The Chevrolet Volt is a plug-in hybrid car manufactured by General Motors, also marketed in rebadged variants as the Holden Volt in Australia and New Zealand, Buick Velite 5 in China, and with a different fascia as the Vauxhall Ampera in the United Kingdom and as the Opel Ampera in the remainder of Europe. Volt production ended in February 2019.
Sales of the 2011 Volt began in the United States in mid-December 2010, followed by various European countries and other international markets in 2011. Global combined Volt/Ampera-family sales totaled about 177,000 units by the end of October 2018. The U.S. is the leading market, with 152,144 Volts delivered through the end of 2018, followed by Canada with 16,653 Volts sold through September 2018. Just over 10,000 Opel/Vauxhall Ampera cars had been sold in Europe as of June 2016[update], with the Netherlands leading the European region. As of September 2018[update], the Volt/Ampera family of vehicles is the world's all-time best-selling plug-in hybrid vehicle, and the Volt is also the U.S. all-time top-selling plug-in electric car.
The Volt operates as a pure battery electric vehicle until its battery capacity drops to a predetermined threshold from full charge. From there, its internal combustion engine powers an electric generator to extend the vehicle's range as needed. When the engine is running it may be periodically mechanically linked (by a clutch) to a planetary gear set, and hence the output drive axle, to improve energy efficiency. The Volt's regenerative braking also contributes to the on-board electricity generation. Under the United States Environmental Protection Agency (EPA) cycle, the 2013/15 model year Volt all-electric range is 38 mi (61 km), with a combined electric mode/gasoline-only rating of 62 mpg‑US (3.8 L/100 km; 74 mpg‑imp) equivalent (MPG-equivalent).
The second-generation Volt's improved battery system and drivetrain increased the all-electric range to 53 miles (85 km), its EPA-rated fuel economy in charge-sustaining mode to 42 mpg‑US (5.6 L/100 km; 50 mpg‑imp), and the combined city/highway fuel economy in all-electric mode to 106 MPG-e, up from 98 MPG-e. Deliveries to retail customers in the U.S. and Canada began in October 2015 as a 2016 model year.
The Volt has won several awards, including the 2009 Green Car Vision Award, 2011 Green Car of the Year, 2011 North American Car of the Year, 2011 World Green Car, 2012 European Car of the Year, and 2016 Green Car of the Year. Controversies regarding the Volt include the extent to which the U.S. federal government may have participated in the Volt’s development, which continued through General Motors' 2009 government-led bankruptcy, and concerns about the battery-pack fire risk following a crash test that the National Highway Traffic Safety Administration (NHTSA) performed on a Volt in 2011. At the completion of its investigation, NHTSA concluded that no discernible defect trend exists.
The Society of Automotive Engineers' (SAE) definition of a hybrid vehicle states that the vehicle shall have "two or more energy storage systems both of which must provide propulsion power, either together or independently." General Motors has avoided the use of the term "hybrid" when describing its Voltec designs, even after the carmaker revealed that in some cases the combustion engine provided some assist at high speeds or to improve performance. Instead General Motors describes the Volt as an electric vehicle equipped with a "range extending" gasoline-powered internal combustion engine (ICE) as a genset and therefore dubbed the Volt an "Extended Range Electric Vehicle" or E-REV. In a January 2011 interview, the Chevy Volt's Global Chief Engineer, Pamela Fletcher, referred to the Volt as "an electric car with extended range."
According to the Society of Automotive Engineers (SAE) definitions, the Volt is a plug-in hybrid vehicle, due to the combination of an internal combustion engine and two electric motors, along with a battery that can accept off-board energy. The Volt operates as a purely electric vehicle for the first 25 to 50 miles (40 to 80 km) in charge-depleting mode. When the battery capacity drops below a pre-established threshold from full charge, the vehicle enters charge-sustaining mode, and the Volt's control system selects the most optimally efficient drive mode to improve performance and boost high-speed efficiency.
The Chevrolet Volt concept car debuted at the January 2007 North American International Auto Show, becoming the first-ever series plug-in hybrid concept car shown by a major car manufacturer. The Volt concept vehicle had four doors with a rear liftgate and seating for four passengers. This was a significant change in design when compared to the General Motors EV1 of the 1990s, which only seated two to reduce weight and to make the necessary room for the lead-acid battery pack. The top speed was also increased on the Volt, from the electronically limited 80 miles per hour (130 km/h) to 100 miles per hour (160 km/h). The battery pack size was reduced, from about 10.6 cu ft (300 L) in volume in the EV1, to 3.5 cu ft (100 L) in the Volt.
General Motors' then-Vice-Chairman Robert Lutz said the two-seater sports car being developed by Tesla, the Tesla Roadster (2008), and the rapid advancement of lithium-ion battery technology inspired him to push the carmaker to develop the Volt after the 2006 Detroit Auto Show, overcoming internal opposition. Lutz's initial idea was to develop an all-electric car, but Jon Lauckner, General Motors Vice President for Global Vehicle Development, convinced him that to avoid an expensive battery, range anxiety concerns, and lack of public charging infrastructure, they could use a smaller battery pack with a small gasoline engine driving a generator acting as a backup to extend the range, but without a mechanical connection between the gasoline engine and the drive wheels, so it would be a pure electrically driven vehicle without many of the limitations General Motors learned from the EV1 experience.
Most of the Volt initial design parameters defined for the development of the concept car, then referred as the "iCar" in homage to the iPod, were kept throughout the process up to the final production version. A key design parameter was a target of 40 miles (64 km) for the all-electric range, selected to keep the battery size small and lower costs, and mainly because research showed that in the U.S. 78 percent of daily commuters travel 40 miles or less. This target range lets drivers make most travel electrically driven, with the assumption that charging takes place at home overnight. This requirement translated to using a lithium-ion battery pack with an energy storage capacity of 16 kWh considering that the battery would be used until the state of charge (SOC) of the battery reached 30%. This limit to the SOC was necessary in order to maintain operational performance under a wide range of environments, and to minimize the battery degradation to allow at least a ten-year life span. The initial target range for the gasoline engine/generator was set between 250 to 300 miles (400 to 480 km) and the vehicle had to be family size for four or five passengers.
Another key design decision was to develop the concept car based on a new family of common powertrain components for electric propulsion, which initially was called the E-Flex Systems, “E” stands for electric drive and “Flex” for the different sources of electricity, but later was renamed Voltec drive system. The E-Flex or Voltec powertrain is an attempt to standardize many components of possible future electrically propelled vehicles, and to allow multiple interchangeable electricity-generating systems. The E-Flex powertrain has the potential to adapt the vehicles to pure battery electric, to fuel cell-powered or to several other sources of energy to create electricity on board, such as engine-generator sets (genset) fueled by gasoline, diesel, biodiesel, ethanol fuel (E100), or flex-fuel (E85). Regenerative braking would also contribute to the on-board electricity generation. In October 2006 the E-flex powertrain was selected for the new propulsion architecture and the name Volt was chosen by General Motors.
The Volt concept car became the first application of the E-Flex (Voltec) drive system with a combination of an electric motor, the same used in the Chevrolet Equinox Fuel Cell, a 16 kW⋅h (58 MJ) lithium-ion battery pack with 136 kW of peak power, and a genset consisting of a small 1.0 L, 3-cylinder turbocharged flex-fuel capable engine linked to a 53 kW (71 hp) generator. General Motors called this genset an electric vehicle (EV) range extender. The vehicle was propelled by an electric motor with a peak output of 120 kW (160 hp) delivering 236 lb ft (320 Nm) of motoring torque. The concept car featured several advanced materials from GE Automotive Plastics that helped GM reduce the vehicle weight by up to 50 percent.
The Volt concept featured a 12 US gal (45 L; 10.0 imp gal) fuel capacity providing the vehicle a total driving range of around 640 mi (1,030 km), which considered a gasoline fuel efficiency of about 50 mpg‑US (4.7 L/100 km; 60 mpg‑imp) and a 40 mi (64 km) all-electric range. According to General Motors estimates, a daily drive of 60 mi (97 km), combined with an overnight recharge to support the first 40 all-electric miles, would yield an effective gasoline fuel economy of 150 mpg‑US (1.6 L/100 km; 180 mpg‑imp). General Motors also emphasized that the Volt would further reduce dependence on imported oil if E85 ethanol was used instead of gasoline to power the on-board generator engine. Robert Lutz added that if the driver used E85, "the fuel economy figure became 525 miles per (equivalent) petroleum gallon", as only 15% of gasoline is used in this blend. General Motors also noted that actual production of the Volt depended on further battery development, because the required rechargeable batteries needed to make the Volt a viable vehicle did not exist in the market and had yet to be developed. The concept car was actually powered by two 12-volt conventional car batteries, just enough power to allow the vehicle to move at low speeds in the stand.
The production design model officially unveiled on September 16, 2008, as part of General Motors centennial celebration at the Wintergarden headquarters in Detroit. The production model differed greatly in design from the original concept car. The carmaker cited necessary aerodynamic changes needed to reduce the concept car's high drag coefficient of Cd=0.43 down to a more efficient Cd=0.28, though still somewhat higher than the Toyota Prius Cd=0.25. Another reason was the use of General Motors' new global compact vehicle platform Delta II to keep costs reasonable, and shared with the 2010 model year Chevrolet Cruze. Another significant difference from the concept car is the seating, as the production Volt seats four rather than five passengers. This change was due to the higher-than-usual central tunnel that runs from the front console to the rear seat that houses the car's T-shaped battery pack.
After the concept was put into the pipeline for production, General Motors began looking for a partner to develop the Volt's lithium-ion battery pack. The carmaker evaluated about twenty-five different battery cell chemistries and constructions from around two dozen lithium-ion battery makers around the world. Due to their more promising cell technologies, two companies were selected in June 2007, Compact Power (CPI), which uses a lithium manganese oxide (LiMn2O4) cell made by its parent company, LG Chemical; and Continental Automotive Systems, which uses lithium iron phosphate based cylindrical cells made by A123Systems. By the end of October 2007 CPI (LG Chem) delivered their finished battery pack prototypes, and A123 delivered theirs by January 2008. General Motors testing process was conducted at the laboratory the carmaker had created for the GM EV1 program. The battery packs included monitoring systems designed to keep the batteries cool and operating at optimum capacity despite a wide range of ambient temperatures. To ensure the battery pack would last ten years and 150,000 miles (240,000 km) expected for the battery warranty, the Volt team decided to use only half of the 16 kWh capacity to reduce the rate of capacity degradation, limiting the state of charge (SOC) up to 80% of capacity and never depleting the battery below 30%. General Motors also was expecting the battery could withstand 5,000 full discharges without losing more than 10% of its charge capacity. According to GM, as of August 2016[update], no batteries have been changed due to degradation.
In April 2008 General Motors started extensive battery testing. In two years the carmaker put the battery packs to the equivalent of 150,000 real-world miles (240,000 km) and ten years of use. The durability of the battery pack was tested for a broad range of extreme ambient conditions including a shaker table to simulate potholes and a thermal chamber, to simulate temperatures varying from 116 °F (47 °C), typical of the Southwest deserts, to −40 °F (−40 °C) typical of the Alaska tundra. In April 2008 the lithium-ion battery pack was placed in Chevrolet Malibus fitted with the Volt powertrain to be used as test mules for further real-world testing. In October 2008 General Motors chose CPI (LG Chemical) to provide the battery systems for the first production version of the Volt. In July 2008 General Motors confirmed that a non-turbocharged, 1.4 L 4-cylinder engine would be used as the range extender, and that the intention was to build it in Flint, Michigan. In April 2009, General Motors let journalists test the Volt powertrain without the range-extending generator in the body of Chevrolet Cruze sedans that GM used as test mules at the GM Technical Center in Warren, Michigan.
The first pre-production test car based on the final Volt design was built in June 2009, in Warren, Michigan, and by October 2009, 80 Volts had been built and were tested under various conditions. On March 31, 2010, the first factory-built Volt was produced at the Detroit Hamtramck Assembly Plant to test the production line and for quality control purposes, both of the tooling and the pre-production vehicles produced before regular production began.
Tony Posawatz was the Volt Vehicle Line Director from 2006 to 2012, and he was known as employee #1 and led the team from concept to production.
General Motors held a ceremony at its Detroit Hamtramck Assembly Plant on November 30, 2010, to introduce the first Chevrolet Volt off the assembly line. The first Volt built for retail sale was earmarked for display at General Motors' Heritage Center museum in Sterling Heights, Michigan. The second unit was offered at a public auction, with an opening bid of US$50,000 and it was won by Rick Hendrick who paid US$225,000. The proceeds went to fund math and sciences education in Detroit through the Detroit Public Schools Foundation. Deliveries to retail customers in the United States began in mid December 2010. Volt deliveries began in Canada in September 2011. The first deliveries of the Chevrolet Volt in Europe took place in November 2011. The European version of the Volt, the Opel Ampera, was released to retail customers in Europe in February 2012. Deliveries of the right-hand drive Vauxhall Ampera in the UK began in May 2012. The Holden Volt was released in Australia in December 2012.
The 2011 Chevrolet Volt has a 16 kWh / 45 A·h (10.4 kWh usable) lithium-ion battery pack that can be charged by plugging the car into a 120-240 VAC residential electrical outlet using the provided SAE J1772-compliant charging cord. No external charging station is required. The Volt is propelled by an electric motor with a peak output of 111 kW (149 hp) delivering 273 lb⋅ft (370 N⋅m) of torque. Capacity of the battery pack was increased to 16.5 kWh (10.9 kWh usable) for 2013 models, which increased the all-electric range from 35 to 38 mi (56 to 61 km). Other specifications remained the same. The battery pack capacity was increased to 17.1 kWh for 2015 models. This incremental upgrade is likely to reflect in an improvement in range over previous model years, but as of July 2014[update], the 2015 Volt has not been re-certified with the EPA.
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