Chevy Volt Electric Car: 10 Facts

No vehicle in recent history, with the possible exception of GM's now-defunct EV1 electric car, has created as much excitement, expectations, and speculation as the Chevrolet Volt. The electric drive Volt is a groundbreaking vehicle that holds the potential for reshaping the competitive landscape in the auto industry. It is an insightful rethinking of what a car can be and how it should be powered in a world that is increasingly moving away from gasoline and closer to real environmental performance. Here are 10 facts you should know about this high-profile car.

1. The Volt is Not a Traditional Hybrid
While the Chevy Volt has both an electric powertrain and a gasoline engine, it is not a gas-electric hybrid in the traditional sense. The Volt is a plug-in electric vehicle (EV) propelled only by a powerful electric motor. The small gasoline engine works strictly as a range-extending generator to recharge batteries and provide current to the electric motor.

2. E-Flex Architecture Offers Other Engine Options
The initial rollout of the Volt will feature a gasoline engine as the range extending source, but the "Flex" in its 'E-Flex' architecture means other powertrain options are built into the design. A small clean diesel, for example, makes sense for many world markets as illustrated by the Opel Flextreme concept car. GM took the Volt concept in a cleaner direction yet with a fuel cell-charged variant unveiled at the Shanghai Motor Show.

3. Many Commuters Can Run Gas-Free
In the current configuration, a full charge from household current will provide a maximum EV range of 40 miles. So, if your commute is shorter than that the gasoline engine may not need to run at all. Charging outlets at the workplace can double that one-way range, too, which means that the Volt's effective electric-only range may be up to 80 miles per day for commuters, 40 miles each way. The Volt will be ideal for around-town errands and shorter trips where battery electric drive allows zero emissions operation.

4. Lithium-Ion Battery is Key to Performance
The Volt's lithium-ion battery pack is a "T" shaped structure designed to evenly distribute weight down the center tunnel of the car and over the rear wheels. Two versions are being developed with strategic suppliers: A123 Systems is working on a nanophosphate design with cylindrical cells and Compact Power has a manganese oxide stacked wafer Li-ion battery in development. Both configurations show great promise in power, range, and lifecycle testing. GM is leaving the door open for battery technology breakthroughs during the development process and other battery types could be considered.

5. Volt Has a 400 Mile Total Range
After battery power is depleted, the Volt should offer another 360 miles of range with the gasoline engine/generator providing the juice, for a total of 400 miles. The range extender design makes the Volt much more versatile than a pure electric car because there's no wait to recharge batteries if you have places to go. The small six or so gallon gasoline tank can be refilled in a matter of minutes for extended travel.

6. Your Mileage Will Vary
As a plug-in, fuel economy will depend on how long the gasoline range extender engine is operating to provide electricity. In the worst case, when the battery is down to 30 percent charge and the gasoline engine needs to run for extended periods, the Volt should offer 50 mpg or better. If your trip starts with a full charge and is shorter, say 60 miles before plugging back in, then it will involve 40 miles of electric operation and 20 miles with the gasoline engine running. In this case overall fuel economy will be in the neighborhood of 150 mpg.

7. Volt Test Mules Running Around the Clock
GM is testing the Volt powertrain in specially prepared Chevy Malibu test mules. Work is progressing in double-time, with the mules running 18-20 hour double engineering shifts to speed development. Early work was done with nickel-metal-hydride batteries as proof of concept. Those NiMH packs have now been replaced with the latest Li-ion batteries as testing rolls on.

8. The Shape of Change
The actual production Volt will not be identical to the concept car, but it will be recognizable as the Volt. This car has undergone more wind tunnel testing that any product in the history of General Motors and perhaps any car ever. Small changes to the surface are delivering significant gains in lowering the overall aerodynamic drag, which accounts for 20 percent of the energy needed to move the car at speed. The current design is roughly 30 percent cleaner than the concept.

9. What Will it Cost?
From the outset, the goal has been to deliver the Volt for less than $30,000. Some estimates place the early production versions closer to $40,000, with costs coming down as production ramps up. If the design goals are met, GM won't have a problem finding customers for the Volt and future E-Flex variations.

10. Volt Deadline is November 2010
GM officials have not backed off the promised introduction deadline of November 2010 that was announced at the LA Auto Show. To meet that deadline, GM has made Volt development a top priority with considerable resources brought to bear. The Volt has energized General Motors internally and will help the company forge ahead through the tough and competitive times in store for the auto industry.