Chevy Volt Technical Updates From Chief Engineer Andrew Farah

By John O'Dell November 29, 2009

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Chief Engineer Andrew Farah poses with 2011 Chevrolet Volt at Dodger Stadium media drive.


We have questions, readers have questions - and sometimes disagreements with what we've reported previously. So we took a notebook full of queries to Dodger Stadium this afternoon and asked the guy who ought to know just how things work on the Chevrolet Volt.

This is the word, direct from Volt Chief Engineer Andrew Farah.


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1) The battery and battery charging.

  • The 16 kilowatt-hour battery has 8 kilowatts of usable energy and generally doesn't deplete below a 30 percent state of charge.
  • Charging is accomplished from either a 120-volt or 240-volt line. Both will use the same charging port (right) and connector.
  • The 110-volt charging cord (below, right) that plugs into any regular outlet is likely to be the "free" charger supplied with the car, the 240-volt charger is likely to be an option and at least a little bit pricier than the 100-volt charging cord.
  • It takes roughly 8 hours to charge the battery on 120 volts, 3 to 3.5 hours on 240.
  • The battery is never fully recharged by either regenerative braking or the engine-generator once the Volt has gone from charge-depleting, or battery only, mode to charge sustaining, or engine-generator, mode.
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2) Battery-only range.

  • The 2011 Chevrolet Volt will deliver 40 miles of battery-only range on the EPA city cycle, a driving circuit with an average speed of 19.6 mph.
  • Aggressive acceleration, sustained high-speed driving, exceptionally hot or cold ambient temperatures, hills, mountains and other such stuff will diminish the Volt's battery-onl range.
  • If you pull out of the driveway with a full charge, hop on an uncrowded freeway and motor away at 65 miles an hour, you won't get 40 miles on battery power alone.

3) Engine-generator.

  • The 1.4-liter, flex-fuel engine and attached generator kick on when the Volt's battery has approximately 30 percent of its charge remaining. The engine-generator then remains the Volt's principal source of electrical power for the duration of the drive, until the battery is recharged from the grid.
  • The engine-generator does not recharge the battery.

  • It does, however, divert some of its output to the battery when the state of charge drops below 30 percent, as when accelerating up hill or to pass another car when in charge-sustaining mode. In effect, juice from the engine-generator is used from time to time to bring the battery up to what GM calls "zero balance."
  • GM didn't allow us to raise the hood for photos, sorry.

4) Total range.

  • The Volt's 40 miles of low-speed range in battery-only mode will be augmented by 300 miles of engine-generator range, for a total of up to 340 miles, not 300 miles as has been previously reported.
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5)  Transmission, etc.

  • The Volt's beefy shifter handle (right) is mounted just below the center stack and provides five options: Park, Reverse, Neutral,  Drive and Low.
  • The transmission is a single-speed model, however. Reverse merely reverses the polarity of the electric motor that propels the Volt, while shifting into low sends a signal to the powertrain brain to increase the amount of regenerative braking - a useful tool for gathering juice for the battery while heading down a long mountain grade, or to help reduce use of the brake pedal in stop-and-go traffic.
  • Just above and the the left of the shifter handle is a "power" switch that adds almost 30 horsepower to the electric motor's output. It eats into battery range, but give the Volt a bit more oomph.

6) Performance.

  • Electric motor rated at 150 horsepower, 370 lb.ft. of torque.
  • Top speed still listed at 100 mph.
  • Acceleration estimated at "under 9 seconds" for 0-60 sprint.
  • Cold and heat will impact driving performance, but not excessively.
  • Extreme cold and heat for prolonged periods will diminish battery performance, however and might make the Volt a poor choice for some. "If you live in an underground house in Phoenix and have to park the car out in the open up top," is one example Farah provided.
  • Volt's performance in ordinary driving situations is no different in battery-only mode than in engine-generator mode.

7) Fuel efficiency.

  • GM still isn't ready to divulge the specific numbers, but the fuel tank - for either gasoline or E85 ethanol-gasoline blend - is likely to hold somewhere between 8 and 10 gallons, for engine-generator fuel economy of between 30 and 38 mpg (on gasoline, we expect; ethanol reduces fuel efficiency).
  • Factor in the gasoline equivalent of battery energy use and the Volt is likely to turn in a combined city-highway EPA number in the range of 80-100 miles per gallon.
  • As in all fuel economy estimates, real mileage will vary.
Other Edmunds reports on Sunday's dive can be found at Inside Line and Edmunds.com. An Edmunds exclusive video can be viewed here.

John O'Dell, Senior Editor

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henrikii says: 2:55 AM, 11.30.09

A note on fuel efficiency and energy independence

The average American drives 12000 miles per year. When driving a Volt and assuming you plug it in each night during the year only 15% of the miles driven will be on gasoline and the other 85% of the miles driven will be from electricity. That means that you will need to drive 1800 (=12000*0.15) miles on gasoline per year. Assuming the Volt get 35 mpg in the gasoline mode that is 51.4 (=1800/35) gallons spend per year.

In other words, an average Volt driver will get 233 (12000/51.4) miles per gallon.

This could lead to energy independence. If everybody was driving plug-in hybrids like the Volt the US could reduce its annual gasoline consumption from the current 140 billion gallons per year to 21 (140*0.15) billion gallons. 21 billion gallons is about the size of the US ethanol production as projected in 2016.

brn says: 8:49 AM, 11.30.09

John,

I'll read through it more closely, but so far, MUCH better. I think it clears up some of the confusion we had in the other article.

aurakr says: 9:01 PM, 11.30.09

Thank you very much for the clarification.

Do you have any estimates as to what the range would be if you left the house, all charged up, and hit the highway at 65 mph with about a 25mile drive? In other words, what do you estimate the electric only range is under normal driving, not the silly city average of 19.6 mph.

Second, the 30-38 mpg average, why do you figure it so low? The Volt is slightly heavier than the Prius, but is as aero dynamic. If the Cruze will get near 40 mpg with this engine, the Volt should be over that don't you think?

All in all a nice review. I think that GM had better be ready for a lot of criticism about the 40 mile electic range.

I still want one, but now I will be pushing for more information on the range issue. From GM that is. And I want to know what type of fuel economy it gets with the range extender.

scottg8 says: 6:50 AM, 12.20.09

I don't understand why the generator would not recharge the pack. Will it run constantly after hitting that 30% SOC? If so, I thought it would run at a constant speed to maximize efficiency. Is that no longer true. Regardless, it seems there will be times where it generates more power than needed by the motor?

John O'Dell says: 11:05 PM, 12.20.09

GM tells us the engine-generator simply isn't sized to produce sufficient to keep the car running at full performance levels and recharge the full battery pack at the same time. The system does send some of its juice to the batteries, but in most cases (never say never and you'll never be wrong!) it is using most of its output to power the car once it is called into action. Upsizing to an engine-generator large enough to power the car and fully recharge the battery pack would have added weight and cut into fuel efficiency - that old trade-off scenario. As we understand things, it runs in a fairly low RMP range - but not a single constant number.

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