Revolutionizing the Road: Inside Honda’s 0 Series EV Platform and the Saloon Concept’s Journey to Production

Test Run Overview: Honda's Latest EV Model Redefines the Journey to Electric Advancement

During my recent visit to Honda's Research and Development center in Tochigi, Japan, I delved into the extensive technical efforts that have transformed Honda's lineup to electric vehicles, leading to a brief, roughly 10-minute experience of hands-on driving with a camouflaged 0 Series electric vehicle.

It provided a solution to a persistent query that plagued me: In what way is it possible for a vehicle with the sleek and sporty appearance of the Honda Saloon concept to possess a design that's almost ready for manufacturing?

Honda's Sedan Prototype – CES 2024 Showcase

At the Consumer Electronics Show in January, Honda showcased the Space-Hub and Saloon EV designs. The Saloon EV, with its sleek supercar-esque kammback shape, appeared to captivate the audience. This was further amplified when company officials suggested that this eye-catching design was close to being ready for manufacture.

The statement highlights a critical issue: As traditional car manufacturers transition to electric models, the challenge isn't just about developing cutting-edge, cost-effective battery and propulsion technology. A potentially bigger hurdle is designing the rest of the car, or the 'top hat' as referred to in the automotive sector, to integrate with these systems effectively.

Honda's Electric Vehicle Framework known as the

Honda's Electric Vehicle Framework, the 0

Honda's Electric Vehicle Framework: Series 0

Honda asserts that it has the capability to navigate the challenges of conforming to crash-test regulations, providing spacious interiors for passengers, and breaking away from the conventional electric vehicle designs with its profile. This approach exemplifies Honda's new "slim, efficient, and smart" design philosophy that will characterize the forthcoming 0 Series electric vehicles. These cars represent a new chapter for Honda as it moves beyond its GM-supplied Prologue model and transitions to its inaugural range of fully Honda-developed EVs for mass production, with manufacturing set to commence in Ohio towards the end of 2025.

The initial pair of electric vehicles set to debut includes an Acura SUV, initially introduced through the Performance EV concept in August, followed by a market-ready iteration of the Saloon concept.

Honda is not fully prepared to unveil its notably sleek new model in its final form, but it is willing to share insights into the extensive development behind it.

During the Consumer Electronics Show, Honda revealed numerous details concerning their upcoming 0 Series electric vehicles, making it clear that these vehicles will not fall under their existing Accord, Civic, CR-V, or specialty model lines. Essentially, Honda is creating a clear distinction between its electric vehicles and its traditional gasoline, hybrid, and potential plug-in hybrid vehicles. Apart from its electronics platform and user interface, the company does not intend for its electric vehicle architecture to share components with its gasoline and hybrid counterparts.

Prototype of the Honda 0 Series framework (Accord)

Curiously enough, I found myself ready to take the wheel and test the crucial elements of Honda's 0 Series platform, utilized in models like the Accord or CR-V, which includes the base structure and the battery housing, along with the 0 Series suspension system. Although both vehicles underwent adjustments to their suspension and driving systems to better suit their unique weight distributions, I made a beeline for the Accord, following a suggestion that it might offer the most telling demonstration of the 0 Series' performance characteristics.

Honda is rethinking the standard "bulky and weighty" design paradigm for electric vehicles (EVs). The company's focus on "slim, lightweight, and smart" design seeks to overcome the limitations imposed by the traditional notion that EVs must be "bulky and heavy." The common practice of using large battery packs accompanied by cumbersome cooling mechanisms and body designs that try to cater to both sedans and SUVs often leads to a design that is not ideal for the most extreme vehicle models.

The Honda Saloon concept is designed with dynamic aerodynamic features and a sleek shape, aiming to surpass all other production cars in aerodynamic performance. Additionally, it boasts a potential height under 55 inches, yet still offers ample interior room for adult passengers.

The process began with designing a slender, ultra-thin battery pack that doubles as a foundational component. By integrating compact e-axles and utilizing an aluminum-centric frame, the vehicle's weight is centralized. Honda has shortened the protrusions at both ends of the car and has innovated the approach to how the body's bending at the front and back affects the suspension, opting for reduced side-to-side stiffness compared to current automotive standards. According to Honda, this reduces the overall weight and enhances the vehicle's agility.

Honda's Electric Vehicle Framework for the 0

The power pack belongs to a system known as the Integrated Power Unit, which not only serves as the encasement for the battery but also plays a crucial role in the framework of the vehicle's platform. It is fortified with robust rails that, along with the pack, contribute to the vehicle's structural integrity and improve protection against side collisions.

The sleek hood design and aerodynamic shape are made possible by an underlying body frame that isn't designed to accommodate front-mounted engines. The force from frontal impacts is transferred to the sturdy side rails, eliminating the necessity for taller crossmembers at the dashboard level.

The upcoming 0 Series from Honda will feature options for both all-wheel and rear-wheel drive configurations. Honda has developed a powerful 180-kw (241-horsepower) electric motor and a smaller 50-kw (67-horsepower) motor, the latter of which is also utilized in their dual-mode hybrid vehicles. The company boasts that their e-Axle technology is 40% more compact compared to an average of similar units provided by competing original equipment manufacturers (OEMs). While Honda considers these e-axles to be exclusive to their brand, they are actually manufactured by Hitachi Astemo, a company in which Honda holds a controlling interest.

Honda's Electric Sedan Prototype

Conceptual Electric Sedan from Honda

Honda's Electric Vehicle Sedan Prototype

Honda's 0 Series targets a 300-mile range

Honda has set a target for its 0 Series lineup to reach an approximate 300-mile range as per the EPA's testing cycle. This will be accomplished through different sizes of battery packs tailored to hit the mark. The company highlights that their 0 Series models are equipped with a radiant heater and heat pump that cut down the heating energy use by 13%, resulting in a smaller drop in range during cold weather compared to competitors' models.

Honda has pledged that the 0 Series will outperform competitors by 2% in energy efficiency, implying a better range per unit of energy. However, without comparing it to known brands such as Tesla and Lucid, it's challenging to predict Honda's standing.

I had the opportunity to test drive an Accord equipped with a pair of 241-horsepower engines, which theoretically could produce more than 480 horsepower combined. However, Honda representatives remained tight-lipped regarding whether the engines were running at full capacity during the test. As for the fundamental specifications like battery size, Honda has yet to release any updates. They did, however, confirm that all battery modules will be pouch-style, provided by a joint venture between Honda and LG. Details on how fast these electric vehicles can be charged, or whether they will function on a 400 or 800-volt system, have not been disclosed by Honda. Nevertheless, they have assured that future models of the 0 Series, expected in a few years, will have the capability to charge from 15% to 80% in a rapid 10 to 15 minutes, hinting at the possibility of 800-volt charging. These models are also expected to maintain at least 90% of their original battery capacity after a decade of usage.

The vehicles will receive their power units from a collaboration with LG, with delivery coming through a partnership between LG and Honda based in Ohio. While Honda has not disclosed the specific number of cells each module contains, it has stated that its battery management system operates on a wired basis and keeps track of resistance within individual cells.

Prototype of the Honda 0 Series framework (Accord model)

Halvorson engages in a conversation about the driving qualities of the Series 0 with the lead engineer.

Honda introduces an electric vehicle chassis with the Honda Accord model.

I had the chance to take a brisk test drive in the prototype of the Honda 0 Series. At first glance, the vehicle I'm seated in seems to be an Accord, equipped with some testing instruments and a slender screen that doesn't resemble the expansive display of the Saloon concept in the least. However, I've been informed that several elements of this prototype bear a strong resemblance to the near-production version of the 0 Series.

Exiting the preparation zone and onto the straightaway of the compact track, I press down on the gas, fully engaging it briefly before gently navigating the track's bends. It becomes apparent that despite its larger size for an electric vehicle, it handles with greater agility and stability compared to the average Accord. Encouraged by the approving glances from the engineer beside me, I increase my speed on the straight stretch, surpassing the initial limits of the drill and hitting close to 75 mph. Even at that speed, the vehicle's drive system operates with impressive silence.

Prototype of the Honda Series 0 (Accord Model)

In general, this matches the speed of the fastest all-wheel-drive electric vehicles on the market, with the exception of those labeled with Plaid, Performance, or N. Additionally, the motors provide their power smoothly without any shakiness, and they appear to work harmoniously with the systems managing vehicle stability and motion.

The prototype of the 0 Series, which is built on the Accord framework, does not include the final version's steer-by-wire technology. Additionally, the braking system is not the one intended for the final product, and there's only a single, moderate setting for brake regeneration that reduces speed but still necessitates the use of the brake pedal. Honda has not disclosed the battery pack's capacity in this prototype, nor whether its weight is similar to or greater than the production model's battery, or how it compares to the weight of an Accord. However, it has been confirmed that the prototype weighs more than the gasoline-powered Accord.

Prototype of the Honda Series 0 (Accord model)

The prototype model of the 0 Series outperforms the Accord in terms of handling. It is equipped with the 0 Series' advanced air suspension system, which includes air-spring struts at the front and an air springs supported multi-link arrangement at the rear. Additionally, it features the 0 Series' stability mechanism and body regulation technology that utilizes 3D gyro sensors, a technology derived from Honda's ASIMO robots, marking a global innovation for the company.

In summary, my impression is that the car seems to handle turns with stability and sits closer to the ground, much like an Accord. However, the engineer accompanying me pointed out that the seating position in this vehicle is, in fact, a bit higher compared to a regular Accord.

Following my turn at the wheel, I took a moment to observe this unique Accord during its next round, and indeed, it was visibly hugging the curves with the same level of stability I experienced while driving.

I gained a deeper understanding of Honda's innovative strategies in producing electric vehicles as I stepped back from the prototype. Impressively, the battery pack housing is the most substantial single casting Honda has ever produced, even more so than its engines, and it consists of merely five components in contrast to the 60 or more in others, according to Honda. To manufacture these parts, Honda will employ six high-pressure die-casting machines, each with a 6,000-ton capacity, at its Ohio plants. This "megacasting" technique is preferred as it consumes less energy compared to "gigacasting" and offers greater versatility in production.

Honda's 0 Series framework – energy storage unit

Additionally, following a rapid automated trimming phase, a technique known as friction stir welding will be employed to join the components of the pack, ensuring accurately crafted cooling channels. The entire operation seems set for a scale-up in production.

Honda is strategizing to implement a semi-automated flexible manufacturing cell system that grants them the agility to adjust their assortment of battery pack dimensions in response to the fluctuating demands of their vehicles. Honda predicts that about three-quarters of their 0 Series electric vehicles will likely require medium-sized battery packs, with the remaining 25% needing larger ones.

The 0 Series electric vehicles will be produced in Ohio, right next to the traditional gasoline-powered cars. This highlights a key fact: even with their distinct features, the 0 Series EVs are designed to be built together with Honda's internal combustion engine vehicles within a partially automated production line.

Honda has ambitions to significantly scale up the production of substantial aluminum modules for the rear section of their 0 Series electric vehicles, potentially kicking off this initiative in 2028 at their Canadian facility. Additionally, the company is implementing a specialized joining technique known as CDC (constant direct current chopping) that they have developed for use with this particular frame and alloy composition, which results in a more robust connection while consuming less energy.

Platform 0 by Honda

The 0 Series is set to operate using Honda's latest electrical and electronics framework, which is divided into three separate electronic control units (ECUs): the first for safety and self-driving capabilities; the second for controlling vehicle movement, onboard electronics, and power regulation; and the third for the digital user experience. The company is also working on a sophisticated feature for remotely calling the vehicle, along with an extended-reality (XR) function that lets loved ones virtually accompany you on your drive.

Honda has announced that their advanced detection capabilities will encompass lidar technology, a combination of sensors for enhanced long-distance and nocturnal visibility, and their own artificial intelligence. The company aims to provide Level 3 autonomous driving functions. This technology will not require pre-mapped roads, and Honda claims it will evolve into the quickest global system for "all area eyes off" driving during the later stages of the 0 Series development.

Securing an electric four-door car with a genuinely sleek and agile sensation continues to be a tough endeavor. Nonetheless, Honda is confident in its capacity to deliver a car with a low-slung, extended, and broad design alongside two SUVs by 2026. This will be followed by a three-row SUV in 2027, additional SUV models in 2028 and 2029, and a smaller-sized sedan in 2030, all constructed on the 0 Series electric platform.

If it can advance these aspects, proving that what lies beneath is not a constraint, then that's an impressive foundation.

Green Car Reports received several amenities such as transportation and dining to assist in the creation of this report.

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