volvo

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Volvo says it has big plans for South Carolina factory

Volvo is undergoing something of a restructuring. The automaker wants to be fully electric by 2040, but for that to happen, it needs to remain in business until then. Earlier this year, that meant layoffs, but today, Volvo announced it has big plans for its North American factory in Ridgeville, South Carolina.

Volvo has been making cars in South Carolina since 2017, starting with the S60 sedan—a decision I always found slightly curious given that US car buyers had already given up on sedans by that point in favor of crossovers and SUVs. S60 production ended last summer, and these days, the plant builds the large electric EX90 SUV and the related Polestar 3.

The company is far from fully utilizing the Ridgeville plant, though, which has an annual capacity of 150,000 vehicles. When the turnaround plan was first announced this July, Volvo revealed it would start building the next midsize XC60 in South Carolina—a wise move given the Trump tariffs and the importance of this model to Volvo’s sales figures here.

Now, the OEM says it will add another model to the mix, with a new, yet-to-be-named hybrid due before 2030.

“Our investment plans once again reinforce our long-term commitment to the US market and our manufacturing operations in South Carolina,” said Håkan Samuelsson, chief executive. “This year, we celebrate 70 years of Volvo Cars presence in the United States. We have sold over 5 million cars there and plan to sell many more in years to come,” he said.

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An EV that charges 30% faster? Volvo and Breathe think their tech can do it

software-defined battery —

Real-time battery-management algorithms on an embedded processor? Yes, please.

An illustration of a Volvo EV powertrain

Enlarge / Volvo’s electric powertrains are going to get a bit smarter with Breathe’s new real-time battery-management system.

Volvo

Would you like an electric vehicle that can charge up to 30 percent faster than the current breed? If so, you’re not alone—Volvo Cars thinks that’s a desirable outcome, too, which is why the carmaker has invested in and partnered with a British startup called Breathe Battery Technologies. Consequently, Volvo will be the first automaker to add Breathe’s new battery management technology to its EVs, although, before too long you should see Breathe’s tech show up in other EVs, as well as consumer tech devices.

A spinoff out of Imperial College in London, Breathe wants to add some extra brainpower to battery management.

“The frustration that everyone feels is that cell manufacturers brute force and empirically test batteries until they die,” explained Ian Campbell, CEO of Breathe. “They ship the data sheet alongside those batteries that has some numbers baked in, that says “control it according to this A4 piece of paper,” and that significantly underutilizes the complex electrochemistry and materials in the system that they built and shipped.”

Instead of having prebaked charging data that governs that battery pack throughout its life, Breathe instead has developed a dynamic battery management system that provides much more granular control over the pack as it charges. Consequently, it says it can improve charging times by 15–30 percent over current packs.

It seems an intuitive idea—instead of benchmarking a battery at the beginning based on cell specs, why not constantly monitor the pack to know exactly how much charge it can or can’t accept right now?

“It is insanely difficult to take a battery model that is a complicated piece of maths and modeling electrochemistry, to take that to an embedded application processor like the integrated circuit in a Volvo car or any car in the world or any laptop or smartphone,” Campbell told Ars. “That is then fundamentally what enables us to take physics, take equations, algorithms, maths, and electrochemistry, from what’s traditionally been on high-performance computing environments to integrated circuits. By running that real-time, we have the fidelity of control that… enables us to deliver, then, the end-user experience that we really want,” he said.

One can see why an automaker like Volvo might find that attractive—Breathe’s tech requires no hardware changes to Volvo’s EVs, and it’s agnostic of cell chemistry. And since it can run on low-power embedded processors, it’s reasonable to expect it to show up eventually on smaller devices than cars. But Volvo gets to be first.

“For us it’s not important that we have exclusive rights, but it was important for us to be the first mover and with volume as well. Because this is a technology that solves part of the customer pain points with electric cars today,” said Ann-Sofie Ekberg, CEO of the Volvo Cars Tech Fund.

Volvo is keeping coy on exactly which new EV will be the first to feature Breathe’s software, but Ars will keep an ear to the ground to try to find out.

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