivetrain components exclusive of the batteries, such as the traction motors and power electronics.[9]

GM announced in June 2021 it would collaborate with Wabtec to provide Ultium battery modules for zero-emission heavy-haul locomotives, including the FLXDrive.[10]

In 2022, the US Army selected GM Defense to demonstrate an electric military vehicle, using the GMC Hummer EV pickup. In September, GM Defense was chosen to build a heavy-duty pack to power electric military vehicles.[11]

Design

Ultium Drive

Ultium vehicles are powered by a modular family of five drive units and three electric traction motors, known collectively as "Ultium Drive". Mass production of Ultium Drive motors and units is scheduled to start in 2024 at the GM Toledo[12] [13] and St. Catharines propulsion factories.[14] [15]

Traction motors

Planned motors include:[16]

The motors are suitable for front-wheel drive, rear-wheel drive and all-wheel drive configurations. For example, the GMC Hummer EV prototype shown in March 2020 has full-time all-wheel drive and is equipped with three motors, one driving the front axle and the other two driving the rear wheels.[7] The three traction motor types are oil-cooled and share a common stator design.[17]

Drive units

The drive units are single-speed reduction gearboxes which accept one or two traction motors and provide power to the wheels; the gearboxes are integrated with drivetrain electronic control modules. These modules, also known as power electronics, include the traction power inverter, onboard charging module, and accessory power module;[18] integration of these modules into the drive units results in a combined mass that is half that of the equivalent components of the Chevrolet Bolt EV.[19] [20] These drive units are designed and packaged based on the intended drivetrain layout, but share many common components.[21] The five units are:[22]

For the GMC Hummer EV, the drive units provide reduction ratios of 13.3:1 and 10.5:1 for the front and rear wheels, respectively.[23]

Ultium battery

Chemistry

Ultium battery cells feature nickel-cobalt-manganese-aluminum (NCMA) chemistry, and will be manufactured by Ultium Cells LLC, a joint-venture of GM and LG Energy Solution as large format pouch cells.[24] Battery materials will be supplied by LG Chem and POSCO Chemical (cathode active materials) and Livent (lithium hydroxide).[25] [26]

In China, Ultium-branded battery cells use nickel-manganese-cobalt (NMC) chemistry and are manufactured by CATL with cylindrical packaging.[27] With the announcement of the joint venture with Samsung SDI for the fourth US battery plant in April 2023, prismatic and cylindrical Ultium battery cells will be produced domestically.[28]

The next-generation Chevrolet Bolt EV will use Ultium cells with lithium iron phosphate chemistry, which will reduce peak and nominal cell voltage.[29]

Specifications

Each Ultium pouch cell measures approximately and weighs, capable of storing 0.37 kWh;[30] the nominal voltage is 3.7 V and it is rated at 103 Ah. The gravimetric energy density of each cell is ; the corresponding volumetric energy density is . It has a 10-second gravimetric power density of 952 W/kg.[31] For example, the total weight of the 24-module, 576-cell battery for the Hummer EV, with 212.7 kWh usable storage capacity, is .[32] Pouches may be oriented horizontally or vertically, affording packaging flexibility.[30]

Ultium features a wireless battery management system (wBMS), the first such architecture from any automaker.[33] The wBMS was developed in partnership with Analog Devices and contributes to reduced battery costs, as it requires 90% less wiring and reduces volume by 15%.[34]

In late January 2023, it was reported that GM was considering switching to batteries in a cylindrical cell format. This move would reduce volumetric energy density, but could reduce production time and costs.[35]

Assembly

GM announced that cells can be assembled into modules with various configurations and demonstrated three examples:[36]

This way, multiple module sizes are possible, which could be mixed and matched for a certain application and platform.

For example, when 24 cells are combined into a module, and a battery pack is made from 6 to 24 identical modules, this means the pack includes 144 to 576 cells, with a capacity ranging from 50 to 200 kWh.[30] A 24-cell module is wired with three parallel strings of eight cells, each wired together in series, giving a nominal voltage of  V per module.[29] GM claims that they can survive repeated DC fast charging.[30]

For the GMC Hummer EV, there are two layers. At each layer, 12 modules are wired in series, creating a 400 V, 100 kWh battery layer; these two layers are then stacked and wired in parallel, yielding 200 kWh storage capacity for electric motors at the 400V level.[30] For charging at 800V DC fast charging stations however, the two layers can be temporarily switched to be wired in series, allowing for DC fast charging at up to 800 V and 350 kW.[30] The Cadillac Lyriq has a 12-module battery pack, essentially equivalent to a single layer of the Hummer, operating at 400 V (nominal) and capable of charging at a rate of up to 190 kW. Due to the modular nature of the battery pack, vehicles using fewer than 12 battery modules will operate at lower nominal voltages.[29]

In 2024, it was reported by InsideEVs that issues with the machines used to assemble cells into modules had resulted in delays in vehicle production during 2023; it proved to be impossible to increase production speed from 5 to 30 modules per hour per assembly line, but GM was adding module assembly lines to compensate.[37]

Cost

In 2010, the cost of the 16 kWh battery in the Chevrolet Volt was estimated at per kilowatt-hour. With Ultium, GM estimates the cost will be reduced by 90% to approximately $100/kWh. This also is a significant reduction compared to the 60 kWh battery in the Chevrolet Bolt EV, which was priced at approximately $262/kWh in 2017,[38] although GM had negotiated a significantly lower price of $145/kWh from its supplier, LG Chem.[39] Part of the cost reduction results from the novel chemistry, which has 70% less cobalt than the Bolt's battery. In addition, labor costs are reduced because the wiring in each battery pack has been reduced by 88% compared to the Bolt due to the wireless battery management system.[40]

Production

Four production facilities were planned as of 2021;[41] they have since been announced as:

GM also opened an Ultium Center factory in October 2021 in Shanghai, which produces batteries and traction motors for EVs produced and sold in China.[50] In 2022, the United States Department of Energy (DOE) provided a $2.5 billion loan to Ultium Cells to assist in the construction of the three announced plants in the US. It is the first loan from DOE to a battery cell producer under the DOE's Advanced Technology Vehicles Manufacturing program.[24]

In January 2023, GM and LG paused plans to build the fourth battery plant in the United States after having selected the Indiana site the previous August,[51] with GM seeking a new joint venture partner.[52] Later that year, Samsung SDI announced it was entering a joint venture with GM, and the fourth plant would proceed at the Indiana site.[53]

Lower than expected Ultium battery cell production caused GM to idle production of BrightDrop Zevo vans in July 2023.[54] At that time, GM announced plans to expand Ultium module production to CAMI Assembly, where the Zevo vans are built, using cells shipped from the battery production facilities; starting in 2024, Ultium modules assembled at CAMI will be used on-site and shipped to other GM EV plants.[55]

Vehicles using Ultium

Current
Planned

See also

Notes and References

  1. Web site: New Electric Vehicle Battery Technology General Motors. February 15, 2022. www.gm.com. en.
  2. Web site: 2024 Honda Prologue is new electric crossover based on GM's Ultium platform. February 10, 2022. Motor Authority. en.
  3. Web site: GM's Ultium-Based Honda And Acura Confirmed. February 10, 2022. InsideEVs. en.
  4. Web site: March 4, 2020. GM Reveals New Ultium Batteries and a Flexible Global Platform to Rapidly Grow its EV Portfolio. February 10, 2022. media.gm.com. en.
  5. September 16, 2020. Ultium Drive to Help Power GM's All-Electric Future . February 10, 2022. media.gm.com. en.
  6. Web site: LaReau. Jamie L.. GM unveils 11 future EVs, new batteries and its plan to beat Tesla. April 22, 2020. Detroit Free Press. en.
  7. News: GM reveals new EV platform and 'Ultium' battery to help hunt Tesla . Cole, Craig . March 5, 2020 . Road/Show . CNet . 16 December 2022.
  8. GM Reveals New Ultium Batteries and a Flexible Global Platform to Rapidly Grow its EV Portfolio . March 4, 2020 . General Motors . 16 December 2022.
  9. News: GM Ultium Drive, Electrify America pricing, Audi fuel-cell stack: Today's Car News . Halvorson, Bengt . September 16, 2020 . Green Car Reports . 16 December 2022.
  10. News: Wabtec and GM to develop advanced Ultium Battery and HYDROTEC hydrogen fuel cell solutions for rail industry . 16 June 2021 . Green Car Congress . 16 December 2022.
  11. Web site: Johnson . Peter . 2022-10-07 . US Department of Defense embracing electric military vehicles using GM's Ultium Platform . 2022-10-09 . Electrek . en-US.
  12. News: General Motors invests $760 million for EV-related work at Toledo transmission plant . Kalea . Hall . September 23, 2022 . The Detroit News . 29 April 2024.
  13. News: GM Delays Toledo EV Drive Unit Production to Q4 2024 . Iulian . Dnistran . December 13, 2023 . Inside EVs . 29 April 2024.
  14. News: General Motors to build EV motors at St. Catharines propulsion plant . February 21, 2023 . CBC News . 29 April 2024.
  15. News: GM has a hybrid plan for St. Catharines Propulsion, a plant it calls 'critical' . Roseanne . Danese . April 5, 2023 . Automotive News Canada . subscription . 29 April 2024.
  16. Web site: September 21, 2021. GM Reveals All-New EV Motors to Power an All-Electric Future. February 10, 2022. media.gm.com. en.
  17. News: GM details Ultium EV motor family, enabling more range without bigger batteries . Halvorson, Bengt . September 22, 2021 . Green Car Reports . 16 December 2022.
  18. News: GM reveals new Ultium Drive EV motors designed and developed in-house with GM propulsion software . 22 September 2021 . Green Car Congress . 16 December 2022.
  19. News: Will GM's Ultium Drive be the small-block V-8 for a generation of EVs? . Halvorson, Bengt . September 16, 2020 . Green Car Reports . 16 December 2022.
  20. News: GM debuts its Ultium Drive electric motors . Hyatt, Kyle . September 23, 2021 . Road/Show . CNet . 16 December 2022.
  21. GM's Ultium Drive motors are dsigned to replace the small block engine . Patrick Curran . Thom Cannell . November 24, 2020 . GM-Trucks . 29 April 2024 . And the drive unit is built in different configurations for packaging space or for different gear ratios. That's how we come up with the five different drive units. Clearly, much is shared; the architecture is very, very similar, if not exactly the same. Motors are shared between those five [...].
  22. News: This is GM's new series of Ultium Drive electric motors . Jonathan M. . Gitlin . September 17, 2020 . Ars Technica . 29 April 2024.
  23. News: 2022 GMC HUMMER EV Edition 1 first with new Ultium battery architecture; 24-module, dual stack, 350+ miles range . 22 October 2020 . Green Car Congress . 16 December 2022.
  24. News: DOE announces $2.5B loan to Ultium Cells for three US battery cell manufacturing facilities . 13 December 2022 . Green Car Congress . 16 December 2022.
  25. News: GM signs major Li-ion supply chain agreements: CAM with LG Chem and lithium hydroxide with Livent . 26 July 2022 . Green Car Congress . 16 December 2022.
  26. News: POSCO Chemical, GM in large-scale CAM supply agreement to support EV growth . 29 August 2022 . Green Car Congress . 16 December 2022.
  27. News: GM Uses Cylinder Cells In Its Ultium Battery Packs In China . Lopez, Jonathan . February 3, 2023 . GM Authority . 25 July 2023.
  28. News: $3B GM-Samsung battery plant might enable electric Corvette, Camaro . Halvorson, Bengt . April 25, 2023 . Green Car Reports . 25 July 2023 . The new plant will make 'high-performing, nickel-rich prismatic and cylindrical batteries that will be exclusively supplied for GM's upcoming electric vehicles,' according to the announcement. The form factor would make them markedly different than the very large-format pouch cells GM has in the three plants under development and production with Ultium Cells LLC..
  29. News: Here's An Exceedingly Nerdy Explanation of GM's Ultium Battery System . Peter . Holderith . April 26, 2024 . Motor 1 . 29 April 2024.
  30. News: Vanderwerp, Dave . July 7, 2021 . How GM's Ultium Battery Will Help It Commit to an Electric Future . Car and Driver . June 28, 2022.
  31. Web site: Nigel . 2022-06-08 . GM Ultium . 2022-10-09 . Battery Design . en-US.
  32. News: 2022 GMC Hummer EV EPA Documents Reveal MPGe, Weight, Other Details . Hoffman, Connor . Vanderwerp, Dave . February 15, 2022 . Car and Driver . 19 September 2023.
  33. Web site: September 9, 2020. General Motors' Future Electric Vehicles to Debut Industry's First Wireless Battery Management System. February 10, 2022. media.gm.com. en.
  34. News: GM is betting its electrified future on a revolutionary new battery system . Tarantola, A. . April 6, 2021 . engadget . June 28, 2022.
  35. News: General Motors considering using cylinder batteries over pouch for EVs . Lee, Stan . January 25, 2023 . TheElec . 30 January 2023.
  36. Web site: Ultium's Flexible, Unique Battery Cells . gm.com . 30 July 2023.
  37. News: How GM's Ultium Electric Car Revolution Went Off The Rails . John . Voelcker . February 22, 2024 . InsideEVs . 27 February 2024.
  38. News: Voelcker, John . June 9, 2017 . How much is a replacement Chevy Bolt EV electric-car battery? . Green Car Reports . July 6, 2022.
  39. News: Cole, Jay . October 23, 2015 . LG Chem 'Ticked Off' With GM For Disclosing $145/kWh Battery Cell Pricing – Video . InsideEVs . July 6, 2022.
  40. News: General Motors announces new battery platform, claims $100/kWh soon . Gitlin, Jonathan M. . March 4, 2020 . Ars Technica . 16 December 2022.
  41. Web site: August 4, 2021. Q2 2021 Letter to Shareholders. February 10, 2022. media.gm.com. en.
  42. Web site: Ultium Cells Begins EV Battery Production In Ohio . Kane, Mark . September 1, 2022 . Inside EVs . 15 December 2022.
  43. Web site: King . R. J. . April 16, 2021 . GM and LG Energy Announce $2.3B Battery Cell Plant in Tennessee . April 30, 2022 . DBusiness Magazine . en-US.
  44. Web site: April 19, 2021 . LG and General Motors to spend 2.7 trillion won for 2nd factory . April 30, 2022 . THE ELEC, Korea Electronics Industry Media . ko.
  45. News: Ultium Cells investing additional $275M to expand Spring Hill plant to 50 GWh . 7 December 2022 . Green Car Congress . 16 December 2022.
  46. Web site: Lopez . Jonathan . 2024-04-05 . Ultium Cells Spring Hill Begins Battery Cell Shipments .
  47. Web site: Hill. Joshua S.. January 27, 2022. GM and LG Energy commit $A3.65 billion for third Ultium EV battery plant. February 10, 2022. The Driven. en-US.
  48. Samsung SDI, General Motors Plan to Establish Joint Venture for Battery Manufacturing . April 26, 2023 . Samsung SDI . 25 July 2023.
  49. News: Brown . Alex . New Carlisle chosen for $3B EV battery plant . June 13, 2023 . Inside Indiana Business . 25 July 2023.
  50. News: GM Inaugurates New Ultium Center Factory In China . Centeno, Deivis . October 21, 2021 . GM Authority . 15 December 2022.
  51. News: Hall . Kalea . August 18, 2022 . The Detroit News . GM considering Indiana town for fourth battery plant . October 25, 2022.
  52. News: GM, LG end plans for fourth U.S. battery cell plant as automaker seeks new partner . Wayland, Michael . January 20, 2023 . CNBC . 25 July 2023.
  53. News: GM, Samsung SDI teaming to build more than $3B EV battery cell plant in Indiana . June 13, 2023 . AP News . 25 July 2023.
  54. News: Battery shortage forces GM to pause commercial EV production . Gitlin, Jonathan M. . July 18, 2023 . Ars Technica . 25 July 2023.
  55. Web site: GM CAMI Assembly Plant To Start Manufacturing Ultium Battery Modules In 2024 . Rhian . Hunt . July 25, 2023 . GM Authority . 5 July 2024.
  56. Web site: 2023-08-17 . All-Electric 2024 Acura ZDX And ZDX Type S Make Dramatic Global Debut; Arriving Early Next Year . 2023-11-20.
  57. Web site: Feijter . Tycho de . 2023-01-12 . Buick Electra E4 Proves That GM Can Make Attractive Compact EVs . 2023-03-06 . CarNewsChina.com . en-US.
  58. Web site: Site Maintenance . 2023-11-20 . media.cadillac.com.
  59. Web site: Site Maintenance . 2023-11-20 . media.chevrolet.com.
  60. News: Deep Dive: 2024 Chevrolet Silverado EV's Ultium platform . Pritchard, Justin . June 8, 2022 . Driving (Canada) . 2 January 2023.
  61. Web site: Site Maintenance . 2023-11-20 . media.gmc.com.
  62. Web site: 2023-09-28 . Stylish, Sporty, Spacious and All-Electric: Honda Prologue SUV Available Early Next Year with Anticipated EPA Range Rating of 300 Miles . 2023-11-20 . Honda Automobiles Newsroom . en.
  63. Web site: Site Maintenance . 2023-11-20 . www.gobrightdrop.com.
  64. Web site: Site Maintenance . 2023-11-20 . media.gm.com.
  65. Web site: Site Maintenance . 2023-12-14 . media.cadillac.com.
  66. Web site: Site Maintenance . 2023-11-20 . media.chevrolet.com.

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