Author: Green Car Online News

$50 billion VW battery plan could need revamp after Samsung cuts back

VW ID family
Volkswagen, with its plan to build 22 million new electric cars across 70 models by 2030, is ground-zero for concerns over battery supplies.

As more automakers get serious about building lots of electric cars, there are indications that supplies of batteries to power all those cars aren't ramping up as quickly, leading to shortages of batteries, increased competition, restricted sales of some EV models, and potentially rising prices (or at least flattening their trend toward affordability).

READ THIS: VW boosts electric car plans with more models, 22 million EVs in 10 years

Now Bloomberg reports that VW's deals for $56 billion worth of batteries for all those upcoming electric models are in jeopardy as Samsung cut its supply agreement with the automaker after disputes over timing.

Samsung was slated to supply batteries for up to 200,000 or more electric VWs based on assumptions by Bloomberg of 100-kilowatt-hour battery packs, a little bigger than those in the Audi e-tron that just went on sale, and the size of the largest batteries in Teslas. Since many of VW's will use smaller battery packs of 48 kwh, the change could affect many more cars.

2019 Audi e-tron battery pack

VW had named Samsung a supplier for electric models it plans to build in Europe, along with LG Chem (which supplies batteries for the Audi E-tron quattro), and SK Innovation—and for other markets, CATL. Reports have persisted since last fall of battery shortages and price disputes between VW and LG Chem that have affected production of the E-tron at Audi's factory in Belgium.

DON'T MISS: Could battery lawsuits, material shortages delay some EVs?

Tesla CEO Elon Musk has also named limitations of battery supplies from its partner Panasonic as a constraint on production of the Tesla Model 3.

A report from Benchmark Minerals in April showed that lithium-battery supplies could increase by 50 percent a year between now and 2023—that is, if the supply of battery materials can keep up.

CHECK OUT: Report: Battery shortages lead to Audi E-tron production delays

Last year the Trump administration named lithium, cobalt, and other materials for electric-car batteries among “critical minerals” that the U.S. needs to develop domestically and for which it hopes to speed up mining permits.

Following the E-tron from VW's upscale Audi brand, the first electric car in VWs' new lineup of EVs is expected to be the ID 3, which is expected to go on sale late this year.

Byton readies for China production of $45K US-bound electric SUV

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Not too long ago, Byton was another longshot electric vehicle maker with some good ideas. But it’s already outlasted its early hype bubble and is looking increasingly likely to deliver what could be a very enticing combination to three continents—a large, spacious, long-range all-electric SUV with a new kind of interface, at a starting price of $45,000.

What made Byton generate buzz from the start was its announcement at CES 2018 that it was developing its own vehicle operating system, app ecosystem, and interface, banking a lot on the user experience—with “deep integration” details like health monitoring.

While its vivid 48-inch wide-screen system across the entire upper dash drew crowds, a lot of other details then were missing—but those details have gradually been released with enough detail to convince us that Byton has some compelling products in the pipeline.

In an edition of a company supported video blog called the “Byton Inside Reporter” earlier this month, CEO Daniel Kirchert walked through a prototype workshop, where he says last year the company already built 100 early-stage prototypes, built to make sure it can fulfill all the safety and durability requirements.

Byton concept, 2018 Consumer Electronics Show

There he pointed out some of the core attributes of the company’s “skateboard” platform, which will be shared by its first three vehicles and was developed from scratch, including the capability for over-the-air updates that can roll out expanded features, including safety systems and driver aids.

DON’T MISS: Byton brings its big-screen electric SUV back to CES, a step closer to reality

The platform is built around two battery packs, which are mostly carried under the passenger floor, with cells and modules supplied by CATL and capacities of 95 kwh or 72 kwh. In the M-Byte, they’ll equate to a claimed range of 317 miles or 249 miles, respectively, based on very optimistic and outdated European NEDC tests.

One of the noteworthy design points for the platform: The floor will be perfectly flat, and Kirchert points out that the entire air conditioning system has been moved ahead of the cabin—so it won’t take up passenger space.

Kirchert also pointed to the cost-conscious combination of high strength steel and aluminum parts, balanced with the importance of keeping weight down.

Byton M-Byte production interior

Also of note is Byton’s own internal design that allows the steering-wheel touch screen to stay isolated and upright while the driver steers. In seeing the platform laid out like this, we can see how low the cowl and beltlines are relative to the floor—a hint that the production vehicle is going to offer some good outward visibility and sight-lines, even though side pillars from early versions have been thick.

CHECK OUT: Byton reveals self-driving living-room on wheels, the K-Byte, in LA

Kirchert says that the prototypes have already completed the rigors of durability testing, including winter testing in Inner Mongolia, and they’re now doing heat testing. Further, he emphasized quality and safety targets. “I think we use the best of the premium car industry know-how and mindset to make a good-quality car and a safe car—and this has to be done,” he said.

In what sounded like a jab at Tesla, which reportedly went from prototypes to final production in shockingly short order for Model 3, Kirchert added: “These prototypes, the real prototypes, the pre-production trial lot, and the final production; every step is very important.”

Byton M-Byte electric SUV prototype

The next step will be to finish its Nanjing, China, assembly plant, and in two months (July) it will have the first prototypes (and then validation prototypes) coming off the real series-production tools and line.

Byton’s stamping shop can complete a body panel every three seconds and will be one of the fastest such facilities in China, according to the trade publication Robotics & Automation News. And the welding shop, with 335 welding robots from partner Kuka, is 99-percent automated.

The M-Byte will be revealed in production form in July, and will then release the first pricing information and open its pre-order systems. It aims to ramp up series production in the third quarter of this year, and deliveries in China by the end of the year. The K-Byte sedan will follow, and a third model, yet to be teased, is in the development pipeline.

READ MORE: How Byton is developing three electric vehicles at once

When we sat down with chief engineer David Twohig in January—since promoted to chief technical officer—he walked us through some other key details: that the M-Byte will “be a ride car” prioritizing comfort, and that it will be offered in single-motor (rear-wheel drive) or dual-motor (all-wheel drive) versions. Twohig also confirmed that it will use CCS (Combo) DC fast charging, which we anticipate will work at 150 kw or even a little more.

Byton M-Byte and K-Byte concepts

Byton has held many of its financial details close, but in an indication of being smart with limited funds, besides developing one platform for three vehicles from the start it’s turning to Bosch for the vehicles’ power systems and motors. Kirchert reiterated that it plans on an entry price for the M-Byte of roughly $45,000—although options could add a significant amount to that.

As a multi-national effort, including R&D (software and self-driving) offices in California and a design center in Munich, Byton hasn’t adjusted its U.S. plans, or its timeline in light of U.S. tariff tensions. “From the beginning we had this vision to make it a global brand and be firmly committed to this,” summed Kirchert, in a previous video, underscoring that the brand’s on-sale timeline remains in place as late this year for China, mid-2020 for North America, and late 2020 for Europe.

Byton certainly isn’t the first startup EV maker with Chinese connections. But if it can pull off those delivery dates, this brand might actually be the first one to reach the finish line—in U.S. driveways.

GM plans its own nationwide charging network with Bechtel

2019 Chevrolet Bolt EV at public charging station
General Motors, the nation's biggest automaker, is teaming up with construction giant Bechtel to build thousands of chargers around the U.S. with the aim of promoting adoption of electric cars.

The companies will form a joint venture to build the chargers in which Bechtel will provide its expertise in construction and permitting and GM will provide data from its cars and drivers about the best sites to install those chargers.

READ THIS: Barra blogs again: GM plans to double EV, self-driving investments

Executives from the two companies said the chargers won't just be located along interstates to enable long-distance travel but will be sited in underserved and urban areas. The chargers will comply with SAE and IEEE standards, so will be available for EVs from any automaker to use.

Mike Ableson, GM's vice president to EV infrastructure and charging, told CNN, “The way we think about it, we want to put chargers where they're going to have the greatest influence on EV adoption wherever that may be.”

DON'T MISS: Long-range Cadillac SUV to lead GM's next electric-car push, in 3 years

GM has vast data about where drivers of its Chevrolet Volt and Bolt have charged over the years though the company's OnStar system, and in the case of the Volt where the cars have run out of battery power.

Urban areas, where lots of residents live in apartments and condominiums, generally have seen fewer electric car sales, because it is more difficult for those drivers to charge up at home and there are fewer public fast chargers.

CHECK OUT: Chevrolet Bolt EV to get electric sibling, with Michigan plant investment

GM spokeswoman Megan Soule confirmed the plans to Green Car Reports, but said the company had no more specific announcement about timing, types or number of chargers, or branding “at this early stage.” It's however looking to team up with an operating network and aiming to create a “a national-scale network with thousands of fast-chargers.”

CEO Mary Barra has announced plans to convert the automaker's fleet into all electric cars at some undefined future date, and the company plans to release a new electric SUV based on the Chevy Bolt EV the next two years, followed by a new electric-car platform for Cadillac.

Bay Area residents can get $4,000 credit on used plug-ins

Used 2016 Chevy Volt sold through Peninsula Family Service program (CREDIT: Peninsula Clean Energy)
In an effort to get and keep more used cars in its service area, a community utility provider in California's San Mateo County, between San Francisco and the Silicon Valley, is offering its own incentive of $4,000 for qualifying buyers of used plug-in cars, the company announced at the “Future of Clean Transportation” event last week.

Like a few such programs around the country, it helps remedy an issue: Not everyone can afford a Tesla. Not everyone can even afford a new car.

That can make it difficult to spread clean transportation to lower-income populations. And while vehicles bought with new-car inventives eventually trickle down to households with lower budgets, used-car buyers aren't often eligible for any tax credits or rebates.

CHECK OUT: San Diego utility offers $10,000 off Nissan Leaf, BMW i3 electric cars

The program is run as part of Peninsula Family Service's Drive Forward program, which helps low-income buyers afford cars with low interest loans. The program is open to individuals who either live or work in San Mateo County and earn less than $48,560 a year, or families of up to eight who make up to $169,520.

It focuses on plug-in hybrids, rather than pure-electric vehicles, because many of those families can afford only one vehicle, which has to meet all their needs, including out-of-town trips, and because many of those buyers rent their homes and may not be able to move an EV charger with them if they have to relocate.

READ MORE: California utilities commission passes record incentives for chargers

Buyers who want a pure EV and are convinced it can meet their ongoing needs can choose one, however.

“Used plug-in hybrid electric vehicles can provide affordable and reliable transportation for all members of our community who need a car to access better jobs or opportunities,” said Jan Pepper, Peninsula Clean Energy CEO. “Electric cars deliver additional savings to drivers by reducing maintenance and fuel costs compared to a gas-powered car.”

The used car has to be bought from a licensed dealership, many of whom in the area have systems set up to work with Peninsula Family Services' low-interest loan program. The $4,000 incentive goes to the dealership as a down payment on the car.

CHECK OUT: Canadian non-profit offers purchase incentive for used EVs

The company is offering just 100 of the incentives, but says funding may be renewed beyond that.

Several utilities offer incentives for new EV or plug-in car purchases because it helps them sell more electricity, especially at off peak times when it doesn't cost them as much to provide it. On a state basis, one such example is Oregon's Charge Ahead program, which gives qualified low-income households a $2,500 cash rebate towards the purchase or lease of a new or used EV (but not a plug-in hybrid). The program also mirrors one in Ontario, Canada, which offers provincial residents a $1,099 (Canadian) incentive on used EV purchases.

Audi E-tron range, Rivian kitchen, more Piëchs, Chevron charging: Today’s Car News

Rivian R1T electric pickup concept
Rivian built an outdoor kitchen into its electric pickup. We took a road trip to assess the Audi E-tron's range in the real world. And EVgo is bringing fast chargers to gas stations. All this and more on Green Car Reports.

Electric-truck hopeful Rivian is building all kinds of accessories for its upcoming pickup before the model even goes on sale. The latest is an integrated kitchen that slides out of the bed and runs on the truck's batteries.

Swiss electric-car startup Piëch moved beyond plans to build an electric sports car with specs and drawings for two follow-up models, a four-seat GT and a five-passenger SUV.

Audi's 204-mile EPA rated range for the E-tron was downright underwhelming. But based on a new road trip with the electric SUV, we more faith in its real-world numbers and speedy charging.

So far, gas stations have been among the least likely places to “refuel” an electric car. That's about to change with EVgo's plan to build fast chargers at Chevron stations in California.

Fiat Chrysler Automobiles got approval to build the first new factories in Detroit in decades. There it plans to build new plug-in hybrid and electric Jeeps, among other models.

Finally, the Center for Automotive safety, founded by Ralph Nader, has petitioned the NHTSA to reject GM's request to test vehicles without steering wheels or pedals on public roads.

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GM builds new electric architecture for EVs, self-driving cars

General Motors next-generation electrical platform
As future cars go electric, self-driving, and more connected with the outside world, they're going to faster connectivity inside the vehicle.

To that end, General Motors just introduced a new electronic platform for its vehicles that it says can carry 4.5 terabytes of processing power per hour, five times what the current system can carry.

General Motors next-generation electrical platform

It will also bring GM vehicles the ability to receive updates over the air, similar to Teslas.

In a statement announcing the new architecture, GM President Mark Reuss said, “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 company says the system will be necessary to meet its goal of building cars that can support a world with “zero accidents, zero emissions, and zero congestion.”

DON'T MISS: Long-range Cadillac SUV to lead GM's next electric-car push, in 3 years

Reuss announced that the new electronic architecture will arrive in the 2020 Cadillac CT5 sedan, which debuted at the New York auto show in April, and is expected to go on sale later this year. Reuss said the system will roll out across most of GM's lineup by 2023. GM has said that Cadillac will become its lead electric-car brand starting with a new generation of electric models in 2022.

Future Cadillac long-range electric large luxury utility vehicle (rendering), 2019 Detroit auto sho

The new system will offer three levels of ethernet connectivity: 100 megabaud, 1 gigabaud, and 10 gigabaud. Those will also allow the system to be expanded over the life of the vehicle.

GM says the new system rides on top of an updated CAN bus architecture, which the company says will give it even higher speeds, along with the ethernet capability.

General Motors next-generation electrical platform

Perhaps more importantly, the system will bring new cybersecurity protocols to GM's cars. Until now, most cars relied on being removed—or “air-gapped”—from the Internet to resist hacking attempts. But several hackers have demonstrated the ability to break in and take control of cars and raised doubt about the security of those systems as more cars receive software updates at dealers, use electronic keys, and connect their infotainment systems to drivers' cell phone network connections.

READ MORE: Barra blogs again: GM plans to double EV, self-driving investments

GM chairs the Automotive Information Sharing & Analysis Center, a community of private and public-sector partners that shares and analyzes intelligence about emerging cybersecurity risks for the automotive industry.

“The critical role of software and its importance to our vehicles, both now and for years to come, cannot be overstated,” Reuss said.

Seawater could bring breakthrough for hydrogen cars

2015 Hyundai Tucson Fuel Cell, 2016 Toyota Mirai at hydrogen fueling station, Fountain Valley, CA
The biggest problem for hydrogen fuel-cell cars has been where to get a plentiful, affordable supply of hydrogen that doesn't contribute to greenhouse gas emissions.

Now scientists may have come up with what some have called the holy grail of clean transportation: a way to create hydrogen affordably from seawater.

READ THIS: 2019 Hyundai Nexo hydrogen fuel-cell vehicle pricing: Puzzling economics

The salt in seawater has been problematic for electrolyzers that separate hydrogen and oxygen atoms from water molecules, because it quickly corrodes the electrolyzer's anode. Desalinating seawater before putting it through an electrolyzer is too costly,. Most hydrogen is made by splitting methane, which results in large amounts of leftover carbon dioxide, the primary gas scientists have associated with global warming.

As in lithium batteries, the solution is in a new type of catalyst coating the anode.

MUST READ: This one 11-year-old chart explains the problem with hydrogen fuel-cell vehicles

According to a March report in the Proceedings of the National Academy of Sciences, scientists at Stanford developed a new catalyst that incorporates carbonate and sulfate molecules into the iron-nickel coating on the nickel anode. The carbonate and sulfate molecules have a high negative charge that prevents the salt from penetrating the coating and corroding the anode.

In lab tests, the electrolyzer with the coating was able to run for more than 40 days, even with three times the salt concentration of seawater.

CHECK OUT: Electric cars win on energy efficiency vs hydrogen, gasoline, diesel: analysis

Electrolyzing seawater to create hydrogen for fuel-cells solves an obvious problem with today's electrolysis: the supply of fresh water, which is already constrained in many parts of the world, often including Southern California, the home to most fuel-cell cars in the U.S.

The breakthrough doesn't solve all the challenges of hydrogen cars, such as developing a sustainable and affordable distribution network for hydrogen. But if it makes electrolysis viable using renewable energy, it could make the rest of the challenges worth solving.

The Stanford scientists used solar power to run the electrolyzer in their tests.

2018 BMW i3 recalled for circuit-board issue causing sudden shutdowns

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2018 BMW i3
Some BMW i3 models from the 2018 model year are being recalled for an issue that could cause sudden power loss and shutdown.

At root of the issue is a printed circuit board, part of the Electric Motor Electronics (EME) module, that may not have been made to specifications. The issue could cause the lack of electrical contact, causing the EME module to shut down high-voltage electrical power after detecting the condition.

The issue affects 134 BMW i3 REx vehicles and just 25 i3 BEV vehicles. That covers a specific range of build dates in January for the REx and in January and February 2018 for the BEV.

CHECK OUT: 2019 BMW i3 to get bigger battery with 153-mile range

According to paperwork filed by BMW, the circuit board “may not have undergone a sufficient cleaning process during Tier-2 supplier production.”

2018 BMW i3

BMW cites “several field incidents” as leading to the discovery of the issue but is not aware of any accidents or injuries stemming from the issue.

The i3, and especially the i3 REx, have been affected by several significant recalls over the past couple of years:

Last October BMW issued a recall for the charge cords of nearly all 2018 and 2019 plug-in vehicles it built for sale in the U.S.—including the i3.
In 2017 it recalled 19,130 i3 REx models from the 2014 through 2017 model years for an issue with the fuel vent.
BMW also in late 2017 recalled more than 30,000 i3 it had then sold in the U.S. from the 2014 through 2018 model years to reprogram the airbag to accommodate drivers not wearing their seatbelt [yes, still a U.S. requirement].
Under this new recall, dealers will replace the EME module on affected cars. The effort will start around June 7, 2019, and owners will be notified. Those with questions or concerns can call BMW at 800-525-7417.