General Motors will deploy IONATE’s Hybrid Intelligent Transformer (HIT) at its 900,000-square-foot Romulus Propulsion Systems plant in Michigan, marking the London-based grid technology company’s first commercial installation in the United States. The plant is currently scaling production of 10-speed transmissions for GM’s full-size trucks and SUVs following a recent $300 million investment to expand capacity. The collaboration follows IONATE’s projects across European grids and reflects a shared focus on modernizing critical electrical infrastructure with smart grid technology, according to the companies.
Highlights
- IONATE’s Hybrid Intelligent Transformer operates at greater than 99% efficiency while providing real-time visibility into power conditions, according to the company.
- In average deployment scenarios, grids using IONATE’s technology can accommodate 33% more distributed energy resources, carry 25% more power without upgrading poles and wires, and reduce wasted power by 6%, IONATE says.
- The Romulus facility spans 900,000 square feet and is scaling 10-speed transmission production for GM’s full-size trucks and SUVs.
- U.S.-standard 3MVA IEEE units are currently finishing build and test ahead of the rollout, with additional GM plants under consideration for future deployment.
What the Hybrid Intelligent Transformer Does
Delivered in the form of a transformer, the HIT is positioned at the connection point between the grid and on-site energy use. According to IONATE, it senses, analyzes and resolves power disturbances in real time — before they affect plant operations or the surrounding grid — while operating at greater than 99% efficiency. The system integrates into existing substations and facilities, which the company says reduces the need for downtime, infrastructure overhauls and supply chain disruptions.
At Romulus, the deployment is designed to give GM real-time visibility and control into power quality and consumption at sub-millisecond resolution, according to the release, enhancing the plant’s energy resiliency and efficiency while helping identify grid issues that could otherwise lead to outages.
Deployment and Engineering
Engineering teams from IONATE and GM have worked together to bring the technology to Romulus, with U.S.-standard 3MVA IEEE units currently finishing build and test ahead of installation. The companies plan to collaborate on the initial deployment at Romulus and are weighing potential rollouts at other plants across GM’s manufacturing system.
Beyond the individual site, each HIT also functions as a real-time control node coordinated through IONATE’s Aurora software platform, allowing individual deployments to feed into broader improvements in grid capacity and resilience as networks scale. IONATE frames the approach as helping large energy users operate as better grid citizens while preparing infrastructure for future demand growth.
Grid Modernization Amid Rising Power Demand
The companies describe the deployment against a backdrop of industrial electrification, generation expansion and rising AI-driven power demand straining electrical systems that, in many cases, have changed little in more than a century. IONATE positions the Romulus installation as a potential model for other manufacturers, data centers and grid operators facing pressure to modernize energy systems without waiting on broader grid upgrades.
“Deploying the Hybrid Intelligent Transformer with General Motors marks a significant step in reinforcing industrial power infrastructure with solid-state intelligence,” said Matthew Williams, founder and CEO of IONATE. “GM’s manufacturing operations demand the highest standards of reliability, efficiency, and power quality – and that is what we build for. We are thrilled to launch IONATE’s technology in the U.S. with such a titan of American industry.”
“Maximizing efficiency and resiliency is crucial in GM’s manufacturing system, and it’s why we’re implementing innovative technology to enhance our energy management and the overall grid,” said Luis Cervantes, executive director of manufacturing excellence at GM.
The Romulus deployment adds to a broader set of GM grid initiatives, including the automaker’s vehicle-to-grid and grid-scale storage plans.
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