Video: Chevy Volt Teardown Reveals Blueprint for Volt 2.0

By Eric Loveday · February 06, 2012

Ever wonder what's inside the Chevrolet Volt? Well, wonder no more as time-lapse video shows a detailed teardown of General Motors' plug-in hybrid. Though the teardown took three days, the video captures all the details in less than five minutes.

Last week, Munro & Associates tore down a 2012 Chevy Volt to get a full understanding of how the vehicle works. Part of the "Drive for Innovation" initiative, the disassembly was conducted to highlight the technology found within the Volt, from its T-shaped lithium-ion battery pack to individual circuit boards.

The bolt-by-bolt deconstruction was conducted without GM's involvement, but now that the Volt has been dissected, the possibilities of Volt 2.0 are starting to emerge. As Reuters states:

“Surgical deconstruction of the Volt attended by Reuters without the involvement of GM showed how the plug-in hybrid was designed for relatively quick upgrades such as a longer driving range under electric power. By leaving what amounts to a blank slate at the heart of the Volt's complicated electronic controls, GM has cleared the way—if the Volt succeeds—for the quick improvements more common in consumer electronics than the slower-moving auto industry.”

A senior engineer who participated in the teardown adds, "They’re reserving a lot of this real estate for future developments so that they can easily put more components on here if they want to."

"This is, without a doubt, the most advanced board I’ve seen General Motors put out and it’s got room to grow," said Sandy Munro, chief executive officer at Munro & Associates. "This is hot stuff."

About the author

Eric Loveday is an automotive enthusiast who is passionate about everything auto. He purchased a 1970 Chevelle at age 16, quickly outgrew its dated engineering and outrageous consumption of gasoline, and sold it off. Eric developed a true passion for automotive writing after graduating from the University of Michigan with a degree in print journalism. Eric spent most of his time since then ...

Full bio · 152 posts

Comments

· Yegor · 15 weeks ago

Wow! So many electronic circuit boards - at least 17!
7 of them look as complex as computer motherboard!

May be that is why Volt is so expensive?
Is it possible to cut the number of electronic circuit boards?

· Londo Bell (not verified) · 15 weeks ago

"They’re reserving a lot of this real estate for future developments so that they can easily put more components on here if they want to."

I've a 1/2 empty, 1/2 full view of this.

Maybe the Volt was built for "more," i.e. more features, more range, more finesse, etc., but the final product was less than ideal due to cost, reliability, serviceability, etc., hence removal of those features in the production model.

What doesn't make sense to me is the fact that 2007/8 technology (around that timeframe when Volt was being R&D) was used and "reserved" for future advancement, specifically on electronic components? With the pace of technology, that's kind of absurd. It's like thinking that technology will stay the way it is during development, without considering drastic changes.

· theflew · 15 weeks ago

@Yegor - An EV is going to have a lot of control circuitry, more than an ICE car. For an ICE a lot of things are hanging on the engine, pumps, AC, alternator, radiator. For an EV (EREV) those things still exist but are electrically controlled which in some ways is more complicated because they have to be controlled differently.

· RSBaker (not verified) · 15 weeks ago

From the very beginning of its development GM has always stated that the Volt would be very adaptable and upgradable. The revelation after this tear down only confirms what GM has been saying all along. GM also stated that they would not sell the Volt at a loss and that every car would pay for itself which explains the high price. A quick review of the pricing announced from other electric manufacturers shows us also that GM was not "over charging" with respect to price, as the prices of similar models have been at or well above the price of the Volt. If GM can continue to get a steady stream of sales in the US and Europe especially, they have said that the 2nd generation would almost certainly cost less and perhaps have longer electric range. We must also remember that GM has also said that E-REV is also easy adaptable to Diesel and to Hydrogen Fuel Cell. I think Volt in the long run will absolutely be the game changer that many have predicted, sooner if gasoline prices spike again.

· theflew · 15 weeks ago

@ Londo Bell - The Volt concept came out in 2007. I guarantee these electronics were made much later than that. A lot of this probably started out simulated, then some generic boards and finally burned in silicon a couple years later. Also when they talk about future enhancements they don't necessary mean upgrades to existing. By leaving space/capacity on the boards they could do future upgrades without changing buses, enclosures, or board dimensions. We know the Cadillac ELR will have different traits than the Volt - longer range, larger battery, large motor?

By being flexible with the electronics the technology can be reused. I'm sure they could have integrated this thing beyond believe (it's not hard once you know the function), but you lose re-useability doing that and there is little gained outside of smaller packaging. It's not a cell phone - give yourself room to grow.

· Londo Bell (not verified) · 15 weeks ago

@theflew,

If you are talking about OLD technology inside a ICE vehicle, then yes.

We're dealing with electronics here. If your logic is correct, then we should be seeing larger and larger computers. Is that true? From all I know, an iPad is much much better in performance, much much smaller in size, and much much lighter in weight than one of those top-of-the-line PC (Mac or Windows) from just 3-4 years ago.

More importantly, a logic board design can, and most likely will, become obsolete (not even deprecated) in 3-4 years time. Look at RAM development, connector bus development, or even CPU chip development.

Hardware engineering is very difficult to be reused from a timing standpoint. Once a new technology is out, all manufacturers will start building new ones since there will be no profit to keep building the now "old" technology. You may be confused with reuse here in software engineering. That can be done since programming languages have a much longer lifespan than hardware. One (company or person) can still make a lot of money for knowing old programming languages such as C (e.g. Apple), but you don't see any manufacturer building the world's fastest, lightest and best 68030 architecture or Pentinum technology any more...

Now, I'm speaking purely from a computer engineering standpoint, which I know. Maybe the senior engineer who was reverse engineering the vehicle was speaking from a mechanical engineering pov, or that of an electronic engineer.

· theflew · 15 weeks ago

@Londo Bell - I'm speaking as an computer engineer that has worked in the auto industry. IC's used in cars have to last years. Durability is critical followed by cost, and performance. Also you want to use components that might be over spec currently for your needs, so that the same components can be used down the road. For cars you want to design once and reuse as much as possible making small changes during the cars life cycle. Profit in cars comes from the cost of components getting cheaper either by volume pricing or part cost coming down (i.e. battery)

· alt-e · 15 weeks ago

I find this video to be funny because I once was on a committee with the head of the department at GM that did reverse engineering. It was a policy setting committee funded by the State of Michigan. He told me that they bought one of every production model car that anyone made anywhere in the world and tore it down to get whatever info they could out of it. I am not sure if GM still does that post-bankruptcy as this was some years ago.

These days circuitboards can be cheap if bought in volume. So it is not necessary for EVs or PHEVs to be expensive because they need a lot of control boards. It is the battery that drives the price. Although low volume production makes everything more expensive from the boards to the motor.

· Londo Bell (not verified) · 15 weeks ago

@theflew,

If what you've said, is true, then you are actually falling into my view, i.e. that the Volt was built with "better" ideals, but trimmed down a lot in the production version. Just think about it. Build everything with existing technology, throwing everything in there, and "hope" (or pray) that those parts will be used for a long time. Change, or advancement, otoh, will be bad, because that will increase cost, as per your suggestion, and make whatever works now, high probability of failure due to change.

I work in IT industry, and I've seen so many companies being burnt with that philosophy. Being a computer engineer, you know how that is. Maybe the auto industry is different.

Add comment

·

The content of this field is kept private and will not be shown publicly.
  • Web page addresses and e-mail addresses turn into links automatically.
  • Allowed HTML tags: <a> <em> <strong> <cite> <code> <ul> <ol> <li> <dl> <dt> <dd>
  • Lines and paragraphs break automatically.
To prevent automated spam submissions leave this field empty.

All Discussions

It's Official: Ford Now Shipping Focus Electric to US Dealerships

Ford Focus Electric Article · 19 comments

Eric Loveday says:
Over the weekend, Ford Motor Company started shipping its Focus Electric to dealerships in three US states.

Washington Senate Passes Bill to Charge Electric Vehicle Owners a $100 Annual Fee

Article · 49 comments

Eric Loveday says:
If Washington state lawmakers agree, owners of electric vehicles would be charged $100 per year to make up for the lack...

First Tesla Model S Deliveries Scheduled for June 22

Tesla Model S Article · 0 comments

Eric Loveday says:
Tesla Motors officially announced that "several" paying customers will receive the first batch of Model S sedans on...

Drive Report: Electric Renault Twizy Is Cool, But Hard to Love

Article · 1 comment

Laurent J. Masson says:
The Renault Twizy has to be experienced to be understood. It's an Unidentified Driving Object which doesn't try to show...

Dump The Pump

Discussion · 0 comments

Moto_Electric says:
Dump The Pump For the seventh straight year, Americans will celebrate Dump The Pump Day. This year, the “holiday”...

Does EV Quick-Charging By the Minute Make Sense?

Nissan LEAF Article · 23 comments

Brad Berman says:
When drivers of gas-powered cars fill up at the gas station, they know they are paying a certain price for a clear and...

Plug-in Car Sales Get Off to Slow Start in 2012

Chevy Volt Article · 37 comments

Eric Loveday says:
January was not a strong month for plug-in vehicle sales in the US. Nissan reported sales of the all-electric LEAF at...

Leviton Unveils 40-Amp, 6-Hour Charger for Toyota RAV4 EV

Toyota RAV4 EV Article · 15 comments

Eric Loveday says:
Leviton engineered a 240-volt, 40 amp charger for the upcoming Toyota RAV4 EV. Leviton's powerful setup is capable of...

Nissan's Fourth Electric Vehicle to be PIVO-Inspired Urban Commuter

Article · 15 comments

Brad Berman says:
Reports suggest that Nissan's fourth electric-only automobile will be a funky high-tech PIVO-inspired urban commuter...

Most Electric Vehicles Sold Are For Commercial & Industrial Applications

Discussion · 0 comments

Moto_Electric says:
In an October 24, 2011 article, Electric Vehicles Research indicated that currently 60% of the value of the electric...