Global Crisis

Occasionally I cross post content from other websites here (with permission of course) when I think the article is both interesting and exceptionally well done. Such is the case with this post written by Chuck Vossler of BMWBLOG about the repair process of the i3. I think Chuck may have taken particular interest in this story since he recently revealed to me that he has indeed ordered an i3 for his personal use. I have also been talking with him for the past year about his interest in solar electric and am happy to say he has indeed installed a solar array on his home and will soon be joining me in driving his i3 on pure sunshine, or "driving the future" as I like to say. Electric vehicles combined with solar electricity are such a fantastic combination, and adding the second one to your life is such a natural decision to come to once you have the first, as long as it's physically and financially possible to do so.

The entire article and pictures below were written by Chuck Vossler and appeared first on BMWBLOG.


The BMW i3 is truly a revolutionary new car. Revolutionary, however, is not exactly what the repair shop wants to hear when it comes to …

The BMW i3 is truly a revolutionary new car. Revolutionary, however, is not exactly what the repair shop wants to hear when it comes to fixing a totally new car. Never before has any manufacturer made such extensive use of carbon fiber in a mass produced car. One of the main benefits of the Carbon Fiber Reinforced Plastic used in the BMW i3′s Life Module passenger compartment is that it weighs about 50 percent less than traditional steel and also about 30 percent less than aluminum. The Drive Module houses a 22 kWh battery, the chassis and the 170 hp electric motor. Therefore, the new lightweight materials used in the i3 comes with totally new repair processes.


BMWBLOG had the opportunity to tour the BMW North America training facility where technicians for U.S. dealerships come to learn how to repair the very unique lightweight i3. Most consumers won’t really care about the details of how the i3 is repaired but one thing they will care about is what the BMW i3 costs to insure. The more complex and expensive the repair, the higher the insurance premium. A more complicated and challenging service and repair process directly leads to higher ownership costs which will ultimately impact sales.

Fortunately, BMW states that the cost of repairs for the BMW i3 are similar to a BMW 1 Series. This is intriguing given that once a carbon fiber piece is broken, there just is no repairing of it. The entire part/body panel must be replaced. Nonetheless BMW knew the implication of building a car of CFRP and thus designed specific cut away sections in the i3. These are defined segments that when cut will allow the technician to remove the damaged CFRP piece and then bond the new CFRP segment back in with glue.


THE DRIVE AND LIFE MODULES
BMW constructed the i3 in two segments, the Drive Module and the Life Module. The Drive Module contains the electric motor, suspension, lithium ion battery and is the backbone of the car. This module is made mostly of aluminum and its repair process is very similar to other aluminum chassis components that BMW has been producing and repairing for years.

The i3's mostly aluminum Drive Module

The Life Module is the occupant cabin and its backbone is made of Carbon Fiber Reinforced Plastic. This frame and roof are all CFRP where as attached to the sides of the i3 are composite plastic panels. These panels are designed to absorb what would normally dent a metal car and pop back into shape. Added bonus: your i3 isn’t gonna rust.

Aluminum: BMW states that standard “Cold” repair methods for the aluminum components will be used in repair. These include bonding and riveting. These methods have been used by BMW workshops since 2003.

Panels: BMW designed the panels to be replaced via standard screw/clip on plastic plated parts, so not much different really than a standard car.

Glass: The CFRP body which is surrounding and holding the glass can be damaged by a standard glass removal tool, so there is a special tool required here. Overall the mechanism of removing and replacing is similar. Standard glass removal tool uses a strong metal wire that would damage the carbon fiber, so BMW’s tool has something like a super strong fishing line.

Even replacing the glass on an i3 requires a different process and tools

Carbon Fiber Body: This is where repair techniques change significantly from standard cars. There is no pounding out damaged CFRP. In order to repair the i3, the damaged section will need to be cut out at one of the predefined points. These are located at the top of the A, B, C pillars as well as forward and aft of the floor pan.

BMW requires a specialized cutting device that looks part bone saw on the business end and part Dr Who Villain, a Dalek, to vacuum up the carbon fiber particles. Once the carbon fiber body has dis-articulated at the very specific points, the technician then places the new section on and bonds/glues it back together.
This is where my favorite part of the tour came. “This isn’t very complicated but it needs to be very precise,” says a BMW technician. He further added that the time it will take to repair i3 electric vehicles will actually be less than standard cars and thus decreased labor costs with auto repair.
BMWBLOG is happy to report that the insurance cost for the BMW i3 is similar to a 1 Series Coupe. Adding a BMW i3 to my automobile insurance policy will only raise the monthly payment by $42. Take that with a grain of salt as car insurance policies range all over the place depending on driving history, use and location.

The BMW i3 has a 22kWh battery powering a 170 hp electric motor good for an 80 mile range. It has been tested as the most efficient electric car available on the market due to its low weight with extensive use of Carbon Fiber Reinforced Plastic: 124 MPGe. The Range Extended version has a small generator in it which never directly drives the vehicle’s wheels but rather charges the battery while adding roughly 330 lbs to the vehicle curb weight.

Virtually every facet of the i3's manufacturing process is different and BMW is evidently struggling to manage setbacks

According to Jay Cole over at insideevs.com i3 production is currently 50% lower than expected at this point in time. Cole's source is Manager Magazine Online, a German Publication, which states the high rejection rate of the carbon fiber parts made for the car. The article goes on to say that BMW's recent announcement that the company will be investing another 100 million euros to increase the production of carbon fiber is tied to this issue.

Manager also says BMW is only churning out 70 i3's per day which is about half of what they were hoping to be making by now. BMW began i3 production in October so they are four months in and now have over 11,000 i3's on backorder. Plus, US sales are only just beginning so it would appear that even if BMW gets the current problems solved in short order (and that's a big "if"), it will still probably take them nearly a year to catch up with demand since the orders will continue to pile up. It has long been speculated that BMW will have the capacity to make between 30,000 and 40,000 i3's per year once they are running at full production.

It seems we now have some answers to two things which were puzzling US customers recently. A couple months ago BMW announced that US i3's will not have a moonroof available. This comes long after it was announced that the i3's with Giga World and Tera World interiors get the moonroof included with the packages. To make matters worse, most of the i3's here in the US are pre-production European spec cars and they all have sunroofs. So everyone that had the opportunity to test drive an i3 got teased with seeing the moonroof that they were later told they won't be able to have. Then, a few weeks ago BMW announced the first three months of i3 US production would be limited to a "Launch Edition" version. The Launch Edition is fully loaded with every option available on the car and the most expensive Tera World interior. The only thing the customer can choose is the color (and only the metallic colors are available) and if they want the optional 20" sport wheels.

Many people speculated that is was simply a money grab and BMW knew the car would be in high demand so they could get away with making anyone that wanted one of the first i3's in the US buy one that was loaded. Now, with the recent news about production difficulty, I think it's obvious the reasons the moonroof isn't available at launch, and custom ordering isn't available for another three months, is solely because BMW is struggling to refine the manufacturing process and eliminate the problems they are currently having.

I've had the opportunity to talk with many BMW program managers over the past few years. One of the things that has always stood out to me was how on one hand they were really excited about the i3 because of how special and different everything about it is, while on the other hand they would always acknowledge how big a challenge it was going to be. Everything about the i3 is different. BMW has never made a car that required special manufacturing processes for virtually every stage of assembly. Besides the electric powertrain, most of the materials used in the car are even different. While the biggest challenge is likely working with carbon fiber on such a large scale, they are also using more aluminum on a car than they ever have and are using interior materials that they have never worked with before. Then there is the outer thermoplastic body panels which BMW has never used before which has even led to the painting process presenting challenges.

So personally I'm really not surprised by all this. The i3 is a revolutionary new car for BMW, and nobody else is making anything quite like it. Yes, there are some that will look at it and say "It's just another 80 mile electric car, big deal", or "It's nothing more than a Nissan LEAF that costs $50,000". I respect everyone's opinions, and for some people it doesn't represent any more value than a $30,000 Nissan LEAF and that's fine. However when I see the i3 I see the future of the automotive industry and I applaud BMW for taking the enormous risk of building such a radically different car, something that nobody else is attempting to build. Yes, I wish it had more range and I think BMW would have been better served if it could really deliver 100 miles of consistent real world range for most drivers, and it's clear it will not. But that's the biggest knock I can offer and it's far from a deal breaker for me. BMW will get past these initial manufacturing snafu's. The top concern at this point should be quality, which I'm sure it is. The production numbers will increase and by the end of the year I'm sure they will have everything running as smoothly as planned. The question is will the customers wait many months for their i3 to be made? I suppose the people that don't put as much weight on how special it is may not, but those that appreciate how unique the car really is will. After all, there is nothing else out there they can get that is quite like the i3.

Chris Campbell with his Volt. Chris was actually the first Volt owner in the State of Georgia. Now that his 3 year lease is coming to an end he's chosen to replace his Volt with a BMW i3.

Chris Campbell has been following my blogs for a while now, and has commented on many posts. He's an avid electric car supporter and is a member of the BMW i3 Facebook group. Chris has been following the BMW i3 for a while now and he's been really anxious to test drive one. As you'll read below, the driving experience is really important to him - as it is for me. Chris finally has his chance to test drive the i3 (twice actually) and shortly after declared on a post in the Facebook group "I did test drive #2 this morning. That's it, I'm in.". I know Chris knows a lot about EV's, and I know he had his doubts about whether the i3 would be the right EV for him, after all he really loves his Volt. So when I read his declaration, I asked him if he would like to do a guest post here, to offer his story of  how he came to the conclusion the i3 would be the EV that would replace his Volt. He accepted the invitation, and sent me the post below:

GETTING OVER IT AND CHOOSING THE BMW I3

I am an electric vehicle enthusiast.  The wave of EVs in the late 1990s piqued my interested, but it was a lucky chance at a long test drive of a Tesla Roadster in April 2009 that gave me the EV religion.  By 2010 I was ready for a new car and the market was finally ready to give me an EV.  In my case the Chevy Volt was good choice because I have a short commute, well within the electric range of the Volt, but also wanted the ability to take the car anywhere at any time and not have to worry about range.  Note that there was virtually ZERO public charging infrastructure in 2010 when I got the Volt.

Fast forward three years and I'm now at the end of my three year Volt lease, and looking for my next car. The Volt has been great, and in fact I still believe it is the BEST car on the market, especially for anyone new to EVs.  After three years of tweaks, and this year's dramatic price drop, the Volt is even more compelling than when I took my somewhat risky plunge in 2010.  But, for me personally, as my Volt lease ends I'm now looking to move on to the next thing.

I've been following BMW's EV developments closely for a few years now, and after a second test drive this past Friday, I've decided that the BMW i3 is going to be my next car.  I'll explain why, but I'm also going to take a sober look at the car, probably unlike any other i3 review you've seen.

EVs are an absolute thrill to drive, and there was no doubt that my next car would be another EV.  While the environmental and geopolitical reasons for getting an EV are important to me, what really draws me is the sheer power (well, torque) of the electric drivetrain.  Once you experience that "stealth V8" power you just can't live without it.

So, for me, the very top issue in selecting the next car was POWER. How fast was it?  The Volt (and Leaf, even) are deceptively powerful, and a blast to drive, but I consider them to have only the MINIMUM required power.  More is better!  And early reports on the BMW i3 indicated that it was going to be more powerful than anything on the market short of the (sadly unattainable) Tesla models, so I've been following it very closely for over a year now.

There are lots of features that I like about the i3.  The carbon fiber structure is certainly cool.  I'm tall, and the long coupe-style front doors place the pseudo B-pillars (and seatbelt anchors) nicely back and out of my peripheral vision.  The i3 will have an available DC fast charging option, and I decided earlier this year that my next car simply had to have DCFC capability.  The drive train is well engineered, following four years of careful testing in BMW's MINI-E and ActiveE programs.  It's a BMW, so you're going to get a driver's car.

All these things are great, but certainly the car isn't perfect.  No car is perfect.  And in fact, that's how it usually works, right?  You fall in love with a car, then you find out something about the car that you DON'T like, and then you have to decide whether you can get over it.  Do the pros outweigh the cons?

The Nissan Leaf is ugly, has a spartan interior, and has a cheaper battery technology that makes it susceptible to weather extremes.  The Chevy Volt is a bit pricey and can't seat more than two people in the back (and the EV purists turn their noses up at it).  The Ford models have that hulking battery pack messing up the trunk, signifying the worst of "conversion car" engineering.  And so forth -- you can always find something wrong with a car.  Even the vaunted Tesla Model S has problems, most prominently its stratospheric price tag, but upon closer examination there are plenty of other problems.

So, I've got problems with the BMW i3.  Can I get over it?

I'm an engineer, and I can't help but try to analyze this decision soberly and methodically.  Anticipating that I'd be back in the market for a new EV after the Volt lease, a year ago I started assembling my checklist for the perfect electric vehicle.  This long document is a collection of every feature in every EV on the market, and serves as a way to honestly evaluate the cars on the market.  No car is perfect, not even the Tesla Model S, and my list serves to remind me that there are tradeoffs in any car.

With that, I will now itemize the top things that I do NOT like about the BMW i3.  See, I told you this would be unlike any review you'd read!  Again, I've said above that I AM going to buy an i3, in fact I will be happy to be the first in my home state, as I was with the Chevy Volt three years ago, and probably will be as big a cheerleader as anyone about the car (well, except for Tom M...).  But I'm doing this with a clear-eyed view of the pros AND the cons of the car.

In essence, this is a list of the things that I had to "get over" in order to commit to the i3.

IT'S UGLY!












While the i3 has some sexy angles, it has some real stinkers too. Look at it straight on from the front, or straight at the rear.  In both of those angles the weird design is jarring, and the skinny tires jump out at you.  I know, I know, 19-20 inch tires, contact patch size blah blah blah -- it just LOOKS bad.  But it's a thrill to drive!  So I'll get over the looks, or least tolerate the snide remarks.  At least I shouldn't have to worry about those kinds of comments from Nissan Leaf owners, right?  That has got to be the ugliest car on the market, from ALL angles!  Ha!

NO CLIMATE PRESTART ON KEYFOB













You're not going to believe this, but this feature is THE most important feature to me in an EV, putting aside the headline features of the drivetrain, battery and charging technology.  The same way you get addicted to the instantaneous torque of an EV drivetrain, I have become addicted to that little button ON THE KEYFOB of my Chevy Volt that starts up the climate control.  I use it every ... single ... time ... I get into my car (so at least twice daily), from inside the house as I'm getting ready to leave in the morning, and then on the way home as I'm approaching the car at my workplace.  Yeah yeah, sure, I can use the smartphone app -- wanna race?  It takes me 3 seconds (and minimal cognitive engagement) to get the car warming up, and I can do it blind with the keyfob in my pocket.  Try THAT with your smartphone.  Scheduling the prestart doesn't solve this for me because I don't get in the car at the same time every day.

There is a "diamond" button on the i3 keyfob that acts as a panic button, but I've heard a rumor that it is actually *configurable*, and that climate prestart may be one of the configurable options.  If so, congratulations BMW on a brilliant solution, and scratch this off the cons list!  But I haven't seen confirmation, so it remains on my short list of problems with the i3.  Trust me, once you have this feature, you can't live without it.

CHARGE PORT ON WRONG SIDE OF CAR


You will plug and unplug the car EVERY DAY.  That's at least two trips to the charge port location, and therefore it should be as close as possible to the driver's door.  BMW stuck it in the right rear corner, just about the worst possible place.  I'm sure they have their reasons, but from a usability perspective it's just all wrong.  I have seen some factory photos of the CFRP passenger cell that have shown that the interior structure of the car has cutouts on BOTH sides, so it's possible that they may relocate the port to the rear left side in the future, but for now -- it's in the wrong spot and will annoy me twice a day for my entire life with the car.

NO POWER SEATS
Power seats aren't even available as an option.  It takes me forever to get the seat adjusted just right, and thus I really want the memory function of the power seats so I can put it back the way I like it after someone else has driven the car (spouse, mechanic, etc.).  A car that approaches $50,000 when loaded with options should offer power seats as one of those options.  And don't try to tell me that it's left out for energy saving reasons, that's simply nonsense.  I'll buy the weight savings argument, but still, this should be an option.
 
WHAT'S NOT ON THIS LIST

There are many things that other people have complained about that are NOT a problem for me:

- It's a four seater.  You can't put three people in the back seat, even three kids, as there's a console in the middle and no third set of seatbelts.  That's fine with me.


- There is no SOC percentage showing the exact state of the battery charge.  I know the other i3 fans are screaming about this, but I could not care less.  I'll trust the indication of mileage remaining, and will eventually learn how to correct for challenging driving ahead.

- Range: 80-100 is plenty for me.  In fact, using the VoltStats.net data from my last three years of Volt driving, I recently found that 80-100 is perfect for me.  Give me the DCFC interface and even just a hint of a future charging network and I've got all I need.

I GOT OVER IT

And here we are.  I've listed some big problems I have with the i3, and I've listed even more on the full EV checklist on www.ElectrifyAtlanta.com (now updated with i3 data).  And yet ... the drive is intoxicating.  It's got more power (more more more gimme) and can carve through turns like it's on rails.  Check out Chris Neff's recent report on his day with an i3 as a professional race car driver flung it around a racetrack for 10 hours!

It's got good range.  It has a sunroof option, and I love the doors. It offers HD Radio and RDS, which are radio tuner features that I really wish all cars had. I even love the underdog factor of having the SAE Combo DC fast charging interface that all the Nissan and Tesla partisans are howling at.  Game on, let's go.

And so I got over it.  Take my money, BMW, the sooner the better.  Can I be first in Georgia again?

Chris Campbell
www.ElectrifyAtlanta.com

The only question I now have for Chris is what color does he want. Will he choose Laurel Gray like I plan to order?

You can tell this is a US spec i3 by the red and orange reflectors on the edge of the wheel wells. Look at the previous pictures on this blog and you won't see the reflectors there because they were all European spec pre-production i3's

I've had people ask me if I had any high resolution pictures on an i3 in Laural Grey already but till now I didn't. there were a couple pictures out there of i3's with the partial camouflage in Laurus Grey but none since all the wraps have come off. So when I came across these pictures posted on Bimmerpost taken a couple days ago at the Pebble Beach Auto Show in California I grabbed them and figured I'd put them up here for those that want to see this color on a real car and not just on the online Visualizer.

The only thing I'm thinking about with this color is the details get hidden because everything looks nearly black. Another reason I need to see it on a car in person.

I happen to like this color a lot. In fact it may have escalated up to the top of my want list now but I still need to see all the colors on cars in person. Another thing people have asked me about is the blue stripe below the side doors. Can it be ordered in different colors? The answer is no it can't. All of the cars will have the "BMW i Blue" accent there, as well as on the inside of the double kidney faux grill in the front of the car with the exception of i3's ordered in Solar Metallic Orange. The accent color on Solar Orange is called "Frozen Grey Metallic". Unfortunately you cannot mix and match. I suppose the only option you'd have is to customize it yourself and have the pieces painted after you purchase the car if it really bothers you.

You can see the blue trim piece here below the carbon fiber door sill. It's much more visible when you open the door

The BMW i Blue grill really stands out when it's on a Laural Grey i3.

So if you really don't like the standard accent color on your i3 your only options are to repaint it or possibly apply a vinyl wrap - at your expense. I happen to think the trim colors look good, but that is obviously subjective. Actually, if I were to complain at all about the exterior colors, I'd wonder why BMW stuck so much grey scale. Other than the Solar Orange all the other colors are a shade of white to black with slivers and greys in between. The Solar Orange is the only real bold color and I think they could have been a little more creative there. How about borrowing a cool color from the M division?

The Frozen Grey Metallic accent on the Solar Orange i3's will look less prominent than the BMW i Blue will on the other cars in my opinion since it's not as bright of an accent

The display featured on the concept i3. The production version is thought to be very similar to this.

The 2013 BMW i3 will be a revolutionary vehicle. It will be be the first mass produced car that has an aluminum frame and a body made just about entirely out of carbon fiber reinforced plastic. It will use a modern version of body-on-frame design with the aluminum drive module made completely separate from the passenger cell with the latter bolted and glued to the frame near the end of the production line. It will be the first all electric car that the BMW group offers for sale and it will be one of the most efficient vehicles ever offered for sale by any major automobile manufacturer.

It will also, have one of the most advanced and connected electronics and display systems. There hasn't been much written about the i3's electronics, but from the photo's that have been leaked so far, it is obvious BMW is working hard to make the driving experience custom tailored to then needs of an electric car driver. Built in navigation system that will list all charging station within your driving range and destination routing that even includes the part of your trip after you leave the car to use public transportation.

One thing that is interesting is there seems to be two numbers offered as the driving range based on your current state of charge, one that is based on normal driving and one based on the use of the Eco Pro mode which will reduce power to the motor and other energy using devices like cabin heating and cooling system. By doing so the car will use less energy and the range will be extended. The Eco Pro mode will undoubtedly give the car a less spirited driving experience, but when your cutting it close with your available range, believe me you will gladly trade off a bit of acceleration to make your destination. By displaying both estimated ranges, it will help the driver to decide which driving mode is best for that given destination.

Besides in car electronics, the i3 owner will have the ability to perform many functions in the car by the use of a smartphone. You'll be able to precondition the battery and cabin to the desired temperature. You'll be able to plug in a destination and the application will tell you if the car can make it there based on it's current state of charge or suggest charging stations to stop at along the route. It will also alert you once a pre-selected state of charge is attained. This can be very useful. Let's say you plugged in and then went off to run some errands while the car reached a certain state of charge necessary for you to make it home, the car will then send you a text message when that percentage is met, alerting you that it's safe to return to the car and begin your journey.














It going to be really interesting to see just what BMW is working on here, but judging from what is currently leaked, I'm thinking it will be pretty useful (and cool!).

http://www.youtube.com/watch?v=Dk6_kCQtdNE&feature=youtu.be

So here it is. It's been over two years since we first started hearing about the mysterious BMW "Megacity Vehicle" since dubbed the 2013 BMW i3 and we're finally getting an official look at what BMW has been cooking up.

This is a concept, so the production version will be a bit different, but overall the shape will be pretty much what we see here. They will of course lose the glass side panels and roof, both to be replaced with carbon fiber panels as is the entire outer shell. If you compare it to the renderings in the post below this, you see it is kind of a hybrid of a few of them. There haven't been much details released yet, but some of them of note that I did read are the car will have tall 19" wheels, which are very large diameter for a car of this size. The stated purpose for these are that they lower the rolling resistance and improve efficiency. It will also go 0-60 in under 8 seconds. It will charge on a regular household 110v outlet in six hours. That basically means the battery pack is small as previously reported, probably 16 to 18 kWh. It will also have a range extender option that BMW calls i-REx. The range extender will be a small gasoline(not diesel) engine that will only charge the battery pack, it will not have the ability to drive the wheels directly like the Chevy Volt can under certain circumstances.

 I'm sure there will be lot's of info coming out in the next few days, I'll try to get it all up here as soon as it's available.