The electric car, launched in December 2010, had its best sales month in March this year with 2,236 units sold and Nissan is set up to produce as many as 150,000 per year if needed – far more capacity than it yet needs.

The Leaf shares the line with Altimas and Maximas and putting things in perspective, one Leaf makes its way through the line every 15 minutes, or about four per hour, amidst a steady stream of the conventional models.

Last month the Altima sold 37,763 units – edging out the Toyota Camry as the U.S. best-seller by 100 units – so for now and the foreseeable future it is a priority to the Japanese automaker.

But the Leaf and other electric cars to come are expected to increase in importance and sales volume as the tide slowly turns.

To show how the cars are being assembled now, The Tennessean put together this time-lapse video of the manufacturing process involved, and we’re passing it along.

There were several challenges involved in fitting the Leaf into the line including accommodations needed for the fact the Leaf is a smaller car, and its powertrain is altogether different.

The plant is now working three shifts 24 hours per day, and as you can see much of it is automated, reliant on robotic assembly.

The Tennessean

The post Video Shows Time-Lapse Nissan Leaf Assembly appeared first on HybridCars.com.

This week, timed with Earth Day on April 22, Nissan hosted a couple of waves of journalists to take carefully guided tours of its massive new battery plant in Smyrna, Tenn.

The 475,000 square-foot facility is adjacent to its newly online Leaf-assembly operation, and these plants are located an hour north from Nissan’s Decherd, Tenn. plant where the Leaf’s eMotors are built.

The major investment in more EV-making capacity than is yet being utilized is part of a broader goal to localize 85 percent of Nissan and Infiniti production by 2015, and to bring on more EVs in their due season.

Director and Plant Manager Jeff Deaton explains one stage of the multistage assembly process.

Nissan’s battery production can be scaled up to 200,000 complete battery pack assemblies annually. In calendar year 2012, Nissan delivered 9,819 Leafs to the U.S. Do you think the company which knows full well where it’s at has big plans for the EV future?

In any event, the new plant came online just in time to supply the modified 30-year-old Smyrna auto assembly plant where the Leaf now shares assembly line space with Maximas and Altimas.

The battery assembly facility is modeled on best practices learned at Nissan’s “mother plant,” the Zama battery assembly plant in the Kanagawa prefecture in Japan. The Smryna battery factory’s American workers were hand-picked for their skills and talents and sent to Zama so they could come back home and duplicate their Japanese counterparts’ efficiency.

We say the media tour was “carefully” guided because Nissan has developed manufacturing processes to which it staunchly denies access to prying eyes, let alone camera-wielding visitors to wander through and liberally snap images of, lest competitors also learn a trick or two.

In coming days and weeks you will see various media coverage and mentions of Nissan’s battery plant, including some video production, but none of it will be giving away industrial secrets if Nissan has anything to say about it.

Nissan’s stance is understandable given it aims to lead the EV race, and has invested several billion dollars around the globe in order to try and make it so.

A completed Leaf battery pack assembly receives final touches.

The Smryna plant is the largest lithium-ion automotive battery assembly plant in the U.S. and Nissan estimates once it reaches full capacity, it will represent a $1.7 billion investment – all in the name of getting as many all-electric vehicles on the road as possible.

The project is supported also by a U.S. Department of Energy loan for up to $1.4 billion. The taxpayer money was authorized under the Advanced Technology Vehicles Manufacturing Loan Program by Congress as part of the Energy Independence and Security Act of 2007.

Lots of high-ceiling, open, organized, perfectly constructed, OSHA-compliant and relatively quiet automated work goes on continuously. Workers are not needed for much of it.

Led by Renault-Nissan CEO Carlos Ghosn, the Japanese manufacturer is now well positioned in the center of the country to help America in its quest to 1) create vehicles and technologies that can increase U.S. energy independence, and 2) create cleaner means of transportation, and 3) stimulate the American economy.

Thus far 300 extra jobs have been created in the highly automated plant dedicated to zero emissions, and Nissan figures as many as 1,000 jobs could be derived assuming full production volume in coming years.

In It to Win It

In launching its well-under $40,000 all-electric Leaf, and developing manufacturing facilities in Japan, the U.S. and Sunderland, UK, Renault-Nissan is striking early and striking as aggressively as it can to proliferate battery powered transportation for the masses.

Through March 2013, Nissan counts 23,000 Leafs having been delivered in the U.S., and 60,000 globally.

As an already established manufacturer, Nissan can afford to do things in a bigger fashion than, say, Tesla Motors – which has lots of good ideas also, but its pockets are not nearly as deep.

Leafs charge under a small solar canopy outside the main battery plant entrance.

Tesla’s angle has been to connect with its customers and hopefully future customers, but its strategy to tattoo its brand onto the soul of its well wishers has involved proffering such creations as its already discontinued Roadster and now its Model S – cars costing two- to four-times more than the $30,000 or so average new car price.

The California start-up has amassed a wide range of enthusiastic fans – even many who cannot afford its products – by cavalierly beginning what some have said isn’t possible in the face of established U.S. auto sellers – it’s an unfolding saga and sort of akin to a new rendition of a David vs. Goliath story.

Tesla has delivered comparatively few products, but they’ve been perceived as sizzlingly hot creations, and Tesla has all the while promised everyone who cannot yet swing a Tesla to hang on, as the 99 percent is not forgotten even if the 1 percent is presently being served first.

Fear not, says Tesla, plans are to make more affordable cars ASAP, and its plausibility has been deep for many a person who does not subscribe to Sarah Palin’s Facebook page.

Naturally, Nissan had the 2013s lined up for media to take a 20-plus mile drive.

Meanwhile Nissan is making more affordable cars now. They may have less visceral appeal than other upmarket creations, but they work, cost very little to operate, and are more affordable than ever.

The major manufacturer this year took a knife to the MSRP for its updated Leaf SV and SL trim model packages and introduced a base-level S trim level $6,000 less than the lowest priced Leaf from 2012.

The 2013 model year Leafs were only mildly improved in a host of ways, not radically overhauled, and their 24-kwh batteries remain close to the original spec, albeit now made in USA.

“Sshh! Don't tell anyone a gas-powered Honda was occupying one of the EV-only spots at Nissan's Leaf assembly plant. (Actually it belonged to a Blink technician servicing the chargers, and there were extra spots available).

But Nissan has no actual head-to-head competitors selling a truly similar product in all 50 states. Granted EVs are coming along, such as the Honda Fit EV, the more modest Mitsubishi i-MiEV, and other manufacturers like GM and Ford have come out with or are in process of coming out with EVs for limited markets.

Aside from its limited-market RAV4 EV, Toyota has shied away from EVs altogether for now, content to sit back and let others do the heavy lifting while it tries to expand its small hybrid empire against increasing competition. Other automakers too have displayed more hesitancy and conservatism than Nissan.

By itself, Nissan has almost whittled its prices down to other economy cars, or at least to the national average new car price if not much less with incentives.

Another day at the office … building li-ion batteries at America’s largest battery assembly plant.

At the extreme, counting a $7,500 federal tax credit, some people in states where additional subsidies are offered – such as California, Pennsylvania, and others – are taking home the least expensive Leaf for under $19,000.

Despite the maverick appeal of what Tesla is doing on the wild and under-developed EV frontier, the fact is, Nissan’s cars – most notably the Leaf S model – can be had for a fraction of a Tesla Model S.

But Tesla, GM, Ford, Mitsubishi, BMW, and several others have plans for the not-too-distant future, and Nissan knows it, so it continues onward, putting its money where its mouth is.

For the most part.

Last fall, the company announced an enhanced battery warranty retroactive to 2011 and 2012 Leafs, as well as 2013 models. The skinny on this was Nissan will cover battery degradation for 5 years or 60,000 miles which ever comes first for cars that show nine out of 12 possible bars on their power display.

Nissan proudly shows its cutaway Leaf battery pack at the opening of its factory tour.

This roughly equates to 70 percent remaining power – thus significantly degraded range in cars that may only go 73-90 miles more or less to begin with.

It was a concession following a loud outcry from Nissan’s highly vocal early adopting owners, particularly in hotter states such as Arizona, Texas and California where some said extreme range loss was occurring too soon.

Nissan’s move followed despite it not admitting any actual product defect with its non-liquid-cooled battery packs, but the company says it was listening to its Leaf owners. It agreed to an independent Leaf battery probe, among other actions, and in the process, settled a class-action suit with some of its most disgruntled Leaf customers.

In the courtyard between the security entrance and the plant’s front doors.

The enhanced warranty coverage – announced last September on the MyNissanLeaf.com forum in advance of its approximately spring 2013 effective date – does not necessarily promise to restore 12 bars, but is something positive and has been taken with mixed reactions by Leaf owners.

As noted, Nissan did not substantially re-engineer its Leaf’s battery for 2013, and its battery is still not liquid cooled or heated. But the car is expected to score higher in its EPA rating due to efficiencies implemented, and Nissan is saying it should conservatively be good for 84 miles range – if not farther – compared to 73 miles EPA-rated range for the first couple years.

It’s an altogether improved car that saw several customer recommendations come to fruition in its update, and it’s better backed now too.

Back to the Future

Bumps in the road aside, Nissan is leading a pioneering effort as it keeps churning out domestically made batteries assembled according to an elaborate and careful multi-stage process.

One of the steps in battery production (see infographic) involves aging the batteries to let complex chemical reactions take place prior to putting batteries into service.

The Smyrna battery plant has actually been operational for several months now, but full Leaf production only got rolling toward the end of February.

Click on image to expand.

And now we shall see how Nissan’s gambit in electric cars continues to play out. Certainly it was a carefully thought-out business decision, intended to pay dividends if not instantly, then over time.

The yen-to-dollar exchange rate, and costs to ship Leafs from Japan have led Nissan to say the long-term investment on American soil was worthwhile.

Nissan has not said what it would do if Leaf sales remained static, and one insider told us we may see sales on par with the end of last year for a while, but the goal is to grow the business as word gets out that EVs can make sense, and more buyers warm up to them in time.

Also implied, but not stated is Nissan is planning more all-electric models with Nissan and Infiniti badging, and aimed at a variety of demographics.

Do you think the Leaf’s looks might turn off the aesthetic tastes of some buyers? The Leaf comes across like the proverbial ecocar even more than Toyota’s Prius. This styling was based on early adapter preferences expressed, but Nissan knows other people will want an electric car that blends in better. No specifics on this, but stay tuned.

Also, there is no talk at present of subcontracting excess manufacturing capacity and it is designated only for Nissan vehicle requirements.

For now, the plant’s production is scaled down, and Nissan is content to plod along with Leaf demand still the only reason for having built America’s largest EV battery factory.

But you can be sure it won’t be this way any longer than is necessary. Nissan has plans within plans and has shown willingness to push them into being with more boldness than just about anyone.

The post Nissan’s New US Battery Plant Shows Major Dedication To EVs appeared first on HybridCars.com.

The Alternative Fuel Vehicle Roadshow in Tennessee is underway and is co-sponsored by Efacec.

The event stopped in Kingsport and Knoxville, will be in Chattanooga today; and in Memphis March 25 and Nashville March 26. The showcase is open to the public, though registration is required.

Efacec demonstrates its DC fast charger at the showcase. It looks like a fuel pump, but instead of filling cars up with expensive gasoline, it quickly powers them with domestically-produced clean electricity. Instead of plugging in an electric car overnight, Efacec’s fast charger recharges a battery to 80 percent in just 28 to 30 minutes. The company said several are already installed in a number of cities.

“Efacec is helping to power the cars of the future,” said Mario Santos, Efacec’s Director of Business Development for Transportation, Electric Mobility. “Electric cars need charging stations just as gasoline-fueled cars needed gas stations to catch on. The more fast chargers there are, the more likely people in Tennessee and all over the country will be to buy and drive energy-efficient vehicles.”

The event features several clean-energy vehicles — even a school bus — that run on fuels that are not gasoline. In addition to electricity, these fuels include compressed natural gas, propane and biofuel.

Efacec previously sponsored roadshows in Georgia and Florida.

East Tennessee Clean Fuels Coalition director Jonathan Overly directs the program in Kingsport, Knoxville and Chattanooga, while Atha Comiskey with Middle Tennessee Clean Fuels and Paul Rice with West Tennessee will host in Nashville and Memphis.

The Tour is produced by AdVentures, a private company, producing nonprofit and educational events with a social purpose.

The post Clean Energy Vehicle Tour Underway in Tennessee appeared first on HybridCars.com.

Just like U.S. market Nissan Leafs are now built in Tennessee, European-market Leafs will be built closer to their intended market, at Nissan’s Sunderland facility in the UK.

Nissan said it has a longer range, is more practical, better to drive and has even more equipment.

European production of the new model will soon start at Nissan’s Sunderland production facility with more than one hundred changes made to the electric car.

Improvements include an extended driving range, greater recyclability, more interior space, better charging performance, more equipment and greater choice with three versions now available.

Subtle styling changes to the nose of the car have improved its aerodynamic efficiency.

Many of the changes have come as a direct result of feedback from Leaf owners.

In addition to owner input, Nissan has been able to get feedback from aggregated data from the unique Carwings telematics system, which is at the heart of the Leaf. This feature logs information on charging, usage patterns and distance driven.

With the Leaf having been on sale for more than two years, and having delivered more than 50,000 units globally, engineers at Nissan have been able to use some of the data collected to optimize the car in line with actual customer usage.

Changes range from a new powertrain assembly that greatly enhances the car’s practicality to simple modifications, such as the addition of a LED light within the charging port making overnight charging that much easier..

Nissan is also providing a new comprehensive warranty plan for the batteries. As well as covering the batteries against defects in materials and workmanship for five years/100,000 kms (60,000 miles), batteries will be covered by a ‘State Of Health’ clause which covers gradual capacity loss.

Over time, lithium-ion batteries lose a percentage of their capacity, a natural phenomenon. But should battery life reduce quicker than anticipated over the same warranty period it will either be repaired or replaced.

One significant change to the 2013 Nissan Leaf is the move to producing the car in three different locations: North America, Europe and Japan.

In Europe, production will start this spring, as mentioned, in Sunderland in the UK, where the Leaf will be sharing the line with Qashqai and joining Note and Juke.

At the same time, the lithium-ion batteries are already being produced at a new facility nearby on the Sunderland site.

“By sourcing Nissan Leaf and its batteries in Europe, we are underlining our faith not just in the ability of the Sunderland facility to build our most technically advanced car, but also in the fact that electric vehicles can be considered a genuine alternative to conventionally powered vehicles,” said Willcox. “In its two years on sale, the global success of Nissan Leaf has shown that electric vehicles offer viable everyday transport for people with a typical daily commute.

The revised Leaf, which goes on sale in Europe in the middle of 2013, marks an important milestone in Nissan’s global zero-emission leadership. It will soon be joined by pure electric versions of the NV200, to be called e-NV200, in both light commercial van and seven-seat combi versions.

Development is also underway on a dedicated EV taxi based on the e-NV200 while an Infiniti EV is expected in 2015.

Changes to the Euro Leaf

Now assembled together as a single stack, the new powertrain is still an 80 kilowatt AC synchronous motor linked to a Nissan-designed 48-module compact lithium-ion battery, mounted underneath the cabin area to lower the center of gravity.

By moving the charger from the rear of the Leaf to under the hood, Nissan has been able to increase the size of the trunk. This means there is now no obstacle in the middle of the cargo area when the seats are folded, while rear legroom has been increased thanks to reshaped seat cushions, which allow passengers in the rear to put their feet under the seat in front.

Improvements to the heating and ventilation system are based on a new heat pump system which replaces the original ceramic heater. This significantly reduces electrical consumption and delivers an improvement in real-world driving range. This is particularly relevant to markets where drivers rely heavily on the heating and ventilation systems.

The revised Leaf’s real-world driving range has also been improved by the only visual change to the car: a subtly revised front grille helps reduce the aerodynamic drag coefficient from 0.29 to 0.28.

The new Leaf’s driving range is certified at 124 miles (200km) under the New European Driving Cycle (NEDC); the previous model was rated at 109 miles (175 km).

The revised Leaf is said to be more fun to drive thanks to changes to the chassis, steering and brakes engineered at Nissan Technical Centre Europe (NTCE). Main changes have been to damper settings to reduce float and deliver a more agile and dynamic drive without affecting ride comfort. The steering system has been given more weight to provide steering feel more in tune with European tastes while the performance of the brakes has been improved to make them more progressive in use, while also increasing the amount of energy recovered.

Changes have also been made to the Eco driving mode.  A new “B” setting on the transmission increases regenerative braking during deceleration while a separate “Eco” button on the steering wheel extends driving range by altering the throttle mapping to discourage rapid acceleration. The two systems can be operated independently of one another, unlike in the original Leaf.

Other key improvements to the Leaf’s e-Powertrain include reduced internal friction and a more efficient battery and energy management system.

Reduced charging time is also promised by a new option that will cut the conventional charging length in half, from eight to four hours. A new 6.6-kilowatt on-board charger will permit the use of 32-amp charging using the latest generation of chargers installed in domestic and commercial properties. A typical European domestic plug delivers 10 amps.

Other technical innovation enhancements include the new Bose audio system specifically developed for the Leaf and also available on the North American version.

Nissan’s Around View Monitor is another technical innovation now found on the Leaf. This system uses a network of cameras to generate a 360-degree overhead image of the car on the central display, simplifying parking or any difficult maneuvers.

Changes inside include the seats. As well as being redesigned for better support, the front seats now incorporate height adjustment, while a new bio-fabric covering has been introduced.

Where the original model featured material made from 39 percent recycled plastic bottles, the new bio-fabric is 100-percent derived from sugar cane, further improving the Leaf’s overall recyclability and environmental credentials. Leather is also now available, as is a darker and more practical interior finish.

The charging port has been reworked to improve usability and security and its release mechanism now uses an electric switch. Additionally, the charge cable now features an electro-mechanical locking mechanism that removes the requirement to lock the cable to the car manually.

Other detail enhancements include a new i-Key that also controls the charging port cover and cable lock.

These significant updates are incorporated as part of a major range expansion that sees the Leaf adopt the European Nissan three-tier trim line-up of Visia, Acenta and Tekna.

The Visia version offers a lower price entry point while Tekna models feature even more standard equipment than the original model.

Visia models have 16-inch steel wheels with full covers, black door mirror caps and halogen headlights, for example. Acenta versions have 16-inch alloy wheels, suede fabric seat trim, body colored mirror caps and rear privacy glass.

As well as having leather seats as standard, Tekna models come with 17-inch alloy wheels as standard, LED headlights, the Bose sound system and AVM. A new color palette for all versions now extends to seven different colors with solid, pearl and metallic finishes.

The post European-Specific Nissan Leaf To Be Unveiled In Geneva appeared first on HybridCars.com.

VW said in a release that the installation is the largest of its kind among auto manufacturing facilities in the U.S., and the largest of any solar installation in Tennessee.

The Volkswagen Chattanooga Solar Park occupies 33 acres, or half of the 66-acre land parcel adjacent to VW’s manufacturing plant. The solar park contains 33,600 solar modules from JA Solar designed to produce 13.1 gigawatt hours of electricity per year – equivalent to the energy consumed annually by around 1,200 homes in the area.

VW says that the electricity produced from the solar park is expected to meet 12.5 percent of the energy needs of Volkswagen’s Chattanooga manufacturing plant during full production, and 100 percent during non-production periods. The plant covers 1.9 million square feet and employs more than 3,000 people who manufacture the Passat sedan at the plant.

Frank Fischer, CEO and Chairman of Volkswagen Group of America, Chattanooga Operations LLC, said, “We are proud to power up the biggest solar park of any car manufacturer in North America today.”

“The solar park is another proof point of Volkswagen’s worldwide commitment to environmental protection under its ‘Think Blue. Factory’ philosophy, a broadly focused initiative for all Volkswagen plants to achieve more efficient use of energy, materials and water and produce less waste and emissions,” said Fischer.

VW notes that it hasn’t installed the solar modules in order to sell power back to utilities companies. Instead, VW says it will consume 100 percent of the electricity generated from the polycrystalline solar modules mounted on a Unirac racking system. Ten SMA inverters will convert the solar energy from direct current (DC) to alternating current (AC) to be used to power the electrical installations in the manufacturing plant.

In late 2011 the U.S Green Building called the Chattanooga manufacturing facility “the world’s greenest auto plant” and noted it was the first automotive manufacturing plant in the world to receive the top LEED certification. Today, the Chattanooga plant remains the only auto plant worldwide to earn the LEED Platinum certification.

The post VW’s Solar Installation Largest Of Its Kind Among U.S. Auto Factories appeared first on HybridCars.com.

With two years of Nissan Leaf sales just completed, the company announced the launch of the United States’ largest lithium-ion automotive battery plant in Smyrna, Tenn.

The facility – which is making battery components for the ramp-up of production of the 2013 Nissan Leaf early next year – is one of three of its kind in the world operated by a major automaker. two full years of Leaf sales and Nissan will mark this with a new battery production site located in the U.S.

With two years of Nissan Leaf sales just completed, the company announced the launch of the United States’ largest lithium-ion automotive battery plant in Smyrna, Tenn.

The facility – which is making battery components for the ramp-up of production of the 2013 Nissan Leaf early next year – is one of three of its kind in the world operated by a major automaker.

Since December 2010, Nissan has delivered more than 18,000 Leafs to U.S. customers and more than 46,000 worldwide.

This makes the Leaf the most successful 100-percent electric vehicle in modern history.

“Opening this U.S. plant is an important milestone in Nissan’s overarching strategy to foster sustainable mobility around the world,” said Carlos Ghosn, president and chief executive officer of Nissan Motor Co. “Nissan is the zero-emissions vehicle leader, and we are making significant strides as one of the largest producers of electric vehicles and batteries in the United States. The opening of this facility in Tennessee supports our goal of making zero-emissions mobility a reality through American jobs and American manufacturing.”

Nissan says the first batteries produced at the plant have completed the required aging process and are now ready to receive their first charge.

The facility is capable of expanding to produce modules for up to 200,000 batteries annually depending on market demand. Nissan says those batteries can serve as the power source for the all-electric Nissan Leaf and for future vehicles that could be added to the portfolio.

For logistics reasons, the new battery plant is located adjacent to Nissan’s existing vehicle assembly plant in Tennessee, which has been retooled to accommodate production of the Nissan Leaf.

The Nissan Leaf will now be manufactured on the same line as the Altima and the Maxima, allowing volume to be readily be adjusted among the vehicles to meet demand.

Nissan says the 2013 model-year Nissan Leaf will receive a number of technological advancements and feature changes, which will be announced closer to the vehicle’s on-sale date in early 2013.

The recent growth of Nissan’s U.S. manufacturing plants is part of a company-wide strategy to localize core-model production. By 2015, Nissan aims to have 85 percent of all Nissan and Infiniti products that are sold in the United States produced in North America.

Combined, the construction of the battery plant and modification of the Smyrna manufacturing facility represent an investment of up to $1.7 billion when built to full capacity. The project is supported by a U.S. Department of Energy loan for up to $1.4 billion.

Nissan says the loan was issued as part of the Advanced Technology Vehicles Manufacturing Loan Program, program authorized by Congress as part of the Energy Independence and Security Act of 2007. The program is designed to accelerate the development of vehicles and technologies that increase U.S. energy independence, create cleaner means of transportation and stimulate the American economy.

The post Leaf Batteries To Be US-Built, Just Like 2013 Models appeared first on HybridCars.com.