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In freezing Kapuskasing, GM tests whether its EVs can cut it in the cold

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In freezing Kapuskasing, GM tests whether its EVs can cut it in the cold


"...GM’s Cold Weather Development Centre, also known as the Kapuskasing Proving Ground, is the automaker’s only cold weather durability testing site in Canada and the largest facility in Ontario. It’s tasked with testing all GM vehicles destined for the North American market. And as GM transitions to an all-electric future with aims of launching 30 new EVs by 2025 globally, the facility becomes more significant in helping the automaker to assuage people’s worries about range and slow charging....

...On the day we were there in early March, it was minus 20 and we were driving a 2023 Cadillac Lyriq rear-wheel drive to see what an EV undergoes in cold weather tests. First stop is a cold cell block. Used to study the vehicle in a consistent temperature during the thermal cycle, the 30 giant freezer-like units can fit two Bolt EVs inside and replicate temperatures of minus 45. Vehicles undergo a cold soak where they are parked in a cold cell overnight with fans blasting air at minus 30, followed by a warm-up cycle and additional tests within a 24-hour period to ensure everything from the battery to the heated seats operate well.

The Lyriq rides on GM’s new Ultium battery architecture. It’s less expensive to produce, more powerful and uses less cobalt than the batteries found in the Chevrolet Bolt. All GM EVs will have the Ultium battery moving forward.

“The essence of what Ultium is and the way it manages its thermal system is markedly improved over the BEV system [in the Bolt]. We definitely see range [in the Lyriq] that is truer to [U.S. Environmental Protection Agency range] ratings than what we did with the Bolt,” Walton said. And while most EVs lose range in frigid temperatures, “the new Ultium battery pack stays pretty much on par because it self-conditions as you go along. That energy is always present, whether it’s in the battery or it’s coming out in your defroster, that power is always there. We just recycle it and keep the pack warm and ambient,” Walton said.

We see what Walton means during a drive after we speak. The Lyriq’s electric range didn’t drop much in the frigid cold and remained fairly accurate to the distance travelled."
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This is a deceiving statement. The potential for the energy is there, but the cold slows the chemical reactions within the batteries. And in order for the heat transfer to work two conditions have to be met first. 1) There has to be heat available to transfer to the battery pack and heat pumps offer no more efficiencies at -30. 2) The transfer of heat to the pack still required energy which comes from the batteries decreasing range and since the cold has already lowered how much you will get out of the battery, the hit is essentially a double whammy as it has less energy to drive the vehicle and also has to heat the pack/cabin.
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I think you are referring to heat pumps for homes that use outside air as the heat source and lose efficiency as the outsides temps drop? The Ultium heat pump will recover heat from sources such as the electric motors. There's a whole discussion on how the system works over at Preconditioning?
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I have never heard of Kapuskasing before, but now I do.
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I think you are referring to heat pumps for homes that use outside air as the heat source and lose efficiency as the outsides temps drop? The Ultium heat pump will recover heat from sources such as the electric motors. There's a whole discussion on how the system works over at Preconditioning?
Heat pumps all work on the same principles. Take heat from one place and release it in another. To do this it uses refrigerant running through the lines into the battery packs and into the hvac system.. the thing is the colder it is, the harder the heat pump has to work to pull out that same amount of heat and the less heat the refrigerant can transport making them less and less efficient. Vehicles are not excluded from this. They are great at being more efficient up until about -20c and then they start to drop off. Both tesla and hyundai owners have noticed this in their vehicles. GM hasn't magically found a solution to this tough to beat the laws of thermodynamics. I'm not arguing against heat pumps, just again the fact that a cold soaked vehicle at -30 will still give you the same range. If they could even get close to that they would be laughing at tesla, not chasing them.
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Heat pumps all work on the same principles. Take heat from one place and release it in another. To do this it uses refrigerant running through the lines into the battery packs and into the hvac system.. the thing is the colder it is, the harder the heat pump has to work to pull out that same amount of heat and the less heat the refrigerant can transport making them less and less efficient. Vehicles are not excluded from this. They are great at being more efficient up until about -20c and then they start to drop off. Both tesla and hyundai owners have noticed this in their vehicles. GM hasn't magically found a solution to this tough to beat the laws of thermodynamics. I'm not arguing against heat pumps, just again the fact that a cold soaked vehicle at -30 will still give you the same range. If they could even get close to that they would be laughing at tesla, not chasing them.
Question - as the vehicle's electric motors warm up during operation, would the heat pump be able to transfer heat from the motors to the battery, thereby increasing the efficiency of the chemical reaction in the battery? This would bring the range back up to where it would have been if it weren't so bloody cold. Tesla owners see this behavior.

Also, GM and Tesla both recommend you leave your EV on a L1 (GM only) or L2 (Tesla destination) charger when not in use. The car can use this power to assist maintaining battery and electronics temperature.
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Question - as the vehicle's electric motors warm up during operation, would the heat pump be able to transfer heat from the motors to the battery, thereby increasing the efficiency of the chemical reaction in the battery? This would bring the range back up to where it would have been if it weren't so bloody cold. Tesla owners see this behavior.

Also, GM and Tesla both recommend you leave your EV on a L1 (GM only) or L2 (Tesla destination) charger when not in use. The car can use this power to assist maintaining battery and electronics temperature.
Yes, this is how preconditioning works on the ionic 5 and tesla vehicles. However it takes a significant amount of energy and time to heat up a large battery pack so it's usually not useful for short trips. For longer trips the vehicle will start preconditioning the battery to get it to a decent temperature before you attempt to fast charge. Otherwise you will be stuck at a charger for a long time as they throttle down the charging speed the colder the battery is. Fast charging can easily take twice a long with a very cold battery.
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GM hasn't magically found a solution to this tough to beat the laws of thermodynamics. I'm not arguing against heat pumps, just again the fact that a cold soaked vehicle at -30 will still give you the same range.
I'm referring to the heat pump heating/preconditioning the battery during travel by using motor generated heat. Trying to heat a cold soaked battery via the motor, nope. The best defense against cold soaking is to keep the car plugged in if possible.
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Electric motors are just so damn efficient, there's virtually no waste heat like with ICE. You're not burning anything to make power.

Cabin heat is virtually "free" with ICE, the heat from combustion is actually more than the engine can tolerate in most cases so coolant carries excess heat to the radiator (and the heater core, which then gets blown into the cabin. There's no range penalty.

In an EV, even with a heat pump (versus a resistive heater) you will still pay a price for heat. Whether it's battery range, or more electricity used when plugged in.

Seat heaters put the heat directly on your heiney, so they're more efficient than heating the cabin air to warm your body, regardless of which type of heater the EV uses.
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The best defense against cold soaking is to keep the car plugged in if possible.
This helps, but it still doesn't keep the battery at the temperature it needs to be for fast charging. Batteries need to be brought up to around 20c for optimal charging. To do that requires you to actually turn on the preconditioning feature in the vehicle either through the app, or the via the navigation. The batteries aren't kept at those temperatures while plugged in all the time, that would be a massive energy drain.
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Makes you wonder why GM went through the trouble to design and install the heat pump given that it apparently does little to nothing to help heat and precondition the battery... /s :)
I don't need or want "a button to do this". I want a setting. Like "Keep battery above 0,10,20C while plugged in" and there's no "off". It could be pretty well insulated, and it's a big thermal mass, so it wouldn't take a LOT of extra power to hold it warm all winter compared to warming it up every time it needed charging.
Hopefully the quote below will assuage anyone's fears that GM's thermal management hardware and strategy is not smart enough to not only keep the battery happy at a basic operational temp, but have the ability to dynamically regulate pack temperature with multiple heat sources when it is plugged in both for optimal battery charging and for providing a thermal mass source for fast cabin-warmup or pre-conditioning prior to driving. I highlighted the portion that discusses maintaining pack temp once it is both electrically charged and thermally warmed up sufficiently, the charging module will regulate pack temperature.

This is a short excerpt from their thermal system patent application US 2020/0047586. I inserted the (ie. warmed up) to clarify what the patent-ese phrase "charged sufficiently with thermal energy" means in lay terms. Find it and read the complete details for all the different cooling/heating options possible with this system to both flexibly and efficiently maintain effective pack temperatures for all requirements and provide proper cabin temperatures .

Thus, in some instances, the OBCM 36 is a bi-directional battery 38 charging and discharging device. In many instances, the battery 38 is most efficiently charged when the battery 38 is heated to a predetermined target temperature. In one aspect, the predetermined target temperature is approximately 25° Celsius. However, depending on the componentry and the thermal requirements of the thermal management system 12 components, the predetermined target temperature of the battery 38 may vary. In one example, to achieve the target temperature range, the battery 38 can be heated electrically via electrical energy supplied by the OBCM 36. In the example, the controller 16 effectively overdrives the OBCM 36 or drives the OBCM 36 in a calculatedly inefficient manner so as to convert a predetermined amount of electrical energy into thermal energy, e.g., to raise the temperature of the battery 38. In another example, the battery 38 itself is charged in a calculatedly inefficient manner. That is, the battery 38 is charged inefficiently so that a portion of the electrical energy being driven into the battery 38 by the OBCM 36 is converted into thermal energy which is then stored within the mass of the battery 38 while the battery 38 is being charged. In yet another example, thermal energy is directed to the battery 38 via coolant 28 carried by the coolant loop 24 from other heat sources within and external to the coolant loop 24. In some examples, the coolant loop 24 includes a coolant heater 30. The coolant heater 30 is an electrically-powered heater that adds thermal energy to the flow of coolant 28, thereby aiding in bringing the battery 38 up to an optimal charging temperature. In some examples, once the battery 38 has been electrically charged sufficiently, and charged sufficiently with thermal energy (ie. warmed up) the temperature of the battery 38 is regulated by the OBCM 36.
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