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Home > Cover Story > Feature Article
GM's E-Flex design manager discusses the production Chevy Volt
by Scott Anderson

The production Chevrolet Volt set to launch in 2010 will be a hatchback, and will be roomier and rounder than the show car, the vehicle's design leader tells Green Fuels Forecast.

Speaking at the Center for Automotive Research's Management Briefing Seminar here, Bob Boniface, the director of design for the E-Flex vehicles including the Chevrolet Volt, revealed teaser photos of the all-electric drive vehicle - including one of the front quarter and headlights/running lamps, and another of the rear deck.

"The front end of the car became quite a bit rounder, all in the effort to keep the air attached to the surface of the car, because air that stays attached to a surface of the car is smooth air," said Boniface, who also directs the E-Flex studio.

 
E-Flex cars like the Volt are electrically driven, with a small internal combustion engine engaging only when the battery's state of charge drops below certain levels. The plug-in vehicle is being designed to operate for 40 miles on electric drive before requiring the assistance of the 1.4L four cylinder range extending engine.

But Boniface said engineers never had the opportunity to test the concept Volt in a wind tunnel, and when they did, it was clear the drag co-efficient on the concept would compromise the vehicle's electric range goal. As a result, the production model is more aerodynamic than the design concept revealed 19 months ago at the Detroit Auto Show.

Watch Boniface's presentation and wind testing below:

 

"In order to ensure this ability to drive for 40 miles electricity alone, we had to spend a lot of time in the wind tunnel to improve the shape of the car to ensure it delivered on that promise of 40 miles," he said. 

One of the keys to achieving the range target for an electrically driven car is to maximize the amount of kinetic energy that can be recovered through regenerative braking. A high drag body will dissipate kinetic energy moving through the air. Reducing the effort required to move through the air lets more of the effort to slow the vehicle be directed to the motor to recharge the battery.

"But I think (observers) will still recognize it as the Volt. ... It's still a very sporty car, very efficient, very compact and I think people are going to like it," he added.

In addition to the more rounded the front corners, designers added a slight lip to the rear spoiler and altered the execution of the side mirror design.

 

Integration of the Volt's 400lb battery, which runs the length of the center tunnel, hasn't cut into occupant space. In fact, the vehicle is more roomy than the show car, Bonafice said.

"I'm happy to say that we were able to package that battery in the car to the point that when you sit in the car, people ask 'where is the battery?' You don't see it," he said.

Interior appointments include a touch sensitive LCD screen, which will provide navigation and electric drive information. Below that are touch sensitive buttons on the center stack controls and an LCD for a gauge cluster. 

"(It's) very technical, very modern. I think people who are used to this level of modernity in their portable handheld devices are really going to appreciate the Volt," he says.

Boniface lead the design team on the hydrogen fuel cell Chevy Sequel study and was previously with Chrysler where he helped design the 300C and the Jeep Liberty.

Now restoring his third vintage Alfa Romeo, Boniface serves as the "head coach" of the Volt's design team. Asked what what colors future Volt owners will have to chose from, Boniface demurred - revealing only one.

"I will say it is available in black, and it looks fantastic in black."
 
AUGUST 2008
 

 
 



 









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