Voltec Electric Drive System Overview Exceeding customer expectations was top of mind for the Chevrolet Volt

engineers as they developed the Voltec electric drive system. Since the Volt is the industrys first electric vehicle with extended-range capability, the team focused on delivering the most efficient, yet fun-to-drive experience in both electric and extended-range operation.

VOLTEC ELECTRIC DRIVE

Kinematic Architecture
Traction Motor Planetary Sun Gear Planetary Ring Gear Planetary Carrier C1 C3 Battery Pack Inverter

Generator

Final Drive Gearing C2 2.16 ratio

Axle Differential

Unlike most battery electric vehicles, which use a single motor with a fixed reduction gear that steps down the motor speed to synchronize with the wheel speed, the Chevrolet Volt uses a unique electric drive unit to boost efficiency. The efficiency of any electric motor always drops off as it approaches its maximum rotational speed. The Volt drive unit consists of two motors, three clutches and a planetary gear set that improve overall efficiency by reducing the combined rotational speed of the electric motors. This configuration reduces battery drain at highway speeds, adding up to two miles of additional EV range. The Volts motors and gear-set are mounted in-line with the industrys first rangeextending internal combustion engine. Two of the clutches are used to either lock the ring gear of the planetary gear-set or connect it to the generator/motor depending on the mode. The third clutch connects the internal combustion engine to the generator/motor to provide range extension capability. This innovative new drive unit has four distinct operating modes:

ELECTRICDRIVING
Low Speed (1 -Motor)

3.24 ratio

C1

C3

C2 2.16 ratio

Single Motor EV Driving In this mode, the primary traction motor provides all propulsion at lower vehicle speeds and hard accelerations, drawing all of its energy from the battery. The ring gear is locked and the generator/motor is decoupled from both the engine and gear-set. The traction motor can use up to 111 kilowatts of power and deliver 273 pound-feet of smooth, direct torque to provide spirited off-the-line acceleration.

ELECTRICDRIVING
High Speed (2-Motor)

3.24 ratio

C1 1.45 ratio

C3

C2 2.16 ratio

Two Motor EV Driving As vehicle speed increases, the ring gear is unlocked and coupled to the generator/motor. This allows the two motors to work in tandem to provide blended output with higher electrical efficiency. Using the blended output of the slower running motors allowed the team to extract up to two extra miles of pure electric operating range in highway driving.

EXTENDED RANGE DRIVING

Low Speed (1 -Motor Series)

3.24 ratio

C1

C3

C2 2.16 ratio

Single Motor Extended-Range Driving Once the battery has reached its minimum state of charge, the 1.4-liter engine is coupled to the motor/generator via the third clutch. At lower speeds and hard accelerations the Volt is propelled by the traction motor alone with the ring gear locked. The engine-driven generator and battery provides electricity to the traction motor via the inverter. On an average basis, the engine-driven generator will maintain the battery at a minimum state of charge for extended range operation. Since the most efficient way to charge the Volts battery is to plug it in, the generator is only used to maintain minimum battery state of charge. If the battery is drawn down below the minimum level during acceleration or when mountain mode is engaged below about 45 percent charge, the generator will charge the battery up to its minimum state of charge and then maintain it there.

EXTENDED RANGE DRIVING

High Speed (2-Motor C ombined)

3.24 ratio

C1 1.45 ratio

C3

C2 2.16 ratio

Two Motor Extended-Range Combined Driving The blended two motor electric propulsion strategy used at higher speeds in EV driving has also been adapted for extended-range driving. The clutches that connect the generator/motor to both the engine and the ring gear are engaged, combining the engine and both motors to drive the Volt via the planetary gear set. All of the propulsion energy is seamlessly blended via the planetary gear and sent to the final drive. Even in combined extended-range driving, the Volt uses electric power delivered by the traction motor -- the engine cannot propel the Volt unless the traction motor is also powered. That is because, in order for a planetary gear-set to transmit torque, two of the three main elements (ring gear, sun gear, planet carrier) must be driven, or one locked, with the third element providing the output. In the case of the Volt, the traction motor is used in this mode to provide reaction torque for the sun gear, enabling propulsion of the vehicle. By seamlessly blending power from the engine and two electric motors, this sophisticated technology allows the Volt to achieve 10-15 percent better efficiency at highway speeds than would have been possible by using only the single traction motor. At the same time, the Volt always delivers a solid electric driving experience, even in extended range driving, by utilizing the large battery for full electric launches even during brisk accelerations.

Contacts: Kevin M. Kelly Manager, Electric Vehicle and Hybrid Communications Desk: (313) 665-0898 Mobile: (313) 316-9742 kevin.m.kelly@gm.com Randy Fox Phone 313-667-4128 Mobile 313-378-5872 randal.l.fox@gm.com