Category: GM Volt

When the next-generation Chevrolet Volt debuts at the North American International Auto Show in January, it will feature an all-new Voltec extended range electric vehicle (EREV) propulsion system substantially developed from Volt owners including data collected on their driving behaviors.

The Voltec system includes the battery, drive unit, range-extending engine and power electronics. The new system will be more efficient and offer greater EV range and fuel economy compared to the current generation.

"Our Volt owners truly love the EV driving experience, with more than 80 percent of all trips being completed without using any gasoline. We've used their real-world experiences to define the next generation Chevrolet Volt," said Alan Batey, head of global Chevrolet. "By putting our Volt owners at the center of what we do and leveraging our electrification engineering leadership, we've been able to raise the bar and will exceed their expectations with the new Volt."

Enhanced Battery System Capability

General Motors' industry-leading battery technology has been improved for the next-generation Volt. Revised cell chemistry, developed in conjunction with LG Chem, increases storage capacity by 20 percent on a volume basis when compared to the original cell, while the number of cells decreases from 288 to 192. The cells are positioned lower in the pack for improved (lower) center of gravity and the overall mass of the pack has decreased by almost 30 pounds (13 kg).

Approximately 20 million battery cells have been produced for the more than 69,000 Chevrolet Volts on the road today with industry-leading quality levels of less than two problems per million cells produced.

The battery system continues to use the Volt's industry-leading active thermal control system that maintains electric range over the Volt's life.

"The current generation Volt's battery has proven to provide our owners exceptional performance when it comes to quality and reliability," said Larry Nitz, executive director of GM Powertrain's electrification engineering team.

Based on a GM study of more than 300 model year 2011 and 2012 Volts in service in California for more than 30 months, many owners are exceeding the EPA-rated label of 35 miles of EV range per full charge, with about 15 percent surpassing 40 miles of range. Current generation Volt owners have accumulated more than 600 million EV miles.

"It would have been simple for us to tweak our existing battery to provide nominally increased range, but that's not what our customers want," said Nitz. "So our team created a new battery system that will exceed the performance expectations of most of our owners."

EV range estimates will be revealed in January at the North American International Auto Show in Detroit.

GM will manufacture the Volt battery pack at its battery assembly plant in Brownstown, Mich.

Drive Unit Focused On Improved Efficiency

Like the battery system, the next-generation Volt's drive unit was reengineered with a focus on increased efficiency and performance, improved packaging and reduced noise and vibration characteristics. The two-motor drive unit operates approximately 5 to 12 percent more efficiently and weighs 100 pounds (45 kg) less than the current system.

The Traction Power Inverter Module, which manages power flow between the battery and the electric drive motors, has been directly built into the drive unit to reduce mass, size and build complexity while further improving efficiency.

The boost in performance comes from both motors operating together in more driving scenarios, in both EV and extended-range operation. The ability to use both motors helps deliver more than 20 percent improvement in electric acceleration. GM engineers designed the Voltec electric motors to use significantly less rare earth materials. One motor uses no rare earth-type magnets at all.

The new drive unit will be manufactured at GM's Powertrain plant in Warren, Mich.

New 1.5L Range Extender

Energy for extended-range operation comes from an all-new, high-efficiency 1.5L 4-cylinder engine. The engine features a direct injection fuel system, high-compression ratio of 12.5:1, cooled exhaust gas recirculation and a variable displacement oil pump. The Voltec range extender runs on regular unleaded fuel.

"Using the 1.5L engine as the range extender assures owners they can go anywhere, anytime without having to worry about whether they have enough power to go through the Rocky Mountains or on a spontaneous weekend getaway," Nitz said. "It's all about keeping the promise that the Volt is a no-compromise electric vehicle."

The 1.5L engine will be manufactured at GM's Toluca, Mexico engine plant for the first year of production, then shift to the Flint, Mich. engine plant.

The styling of the next-generation Chevrolet Volt is one of the automotive world’s best-kept secrets. Keeping customers and media eager to see the successor to the groundbreaking original at bay until the new Volt debuts at the North American International Auto Show in Detroit in January is tricky business.

First, it is engineers, not designers, who are charged with creating camouflage that balances styling secrecy with the need to validate the Volt and its systems in public.

“If it were up to me it would be a shoebox driving down the road,” said Lionel Perkins, GM camouflage engineer. “The design team wants us to cover more of the vehicle and the engineering team needs to have enough of the vehicle’s weight and aero exposed so that the tests in the development process are consistent with the product that will come to market.”

The engineers responsible for the “cool” designs covering the car might deserve style points but their efforts are intended strictly to hide the metal beneath.

The camouflage package on the next-generation Volt was started six months in advance of early development. Every vehicle is different and tricks are constantly updated to keep spy photographers and the curious guessing.

“Each car is unique. We are like a dress maker, and the car is our model,” said Perkins. “No two models are the same. We need to make the right dress that fits the body we are dealing with.”

The next generation Chevrolet Volt will debut at the 2015 North American International Auto Show in Detroit, Global Chevrolet Chief Marketing Officer Tim Mahoney said today.

The 2016 Volt will build on the award-winning original's strong foundation of technology innovation. Volt sales were up 13 percent in July and more than 65,000 have been sold since it was introduced – making it the best-selling plug-in passenger car in the U.S. market.

"Volt is the perfect example of the ingenuity that drives everything we do at Chevrolet," Mahoney said at the Center for Automotive Research Management Briefings. "Volt fully delivers on the promises of Find New Roads and will continue to provide consumers with the transportation solutions they need and deserve in the future."

Volt owners are driving more than 63 percent of their overall miles in electric vehicle mode, collectively logging more than 500 million gas-free miles since the Volt's retail debut in 2010. That has saved more than 25 million gallons of gasoline.

While the driving range in EV mode can be affected by temperature, driving technique and terrain, the ease with which Volt drivers are avoiding gasoline use demonstrates the Volt's suitability for almost any lifestyle.

Volt owners who charge regularly typically drive more than 970 miles between fill-ups and visit the gas station less than once a month.

The Volt has received multiple customer satisfaction awards from leading third-parties. According to a recent leading independent satisfaction survey, the Volt is the highest-rated compact car under $55,000. Owners are showing their satisfaction as well. For the past three years, a leading customer publication has reported survey results showing more than 90 percent of Volt owners said they would definitely buy a Volt again.

The Volt continues to draw buyers from non-General Motors' products. In the 2013 calendar year, nearly seven of 10 new Volt buyers traded in a non-GM vehicle, the majority of which were Toyota Priuses.

Among its accolades, the 2014 Volt has been recognized for its safety, most recently receiving the Insurance Institute for Highway Safety 2014 Top Safety Pick+ designation for vehicles equipped with an available Forward Collision Alert system.

General Motors is reportedly preparing to introduce its second-generation Chevrolet Volt hybrid sometime in 2015.

The company has developed a new front-wheel-drive hybrid platform for the redesigned model, however it is not expected to feature drastic alterations to the current body style, unnamed industry sources have told Edmunds.

"It is different, but not drastically different," the insider said. "Just really a bit of a styling change to it."

With their main competitor Toyota now offering an entire range of hybrids which account for 28% of all Toyota and Lexus sales and the Prius being the top selling car in California for the past two years, will we finally see GM expand the range to include the Volt MPV which GM revealed way back in 2010?

Former GM CEO Dan Akerson early last year promised that the next Volt will be significantly lighter than the current iteration, with a list price likely around $30,000 to $33,000. The company already dropped the retail price to $34,995 (including $810 destination fee) for the 2014 model year, however a further discount would help the hybrid compete against plug-in offerings from Toyota, Nissan and Ford.

The current Volt provides up to 38 miles of electric-only range before the 1.4-liter four-cylinder generator kicks in. Lower weight will likely bring improvements to electric range and gasoline consumption, though GM has yet to publicly confirm any specifics.

The second-generation model is expected to be launched for the 2016 model year.