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GM executive chief EV engineer says reducing cost of plug-in vehicles is 'huge priority'

As we know, another major automaker investing heavily in electrified vehicles is General Motors, and it's doing things much differently than rivals BMW, Ford or Nissan. The Chevrolet Volt extended-range EV is a modest seller at its $35,000 sticker price but a huge hit with owners. The Chevy Spark BEV, still in limited availability, puts smiley faces on its owners and drivers. The just-introduced Cadillac ELR, a sharp-looking, fun-driving $76,000 luxocoupe take on the Volt's EREV mechanicals, has admittedly low sales expectations. With this interesting trio in showrooms and much more in the works, the third vehicle electrification leader I collared for an interview at Detroit's North American International Auto Show (see #1 and #2) was Pam Fletcher, GM's executive chief engineer, Electrified Vehicles. ABG: Why do your EREVs need four-cylinder power to extend their range when BMW's i3 makes do with an optional 650 cc two-banger? "We designed [the Volt and the ELR] to go anywhere, any time" - Pam Fletcher PF: I get that question all the time: why not something smaller? You don't really need that much. You use the electric to its ability, then you just need to limp. But we designed those cars to go anywhere, any time, and we don't want their performance to be compromised. If you're driving through the mountains, we don't want you to be crawling up grades, or to be limited on any terrain. So it's optimized to be able to travel literally the biggest grades and mountain roads around the globe at posted speeds. Because what if you can't? Another good reason: when the engine is on, you have to run it wide open throttle, max speed, most of the time. And while we can do a lot with acoustics, and the ELR has active noise cancelation, a small-displacement, low cylinder-count engine at high speed, high load all the time isn't something you want to live with. That's how we came up with the balance we did among the key factors of performance, NVH [noise, vibration and harshness] and range. ABG: Where you go from here? Is the range-extender engine due for an update? PF: We know and love the current Volt, and there is still a lot of acclaim about it, so we think it's a good recipe. But we are heavily in the midst of engineering the next-generation car, which I think everyone will love and be excited about.

New Takata problem results in recall of 414 GM vehicles

An airbag-inflator rupture discovered by Takata during testing has resulted in a new recall affecting 414 vehicles from General Motors, including 395 of them in the US. This latest campaign covers 2015 model-year examples of the Buick LaCrosse, Cadillac XTS, Chevrolet Camaro, Equinox, Malibu, and GMC Terrain. There are no reported breaks in any of these vehicles on the road, and the company estimates only one percent of them actually have the faulty parts. According to documents submitted to the National Highway Traffic Safety Administration (as a PDF), one side-airbag inflator failed a cold test at -40 Fahrenheit "releasing high pressure gas and propelling the separated components apart." The supplier told GM about the failure the next day. In these vehicles, the safety device might not only burst but the bag could inflate incorrectly, as well. GM and Takata say that a cause is not yet known, but they are "conducting an investigation." GM will begin notifying affected owners via overnight mail on Oct. 19. Dealers will replace the side airbag modules on all of the affected vehicles with new components outside of the suspect lot. All of the removed parts will also be collected for further study. Takata's faulty front airbag inflators have resulted in a serious scandal for the supplier. Initial figures indicated 34 million US vehicles are need of repair, though more recent figures have knocked that down to 23.4 million bad parts in 19.2 million automobiles. GM was already among the dozen automakers with models to fix, and some of its pickups were affected, along with the Saab 9-2X and Pontiac Vibe. GM Statement: General Motors is recalling 395 cars and crossovers in the U.S. because one of the front seat side air bags inflators may be defective. In the event of a deployment, the air bag's inflator may rupture and the air bag may not properly inflate. The rupture could cause metal fragments to strike the vehicle occupants, potentially resulting in serious injury or death. GM is unaware of any incidents involving vehicles with these components, which were part of a lot in which one inflator failed acceptance testing at the supplier. Dealers will replace the side air bag module or modules in affected vehicles. Including Canada, Mexico and exports, the total population of the recall is 414, GM estimates 1 percent of the recalled vehicles may have the defect.

Recharge Wrap-up: Ford steals Best Green Brand spot from Toyota, EV buyer survey goes online

Chevrolet is one of the Top Global Green Brands of 2014, according to brand consultancy firm Interbrand. Chevy ranks number 32 on the list, which cover brands across a wide variety of segments. The report measures brand perception and brand performance, and the gap between the two is small for Chevrolet. "The company is not only actively demonstrating its environmental commitment," says Interbrand CEO Jez Frampton. "It's communicating those efforts in an authentic way that resonates with customers." Chevrolet cites its Spark EV, Volt and Cruze models as reason for its green cred. This is the first time Toyota didn't take the top spot. Being 32nd is good and all, but other automotive brands ranked much higher than the Bowtie. Ford, Toyota, Honda and Nissan took the top four spots in the report, respectively, with BMW, Volkswagen and Mercedes-Benz all besting Chevrolet. The big takeaway here is that Ford topped the list. In the Top Global Green Brand list's four-year history, this is the first time Toyota didn't take the top spot. Ford was second on the list last year, and 15th in 2012. "Ford embodies everything the business of the future must be: efficient, visionary, flexible, adept at problem-solving, cooperative, and focused on creating shared value," Interbrand says on its website. "From unveiling a first-of-its-kind solar-powered vehicle, the C-MAX Solar Energi Concept, to partnering with peers across sectors to do the seemingly impossible - like creating bio-plastic out of tomato fiber with Heinz-Ford is showing us what's possible." It bears mentioning that Ford's most recent MPG adjustments came after the study was conducted. Ford is also making the news for its 1.0-liter EcoBoost engine earning International Engine of the Year for the third straight year. Awarded Best Engine Under 1.0 Liter, the turbocharged three-cylinder motor earned high praise from judges. "This year's competition was the fiercest yet, but the 1.0-liter EcoBoost continues to stand out for all the right reasons – great refinement, surprising flexibility and excellent efficiency," said International Engine of the Year co-chairman Dean Slavnich. "The 1.0-liter EcoBoost engine is one of the finest examples of powertrain engineering." The 123-horsepower engine powers the Fiesta 1.0-liter EcoBoost, and will be available in a version of the Ford Focus in the US later this year. See more about the award in the press release, below.