Honda’s 0 Series EV: Pioneering Thin, Light, and Wise Design for a New Era of Electric Vehicles

Test Drive of Prototype: Honda 0 Series Charts New Course in Electric Vehicle Development

During a visit to Honda's research and development center in Tochigi, Japan, last week, I delved into the extensive engineering efforts behind transforming Honda vehicles into electric models. This exploration concluded with roughly 10 minutes behind the wheel of a camouflaged 0 Series electric vehicle.

The Honda Saloon concept provided a solution to a question that I couldn’t stop pondering: How can a vehicle that appears so sleek and sporty be nearly ready for mass production?

Honda Sedan Prototype – CES 2024

During the January CES event, Honda introduced its Space-Hub and Saloon EV concept vehicles. The Saloon EV, with its sleek kammback design reminiscent of a supercar, particularly captured attention. This excitement was further fueled by executives' statements suggesting that its eye-catching design was close to entering production.

This highlights an important issue: for traditional car manufacturers, developing advanced battery and propulsion systems is just one hurdle in the transition to electric vehicles. The more significant challenge might be designing the rest of the vehicle, known in the industry as the "top hat," to complement these new systems.

Honda's 0 Series Electric Vehicle Platform

Honda's 0 Series Electric Vehicle Framework

The Honda Platform for 0 Series Electric Vehicles

Honda claims it can overcome the challenges posed by crash-test regulations, spacious passenger interiors, and conventional electric vehicle designs to make this particular model work. This vehicle exemplifies Honda's new "thin, light, and wise" engineering approach for its forthcoming 0 Series electric vehicles. These models mark a new beginning, moving beyond the GM-supplied Prologue and paving the way for Honda's first own-engineered mass-production EV family, set to be manufactured in Ohio beginning in late 2025.

The initial pair of electric vehicles (EVs) set to debut include an Acura crossover, which was hinted at through the Performance EV concept revealed in August, followed by a production-ready model based on the Saloon concept.

Although Honda is not fully prepared to unveil this particularly sleek future model in its final production version, the company is prepared to provide an insight into the extensive efforts happening behind the scenes.

At the CES event, Honda shared extensive details about its upcoming 0 Series electric vehicles, making it clear that these new models will not be versions of the Accord, Civic, CR-V, or any specialized models. Essentially, the electric vehicles will stand apart from traditional gasoline vehicles, hybrids, and perhaps plug-in hybrids. Apart from the electronics platform and user interface, Honda intends to keep the EV framework and platform distinct from that of its gasoline and hybrid models.

Prototype of the Honda 0 Series platform (Accord)

It's somewhat paradoxical that I found myself ready to explore crucial components of Honda's 0 Series platform, specifically in an Accord or a CR-V. This included the floor, battery case, and the 0 Series suspension. While both models had their suspension and drive systems adjusted to suit their individual weight balances, I was drawn to the Accord based on a recommendation that it might offer the most insightful glimpse into the driving dynamics of the 0 Series.

Honda is questioning the notion that electric vehicles (EVs) must be "thick and heavy." The company is focusing on a design philosophy centered on "thin, light, and smart" to break away from the traditional idea that EVs require hefty battery packs, large cooling systems, and robust body structures. These conventional designs often aim to cater to the needs of sedans and SUVs but can fall short when applied to more extreme types of vehicles.

Featuring dynamic aerodynamic enhancements and a sleek design, the Honda Saloon concept aims to deliver superior aerodynamics compared to any existing production vehicle. Despite its overall height potentially being under 55 inches, it is designed to ensure ample interior room for adult passengers.

The vehicle's placement was achieved by designing a slender, extremely low-profile battery pack that serves as a structural component. The use of streamlined electric axles and a body primarily composed of aluminum helps concentrate the vehicle's weight near its center. Additionally, Honda has minimized the overhangs and reconsidered how the bending of the body at the front and rear impacts the suspension, opting for reduced lateral stiffness compared to typical vehicles. According to Honda, this approach decreases weight and enhances agility in driving.

Honda's 0 Series Electric Vehicle Platform

The power unit, which includes the battery pack, is designed as an Integrated Power Unit. This means it serves both as the casing for the battery and as a crucial component of the platform's structural framework. It is reinforced with sturdy rails that, along with the battery pack, function as a structural element of the vehicle, improving protection against side impacts.

A key factor enabling the lower hoodline and aerodynamic shape is the underlying body design, which was not originally intended to accommodate front-mounted engines. The paths for frontal offset forces integrate with the robust rails in such a manner that eliminates the necessity for elevated cowl crossmembers.

Honda's 0 Series lineup will feature models that come with either all-wheel drive or rear-wheel drive options. Currently, Honda offers an electric drive system with a power output of 180 kW (241 horsepower) and another 50 kW (67 horsepower) unit that is also used in its hybrid vehicles with two modes. The company claims that its e-Axle technology is 40% more compact when compared to an average of similar systems from other original equipment manufacturers. Although these e-axles are branded as Honda's own technology, they are manufactured by Hitachi Astemo, a company in which Honda holds a majority ownership.

Honda's Concept for an Electric Sedan

Concept for Honda's Electric Sedan

Honda's Concept for an Electric Sedan

Honda's 0 Series Targets 300-Mile Range

Honda is setting its sights on delivering approximately 300 miles of range across different models in its 0 Series, according to the EPA cycle. To accommodate this target, the sizes of battery packs will differ among the models. The company highlights that the 0 Series incorporates a radiant heater and a heat pump, allowing it to cut down heating energy usage by 13%. Additionally, the 0 Series is designed to experience less range reduction in cold weather compared to competing models.

Honda claims that the 0 Series will have a 2% higher efficiency compared to the average of its competitors when it comes to the range achieved per unit of energy. However, without detailed comparisons to specific brands like Tesla and Lucid, it remains challenging to predict Honda's exact standing.

The Accord I test drove was equipped with a pair of 241-horsepower engines, potentially delivering over 480 horsepower in total. However, Honda representatives did not verify if these engines were reaching their maximum power output in this instance. While Honda did not provide new details on essential specifications like battery capacity, it did confirm that the battery modules will exclusively be in pouch form, sourced from a partnership between Honda and LG. The company also hasn't disclosed charging rate figures or confirmed whether these electric vehicles will use a 400-volt or 800-volt system. Nonetheless, Honda assured that future iterations of the 0 Series, expected in a few years, will be capable of charging from 15% to 80% in just 10 to 15 minutes, indicating the use of 800-volt technology. Additionally, these models are expected to retain no less than 90% of their original battery capacity after a decade of use.

These models are set to receive battery cells through a partnership with LG, which will be provided by an LG and Honda joint venture located in Ohio. Although Honda has not specified the number of cells included in each module, they have explained that their battery management system is wired and keeps track of resistance for each individual cell.

Prototype of the Honda Accord built on the 0 Series platform

Halvorson talks about the driving features of Series 0 with the lead engineer.

Honda Accord to Feature 0 Series Electric Vehicle Platform

A brief test drive of the Honda 0 Series prototype

Returning to the initial sneak peek, the vehicle I'm inside resembles an Accord at first glance. It features some experimental controls and a modest display screen, which starkly contrasts with the expansive display envisioned in the Saloon concept. However, I've been informed that several components of this vehicle are quite similar to what the final version of the 0 Series will look like.

I exit the staging area and drive onto the straight section of the compact road circuit, pressing the accelerator to the floor briefly before carefully navigating the track's bends. I soon realize that although this electric vehicle is on the heavier side, it handles with more agility and balance compared to a standard Accord. With approval from the development engineer sitting beside me, I accelerate more aggressively on the straightaway than initially planned, ultimately hitting around 75 mph. Impressively, the propulsion system remains exceptionally silent even at this speed.

Prototype Series 0 by Honda (Accord Model)

In general, this vehicle's speed matches that of the fastest mainstream all-wheel-drive electric vehicles, excluding those with Plaid, Performance, or N designations. At the same time, the motors provide torque smoothly and without any vibrations, working harmoniously with the systems managing stability and body control.

This 0 Series prototype, which is built on the Accord platform, does not include the steer-by-wire technology that will be found in the final production model. Additionally, its braking system is not at the production stage, offering just a single, moderate level of brake regeneration. This requires the use of the brake pedal to slow down significantly. Honda has not disclosed the battery pack's capacity in this prototype, nor have they revealed whether its weight is similar to that of the production model or how much it outweighs a conventional Accord. However, it has been confirmed that this prototype is heavier than a standard gasoline-powered Accord.

Prototype of the Honda Series 0 (Accord)

Prototype of the 0 Series surpasses Accord in handling

The prototype is equipped with the 0 Series' advanced air suspension system, featuring air-spring struts in the front and a multi-link configuration with air springs in the rear. It also boasts the 0 Series' stability system and body controls, which include cutting-edge 3D gyro sensors, a technology first introduced by Honda's ASIMO robot line.

In my view, this car resembles an Accord with a lower stance and improved cornering ability. However, the engineer accompanying me points out that the seating position, or H-point, in this vehicle is actually a bit elevated compared to a regular Accord.

After taking it for a drive, I stepped aside to observe this unique Accord during another lap and visually verified that its cornering remains as level as it feels from the driver's seat.

Stepping away from the prototype, I gained a deeper understanding of Honda's ambitious plans for innovation in the production of their electric vehicles. Notably, the casing for the battery pack is the largest single cast component Honda has ever manufactured, even surpassing the size of their engine parts. According to Honda, this battery pack case consists of only five parts, in stark contrast to the 60 or more parts used by some competitors. To create these components, Honda will employ six high-pressure die-casting machines, each with a capacity of 6,000 tons, at their facilities in Ohio. This method, known as "megacasting," is more energy-efficient than "gigacasting" and offers greater flexibility in production.

Honda's 0 Series framework – energy storage unit

Additionally, following a swift robotic cutting procedure, a novel technique known as friction stir welding will join the components of the pack, ensuring accurate cooling pathways. Everything seems set for scaling up to mass production.

Honda is set to implement a semi-automated production system with flexible cells, enabling rapid adjustments to the size of battery packs according to vehicle demand. The company expects that approximately 75% of its 0 Series electric vehicles will feature medium-sized battery packs, with the remaining 25% being equipped with larger packs.

The 0 Series will be produced in Ohio along with gasoline-powered cars. This highlights a significant aspect: Despite the variations, the 0 Series electric vehicles are designed to be manufactured alongside Honda's internal combustion engine vehicles in Ohio, utilizing a semi-automated production line.

Honda has announced its intention to produce significantly larger aluminum rear body modules for its 0 Series electric vehicles in the near future, with production expected to begin around 2028 at its facility in Canada. The company is also implementing a specialized joining technology known as CDC (constant direct current chopping), which Honda has developed specifically for this type of body frame and alloy. This method promises to be more energy-efficient and to create stronger welds.

Platform of Honda's 0 Series

The 0 Series will operate using a novel electrical and electronic framework developed by Honda, which involves three different electronic control units (ECUs). The first ECU focuses on safety and autonomous driving systems, the second manages vehicle dynamics, body electronics, and energy use, and the third is dedicated to the digital user experience. The series is set to include a sophisticated summon capability and an extended-reality (XR) feature that enables friends or family to accompany you on a virtual journey.

According to Honda, their advanced detection system will integrate lidar technology, combine multiple sensors for extended range and nighttime driving, and utilize their unique artificial intelligence. They aim to provide Level 3 driver assistance capabilities. Unlike some systems, this one will function beyond just mapped roads. Honda claims that, as the 0 Series develops, their system will ultimately become the quickest globally for "all area eyes off" driving.

Creating a fully electric sedan that maintains a low and agile feel is still difficult. However, Honda is confident it can deliver a low, elongated, and broad sedan, along with two SUVs by 2026. The company plans to introduce a three-row SUV in 2027, followed by additional SUVs in 2028 and 2029, and aims to roll out a compact sedan in 2030, all utilizing their 0 Series electric platform.

If it can move these forward, demonstrating that the underlying elements aren't the constraints, that's a significant beginning.

— In order to produce this report, Green Car Reports received support such as travel arrangements and meals.

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