GM-VOLT : Chevy Volt Electric Car Site

As some readers may know, I am one of 100 people in New York who are leasing the MINI E electric car for one year.  I recently passed 5000 miles of driving the car, and for the most part am very happy with it, especially in that all those miles have been covered without using one drop of gasoline.

As the car is technically a mule or prototype, it is not production-ready and has had some issues.  A month or two ago it began popping loudly into neutral whenever the accelerator was floored.  The power electronics control unit was replaced and after that it  almost never happened (it happened one more time). So I’m gentle with the accelerator.

The other day I was driving to work and went over an unexpected construction zone pothole.  The car was jostled and suddenly it went into neutral.  After that it could no longer be put into drive.  Despite turning it on and off and moving the shifter in and out of drive neutral and park several times, that was it, dead.  A tow truck was called and off it went to the dealership for a MINI “flying doctor” to come and repair it. After a few days I found out it was the power electronics control unit again which was again replaced.

This made me immediately realize the importance of extensive testing of new electric cars over rough road conditions, potholes and the like.  With new technology electric cars there may be cables that can simply come out stopping the car dead in its tracks.  Fickle electrical connections andsensitive electronics may be more vulnerable to these effects than mechanical combustion powertrains which have been road-tested for a hundred years.

I reached out to Volt vehicle line director Tony Posawatz to see how carefully GM was evaluating pothole effects on the Volt prototypes.

He responded graciously:

We do more tests to our cars and especially the Chevy VOLT than anyone could imagine including some pretty severe potholes on our Milford Provings Grounds and other very difficult road surfaces. As you know, the car quite easily navigated up and down Pikes Peak, through the hills of West Virginia as well as Death Valley during the hottest part of the summer (it was 118 degrees when I called once to check on the team).

So although there may be a lot of new electric car startups on the horizon, the Volt may well have as another advantage GM’s long heritage of specialized quality control testing facilities and expertise.  As has been said before, they must get this one perfect.

An astute observer noticed none other than a pre-production Chevy Volt integration vehicle nonchalantly parked in a neighbor’s driveway.

A fleet of eight of these vehicles just returned from a 3-day 1200-mile extended test drive last week, and perhaps one of the lucky participants got to take one home for the weekend. It is known that 80 of these cars are in existence and nvolced in continuous and extensive testing

General Motors engineers are often given the opportunity to take home pre-production vehicles prior to launch.  In fact, some of the learning that goes into the refinement of these vehicles is derived from these take-home experiences.

However, these IVer Volts are unusually early in development for this type of endeavor.  Most pre-production cars are taken home just a few months prior to launch when they are usually at a high level of refinement. The fact that they are already allowed home appears to confirms the great confidence GM has with their robustness and the particularly advanced level of development they have already achieved in such a short time.

No, its not my house.

Apparently this is nothing new. According to GM spokesperson Rob Peterson, “several engineers have already taken these vehicles home over weekends.”

Source (Autoblog)

On Tuesday morning, eight Chevy Volt integration vehicles left the Milford Proving grounds compound in Michigan on a historic extended test drive into Pittsburgh, Pennsylvania.

The cars were driven for more than 9  hours and 300 miles continuously in a special effort to analyze their behavior, performance, and comfort on such a long drive in real word conditions.

Key personal in attendance on the drive included Volt chief engineer Andrew Farah, Volt vehicle line engineer Tony Posawatz, and advanced technology engineer Larry Nitz.

“Development drives are key milestones for every vehicle program,” said GM spokesperson Rob Peterson. “The extended seat time allows the engineers to experience every aspect of the vehicle – from ride, handling and performance to the comfort of seats. The drives also help uncover engineering issues that need to be resolved before the vehicles are put into the hands of customers.”

“Having the capability to drive several 100 miles in a day is a significant advantage for the Volt team too,” said Peterson. “Remember, the EV1 team needed to be trailered to areas like Pikes Peak or Pennsylvania for testing, or trailer a small generator to extend the vehicle’s range.”

Lead engineer Andrew Farah wrote the following observations about the drive:

HVAC comfort is good, and sound quality in the NVH (noise, vibration, handling) vehicle is excellent.

We have uncovered a number of minor issues with some of the gauges and displays. Up-level sound system makes XM really sound great!

City traffic in Pittsburgh was just what we were looking for after the rolling grades outside of town. On the way in, we all put the transmission selector into the “L” position and this worked as intended in the stop-n-go conditions. At speeds under 35 mph, you can basically drive with one foot because of the heavier regenerative drag as you fully release the accelerator. It is smooth and blended. Seat comfort evaluations are also being conducted. We have our top 3 comfort configurations from previous activities. So far, the top choice seems to be clear, but there is still some work to do.

This was the longest continuous real world drive to date the Volt development vehicles undertook in a single outing, and illustrates how the Volt is capable of doing what no pure battery EV could do.

Besides providing the engineer with valuable data on how to make the cars as perfect as possible, it also produced some very cool photo ops.

Meanwhile GM also announced it was investing over $200 million to upgrade several production facilities in preparation for building the Chevy Volt and Cruze.  In particular, the engine plant in Flint where the 1.4 L Volt engine-generator and 1.4 L turbocharge Cruze engine will be made was allocated $202 million.

GM has just about finished production of 80 integration-vehicle version Chevy Volts. These are full production intent cars that are being used for extensive road testing to generate learning engineers can use to further refine the vehicle for production.

Part of that learning involves putting the car through rigorous real-world driving conditions. We have already heard the cars have performed well in the mountains of Tennessee and the heat of Death Valley.

A very storied and symbolic place to drive is Pike’s Peak. A GM engineer by the name of John Blanchard has written about and confirmed the Chevy Volt has climbed the peak.

This location is interesting because it is 14,115 feet high and has a 19 mile road going up to the summit. It represents the scenario of the car being in generator mode and requiring continuous sustained energy to climb the very long steep grade.

Blanchard confirmed “the Volt was in extended-range mode for the most part of this segment.” On the uphill portion the team was “making sure the Volt could climb the steep inclines and operate at a high altitude.”

As the picture shows, Volt made it to the top, and “climbed the mountain faster than we anticipated,” he wrote. How fast you say? Blanchard didn’t.

The team also evaluated the Volt’s downhill performance too which interestingly represents a long and continuous opportunity to regenerate energy.

“The regenerative feature produced a good amount of energy back into the battery,” said Blanchard. “We were also pleasantly surprised with the temperature of our brakes.”

Back in the summer of 2008 I speculated with the Volt’s chief engineer Andrew Farah whether the Volt (which didn’t exist then) would be limited in speed to due power limitations on Pike’s Peak.

He had said “it’s a problem if you want to do it at 90 mph, but it’s not a problem to get you to the top.”

“There are limitations to the E-REV concept,” he said. “But the people who will experience a problem with this are far and few between.”

It is great news to see that the day the Volt actually did climb Pike’s Peak has really arrived.

Source (GM)

The Chevy Volt is now in the pre-production phase. GM has been building about 80 of these fully functional production intent prototypes, and are likely to be finished with this phase within days. Those cars are undergoing extensive testing and the learning and tweaking will be applied to the final production cars.

Part of this test process is seeing how the cars behave in real-world situations.

I received the following note from Volt fan Jim Northrop who lives in Nevada near Death Valley. Since it sent chills up my spine I thought I’d share it here (with Jim’s permission):

It was the best lunch I’ve had in a long time…. It was 11:55 AM. I was waiting for a traffic light in Pahrump, Nevada, on my way home for lunch and what should pass in front of me, headed North on Nevada Highway 160, but five (5) mysterious cars: silver and also white, with strange masking panels, antennae, and Michigan manufacturer plates. The fifth car was lagging and I had a chance to study the grill, gold accents, silhouette, then the rear spoiler. I had seen these features somewhere… they were Volts!! The “Fleet”. I quickly fell in behind, but intervening vehicles kept me distant and I couldn’t pass. I was hoping they would turn on Bellvista which is a popular route to Death Valley Junction and my house. Lucky for me they did make this turn and the chase began. I drove uncharacteristically fast to catch up, passing what I now believe was a large white Chevy “support van” and a few other cars. Finally, the trailing Volt was in reach. I was going way too fast as I pulled up and abruptly slowed next to the Volt–the two occupants didn’t give eye contact–they were probably busy praying they would survive this scary encounter with me (sorry guys). Momentarily mesmerized, I again accelerated, and pulled in front. I was now gaining on the other 4 Volts which were beginning to slow for the stop sign at Leslie. I pulled up behind the fourth Volt (sorry guys, I didn’t mean to scare you, but was completely focused on that round, gray, plug/cap centered low on your rear bumper–darn near caused the first Volt wreck…gasp!) Once I came to my senses and stopped, I honked my horn a few times, and grinning from ear to ear, gave driver and passenger excited “thumbs up”. They both gave me firm thumbs up in return and away they went. I rolled the stop and accelerated to catch them–they easily pulled away from me in my 2005 ,V8 Silverado– acceleration was comparable to my wife’s V6 07 Malibu (I know this as she always tries to beat me home, often from this same stop sign). Noteworthy… they had their windows up which meant they had to have their A/C’s on (in our heat)– strong acceleration!! They continued West, on Bellvista, toward the foothills. So excited, I forgot to eat lunch, too busy calling everyone I know… They are really beautiful, artistically sculpted automobiles. Wow! Very, very Impressive!!! Thanks GM for your commitment to the Volt, and for bringing them through our town today. By the way GM, please send some to Pahrump Valley Auto Plaza, a Volt is on my Christmas list.

Jim, didn’t have a camera with him, but apparently another lucky guy from internetautoguide caught a glimpse of this same fleet in a parking lot (photo above)

Alex Cattelan is a GM engineer working on development of the Voltec powertrain, and has been involved in the Volt program ever since the beginning.

She recently had the chance to drive a pre-production Volt out among a fleet of seven cars to Knoxville, Tennessee.  Cattelan also noted she has previously driven pre-production and mule Volts in cold Canadian winter conditions, high altitudes in Denver, and the scorching heat of Death Valley, and through it all “we have not found any surprises,” she wrote.

Cattelan says that the “twisty, winding roads” of Knoxville are particularly a place where “you really get to see what a car is made of.” And in that place she said of the Volt’s performance from a driver experience standpoint “we are happy with the results.”

She explains it was in those mountains of Tennessee that GM worked to “calibrate how the Volt’s battery energy, fuel efficiency, and drive quality work together in real world conditions.”

She explains that a car must give back to the driver what he or she would expect, and the Volt is no exception. It must feel right and respond intuitively. She says it should have the same feeling both in EV and charge sustainting mode, should climb hills as needed and if its 95 degres outside “take the heat.”

In all these ways on those mountains the Volt lived up to her expectations.

In an almost poetic fashion she writes:

As I stood next to the Volt on top of a mountain last weekend, I felt overwhelmingly enthusiastic about its capability.

I’m confident that Chevy Volt drivers will feel invigorated like I do by its exciting, smooth, quiet, and fuel-efficient performance.

I imagine there’s a lot of people just waiting to get their chance to see for themselves, myself among them.

Source (GM)