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Recharge Wrap-up: Tesla details factory expansion; Ford and SunPower raise money for Sierra Club

Tesla has revealed the details of the upgrade of its Fremont, CA factory. One major change is the addition of a dedicated production space for the dual-motor P85D version of the Model S. Robots will be doing the battery installation on the Model S to save some time, and new export docks allow Tesla to get the cars out the door and on the way to their new owners more quickly. The new robots that move the cars around the factory have been named after X-Men characters, which makes our inner geeks smile. Check out the factory upgrade in the time-lapse video below and read more at Teslarati or at the Tesla Motors Blog. A program in Beijing for privileged registrations for EVs hasn't had much success. Of the 1,424 lottery winners, only about 30 percent went on to register an electric car despite a two-month extension of the deadline to do so. Buyers are likely discouraged by the lack of charging infrastructure, which the city hopes to ameliorate with the addition of 1,000 new charging stations by the end of the year, and by requiring new and renovated developments to set aside parking specifically for EV charging. Read more at Green Car Reports. The UC Davis Institute of Transportation Studies suggests that laws designed to protect dealers and consumers are stymieing the adoption of EVs. Laws like the ones certain states have in place that block or otherwise restrict Tesla's direct-to-consumer business model are not helpful for companies that want to introduce new products to the market. They prevent companies from passing on savings to customers for whom they would likely make the difference in a purchasing decision. One possible solution would be to allow exemptions to certain selling restrictions for a certain number of vehicles sold. "This could give automakers the degree of control needed to work out kinks with early customers, develop scalable processes for supporting PEVs, and ensure that effective dealer performance standards are in place before handing the reins over to wholly independent retailers," according to UC Davis ITS. Read more at the UC Davis website. Volkswagen says its environmental program, called "Think Blue. Factory," is meeting the automaker's own sustainability targets. The main purpose of the program is to move toward eco-friendlier carmaking at each of its plants worldwide.

10 automakers sued over keyless ignitions

Keyless ignition has rapidly proliferated throughout the auto industry to become a fairly normal feature on new cars. It's supposed to offer the convenience of keeping the fob in your pocket and just pressing a button to drive away. However, ten major automakers are now being sued in US District Court over claims that the system is dangerous, Reuters reports. The suit alleges that people are forgetting to shut off the engine, and the lack of an idle timer is the cause for 13 deaths by carbon monoxide poisoning and multiple injuries. The suit currently includes 28 plaintiffs, according to Reuters, but the lawyers are asking for class-action status to potentially add many more. The case goes after a major swath of the industry, including BMW, Daimler, FCA, Ford, General Motors, Honda, Hyundai, Nissan, Toyota, and Volkswagen, plus their related brands like Acura, Infiniti, Mini, and Lexus. In all, over five million vehicles are affected. The assertion here is that people walk away from their vehicle without shutting it off because they believe the engine shuts off automatically. If parked in a garage, carbon monoxide can build up, leading to poisoning. The lawyers claim automakers know this is a problem and also cite 27 complaints to the National Highway Traffic Safety Administration about the issue, according to Reuters. The plaintiffs are asking for an automatic shut-off and damages from the companies. These concerns have come up before, though. Toyota previously faced a lawsuit over a carbon monoxide death after a woman accidentally left her Lexus running. Also earlier this year, GM recalled 64,186 examples of the 2011-2013 Chevrolet Volt because owners weren't shutting them off. The problem resulted in two injuries, and the company released a software update to limit the idling time.

Next Ford F-150 delayed for aluminum body panel issues?

The timetable for next-generation Ford F-150 may be in trouble if a report from The Truth About Cars is true. The next F-150 is slated to make extensive use of weight-saving aluminum in its body, but the aluminum alloy provided by suppliers hasn't met Ford's requirements in the earliest phases of pre-production, according to the report.
The F-150 represents a huge portion of Ford's profits and is the best-selling truck in the US, even in the face of increased pressure from cross-town rivals General Motors and Ram. While the current truck is treading water against its competition, we'd be lying if we said the F-150 weren't growing quite long in the tooth.
If production of the next-generation of the Ford cash cow, said to be based on the Atlas Concept from the 2013 Detroit Auto Show (pictured above), is delayed, it could be bad for Ford. Production at Ford's Dearborn Truck Plant is already set to be delayed six to ten weeks, missing an internal on-sale deadline of Memorial Day.