Nov 21

Volvo To Increase Production of 2014 V60 Diesel Plug-in Hybrids

 

By Philippe Crowe

Volvo is expanding production to be able to build up to 6,000 units of its V60 Plug-in Hybrid. If you recall, this efficient diesel-electric car is capable of 31 miles all-electric range at speeds up to 74 mph.

As Volvo stated it, after the initial batch of 1,000 model year 2013 cars, the assembly line will increase to 4,000-6,000 cars as of model year 2014.

The assembly of the V60 Plug-in Hybrid, which was the world’s first diesel plug-in hybrid, is integrated on the same line as the company’s other models at the Torslanda plant in Gothenburg.

Volvo_V60_PHEV_Production

The extended-range, multi-mode hybrid vehicle has 4WD, towing capability, and respectable seating and cargo space. Could GM benefit from such a car in its lineup?
 

Volvo had previously stated the production for the 2014 model would be at 5,000 units. It looks like the success of the first year of production has Volvo optimistic about the model’s sales success.

Volvo says it considers this is a remarkable achievement considering that the sophisticated plug-in hybrid technology includes two complete drive trains and a powerful battery.

“We are first in the industry to integrate a plug-in hybrid in an established production flow together with other car models,” says Peter Mertens, senior vice president Research and Development at Volvo Car Corporation. “The integration in the standard production flow gives the plug-in hybrid buyer the possibility to choose in principle all options available for the standard V60.”

Integrating the plug-in hybrid to the regular production process has led to parts of the final assembly line being rebuilt and modified. The adaptation makes it possible to smoothly integrate the assembly of over 300 more parts that are included in the plug-in hybrid compared to an equivalent V60.

Volvo_V60_productionline

 

The following examples give an idea of the challenges in integrating the production flow:

• The electric motor along with its drive shafts is fitted on the same station as the final drive on the standard four-wheel drive models

• The cooling system and the high voltage cables are assembled on the Pallet, which is used to assemble the car’s drive train and chassis parts

• The battery pack is lifted in through the car’s tailgate short side forward. It is then spun a quarter of a turn in the passenger compartment – a maneuver that takes 60 seconds and is carried out with less than 20 millimeters (0.787 inches) to spare

“The 11.2-kwh lithium-type battery is the single most complex system in the car. The precision maneuver to get it in place is an excellent example of the state-of-the-art assembly process,” says Peter Mertens.

Volvo says it considers the Volvo V60 Plug-in Hybrid the synthesis of close cooperation between Volvo Car Corporation and Swedish electricity supplier Vattenfall.

The two companies have financed the development project jointly.

“The V60 Plug-in Hybrid is a unique car, a historic step, not only for Volvo Car Corporation but for the entire car industry. The first year’s 1,000-car batch was sold out even before the car reached the showrooms and the order books for next year’s cars are already filling up,” concludes Peter Mertens.

The first 1,000 units of the Volvo V60 Plug-in Hybrid, of 2013 model year, were only available in a “Pure Limited” edition with Electric Silver paint. The diesel-electric car is also distinguished by aero-designed 17-inch wheels, integrated exhaust tailpipes and a number of bodywork features highlighted in glossy black.

According to Volvo, fuel consumption is just 1.8 l/100 km (130 mpg) in hybrid mode.

As Volvo explains, three pushbuttons give the car three entirely different temperaments:

• In Pure mode the car is powered solely by its electric motor as much as possible. If the battery pack has been recharged with electricity from renewable sources, its range is up to 31 miles [capable of speeds up to 74 mph] and its carbon dioxide emissions are zero. The electric range varies with terrain, climate and driving style.
Hybrid is the standard setting whenever the car is started. The diesel engine and electric motor cooperate to ensure optimal balance between driving pleasure and environmental footprint. CO2 emission (NEDC, mixed driving cycle for certification) is 49g/km [65 percent lower than a V60 with the same engine]. Fuel consumption on this same [optimistic] drive cycle is 1.9l/100km [124 mpg]. The car has a total range of up to 620 miles.
• In Power mode the technology is optimized to give the car the maximum possible power. The diesel engine and electric motor have a total power output of 215+70 [285] horsepower and maximum torque of 325+148 [473] pound-feet. The electric motor’s lightning-quick torque delivery contributes to the car’s acceleration from 0 to 62 mph in 6.1 seconds.

This entry was posted on Wednesday, November 21st, 2012 at 5:55 am and is filed under General. You can follow any responses to this entry through the RSS 2.0 feed. Both comments and pings are currently closed.

COMMENTS: 21


  1. 1
    Darius

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    Nov 21st, 2012 (7:07 am)

    That’s stuff for Lyle consideration.
    impressive video.
    Battery located in the spare wheel compartment. Where spare will located for plug-in Volvo?


  2. 2
    Nelson

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    Nov 21st, 2012 (8:20 am)

    I guess replacing the battery in that Volvo V60, will be cost prohibitive 10 years down the road due to labor alone.

    NPNS!
    Volt#671


  3. 3
    George S. Bower

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    Nov 21st, 2012 (8:21 am)

    Another electric People mover that is selling well along with the Ford C-Max Energi.

    Sounds like GM’s MPV would be a winner.


  4. 4
    Mark

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    Nov 21st, 2012 (8:33 am)

    Imitation is the best form of flattery ! But adding the desiel in to the mix, as well as allowing for control over the drive mode takes the volt concept one step further. It will be interesting to see how it sells vs the standard V60.


  5. 5
    Steve

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    Nov 21st, 2012 (8:41 am)

    Sounds like the dealers will be cursing corporate if they need to do a battery replacement under warranty.


  6. 6
    Raymondjram

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    Nov 21st, 2012 (8:41 am)

    Nelson:
    I guess replacing the battery in that Volvo V60, will be cost prohibitive 10 years down the road due to labor alone.

    NPNS!
    Volt#671

    Yes, it will! According to the post above:
    The battery pack is lifted in through the car’s tailgate short side forward. It is then spun a quarter of a turn in the passenger compartment – a maneuver that takes 60 seconds and is carried out with less than 20 millimeters (0.787 inches) to spare
    “The 11.2-kwh lithium-type battery is the single most complex system in the car. The precision maneuver to get it in place is an excellent example of the state-of-the-art assembly process,” says Peter Mertens.

    I prefer the underside method that GM developed, such that the Volt battery could be replaced in less than one hour. The Volvo battery replacement needs a winch that only a specialized service bay could have. So any battery replacement on this Volvo will be expensive out of warranty.

    But I had two leased Volvos (one was a turbo), and they gave great service, so I hope Volvo’s hybrid is successful. The electric range is short for the high price that this Volvo will cost to buy.

    Raymond


  7. 7
    Loboc

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    Nov 21st, 2012 (9:36 am)

    Raymondjram: The Volvo battery replacement needs a winch that only a specialized service bay could have.

    A standard engine hoist should work. Might need a special lift harness.

    I think all these ‘modes’ could be done using other driver input.

    For example, if you stomp on the go-pedal, it should automatically go to ‘power’ mode.

    If you’re obviously in stop-n-go traffic, it should automatically switch to ‘EV’ mode. Etc.

    There needs to be an automatic ‘mode’ that is standard. There are already way too many distractions with these new panels and no-switch switches.


  8. 8
    DonC

     

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    Nov 21st, 2012 (10:37 am)

    This seems more like an amped up standard hybrid more than an EREV. One of the great advantages of the Volt is the smooth and responsive electric drive at all speeds. Alternatives like the PIP and the Energi and this vehicle aren’t going to provide this because the motors and batteries simply won’t support it. In this case saying you can go 31 miles in pure electric mode sounds great, but it’s only going to be great if your idea of a satisfying experience is having a vehicle this large powered by a 70 hp motor putting out 148 pound-feet of torque (by comparison the Nissan Leaf has an 80 hp motor which puts out 210 pound-feet). Really not comparable to what you experience in the Volt or any other electric vehicle where the electric drivetrain is designed to provide total propulsion.

    Adding the diesel engine doesn’t make any sense for the US market. Here you can’t make up for the added costs with lower fuel prices because we don’t subsidize diesel like they do in Europe.

    That said, you have to love the fact that there are more electric options coming out every day!


  9. 9
    MrEnergyCzar

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    Nov 21st, 2012 (10:41 am)

    This is a pricey car but if they sell those few thousand, maybe the drivetrain will make it to the lower cost Volvo’s…

    MrEnergyCzar


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    Tom

     

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    Nov 21st, 2012 (11:22 am)

    It can tow !! I want one. Does Ford still own Volvo? Probably 0 chance of ever seeing one in the USA.
    Tom


  11. 11
    George S. Bower

     

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    Nov 21st, 2012 (11:27 am)

    DonC:
    This seems more like an amped up standard hybrid more than an EREV.

    I thought it was AWD with the electric motor driving a separate set of wheels.


  12. 12
    Noel Park

     

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    Nov 21st, 2012 (11:39 am)

    Nelson:
    I guess replacing the battery in that Volvo V60, will be cost prohibitive 10 years down the road due to labor alone.

    NPNS!
    Volt#671

    #2

    That’s assuming that Volvo will even be around in 10 years. I dunno, maybe Geely’s marketing plan is to sell them in China. They seem to be selling like cold cakes here.

    If they’re happy with 6000 units a years, why is everybody whining about Volt sales being too low, LOL?


  13. 13
    Noel Park

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    Nov 21st, 2012 (11:43 am)

    Tom:
    It can tow !! I want one. Does Ford still own Volvo? Probably 0 chance of ever seeing one in the USA.
    Tom

    #10

    Nope. Ford sold it to a Chinese company, Geely Holding Group. What they plan to do with it I cannot imagine. No Chinese cars for Noel, thank you very much. Even if they do make them in Sweden at the moment. Go Volt! Next case.


  14. 14
    azm-volt

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    Nov 21st, 2012 (11:49 am)

    All these cars are almost a decade behind the volt. Doesn’t GM have patents on the whole voltec design??? because everyday we see a new cheap knock-off that still can’t stack up. Great job on the development and testing of the volt GM! None of these new knock-offs are being tested as thoroughly. Jmho.


  15. 15
    Mark Z

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    Nov 21st, 2012 (11:53 am)

    The video is excellent and shows the battery being installed in seconds with the major spin taking place in about one second! Add another second for the extra positioning spin. They make it look easy!


  16. 16
    America1st

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    Nov 21st, 2012 (12:03 pm)

    Too bad its owned by the Chinese. Still, we need to get off oil.


  17. 17
    TomServo

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    Nov 21st, 2012 (12:59 pm)

    A very interesting addition to the vehicle world, I agree with comments that diesel power probably doesn’t make sense here in the US and on a personal note I wouldn’t buy a car owned/controlled by the Chinese.

    We are giving them the rope to hang us, one small acquisition at a time. One has to wonder what would have happened to GM if allowed to file bankrucay? And consider many of these companies have defense related businesses. That scares me.


  18. 18
    Logical_Thinker

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    Nov 21st, 2012 (2:58 pm)

    This car, while fairly nice, shows just what a fantastic job GM has done with the Volt. This car has less AER, and costs (IIRC) about $60 K. Yes, it does have towing capability and five seats, but not a very impressive showing. Also, to be getting even their 31 mile AER they must be using a much higher percent of the battery than the Volt –> anticipate reduced battery lifespan. (depending heavily of course on battery tech utilized… if much better battery aka A123 nanophosphate, a greater DOD may be perfectly fine).

    Would not buy.


  19. 19
    Noel Park

     

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    Nov 21st, 2012 (6:54 pm)

    Logical_Thinker: This car, while fairly nice, shows just what a fantastic job GM has done with the Volt.

    #18

    Well said. +1


  20. 20
    Sean

     

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    Nov 21st, 2012 (11:29 pm)

    Wow!

    This has got to be the most exciting news in a very, very, very long time!

    When was the last time we read about a new green tech car being featured here on gm-volt.com?

    Also I can’t say if this car will have a US release?

    But would it be cool if BMW could make a Plug-In-Hybrid of the Jetta TDI!

    As you know it get’s up to 44 MPG.

    Now how fuel efficient do you think the Jetta TDI Plug-In-Hybrid would be?

    Also isn’t GM releasing a diesel in the future if so I forgot what that car is called unless it’s a Spark not sure but I’m glad that GM will be releasing an electric Spark next year and if I’m right?

    There diesel that’s suppose to get about the same MPG as the Prius will be launched either next year or 2014?

    If you know what car I’m talking about let me know.

    Now this is history in the making!

    More Hybrids, Plug-In-Hybrids,EV’S,and EREV’S the better!


  21. 21
    kdawg

     

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    Nov 22nd, 2012 (1:47 pm)

    Sean: Also isn’t GM releasing a diesel in the future if so I forgot what that car is called

    Cruze Diesel

    http://www.washingtonpost.com/cars/2014-chevrolet-cruze-diesel-preview/2012/09/06/dce67168-f85e-11e1-a93b-7185e3f88849_story.html