GM-VOLT : Chevy Volt Electric Car Site

The other day I was in my office when my cell phone rang. I picked it up and on the other end heard a strong voice with a slight Texas drawl, “Dr. Dennis? Hi , Ed Whitacre here.”

You could imagine how taken aback I was, caught by surprise, but quite thrilled and honored.

You see I had been trying to reach out to Mr. Whitacre for a while to learn about his perspective on electric cars, and thanks to GM communications leadership it very suddenly became a reality.

I joked with him that we shared something in common, neither he or I knew much about cars before we started these roles, and he agreed. “I don’t know anything about cars, ” he admitted.

But clearly he knows how to run a business.

I asked why he took the job at GM.

“The government called me in the summer, the Treasury Department, and asked me if I would consider being Chairman,” he said. “I had been at AT&T many years and was happily retired and so I said no I won’t, and they called back the next day and the next day and my conscience finally got to me and I agreed to be Chairman of the Board. I did that for about four months.”

Since it wasn’t much publicized I asked about why Fritz Henderson was fired.

“The board had the feeling GM wasn’t moving quickly enough or the right way, so Fritz left,” he said. “He’s a great guy and he left. I’m pretty old but there wasn’t any other candidate at the time. I had been chairman of AT&T for 17 years so I said yes I could be the CEO.”

“I don’t expect to stay in the position long,” he said. “There’s a search committee doing a search.”

As you might know, Mr. Whitacre also sits on the Board of Directors of ExxonMobil, one of the world’s largest petroleum producers, and it is of interest to see how he might reconcile that with the mission of GM’s Chevy Volt, to help wean our country off of oil.

“ExxonMobil is very concerned about the environment and the future also,” Whitacre said. The company works towards “finding different sources (of energy) and converting to natural gas.”

“We provide the fuel to a lot of powerplants that generate electricity, and there’s a lot of scientific work as well like growing algae (for biofuels),” he added.

He described ExxonMobil as being “responsible citizens,” and noted there is opportunity for the company in a world of electric cars.

“They’re tuned into the electric car,” he said. “As good as (our electric cars) are, the electricity has to be generated by some fossil fuel.”

That the CEO of GM reached out to me and us, and was genuinely thankful for our work here on GM-Volt.com is a very, very wonderful thing. Stay tuned for some more of our conversation.

I had the following discussion with Alex Cattelan who is the Chevy Volt’s chief powertrain engineer. She has a very deep understanding of how the car operates and recently drove in a fleet of integration Volt prototypes through rugged mountains of Knoxville Tennessee.

Do you feel the charge-sustaining (CS mode) experience is now pretty solid and are you pleased with it?
We are definitely pleased with the level of progression we’re at. We are right on track to where we need to be in terms of the next stages of development we need to do to meet our target. Is it commercial right now, no, but that’s why were taking the time to get it to be commercial. Does it have the capability of being commercial, absolutely. We’ve proven that to ourselves.

We just took our leadership through a test drive in Warren (Michigan) and comments are that they cant tell when the engine is coming on or off. Those are the kind of things we like to hear.

You drove the IVs around the mountains of Tennessee. What about those big hills and the generator. It sounded like it drove very briskly powerfully and effortless is that true?
Yes, absolutely. Some of our control capability to utilize the battery, the engine, and the motors and to be able to optimize for high load and low load situations we’ve been working on developing that stuff for the last year and half an I couldn’t tell you how happy I was when I was in Knoxville because that’s when I had the opportunity to see it all come together. A lot of those bits of software all came together on one trip and it was a joy to drive.

So you took it up some steep hills and mountains?
Absolutely. We were in the Cherokee area taking it up through those hills and a lot of situations following it. It was a very touristy area. Following the speed of traffic, absolutely no problem, and where I had opportunities I certainly like to push the limits of the vehicle, and we did on those mountains, and I could not get it to degrade in performance.

That’s in charge sustaining mode?
Certainly in charge depleting, we have no issues because we have battery power, I’ve got it all at my fingertips. Now in charge sustaining we know that the engine power is slightly less than the peak vehicle power but we have controls ways to manage that and to utilize the engine in conjunction with the battery to get a little bit of extra power when we need it, and replenish it back when we don’t.

I know the battery runs down to roughly the 30% level before for the engine comes on. Is that 30% itself the whole potential buffer band?
We certainly don’t utilize the full 30% but there’s a portion of that that we utilize as a buffer.

You wouldn’t go to zero ever?
No. When the engine cannot meet peak load requirements we’ll suck a little bit out of that buffer and as soon as we have a situation when we can, we’ll put it right back in. All the controls that we work do that to optimize not only the driveability but the efficiency as we’re doing it, NVH (noise vibration harshness) as we’re doing it, the total driving experience as well as to protect the battery from a life experience. This is what allows us to give really good warranty life on our batteries as we’re doing I all in a controlled fashion.

NEW: Discuss this story in the GM-Volt Forum

Around 3 years ago, a neurologist named Lyle Dennis decided he just had too much free time on his hands and decided to start a site chronicling the progress and development of a vehicle named the Chevrolet Volt.

Since then, Lyle has researched, interviewed and penned well over a thousand articles on the subject. To date, not a day has gone by without a fresh article for the readership to comment on, no small feat…especially considering his day job.

A few months ago, Lyle ruined his consecutive streak of articles by graciously allowing me to fill in and do some guest pieces, and ever since then I have been nagging him to let me do a story just on him.

Until today, Lyle had rebutted my requests saying that the readership would prefer more Volt-related news, and that the site was not to focus on him, blah, blah, blah. I’m chalking his refusal up to him just being a all around humble/good guy who really doesn’t crave the spotlight…because what he has accomplished here, the hours he puts in, and the access he has been granted inside GM for our benefit is nothing short of remarkable.

So what changed? How did this article come to exist? Well, charity finally got him to buckle…as in, I promised to give Lyle’s charity a pop in exchange for 7 questions. Lyle agreed.

On Sunday Lyle will be running in the NYC Marathon for the American Heart Association. The event looks to have over 40,000 participants and covers 26 miles of New York asphalt. Perhaps you have seen the little ads poking their heads up around the site to donate? I encourage anyone who can, to support Lyle on his run.

…and now the questions.

1.) I’ll start you off easy, can you fill us in on the NYC Marathon, your charity…and how does one run marathons, be a doctor and still find time to run this site?
I love running the NYC marathon, this will be my fifth in a row. It seemed like a good idea to do it for charity this year. As a stroke neurologist, I chose to run for the American Heart Association which is the parent organization of the American Stroke Association.

The only way to find time for all these things is to get up very early in the morning, and go full steam until its time for bed again. Every day is kind of a marathon itself.  As you can see I’m not one to sit idle.

2.) Follow-up question: What does your family think of the site? Does your spouse still speak to you?
I am very fortunate to have a supportive wife and 3 beautiful children ranging in age from 3 to 10. There are times my wife has heard enough about electric cars, and my kids know a little too much about them too.

3.) If you had the option to buy either the Concept or Production Volt in November of 2010? Which would it be?
Believe it or not, I actually prefer the production design. Yes the concept was cool but it doesn’t seem realistic. Also I think making a car palatable for the widest swath of the population will help lead to highest sales volume and thus lead to less oil used. The Camaro, for example, is very striking in design, but not everyone is willing to drive one.

4.) It is a well known fact that all .com owners are multi-millionaires, does it cause conflicts with GM executives when you are able to fly your jet to all corporate events and they now have to fly commercial?
Sorry that .com rule doesn’t apply to bloggers =)

5.) From your own ‘want’ list survey. What is the most you are willing to pay for a Chevrolet Volt (in USD)?
I think $40,000 is the number. I realize its high for the mass market but to me its worth it to be an early adopter.  With time it will come down considerably.

6.) We know you are currently driving a electric Mini, and have tested several electric cars from different manufacturers, if GM gave you a free pass and let you change one thing about the Volt, what would it be?
I’ll pick two; a third seat in the rear and 50 amp 220V charging capability.

7.) What happens to GM-Volt.com past the launch of the actual car? How do you see the site evolving once the car is mainstream?
The site has been a fascinating experiment for me. I started it with no idea if it would ever be noticed, so all of its attention has been a great surprise.

In my very first post in January 2007 I promised to continue the site to the launch and beyond, so that hasn’t changed.

I hope post-launch it will be the go-to place for all things Volt and for Volt owners to hang out and interact, free of corporate oversight and spin.

I also hope to implement, besides the forum, the ability for anyone to create their own microblogs within the site and to be able to post frontpage content in real time, along with what I contribute.

8.) Yeah I said only 7 questions, but this is one is important…and Lyle will probably not answer anymore questions from me. Ever. Who are you pulling for? Yankees or Phillies in the World Series?
I was born in the Bronx and live in NY Statik…do you really need to ask?

Sidenote: My thanks to Lyle for doing this quiz even though he didn’t really want to…and for giving us a little piece of the internet to call ‘home’ everyday.  Please donate to the American Heart Association in support of Lyle’s November 1 2009 marathon run by clicking here.

Prabakhar Patil is the CEO of Compact Power Inc.  CPI is a subsidiary for LG Chem, the Korean company that was awarded with the Chevy Volt cell supplier contract.  CPI helped GM to develop the packs for the Volt.  I had a chance to interview Dr. Patil on the current status of the relationship and operations.

Where are things with respect to pack development and considering GM’s announcement about in house pack and your relationship with them?
The relationship is good and unchanged because the decision for GM to manufacture the pack in-house after they got into volume production had been made some time ago. We agreed to it in the spirit of partnership because for strategic reasons it was important for GM to do this in house, even though we were prepared to support them in high volume production.

Right now nothing has really changed. As you know we shipped around 50 packs last year, this year we are shipping around 400 packs and that continues to happen. We are validating the pack design, the manufacturing process etc, and these are the prototype packs that are going into GM vehicles. That part is exactly the same as it would have been were we to make the high volume production packs.

So the prototype packs are currently being produced at your facility?
Yes, and they will continue to be made here until GM’s facility is up and running.

Are you helping GM to prepare their facility?
We work together. It’s a joint team that is actually at work.

As a subdivision of LG Chem, will you continue to work in GM’s facility?
No, once the production moves to their facility our role will be more supportive.

LG Chem got a $150 million DOE grant for setting up a cell manufacturing facility that will be locating in Michigan?
As you know, up to now the cells are made in Korea and we assemble, engineer, design and manufacture the pack here. The DOE grant is targeted at making the cells here. That has always been our plans and our footprint but this helps expedite the process.

So you are going to build a US battery factory from the ground up with that money?
Yes.

When will you start construction?
We probably will complete the site selection process by the end of this year and then we’ll be breaking ground sometime next year. We have to go through all the permits and site preparation and all that stuff. More importantly in terms of production, the first of the cell lines in that new facility we expect to come on in production rates by second quarter of 2012. It will be fully done with all of the cell lines and electrode lines and all that stuff a year later. At that point, it will be capable of producing enough cells to support anywhere from 50,000 to 250,000 vehicle packs depending on how many cells the packs contain.

Is that factory going to solely be used for the Volt pack or might it be used for other automakers?
It is not tied to a single application or customer, that’s part of the flexibility that we will have that it can support different applications. Because as you know the cells for the Volt will initially come from Korea. In fact, that cell line is already up. It has to be in order for us to have certified cells that have to be ready well ahead of the vehicle launch so GM can go ahead with the pack validation and so forth.

That cell line is already up. That will be used to supply cells for the Volt until the cell line here comes on line, so we have a lot of flexibility.
As far as GM or any other customer is concerned they won’t be able to tell the difference as to whether the cell is made here or in Korea.

The cells for the Volt, are they pretty much going to be a standard LG automotive cell for all applications or are you developing differently nuanced cells for different applications?
There have to be different nuances. For example, if you go from a non plugin hybrid to a BEV there are three discrete types of cells that you need. On plugin HEV like hybrids, the power to energy ratio is high, because those hybrid configurations don’t need large pure electric range.

On the other end of the spectrum the battery electric vehicle where the energy density requirements are very significant when you get to 50 or 100 miles of range. The P to E ratio in that case is relatively low then. Plug in HEV cells like the Volt are in between in order for the cells to be optimized we have to tweak the chemistry or the recipe.

Alex Cattelan is head of the Volt propulsion engineering team.  I had the chance to discuss the current state of Chevy Volt development from her perspective.

What is your role in the Volt program?
I head up the team that does all of the propulsion systems for the Volt. That includes motors, power electronics, we don’t do the battery but we work extensively with the battery team to do the integration of the battery, and the EV propulsion system

Are you only working on the Volt?
I am dedicated to the Volt and I heave a team of people that are dedicated to the Volt and I’m extremely enthusiastic about the Volt. We have segregated a team of people that are working on the Volt and the Volt only.

What are you doing now?
The specific stage of the program that we are in, for powertrain, is building on our third level of hardware which is integrated in the the vehicles. We’re doing all of our validation testing on that level of hardware; we’ve got past development where the architecture needs to be, through two generations of hardware we’ve confirmed all of our performance requirements with that architecture.

There are three major areas I’m focused on right now. Making sure that all of our hardware that has been built to date, that third level of hardware is in testing. We are validating all of our parameters for it; durability, that’s the hugest piece, the reliability, making minor fixed to areas that we’d like to improve.

The other major area that we’re focused on is the calibration of the system which is huge, because it’s a very complex system from the perspective of the torque generators we have, the engine, the motors, the power electronics. So we’re tuning all of those systems to make the vehicle fun to drive, to meet all of our efficiency requirements, our drivability requirements, noise vibration and harshness requirements, and we are now entering the phase of program where we will do all of the development for certification. So that’s fuel economy label certification, and that will continue for some months now. We’re going to test per the procedures that are being developed for this program and verify that all of our calibration is tuned in for optimization of the driving experience along with the efficiency of the vehicles. And that’s really the stage that were tuning into now.

In addition the third element that we’re working on is tuning in the manufacturing systems. So we’ve been building our production in our manufacturing plant and we’re right now preparing for what we call pre-production level hardware. That before we build saleable parts we’re going to build pre-production parts in the assembly plant so that its ready for volume. Make sure that our suppliers are prepared for that, make sure that our supplier’s tools are prepared for that and tweaked for quality, our manufacturing plant is tweaked for quality. I was just there last week and walked through all of their systems and systems development to make sure there ready for the production phase.

So those are kind of my three major areas of focus right now.

When you mention the production plant are you talking about Detroit-Hamtramck (DHAM)?
No that’s vehicle assembly plant but ahead of that we’re going to our suppliers and their manufacturing plants for individual parts and systems. And in addition, our drive unit and engine have their own manufacturing facilities that we are walking through and making sure they are ready.

Is GM building its own electric motor for the Volt?
The motor is actually supplied to us but we will be integrating that motor in our drive unit so its encased in our drive unit, we provide tooling, rotating components and all of that which is built in a manufacturing plant owned by GM. We are getting ready to do all of that manufacturing , so the housings, for example we take the castings from a supplier we do all the machining of the housings, the bearing the gearing, all of that kind of stuff.

So you get some of the parts from outside but you put them all together?
Exactly, so it’s a manufacturing step that happens and we send that drive unit and that engine to the assembly plant in DHAM for installation into the vehicle.

Have they done anything at DHAM yet to get ready?
There’s a ton of work going on at DHAM to get ready, and we’ve built our what we call our integration vehicle, and we’re towards the end of that phase. That is being built in pre production operations, however the DHAM team has been very integral in those builds. They have been overseeing the builds they’ve been doing slow builds, they’ve been identifying all issues for their production processes. They’re currently working on tooling for the body. There’s a number of things that DHAM’s doing to get engaged and ready. Because the next phase of vehicle, which is not a saleable vehicle yet, but its our next phase of product, will be built in DHAM so they are getting all of their systems tuned, the personnel trained and ready to go.

When will the first vehicle be built at DHAM?
We’re tuned towards first quarter of next year for that date.

eTec is the wholly-owned and largest subsidiary of Ecotality (ETLY.OB) and recently received a $99 million matched DOE grant to deploy and study EV charging infrastructure using Nissan LEAF vehicles.

I had the chance to speak with eTec’s CEO Don Karner about the coming electric car charging infrastructure revolution.

Tell us about your recent DOE grant and what it means?
The grant is to evaluate charge infrastructure and to try and develop a model for the effects of deployment of charge infrastructure in support of grid-connected vehicles.

It’s not a vehicle demonstration, and its not an infrastructure demonstration per se. The idea is to develop a mature charge infrastructure in five different geographic areas, diverse areas that have different demographics, different geography, different customs and value systems, different employers and to look at deploying infrastructure both at people’s residences after they buy a vehicle and in commercial locations which could be employers, parking structures or retail locations. Also deploying them in true street side public applications, city-owned parking that’s open to the public.

Then to look at utilization of that charging infrastructure such as which chargers are being used, and which ones are not. Why is one charger used more than another or one location more effective than another? How are people willing to extend the mission capability of the vehicle by using charging away from home?

Obviously if all you have is home charging then basically you have a limited radius within which you can operate the vehicle. The infrastructure outside the home both commercial and public is to allow you to extend the range of the vehicle and its usefulness. And with the idea of range extension we’ll also be deploying some level 3 fast charge infrastructure in commercial locations.

Doing that on a grid is the concept initially going in so you’re never more than a certain distance from a fast charger. Now that will be modified somewhat by use. There may be some areas that have a heavier use so you’ll have denser locations or multiple chargers at that single location.
The infrastructure will be initially deployed using a roadmap developed by involving stakeholders in the areas; employers and city government to help us determine locations.

We have partners on board that have the ability to come up with specific locations. For example, a company called CB Richard Ellis which is a major commercial real estate manager so they have millions and millions of square feet being managed for clients and millions of square feet that they own and lease out. So in every one of these cities they have a number of buildings with parking garages and they have retail outlets with parking lots that if the stakeholders say we ought to have to chargers in this area, they might be a source for us to locate the chargers.

We have BP that operates the AM-PM chain of gas stations, one of the things we wanted to try was does it make sense to put some fast charging in traditional fueling stations?

We’ll deploy the infrastructure then we’ll look at how it’s being utilized and also look at how we can provide better information to the vehicle operators are about where chargers are, what their availability is, and in order to develop a balance between information and actual hardware. Obviously if you’re completely ignorant about where chargers are you want to have a lot of them out there so that if you’re driving down the road you see them. But if you have electronic information that told you where chargers were and what their availability is and aids to help you do trip planning, are those going to make it easier for you to extend the range of the vehicle and therefore get you to use the vehicle more or is it just that you still need lots of chargers out there.

So these are all different aspects of the study and evaluation that we’d like to do over a 24 month period while all the data is being collected.

So we deploy charge infrastructure, deploy vehicles, get the system operating and we need a significant enough density of vehicles and infrastructure that’s really representative of what a fully developed electric vehicle economy might look like. So even though it’s a thousand vehicles in each city we still have to mindful of keeping it fairly tight because there are big cities. Then we collect data, store it in a database at the Idaho national lab and then we have various partners like Ohio State University and University of California Davis, the Idaho lab personnel plus all the other scientists in the nation’s science laboratory system to help us look at that data evaluate it look at successes and failures because many times you learn more from something that didn’t work than something that did. At the end, come out with guidance for the next 50 or the next 500 cities as to how they should most effectively deploy infrastructure.

Are you only using the Nissan LEAF vehicles in this study?
The vehicle side will be LEAF vehicles. The chargers that are being deployed are compliant with the SAE J1772 standards so they’re available to any vehicle.

But you will only be studying the behavior of those people driving LEAFs?
That’s initially where we are at right now. That may change over time and its certainly one of the things that the DOE made some stimulus awards to other car companies. None of them were in the cities that we’re operating in, but there may be some interest on DOE’s part to gather data in the cities where those vehicles are being deployed or to make vehicle available for purchase in the cities where the infrastructure is. You’ve got a built in infrastructure it makes sense to use that as a market for all electric vehicle whether it’s a Volt or a Ford transit.

Is your company a hardware producing company or are you coordinating the hardware of others? I’m wondering how your company fits into this.
We build both the level 2 and level 3 hardware. And we were very involved in the late 90s and early 2000s in deployment of EVs in response to the zero emission mandate in California. So we installed all of Chrysler’s infrastructure nationwide for the Epic minivan. We installed a lot of infrastructure for Ford, but not so much for GM. They typically worked through utilities to make that happen. We were buying others EVSEs in those days. We did make the 90 kw fast charger for the Chrysler minivan. Then when the auto EVs went away we had already been working with airport ground support equipment and material handling lift trucks on fast charging and we continued to do that over those 8 or 9 years. So we are in a number of airports through North America supporting both the airports and the airlines with material handling chargers across the country. We’ve got like 5000 chargers deployed throughout North America in industrial applications. We also have a line of chargers for neighborhood vehicles and things like that.

Now with the auto EVS coming back into play were rolling back into fast chargers to support the auto road applications and the level 2 EVSE to support both home and commercial and public charging.

So level 2 is the 240V?
240 V, 40 amp breaker supplying nominal 32 amps to the vehicle. That’s just the AC pass-though stuff. AC charging is typically level 2 and we believe that’s what’s necessary even with PHEVs a lot of folks are advocating just plugging them into convenience outlets, but we think there’s a lot of advantage to having level two charging for those as well. That’s the infrastructure that’s going to roll out. It’s going to be out there so you might as well make the vehicles compatible with it.

Aren’t there several companies out there making level 2 chargers?
Clipper Creek has been in it for some time. They were there in the late 90s as well, in fact we sold a lot of Clipper Creek equipment back then, it was called EVI. The same principles that were part of EVI have now formed Clipper Creek and the box is very similar to what is was in the 90s. Its basically just a smart contactor that checks to make sure everything is safe and then turns on AC to the vehicles.

Now there’s Coulomb and they have a public charging solution for street side parking. In fact they are part of our program for cities that want to do street side parking and collect revenue. Coulomb has a very neat revenue system.

How about level 3 chargers, there are claims about 10 or 30 minute fast charges, and EEStor says they can recharge 52 kwh in 5 minutes. Is all of this stuff realistically possible on today’s grid. Is your equipment able to do that and what are the special demands that such equipment would have?
Well, we’re capable of doing almost anything with respect to fast charging. But you put your finger on it, what’s practical? What’s practical is probably in the 40 to 50 kw range as a power level. And 200 amps as a current level, because you have to get the current onto the vehicle, and once you go above 200 amps, the cord and the connector get very large and some people talk about water cooling and it gets to be a very complicated device. So that translates to if you take the LEAF and you say it has a 30 kwh pack, if you’re charging at 40 kw if you came in at let’s say 40% state of charge and you want to go to 80% state of charge, you have to put in 12 kwh. I’ve got a 40 kw charger so its going to be about a third of an hour or twenty minutes. That’s a very reasonable power range. Can you charge harder? Absolutely, but then you start looking at whether you have the power available at a retail location where somebody wants to come and charge. Let’s say it’s a Starbucks and you want to come in and get a latte, do you really need to turn the vehicle around in 5 minutes? And if so, is Starbucks willing to double the electrical service that they have to supply that power? That hasn’t been our experience in the past. If that’s where everybody goes and it turns out absolute speed is of the utmost importance, then the market will adapt. What we’re looking at with the LEAF is in that 40 kw range and that fits very nicely in strip centers and other commercial locations. You can fit 40 kw into their existing electrical service and you don’t have to spend a lot of money expanding the electrical service.

Does the 40 kw charger run on 200 amps?
It would output a maximum of 200 amps. So if you had a battery pack that was let’s say 400V, to get to 40kw you only need 100 amps. So your cord and connector that connect to the vehicle would be limited to 200 amps. Let’s say you pull up to the vehicle that only has a 150 volt battery. I’m only going to be able to charge that at 200 amps so Im going to be limited to 30 kw. I may have more power capability in my charger but I’m limited by my cord and connector.

Most of the EVs, in fact all of them, all are in the range of 300 to 400 volts. To get the 40 kw you only need the battery to be above 200 Volts to stay below the 200 amps and virtually everyone is doing that.

I don’t think that 200 maps is very restrictive based on what coming to market.

Don’t most residential homes have 200 amp service?
It just depends on where you are in the country. We’re in Phoenix and yes 200 amps is pretty much the standard. A lot of homes out here actually go to 400 amps because there’s a lot of air conditioning load in Phoenix. So typically we don’t have any problem out here, plus all of the houses are relatively new.

If you go to a beach community in California, you may find only a 60 amp service on a little bungalow that doesn’t have air conditioning, for example. If you go to the northeast, an old brownstone there may only have a 50 or 60 amp service.

One of the challenges is to retrofit America with EVSE. In new construction many localities are going to the point where you have to put a 240V 40 amp service in the garage. Once you’ve done that actually installing the EVSE is a fifty dollar job. It’s no big deal. If you do it when the house is new, it’s easy. It’s the retrofit that’s expensive. We’ve got a lot of houses that will have to be retrofitted in America.

How about commercial places like parking garages, strip malls, and gas stations, do these places have a lot of current available?
Usually they’ve got plenty of electric service, the challenge there is typically you want the charger somewhere out in the parking lot and that power is not in the parking lot so you end up doing a lot of concrete and asphalt cutting and trenching with conduit but the electric service is there. If you do it as you build new facilities its very cheap because you’re trenching to put in light poles anyway.

When does your 2 year study actually start?
Nissan will be launching their vehicle in the fourth quarter of next year so well spend the next year basically working with stakeholders locating chargers and getting chargers installed in the commercial space. Then as the vehicles roll out we’ll be installing the chargers in residential places or if it is a fleet vehicle, the overnight location for that fleet vehicle.

Then we anticipate about 6 months of time to populate the vehicles and then we’ll operate in a data collection mode after that.

What are the 5 cities?
Seattle, Portland, San Diego, Phoenix and Tucson and also the interstate corridor between those two cities. In Tennessee there are three cities that form a triangle; Chattanooga, Knoxville, and Nashville.

No plans for NY?
Not as part of this project. Nissan will be looking at rolling the LEAF into NY but we won’t be studying infrastructure there.

Your company is national?
Yes. We cover all of North America.

What is the relationship with Ecotality?
Ecotality is our parent company and we are a wholly-owned subsidiary. Ecotality is a publicly traded company.

Do they do other things besides EV infrastructure?
Yes they have some other companies that do some fuel cell work and batteries and electronics assembly.

Is eTec a big portion?
We’re the biggest division of them.

Do you anticipate that the infrastructure rollout will take 10 years or more?
We’d like to think that coming out of this we’ll have some models in the commercial space that will show people there’s an economic benefit to them to install chargers whether it be an employer that receives employee benefits or a retailer that generates customer loyalty by having chargers. Or chargers that are installed with a subscription and revenue system like Coulomb’s.

This gives us the opportunity to demonstrate a number of value chains that can associate with the chargers. The hope is that when we come out of the project we’ll have demonstrated various way that people can make these chargers economically viable. And we’ll get some viral expansion with OEMS coming into areas to sell vehicles and retailers will decide to put in chargers to make money, and this thing starts to grow by itself.

So do you expect a strong national infrastructure in under ten years?
Yes. I think if we’re going to have a successful rollout of battery electric vehicles we have to have infrastructure to support it. If we’re going to roll out PHEVs and were going to receive benefit from them, again having a strong infrastructure is going to be important. If you have a 20 mile PHEV and you drive 18 miles to work, you’re going to want to be able to plug in at work so you run home on electric.

This infrastructure allows the vehicles to be used in more expansive missions to allow more of what people need to do on a daily basis, and so it’s going to expand the market for those too.

How much does a Level 3 charger cost?
The biggest part of the cost tends to be the installation, but generally in power electronics like that you can look anywhere from 50 cents to a dollar a watt. So you’re looking at 20 to $40,000. It’s on the order of what it costs to install a gasoline pump.

It seems like level 3 chargers are going to be a relatively small contribution to the overall charging infrastructure?
One would think so, that’s what you’d like to have happen. You’d like people to mostly charge at home and at night, that’s the prime objective. The usable available infrastructure is there to help them extend the usability of their vehicles.

The level 3 chargers provide an insurance policy, so if you decide you need to go farther you can stop for 10 minutes, get a hit, get another 20 or 30 miles and then you can do what you need to do and get home.

You could imagine its not like a gas pump, if you have one level 3 charger and everyone is pulling up with EV’s the lines would be miles long if it takes a half an hour to recharge.
Right, and that goes back to information, people need to know availability, because you’ll have several chargers within a relative short radius. If we’re seeing chargers continually busy during peak tines it’s a signal of success, but tells us we probably need to put in more chargers