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Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

  • Volvo V60 Plug-In Hybrid Production
  • Volvo V60 Plug-In Hybrid Production

Volvo Car Corporation claims that its V60 Plug-in Hybrid is the world's very first diesel plug-in hybrid. That might be the case – there's a limited number of Peugot 3008 Hybrid 4s in Europe and Hino Trucks launched its Class 5 work truck for the US market earlier this year – but both of these vehicles are diesel hybrids, not plug-in hybrids. So, Volvo has is telling the truth here, at least in terms of what global automakers are producing. And it's that production that's most important here.

Volvo's production and sales forecast is small scale, but it does seem to be moving the metal. Volvo initially announced a target of making 1,000 of the 2013 models, but high advance orders led the company to ramp up production levels. Production will increase to between 4,000 and 6,000 cars for the 2014 model year.

It's not clear when these V60s will be arriving in the US. Americans have become more interested in buying "clean diesel" vehicles, and the plug-in hybrid mileage benefits could add to the V60's market appeal. They're not cheap – reports said it would cost around the equivalent of $81,000 US –but they are expected to sell out in Europe. "The first year's 1,000-car batch was sold out even before the car reached the showrooms and the order books for next year's cars are already filling up," said Peter Mertens, senior vice president of research and development at Volvo, in a statement.

One aspect of the V60 plug-in hybrid that Volvo is calling out is that it has 300 more parts than the conventional internal combustion engine version of the V60. This requires additional equipment and systems at the final assembly line to smoothly integrate the process. One example of the integrated production flow is the electric motor fitted on the same station as the final drive on the standard four-wheel drive models. Another one deals with the battery pack being lifted in through the car's tailgate, short side forward, and then it gets spun a quarter of a turn in the passenger compartment.

"The 11.2 kWh lithium-type battery is the single most complex system in the car. The precision manoeuvre to get it in place is an excellent example of the state-of-the-art assembly process," Merten said.

Show full PR text
Volvo Car Corporation ramps up assembly of the world's first diesel plug-in hybrid

Volvo Car Corporation is now ramping up production of the new Volvo V60 Plug-in Hybrid. After the initial batch of 1,000 model year 2013 cars, production will increase to 4,000-6,000 cars as of model year 2014.

The assembly of the world's first diesel plug-in hybrid has been successfully integrated on the same line as the company's other models at the Torslanda plant in Gothenburg.

This is a remarkable achievement considering that the sophisticated plug-in hybrid technology includes two complete drive trains and a powerful battery that provides a range of up to 50 kilometres on pure electric power.

"We are first in the industry to integrate a plug-in hybrid in an established production flow together with other car models," says Peter Mertens, Senior Vice President Research and Development at Volvo Car Corporation. "The integration in the standard production flow gives the plug-in hybrid buyer the possibility to choose in principle all options available for the standard V60."

Over 300 more parts
All the additional equipment and additional systems in the plug-in hybrid have led to parts of the final assembly line being rebuilt and modified. The adaption makes it possible to smoothly integrate the assembly of over 300 more parts that are included in the plug-in hybrid compared to an equivalent V60.

A couple of examples of the integrated production flow:
  • The electric motor along with its drive shafts is fitted on the same station as the final drive on the standard four-wheel drive models.
  • The cooling system and the high voltage cables are assembled on the Pallet, which is used to assemble the car's drive train and chassis parts.
  • The battery pack is lifted in through the car's tailgate short side forward. It is then spun a quarter of a turn in the passenger compartment - a manoeuvre that takes 60 seconds and carried out with less than 20 millimetres to spare.
"The 11.2 kWh lithium-type battery is the single most complex system in the car. The precision manoeuvre to get it in place is an excellent example of the state-of-the-art assembly process," says Peter Mertens.

Increasing demand
The Volvo V60 Plug-in Hybrid is the synthesis of close cooperation between Volvo Car Corporation and Swedish electricity supplier Vattenfall. The two companies have financed the development project jointly.

"The V60 Plug-in Hybrid is a unique car, a historic step, not only for Volvo Car Corporation but for the entire car industry. The first year's 1,000-car batch was sold out even before the car reached the showrooms and the order books for next year's cars are already filling up," concludes Peter Mertens.


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    • 1 Second Ago
  • 22 Comments
      paulwesterberg
      • 2 Years Ago
      For that kind of money I would rather have a model S, but there is enough room in the marketplace for this car.
      marcopolo
      • 2 Years Ago
      Interesting vehicle. It will sell well in Europe, and should allow for export to the PRC where an PRC owned, luxury European import diesel-hybrid would be considered a very desirable prestige vehicle. Even a limited success of the vehicle will allow for a technology transfer to Geely's PRC manufacturing operation.
        Rotation
        • 2 Years Ago
        @marcopolo
        Does anyone offer wagons in China? I didn't see any.
      Smoking_dude
      • 2 Years Ago
      where is the video me no see.
        Chris M
        • 2 Years Ago
        @Smoking_dude
        Mentioning "with video" but then not providing any video or any link to any video is sheer carelessness. Ah, but mistakes happen.
        • 2 Years Ago
        @Smoking_dude
        There's a video of the V60 in production on YouTube - http://www.youtube.com/watch?v=oq1b9fRijHQ They've integrated it into the normal production flow, rather than having to create a separate assembly line for it.
      diffrunt
      • 2 Years Ago
      When I blew up the shot of chassis waiting for body , this old mech almost dropped his wrench. The failure possibilities are at least 50 times the Tesla
      Rotation
      • 2 Years Ago
      These most likely will not be arriving in the US. "Clean Diesel" is cleaner than old Diesel but they cannot meet PZEV regulations at this time so they cannot get California carpool lane stickers. As we saw with the Volt the sales difference between being eligible for these stickers and not being eligible is huge.
        wxman
        • 2 Years Ago
        @Rotation
        "... "Clean Diesel" is cleaner than old Diesel but they cannot meet PZEV regulations at this time so they cannot get California carpool lane stickers...." Nissan claims that it has developed clean diesel technology that meets SULEV (http://www.nissan-global.com/EN/TECHNOLOGY/OVERVIEW/sulev_lcdt.html). Since diesel has essentially no evaporative emissions, this Nissan technology could hit PZEV if it can maintain the SULEV levels to 150,000 miles FUL. No current diesel vehicle is certified SULEV/PZEV, although it appears to be technically achievable.
      2 wheeled menace
      • 2 Years Ago
      $81k hybrid? looks like they've really got their finger on the pulse of market demand... *borat voice* NOT!
        2 wheeled menace
        • 2 Years Ago
        @2 wheeled menace
        1000 initial preorders is a drop in the bucket, compared to the numbers of preorders you get with other cars. What matters to Volvo ( maybe they have a business case for selling a few thousand of these at a sky high price ) has nothing to do with this; you and me are consumers - we are not Volvo. There is a demand to lower the price of EVs, plug-in hybrids, and regular hybrids. These cars won't put a single dent in the problem with oil, and gouging for a car like this during a worldwide recession is foolish. Yeah; some of the upper crust can afford it, but there are better cars out there for them to buy.
          Joeviocoe
          • 2 Years Ago
          @2 wheeled menace
          " These cars won't put a single dent in the problem with oil " The problem with oil will not be solved by a single car,.... but by a slow and painful death of a thousand cuts. We will see a noticeable decline in oil consumption only after every automaker has several plug in (or true alt-fuel) models available... and in EVERY segment, including the high price segment. Automakers CAN and WILL produce mass market, low costs plugin models... but NOT AS THEIR FISRT MODEL. The technology needs to develop from the top down.
          mustang_sallad
          • 2 Years Ago
          @2 wheeled menace
          Seriously, anybody who rips on automakers for selling plug-in vehicles at a price that actually makes money should take a step back and simply be thankful that a) there are people who are willing to pay the price to be an early adopter, and b) there are other companies willing to lose money on these early products. The fact is, new technology is being developed, and as long as it's being put on the road, accumulating miles, it's pushing things forward to the point that it won't need to be subsidized in the near future, and we'll all benefit from these early players.
          brotherkenny4
          • 2 Years Ago
          @2 wheeled menace
          It really doesn't matter if the car companies make money or not on these. It matters that they each produce some and that battery companies get business and make money. LGChem is the supplier of the battery. It looks to me like they (LGChem) is has a few of these vehicle (the volt and ford EV too) and so should be successful in this business. In a profitable business they will have the oportunity to learn lessons in real manufacturing environments and to use quantities of scale to drive the price down (including the ability to set up favorable supplier contracts due to large quantity purchases). Every vehicle they get contributes to there strength of position in the market. LG is the early favorite right now. By the way, I think the car companies are gouging somewhat, they are trying to reduce their risk, which includes development cost and the potential for customers sue over safety and performance concerns. I mean look at all the clap trap regarding battery safety. It's like the lawyers are setting up for future business. Nevermind that batteries are safer than a tank of gas, it is the new that is dangerous and scary to the mindless followers. The fear controlled masses are made to fear batteries to protect oil companies.
          Rotation
          • 2 Years Ago
          @2 wheeled menace
          mustang_sallad: That's an interesting opinion. But that's all it is. I don't care about companies. So I don't care if they make money or not. And I don't care about the fringes picking up on oddball plug-in vehicles (hello, Fisker!). What I'm looking for affordable, efficient cars that will make a dent in the marketplace. And this vehicle is not one of those nor does it seem to advance the state of the art in any way. Call me selfish if you want, but no, I don't have to be thankful that there are suckers out there to buy this vehicle or any other.
          HVH20
          • 2 Years Ago
          @2 wheeled menace
          Its not price gouging, putting 2 drivetrains in 1 vehicle (one of them being brand new) and having relatively low volume costs quite a bit of money. Not to metion diesels cost more to start with too. They will be lucky to break even on this program.
        Electron
        • 2 Years Ago
        @2 wheeled menace
        To be fair the $81K seems to be based on an estimated €65000 price in Europe that would include ~20% taxes. Still, 300 extra parts and a complex production process...The PHEV concept is never going to be a cheap way to solve the EV range conundrum.
        Letstakeawalk
        • 2 Years Ago
        @2 wheeled menace
        "The first year's 1,000-car batch was sold out even before the car reached the showrooms and the order books for next year's cars are already filling up," said Peter Mertens, senior vice president of research and development at Volvo, in a statement." All that matters to Volvo is that they sell their expected production. It's doesn't have to be mass-market in order to be consider a success.
      brotherkenny4
      • 2 Years Ago
      Anyone know the battery supplier?
      • 2 Years Ago
      For those looking for the video that seems to be missing from this post, try this one, showing the V60 hybrid production facility. http://www.youtube.com/watch?v=oq1b9fRijHQ Hybrids are popular in Europe because in many countries we get taxed based on a vehicle's emissions, and a hybrid allows us to keep a decent level of performance while reducing CO2 output. Personally, I think the growing number of hybrids is a good way to get us used to the idea of having electric motors instead of engines. As I see it, battery technology is still the hold-up, though.
      • 2 Years Ago
      " there's a limited number of Peugot 3008 Hybrid 4s in Europe" Peugeot and Citroen sell 3 different models of diesel Hybrid: the Peugeot 3008 and 508, and the Citroen DS5 In France alone for October, Peugeot/Citroen sold 488 hybrid 3008, 459 hybrid 508 and 362 DS5. And they are sold all over Europe, so it is safe to assume that several thousand of them will be sold in 2012
      raktmn
      • 2 Years Ago
      Trying to divine US prices by just converting the price in euros to USD is notoriously inaccurate.
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