Chevrolet BrightDrop

Chevrolet BrightDrop
2022 BrightDrop Zevo 600
Overview
ManufacturerGeneral Motors
Also calledBrightDrop Zevo (2022–2024)
Production2022–present
AssemblyCanada: Ingersoll, Ontario (CAMI Assembly)
Body and chassis
ClassMedium duty truck
Body styleDelivery van
LayoutFWD & AWD
PlatformUltium
Powertrain
Electric motor1 or 2 Ultium Drive units
Battery121 or 173 kWh
Electric range160–270 mi (257–435 km)
Dimensions
Length238–290 in (6,045–7,366 mm)[1][2]
Width106 in (2,692 mm)[1][2]
Height109 in (2,769 mm)[1][2]
Curb weight7,200–8,500 lb (3,300–3,900 kg)[1][2]

The Chevrolet BrightDrop,[3][4] formerly the BrightDrop Zevo, is a battery electric delivery van produced by General Motors (GM). It was unveiled at the Consumer Electronics Show on 12 January 2021 under the BrightDrop brand, with production starting in December 2022.

The van is available in two models, the larger BrightDrop 600 (formerly Zevo 600) and the smaller BrightDrop 400 (formerly Zevo 400). In August 2024, GM announced that the BrightDrop Zevo 600 and BrightDrop Zevo 400 would be renamed to Chevrolet BrightDrop 600 and Chevrolet BrightDrop 400 respectively and will be available through select Chevrolet dealerships.

History

[edit]

Rumors began circulating in June 2020 that GM was working on an all-electric delivery van, codenamed "BV1".[5] According to earlier reports from December 2019, an all-electric van would be built at Detroit/Hamtramck Assembly. At the time, the two contracts for 100,000 Rivian EDV electric delivery vans ordered by Amazon and 10,000 Arrival Vans ordered by UPS were collectively valued at US$4 billion.[6]

FedEx Zevo 600 in Hawthorne, California (2024)

The BrightDrop EV600 was unveiled as the marque's first vehicle at the Consumer Electronics Show in Las Vegas, Nevada on 12 January 2021 along with the EP1 electric pallet cart; GM announced that FedEx had ordered 500 EV600s.[7] The smaller EV410 was first shown that September;[8] telecommunications company Verizon was the first customer for the smaller van, with deliveries scheduled for 2023.[9] In April 2022, BrightDrop announced it had renamed its products; the EV600 and EV410 became the Zevo 600 and Zevo 400, respectively. In addition, the EP1 was renamed to the Trace (e-cart spelled backward).[10][11]

GM partnered with KUKA, a close supplier, to build the first batch of vehicles in Michigan so they could meet their 2021 delivery target.[12] GM was scheduled to shift Zevo production to the CAMI Automotive factory at Ingersoll, Ontario in November 2022.[13] Some of the robots and tools made and used by KUKA to assemble the initial batch will be transferred to CAMI; CAMI staff have been using the initial batch to refine the production processes.[14] Zevo 600 production at CAMI began on December 5, 2022. At maximum capacity, CAMI will be able to build 50,000 Zevo vans per year. Production of the smaller Zevo 400 is scheduled to start in late 2023.[15]

In addition to FedEx and Verizon, the fleet management company Merchants Fleet placed the largest single order of 18,000 EV600 and EV410 vans by November 2021.[16] FedEx received the first 5 EV600 vans from a 500-vehicle fleet order in December 2021, which they will operate out of their Inglewood, California facility;[17][18] the delivery company increased its order by 2,000 additional units and Walmart reserved 5,000 units in January 2022.[19] Consumer sales are scheduled to commence in 2022.[20] In September 2022, Hertz announced it would order up to 175,000 electric vehicles from GM, including an unspecified number of BrightDrop Zevo 600 vans.[21] BrightDrop announced its first order from outside the US in December 2022; it will deliver vans to DHL Express Canada.[15]

Orders for the Zevo 400 were opened in August 2023 for the 2024 model year. At that time, a smaller, 14-module battery was introduced as standard equipment for all Zevo models, along with interior design changes.[22] That October, due to Ultium battery supply issues, production of all BrightDrop Zevo vans was paused for approximately six months until April 2024.[23]

On January 11, 2024, GM recalled all 2022 Model Year BRIGHTDROP EV600 per NHTSA Campaign Number 24V014000; the total number of vehicles affected is 66, of which GM estimates 5% are affected with a front-drive unit that may leak oil and cause fire. The recall was not due to the high-voltage traction battery.[24][25]

It is anticipated the replacements for the Chevrolet Express / GMC Savana, scheduled for the 2026 model year, will also use Ultium battery technology and may use a smaller version of the Zevo platform.[26]

For the 2025 model year, the BrightDrop brand was dropped, and the van was renamed the Chevrolet BrightDrop.[3]

Design

[edit]

The Zevo range is based on the Ultium battery announced by GM in 2020.[27] Because the van does not need a drive train axle, engineers were able to lower the step-in height by 2 inches (5.1 cm), improving ergonomics and reducing the physical strain on delivery drivers.[28] The body is made of composite materials incorporating recycled content, riding on a typical battery-electric vehicle skateboard chassis with the underfloor traction motors and battery lowering the vehicle's center of gravity.[29] The chassis uses high-strength steel in the rocker panels, door reinforcement beams, floor structure, and side pillars extending forward from the front firewall.[30]

BrightDrop Zevo specifications[1][2]
Model
Parameter
Zevo 400 Zevo 600
FWD AWD FWD AWD
Dimensions (external) Wheelbase 153 in (3,886 mm) 183 in (4,648 mm)
Length 238.61 in (6,061 mm) 290 in (7,366 mm)
Width (w/ mirrors) 106.2 in (2,697 mm)
Height (excl. antenna) 109.2 in (2,774 mm) 108.79 in (2,763 mm)
Cargo
(interior) 		Length 117.51 in (2,985 mm) 168.9 in (4,290 mm)
Width (wall to wall) 83.68 in (2,125 mm)
Height (door open) 76 in (1,930 mm)
Volume 412.1 cu ft (11.67 m3) 614.7 cu ft (17.41 m3)
Weight Curb EW2 Std 7,240 lb (3,280 kg) 7,470 lb (3,390 kg) 7,590 lb (3,440 kg) 7,820 lb (3,550 kg)
ETJ Max — 8,170 lb (3,710 kg) — 8,520 lb (3,860 kg)
Payload EW2 Std
  • C5F: 2,510–2,690 lb (1,140–1,220 kg)
  • C7E: 3,520–3,710 lb (1,600–1,680 kg)
  • C5F: 2,280–2,460 lb (1,030–1,120 kg)
  • C7E: 3,290–3,480 lb (1,490–1,580 kg)
  • C5F: 2,190–2,340 lb (990–1,060 kg)
  • C7E: 3,200–3,350 lb (1,450–1,520 kg)
  • C5F: 1,970–2,110 lb (890–960 kg)
  • C7E: 2,980–3,130 lb (1,350–1,420 kg)
ETJ Max —
  • C5F: 1,560–1,770 lb (710–800 kg)
  • C7E: 2,570–2,780 lb (1,170–1,260 kg)
 —
  • C5F: 1,250–1,420 lb (570–640 kg)
  • C7E: 2,260–2,430 lb (1,030–1,100 kg)
GVWR C5F 9,990 lb (4,530 kg)
C7E 11,000 lb (5,000 kg)

Powertrain

[edit]

The first vans were equipped with an all-wheel drive system using two traction motors, one each for the front and rear axles, and the combined output is 300 hp (220 kW) and 390 lb⋅ft (530 N⋅m).[31] A front-wheel drive variant was introduced with the 2025 model year; single-motor peak output is 240 hp (180 kW) and 300 lb⋅ft (410 N⋅m).[23][32] Deleting the rear traction motor reduces curb weight by 220–240 lb (100–109 kg).[33][34]

The regular production option (RPO) ETJ "Max" high voltage traction battery in the Zevo uses 20 Ultium modules; for comparison, the GMC Hummer EV uses 24 Ultium modules and has an usable capacity of 212.7 kW-hr,[35][31] and the Zevo "Max" battery has an estimated capacity of 173 kW-hr.[36] The 20-module "Max" battery is available only with all-wheel drive. A smaller 14-module "Standard" battery, RPO EW2 is available for both front- and all-wheel drive models; the curb weight decreases by 520–700 lb (240–320 kg) with the "Standard" battery;[1][2] estimated capacity of the "Standard" battery is 121 kW-hr.

The Zevo 600 is capable of recharging at rates of up to 120 kW (DC) or 11.5 kW (AC).[35][37] A 19.2 kW (AC) charger is available as an option.[23]

The combined (city + highway) estimated driving range is 159 and 272 mi (256 and 438 km) with the standard and max batteries, respectively;[38] at launch, the range was estimated at 250 mi (400 km),[7][39] which allows the vans to charge overnight for a full day of deliveries. Typical delivery routes average between 100 and 150 mi (160 and 240 km) per day, and the range was designed initially to ensure that delivery drivers could complete an entire route with confidence regardless of weather or traffic conditions.[40] In addition, more gentle or partial charging cycles can be applied, which would prolong the life of the traction battery.[35]

Cargo

[edit]

The Zevo 600 has an advertised 600 cubic feet (17 m3) of cargo volume and a GVWR of under 10,000 pounds (4,500 kg),[41] providing an estimated payload rating of 2,200 lb (1,000 kg).[37] The smaller Zevo 400 has 410 cu ft (12 m3) of cargo volume,[40] with a body approximately 20 ft (6.1 m) long, designed to fit in a standard parking space; the Zevo 400 rides on an approximately 150 in (3,800 mm) long wheelbase.[42]

There are two rear axle options available; the standard, designated RPO C5F, carries a gross vehicle weight rating of 9,900 lb (4,500 kg), while RPO C7E uses an uprated rear axle to increase GVWR to 11,000 lb (5,000 kg), accommodating greater payload weight.[1][2]

The Zevo 600 has a sliding curbside door that is 3 ft (0.91 m) wide to facilitate moving bulky packages, and the dashboard on that same curb side has a depression that can accommodate two standard United States Postal Service bins.[37] The cargo area is separated from the driver's compartment with a sliding bulkhead door, and a translucent roof is available along with standard motion-activated LED lights to illuminate the rear,[31] which will accommodate a standing person who is 6 ft 4 in (1.93 m) tall without stooping.[37] When the exterior roll-up door is up, the rear opening measures 60.0 in (1,520 mm) wide and 72.0 in (1,830 mm) high.[43]

Driver assistance

[edit]

Advanced driver-assistance systems include pedestrian detection, automatic emergency braking, and a rear-view camera. For the driver's convenience, the vehicle has parking assistance and may be locked, unlocked, or started remotely; fleets can monitor battery state of charge and track vehicle locations remotely as well.[37] The steering wheel and seat are equipped with haptic technology to warn the driver of potential hazards through vibration.[44]

Current displays use Android Automotive OS, but the interface may be customized in the future.[31] Electronic systems and accessories are operated from the low-voltage (12V) battery, which is carried at the driver's feet.[30]

Guinness World Record

[edit]

In April 2022, FedEx driver Stephen Marlin set the Guinness World Record for greatest distance traveled by an electric van on a single charge, driving a Zevo 600 from New York City to Washington, D.C., a distance of approximately 260 miles (420 km).[45][46]

References

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  1. ^ a b c d e f g "BrightDrop Zevo Dealer Ordering Guide" (PDF). GM Envolve. May 12, 2023. Retrieved 5 July 2024.
  2. ^ a b c d e f g "BrightDrop Zevo Dealer Ordering Guide". GM Envolve. June 7, 2024. Retrieved 5 July 2024.
  3. ^ a b "BrightDropped: General Motors Moves Its EV Delivery Van Unit to Chevrolet". Autoweek. August 29, 2024.
  4. ^ "Chevrolet BrightDrop". GM Envolve. Retrieved August 29, 2024.
  5. ^ O'Kane, Sean (June 4, 2020). "General Motors is reportedly working on an electric delivery van". The Verge. Retrieved 3 November 2022.
  6. ^ LaReau, Jamie L. (June 4, 2020). "GM is working on an all-electric work van to build at Detroit-Hamtramck plant, report says". Detroit Free Press. Retrieved 3 November 2022.
  7. ^ a b Cole, Craig (12 January 2021). "GM introduces BrightDrop, a logistics-focused electric side hustle at CES 2021". Cnet. Archived from the original on 12 January 2021. Retrieved 12 January 2021.
  8. ^ Jones, KJ (October 6, 2021). "BrightDrop EV410 First Look: GM's Smaller Electric Delivery Van". Motor Trend. Retrieved 2 November 2022.
  9. ^ Wayland, Michael (September 28, 2021). "GM's commercial EV business BrightDrop to supply new van to Verizon". CNBC. Retrieved 2 November 2022.
  10. ^ Hall, Kalea (1 April 2022). "GM's BrightDrop announces new names for its EV products". The Detroit News. Archived from the original on 5 April 2022. Retrieved 2 April 2022.
  11. ^ Violette, Maria (April 1, 2022). "BrightDrop rolls out new product names and branding system" (Press release). BrightDrop. Retrieved 2 November 2022.
  12. ^ LaReau, Jamie L. (13 July 2021). "GM confirms hiring supplier to build first electric vans for BrightDrop". Detroit Free Press. Archived from the original on 7 March 2022. Retrieved 2 April 2022.
  13. ^ Klayman, Ben (12 July 2021). "GM turns to supplier to build initial EV vans while it readies plant in Canada". Reuters. Archived from the original on 2 April 2022. Retrieved 2 April 2022.
  14. ^ Abuelsamid, Sam (September 28, 2021). "Brightdrop Completes First Of 500 Electric Fedex Vans, Adds Smaller EV410 For 2023". Forbes. Retrieved 2 November 2022.
  15. ^ a b Priddle, Alisa (December 5, 2022). "GM's BrightDrop Electric Commercial Vans Ramping Up Production". Motor Trend. Retrieved 6 December 2022.
  16. ^ Alamalhodaei, Aria (November 18, 2021). "GM's electric delivery unit BrightDrop expands deal with Merchants Fleet". TechCrunch. Retrieved 3 November 2022.
  17. ^ Mihalascu, Dan (17 December 2021). "GM's BrightDrop Delivers First EV600 Electric Vans To FedEx". InsideEVs. Archived from the original on 5 April 2022. Retrieved 2 April 2022.
  18. ^ Hawkins, Andrew J. (December 17, 2021). "FedEx receives its first electric delivery vans from GM's BrightDrop". The Verge. Retrieved 3 November 2022.
  19. ^ Bellan, Rebecca (January 5, 2022). "GM's BrightDrop brings on Walmart as new EV customer as FedEx ups existing order". TechCrunch. Retrieved 2 November 2022.
  20. ^ "GM creating new EV business to speed delivery, logistics — BrightDrop". Detroit News. 12 January 2021. Archived from the original on 12 January 2021. Retrieved 12 January 2021.
  21. ^ Bellan, Rebecca (September 20, 2022). "Hertz will order up to 175,000 EVs from General Motors, including BrightDrop vans". TechCrunch. Retrieved 2 November 2022.
  22. ^ Lopez, Jonathan (August 13, 2023). "2024 BrightDrop Zevo To Get New Configurations". GM Authority. Retrieved 5 July 2024.
  23. ^ a b c Hunt, Rhian (April 22, 2024). "2025 BrightDrop Zevo 400 And 600 Finally Get FWD, AWD Variants". GM Authority. Retrieved 5 July 2024.
  24. ^ "NHTSA Campaign Number: 24V014000". January 11, 2024.
  25. ^ "Brightdrop recall not down to inherent battery risks". EV inFocus. 2024-01-23. Retrieved 2024-01-24.
  26. ^ Lassa, Todd (June 29, 2022). "GM Will Replace Chevrolet Express, GMC Savana with EVs in 2026". Autoweek. Retrieved 3 November 2022.
  27. ^ "GM's New All-Electric Delivery Van Gets 250 Miles of Range". Road & Track. 12 January 2021. Archived from the original on 12 January 2021. Retrieved 12 January 2021.
  28. ^ Peters, Adele (2021-12-17). "FedEx's new delivery vans are all-electric, and redesigned with the driver in mind". Fast Company. Archived from the original on 2021-12-19. Retrieved 2021-12-19.
  29. ^ McIntosh, Jil (April 25, 2022). "First Drive: 2022 BrightDrop Zevo 600". Driving.ca. Retrieved 3 November 2022.
  30. ^ a b "Information for first and second responders: Emergency Response Guide, BrightDrop EV600 Truck / Van Li-ion Battery". National Fire Protection Association. Retrieved 3 November 2022.
  31. ^ a b c d Baldwin, Roberto (May 30, 2022). "What it's like to drive GM's BrightDrop Zevo 600 electric delivery van". Autoblog. Retrieved 3 November 2022.
  32. ^ Lopez, Jonathan (December 8, 2021). "BrightDrop EV600 Will Be Available With Front-Wheel Drive: Exclusive". GM Authority. Retrieved 3 November 2022.
  33. ^ "2024 Zevo 400 Specifications & Highlights" (PDF). GM Envolve. September 2023. Retrieved 5 July 2024.
  34. ^ "2024 Zevo 600 Specifications & Highlights" (PDF). GM Envolve. September 2023. Retrieved 5 July 2024.
  35. ^ a b c Carney, Dan (April 22, 2022). "GM's BrighDrop EV Sets a Record on its Rush to Mass Production". Design News. Retrieved 3 November 2022.
  36. ^ "BrightDrop ZEVO 400 Battery Electric Vehicle". California Air Resources Board. Retrieved 5 July 2024.
  37. ^ a b c d e Cole, Craig (September 22, 2021). "Exclusive first look: BrightDrop EV600 electric delivery van". Road/Show. CNet. Retrieved 3 November 2022.
  38. ^ "BrightDrop Zevo: The All Purpose, All Electric Walk-In Van". GM Envolve. Retrieved 5 July 2024.
  39. ^ Lutz, Hannah (1 April 2022). "BrightDrop renames electric delivery vans". Automotive News. Crain Communications. Archived from the original on 2 April 2022. Retrieved 2 April 2022.
  40. ^ a b Priddle, Alisa (September 28, 2021). "GM Starts BrightDrop Electric Delivery Van Production, Expands Lineup". Motor Trend. Retrieved 2 November 2022.
  41. ^ "PG&E EV Fleet Program Summary of Zero Emission Vehicles and Equipment for Distribution and Delivery Fleets" (PDF). Pacific Gas and Electric Company. Archived (PDF) from the original on 2 January 2022. Retrieved 24 April 2022.
  42. ^ McEachern, Sam (September 28, 2021). "Smaller BrightDrop EV410 Electric Delivery Van Makes Official Debut". GM Authority. Retrieved 3 November 2022.
  43. ^ Lopez, Jonathan (January 19, 2021). "BrightDrop EV600 vs. ICE-Powered Rivals: Dimensional Comparison". GM Authority. Retrieved 3 November 2022.
  44. ^ Jenkins, Lisa Martine (April 1, 2022). "I drove an electric delivery vehicle and no one got hurt". protocol. Retrieved 3 November 2022.
  45. ^ LaReau, Jamie L. (22 April 2022). "Driver sets Guinness World Record in a GM electric commercial van". Detroit Free Press. Archived from the original on 23 April 2022. Retrieved 24 April 2022.
  46. ^ "Greatest distance travelled by an electric van on a single charge". Guinness World Records. Archived from the original on 24 April 2022. Retrieved 24 April 2022.
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