BMW "Conversations" Video From the New York Auto Show

Rich Steinberg, manager of electric vehicle operations for BMW North America asked me if I would participate in a live Facebook Q&A at the New York Auto show last week. The plan was for me to answer general questions about living with and driving an electric car because of my experience with the MINI-E, and Rich would answer questions specific the the BMW ActiveE, which was being introduced at the show.

BMW does these Q&A Facebook sessions frequently and they call them BMW Conversations. You can view all the past Conversations on the BMW USA Facebook group page.

I had a nice time doing it and got to talk to the whole BMW electric car team. Everybody is excited about the launch of the ActiveE and that includes me. It looked fantastic and will have features like active thermal management, the ability to precondition the cabin and batteries as well as four seats and a trunk. As much as I love my MINI-E, I think I'm going to love the ActiveE even more.

MINI-E Pioneers Get Exclusive Look at the ActiveE!

Aaron Singer of BMW explains some of the ActiveE features to the MINI-E pioneers

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Last night the East Coast Mini-E pioneers were invited to a sneak preview of the BMW ActiveE at the New York Auto Show. The show doesn't actually open to the public until today, but BMW wanted the loyal MINI-E pioneers to get the first look at the successor to the MINI-E, and the final test vehicle they will be making before the 2013 BMW i3 hits showrooms. For those of you that are unfamiliar with the i3, it will be the first all electric car that BMW sells, and is scheduled to be offered for sale in 2013. The MINI-E, and now the ActiveE were low production test vehicles, leased to customers to help BMW refine the hardware and learn and overcome the challenges of introducing an all electric vehicle to the public so when they do sell the i3, it will be the best electric vehicle available. 

MINI-E customers have been promised that if we want to lease the ActiveE this year when the MINI-E program ends, that we would be guaranteed to be the first in line for one, and last night BMW took the opportunity so show us here on the East coast the car in person. A similar event is planned for the West Coast MINI-E pioneers next month. After the roughly 45 minute Q&A and everyone had a chance to sit in and check out the car, we were all taken out to dinner compliments of BMW. I'd like to than Rich, Hugo, Marian, Teresa and Aaron of BMW for hosting such a great event and making the MINI-E pioneers feel special. Taking the time in a very busy Auto Show week to spend a night with some of your customers was really appreciated by all of us. 

The cost will be very similar to the MINI-E's lease price, $2,250 down and $499/month which comes out to  $593/month over the course of the term. We are currently paying $600/month for the MINI-E, but that included comprehensive & collision insurance and the installation of the home charger. The cost of insurance and home charger have not been mentioned by BMW, so I'm guessing that means it will be the lessees responsibility. I think they would have announced that it would be included in the lease price if that was their intention. To be fair, no other lease program currently includes insurance and the home charger like the MINI-E program did so I won't be surprised if we are told that those things are our responsibility. If you add the cost of the insurance and the home charger, I'm guessing that will add about $2,400 to the total cost, or about $100 per month. We all have the electrical lines running to our current chargers, so all we need are the new chargers hooked up. The AeroVironment chargers that the ActiveE will be using can be purchased for $1,000 retail. I'm sure we'll get a better price since BMW is buying about 800 of them and the installation will take all of 15 minutes. Personally I plan to do the installation myself if BMW wants us to pay for it. My personal electrician will do it for me for $100; permit and all, I already asked him. The insurance should only cost  an extra $500 or $600/year since we're already paying the liability insurance for the MINI-E.

In case why anyone was wondering why my picture is on the jumbo screen behind the car in the photo above, it's because they were playing a video advertisement for the ActiveE in which, for a brief second or two, they played a clip from one of the short films about the future of mobility that I was in, so I waited until that moment came up and quickly snapped the photo! 

Anyway, the ActiveE looks awesome and although I'm really going to miss #250, I think the amenities offered in the ActiveE will take the edge off missing this car. The active thermal management and ability to precondition the cabin and battery(warm or cool it while still plugged into the grid) should make the car much better for me to drive in the cold snowy winters here in the North East. Plus, having a backseat and trunk will be nice also.

I'll be posting more about the event and the ActiveE in a day or so on my BMW ActiveE blog (You know I had to make a successor to this blog, right?) so check it out if you want to know more about the BMW ActiveE. Maybe you even want to apply to lease one also? Details on how to apply to lease an ActiveE will be posted on my ActiveE blog as soon as they are announced which should be in a month or two.

MINI-E Dismantle, Battery Pack Replacement

It all started about a two months ago when I sent an email to Richard Steinberg, manager of electric vehicle operations and strategy for BMW North America. I asked him if BMW would replace the battery pack in MINI-E #250 because the original pack now has 53,000 miles and is beginning to degrade so my range is suffering. Richard gave me the usual company line about how the lithium ion batteries are expensive and if they did it for me then they'll have to do it for everybody and it will blow their whole bloody budget out the window.

First we disconnected the high voltage battery

Nonetheless, he said he would call Munich and see if it could be arraigned. A few weeks later Richard sent me an email and directed me to give him a call. I did just that and he prefaced the call by saying he wanted me to know he did all he could, but the BMW top brass wouldn't authorize it. He then told me all about a conference call he had with none other than BMW CEO Dr. Norbert Reithofer, Project i boss, Dr Ulrich Kranz as well as Hugo Vangeem and Marian Hawryluk who are electric vehicle project managers for BMW. Noticeably absent from the discussion was BMW North American president, Jim O'Donnell, but from what I'm told, they don't really let him make any decisions around there anymore anyway.  In any event after some discussion, the answer was "No new batteries for Tom".

I ordered 7 boxes, each with 5kWh

Those of you that know me, know that I don't particularly like being told no. In fact, I've been known to go to great lengths and at great expense to turn no's into yes. This wouldn't be any different. If BMW wouldn't give me a new pack, I'll just install one myself! So the quest began. 

We begin to take out the PEU

I quickly realized that it's not difficult to procure batteries for an EV as there are lot's of home conversion websites you can order anything you need from. It was a cinch to get the same exact cells used by BMW in the MINI-E. So last Saturday it was time to do the dirty work. Luckily, I have become friends with one of the area's leading EV mechanics and he offered his shop and services to do the swap. He really likes the MINI-E, so he looked forward to the opportunity to take one apart.  It didn't take us long to realize that much of the cars electronics had to be removed to replace the battery pack so we figured it would be better if we just did a complete dismantle. EV's are really simple and taking one apart and putting it back together is much easier than an internal combustion engine car, where only a experienced mechanic should even think about doing so.

Opening the PEU isn't allowed: oops!

Lot's of wires to reconnect!

  

EVERYTHING was removed!

Mind you, this isn't exactly allowed by BMW so there might be some splainin' to do once they realize I took part one of their precious prototypes. In the end, we did the swap, put everything back together and MINI-E #250 is running like new. If anyone want's some more photo's of the car when it was all taken apart, just ask!

PEU & motor assembly is all one piece

The suspension was in great shape

UPDATE: After a week of driving #250 with the new batteries, I can report the range is back to like it was when the car was brand new!
Mission accomplished!

UPDATE #2:  4/2/11: Just in case you didn't figure this out yet, it was an April Fools post and never actually happened. The car still has great range, although it may be starting to have slightly less now that it has been charged over 1,000 times and driven 53,000 miles. I plan on doing a range comparison post soon that will compare the cars range in different temperatures in the first year and second year I've had it.

If I had done what I said I did, BMW would probably be at my door today with a bus load of lawyers and repossess the car from me. Before getting the car, the trial lease participants all had to sign documents that we wouldn't alter the car in any way, we aren't even allowed to change a tire or put on window tint. Besides that, the battery pack is located behind the seats in the car so if we did change the pack, we wouldn't even have to open the hood, let alone dismantle the entire car!  I did take a photo of us removing a muffler, but figured if I posted that one, nobody would have been tricked! I hope you had fun with this!

Richard Steinberg Talks ActiveE at Geneva

Richard Steinberg, Manager of Electric Vehicle Operations and Strategy, presents the BMW ActiveE at the 2011 Geneva Motor Show. I have written quite a bit here on this car, as I will be driving one when I turn in the MINI-E later this year. BMW has just unveiled the production version of the ActiveE this week at the Geneva Auto Show and Richard was there present the car. (You know, you could have brought me along too Richard)

Munich, We Have a Problem!

 

That icon you see of a plug with an exclamation mark is what the car is supposed to show if you have the car plugged in and charging and you try to start it up. The car will not start while it's plugged in so you cannot make the mistake of driving off while it's still tethered to the EVSE wall charger attached to your home. That would be like driving away from a gas station while the gas nozzle is still pumping gas into your tank, something that does happen every once in a while and is extraordinarily dangerous and at best only results in a destroyed gas pump and a huge insurance claim. At worst a spark ignites the spilled gasoline and the whole place blows up, along with you and the people working there!

The problem I have is that this icon is coming on and the car isn't plugged in. This means for some reason the electronics thinks the car is plugged in and won't allow me to start it. Plus, if I try to charge it the red protection light on the EVSE lights up which means it has gone into protection mode because there has been a problem detected. So basically I can neither start nor charge it, which leaves me with little choice than to have her towed in to Morristown MINI for the "flying doctors" to take a look at it. 

This is the first time I have had a problem and the car needed to be towed in about a year as the car has proven to be very reliable considering it is a prototype test car and even this time I believe I had a hand in on it's demise. On Sunday night I was charging outside at my restaurant in the rain. We had quite a storm and it was really pouring. When I unplugged the car, I quickly put the cap on the receptacle on the car as to not allow rain to get it wet. What I failed to realize was the the plastic cap had filled with rain water and when I slid it on the charge receptacle it flooded the area with water. 

I drove home without a problem, but when I arrived and went to charge the car, I noticed how wet the plug area was and that there was actually a lot of water inside the plug receptacle. I dried it off as best I could and left the cap off overnight to let it air out. I didn't need to charge the car to get to work the next day so that wasn't going to be a problem. In the morning when I tried to start the car all I would get was the icon pictured above, meaning the car believed that it was plugged in which it wasn't. By now the area looked dry, but I guess inside was still wet so I let the car sit all day and took my Toyota to work. 

This morning I got up and tried to turn it on again but I still get the plug icon. I figure that if it hasn't dried out in roughly 36 hours then the water probably did some damage that needs to be fixed so I called for a tow and it's now off to Morristown MINI. I figure this was 50% my fault and 50% the cars fault. I definitely shouldn't have poured water on the receptacle, but the car should be able to handle screw ups like this, there are plenty of idiots like me out there that make mistakes. I'm sure they could design the plug area better to prevent problems like this from happening and that is exactly what the MINI-E program is about; finding design flaws like this and correcting them so future EV's that actually make it to the showroom don't have them. The more I think about it, the MINI-E program was a brilliant idea. BMW is getting more real world data and information with this program than they could ever get with internal testing, and they are getting us to pay a lease payment to participate! Genius! So I sent Rob Healey, technical coordinator for the MINI-E and Vincent Immerso, MINI-E service adviser for the MINI-E at Morristown MINI an email that detailed the issue and a heads up that they should expect the car shortly.

Within an hour I got a call from Vincent and then an email from Rob to let me know they will get right on it today and get me that car back as soon as possible. Vincent asked me if I needed a loaner car, which I declined for the time being, and Rob informed me that Shaun Gillilan, one of the flying doctors was already en-route to check out #250. That is some great service!

So it looks like there is no need to call and complain to Richard Steinberg, manager of BMW's North American electric vehicle operations or Dr. Norbert Reithofer, BMW CEO to make them aware of this problem. The rank and file have this under control.

UPDATE: The car was fixed the same day and I already picked it up. As I thought, the problem was caused by excessive water infiltrating the plug recepticle. My bad!

Front Page News Story on Me & #250!

Recently I was contacted by Mike Frassinelli, a reporter for the Star Ledger, New Jersey largest newspaper with a daily circulation of over 300,000. He wanted to do a story on me and the fact that I'm driving an electric car and also charging the car with electric that I generate myself from my home solar array. Being the media hound I am, I happily agreed and he came over to my house with a photographer about a week later. We talked for a while, took some pictures and I even let him drive the car for a while. Mike is a great guy and a good journalist, asking all the important questions and even following up my interview with a conversation with Richard Steinberg, head of BMW's electric car division here in the US.

A few days later I heard from Mike and he told me that it looked like the story would run in Sundays paper but that was tentative. Then on Saturday, the day before it was to run, he called me back again and said he had good news and bad news. The bad news was that it wasn't going to be in Sundays paper. He then went on to say the good news was that the paper liked the story so much, they want to put it on the front page and Sunday wasn't possible. Wow, front page ink! That was good news.

So on Tuesday, August 31st, I started getting text messages from friends early in the morning. . The first one came at 5:50am  and said "I'm staring at some goof-ball on the front page of my morning paper, you really out did yourself this time". That was how my day was to be. I had dozens of telephone calls, text messages and emails. Also just about everyone that came to the restaurant that day had the paper in hand and wanted to talk to the "celebrity" some even had a pen and joked about wanting my autograph.

It was a fun experience and hopefully I got some people thinking about electric cars and solar electric. The combination is really great and hopefully a model for future personal transportation.

You can read the entire article from this link.

Private tour of the MINI-E repair facility BMW headquarters in Woodcliff Lake, NJ

Rob Healey is on the far right with the "Flying Doctor" Crew    (Sorry guys, I don't remember everyone's name)

This morning I drove to BMW's North American headquarters to attend the kick off of the "MINI Takes The States 2010" tour across America. It is basically a MINI road rally that starts on both coasts and ends up in Denver, Colorado. I don't think too many people are actually driving the entire route(maybe I'm wrong) but lots of MINI owners are going to drive specific legs of the rally and today it started with about 100(or more) cars leaving the Woodcliff Lake, NJ headquarters and heading to the first stop in Philadelphia. Obviously, I wasn't going to try to participate in the road rally since Philadelphia is a little out of my single charge range, but I wanted to attend the event to offer my support as well as say hello to some of the people in the MINI-E program that I know.

I arrived at around 8:30am and there were already a lot of people there. They had a new MINI Countryman on display which was nice to see. All of the cars that were going to participate in the rally were lined up three cars wide and looked to be about 30 cars deep. Since I wasn't participating, they directed me to a parking lot close to the gathering of people and right in front of the main entrance. As I approached, I saw about 6 MINI-E's parked in a row so I parked right next to them. When I got out, I realized that these were corporate cars that were being used to give test drives to the people there today. I was surprised how good they all looked, like they were brand new, but I'll get to that later.

I signed in, got a bag full of MINI goodies and some food and the first person I saw was Nathalie Bauters, communication manager for MINI. Nathalie contacted me a few months back and arraigned for me to have press credentials for the NY Auto Show because there were journalists from Germany that wanted to interview me about my experiences with the MINI-E. I then ran into Richard Steinberg, the manager of BMW Electric Vehicle Operations & Strategy. Richard and I have communicated via email and by telephone, but never met in person. It was nice to say hello in person and talk for a while about the MINI-E and electric cars in general. 

I then took a walk around of the facility as they were letting people see some of the vehicle testing rooms. There was even a MINI-E in one of the rooms with a AC Propulsion motor and PEU out for display on the counter next to the car. There was nobody there to talk about the MINI-E though. When I walked outside, Richard had a reporter there that wanted to do a short video interview with me and talk about the MINI-E. He also introduced me to Rob Healey who is the technical coordinator for the MINI-E. After I did the interview, Rob asked me if I wanted to take a private tour of the MINI-E repair facility where the "flying doctors" work on all the MINI-E's from the East Coast. You know I wasn't going to turn down this opportunity.   

First, he took me to an area where there were no complete cars, just parts. Everything from MINI-E's were on shelves from seats to battery boxes. There was even a huge vice there where he explained they put battery modules in to squeeze them to test that they can withstand the pressure. We then went to a parking garage where there were about 6 MINI-E's that were in various states of dissemble.  One of them had the entire interior including the batteries removed. It looked strange to see the car in that state. Then there was another that was really torn apart. So much so that I wondered why they even kept it. Without me saying anything, Rob offered "That one is used for parts" so that made sense. Sorry there aren't any pictures of the "inner workings" of the facility, but I didn't even ask if I could take pictures there because it was obvious to me that wouldn't be allowed.

We then walked over to the area where all the MINI-E's come to be repaired. There are two lifts dedicated to the MINI-E's and one of them even had a car on the lift being worked on. As when I first saw the cars in the parking lot when I arrived, I noticed how new and clean the car looked, like it was brand new. When I asked Rob about it, he said that all the cars that were returned after the first year lease were completely reconditioned. They had new front and rear bumpers installed, repainted as needed, new side view mirror covers, completely cleaned and reconditioned and anything that looked worn at all was replaced. Also, all of them got the giant plug decals put on the doors which was optional for us when we first got the cars(I declined). So that explained why all the MINI-E's I saw outside looked brand new. Before they ship them to France, China, Japan & the UK to be re-leased they really reconditioned them well, so much so the cars looked brand new. Actually I'm a bit jealous, maybe they'll spruce #250 up a bit the next time she's in for service. ; )

So the event went better than I expected. I had really went to show support for the rally and say hi to some of the MINI-E people and I ended up getting a private tour of the inner workings of the MINI-E program. I'd like to thank Rob for taking the time to show me around.

MINI-E Program Extended, Will Transition To The ActiveE!

While the trial lease participants haven't yet been notified, it appears as though BMW has announced what we all expected, they are going to extend the MINI-E leases beyond the one year we all agreed to. How many of the existing participants agree to continue will depend greatly on how much the monthly payment will be. We are currently on the hook for $850.00 per month which does include all maintenance and collision and comprehensive insurance. I think most of us agreed to be in this program because we wanted to be part of something that we believe in, not because we think the car is worth an $850 per month lease payment. I know that's way I got involved. I wanted to offer my help and support in the hope that I could help prove that there is a market and demand for electric vehicles. That many people are sick of polluting the air we breath and paying outrageous amounts of money for gasoline while we send billions of dollars for imported oil to radical regimes that are no friend to the US.

I would definitely like to continue and extend my lease for another year, provided the second year lease payments are much lower than $850. I do think BMW will be reasonable here since it is in their best interest to keep many of the same participants involved. We all have installed and inspected wall chargers and that was probably the biggest hurdle for BMW in getting this program off the ground. (Follow this link to read Richard Steinberg's MINI-E program overview.) To now remove all the chargers and install them in new locations just makes no sense at all as the cost would be about $2,500 per participant. Removing that cost alone should knock $200.00 off the monthly payment. I'm going to go out and say I expect the lease offer for the second year to be $450 to $500 per month. I think if the cost is in that range most of the participants will re-up and be happy about it.

Finally, the real carrot in continuing the lease is that BMW is planning on offering a similar lease program for the ActiveE and it's scheduled to begin mid 2011 which is when our lease extensions will end and they are planning on offering us the option to transition into an ActiveE. Now that's what we all have been waiting to hear. The only question I have is "Why another trail lease?" How much data and research do they need. Other auto manufacturers have already announced that they will sell EV's and extended range plug in hybrids in the near future. BMW needs to get out there and announce that they will be selling these cars soon, not only testing them. I believe we will hear a similar announcement soon because I do believe they are committed to selling an EV soon, and that they are just waiting for the right time to announce it. For now we'll have to live in the "research" stage. I'm up for it, the only question is: can I transfer my license plates to the ActiveE?

Wall Charger Passes Inspection! FINALLY!

It's been over five months since my wall charger was installed in my home and it finally passed inspection by the Chester Township electrical inspector. I don't want to rehash the issues the inspector had with it and why he originally failed it, I have written about it more than a few times on this blog already so if any is really interested, just look up the previous posts on the subject. What matters most is that six months to the day that I took possession of the car I finally have an approved, working wall charger in my garage. Richard Steinberg of BMW will sleep well tonight once he reads this post.

New Wall Charger (sticker included)

A couple day's ago I had the electrical contractor that installed my wall charger come back and install a new wall charger. The first one worked fine, there were no functional issues at all. The problem was it didn't have a sticker on it that said it was tested as a complete unit and my local electrical inspector failed it when he did the inspection. This has turned out to be the single biggest problem MINI has had to deal with in the whole program. In fact, there are rumors that Richard Steinberg of BMW wakes up at night in cold sweats screaming "It has the sticker, it has the sticker" but this has not yet been confirmed.
There are somewhere between 450 and 500 Mini-E's on the road now and only a handful have had inspectors fail them over this issue. Basically, the problem comes from the fact that the wall charger and the cable that is attached to it were both tested and approved by Underwriters Labs, but they were tested separately and not a complete unit and some of the New Jersey inspectors would not accept it. None of the 100 or so chargers in New York failed and I think only 1 or 2 out of the 250 in California failed. The crazy thing is, the new charger is EXACTLY the same as the one they took away other than a shiny sticker on the cable. In fact, the "bad" charger that was taken away will go back to the factory where they will put the sticker on the cable and ship it out to be used again, but now it's safe because of the sticker. That's one powerful sticker, let me tell you. I'm now scheduled for re-inspection next week, lets hope the sticker does it's magic and we can finally put this charger issue to rest.

The devil is in the infrastructure

If you talk to most people about EV's and ask them why they think there aren't really any available to purchase (Unless you have $110,000 for a 2 two seat Tesla) chances are you'll get answers like "Battery technology isn't there yet" or "Because big oil has spent tens of millions of dollars to keep them from being made available" or even "EV's require such little maintenance that auto manufacturers won't make them because they'll lose so much money on repairs". Over the past few years I have had a lot of conversations with friends and acquaintances on the very subject so I know what people think. Personally, I think all of those reasons have some degree of legitimacy, but having now been part of the Mini E program I realize that perhaps the biggest hurdle is the infrastructure. Mini is struggling with different state and local electric codes and getting chargers installed for all of the participants has been more difficult than they anticipated. The auto manufacturers know this is going to be a big issue and require a lot of time and resources. This is going to add to the already high cost of making EV's because of the high cost of the batteries. Last week I posted about how New Jersey in particular has been a tough state for Mini to get the chargers approved for use in. It's such a new industry that I think some of the inspectors are being overly cautious when they inspect the chargers. In reality, the chargers are really not much more than a 220V outlet like you already have in your home for an electric range of clothes dryer. All the electronics that control the charging are built into the car. This is just one aspect of the infrastructure challenges the auto manufacturers will face as they develop and manufacturer EV's

Last week, at the California Air Resources Board's 2009 ZEV Technology Symposium, Richard Steinberg the Mini-E program manager made a presentation that detailed the program. Richard spent a lot of time on infrastructure issues, and one of the most telling lines of the presentation was "BMW/MINI is in the car business; BEV's placed us in the infrastructure business" Talk about leaving your comfort zone! The presentation talks about how quickly the program moved along. BMW only started talking about making a Mini E in the Spring of 2008. They engineered, built and shipped 500 electric Mini E's in less than 12 months! Clearly making the cars is not the big problem, it's going to be charging them. I do give BMW a lot of credit now, more than I initially did. Nobody else has put an EV on the road for real world testing since GM's Ev1 and Toyota's RAV4 EV, and both of those projects ended quickly without the manufacturers committing to continue EV production. BMW has created the Project i program with the sole purpose of building and selling EV's. The Mini E is the beginning, not the end, as was the case with the EV1 and the RAV4.

The good news is that BMW isn't going it alone. Just about all the major auto manufacturers are working on EV's and while thy won't be sharing secrets about the cars they plan to produce, they are working together on Infrastructure Standardization. Public charging stations will need to be able to be used by all EV's and have 220V and 110V capabilities. Issues like should the chargers have an attached cable or should the cable be portable and carried in the car? Recently it was announced that SAE standard J1772 plug would be used as the industry standard, but it doesn't seem like all the auto manufacturers are on board with that decision and discussions are ongoing.

As with all new technologies, there is a learning curve and a tremendous amount of time and investment needed in the very beginning. I'm sure BMW didn't think this would be a walk in the park, and I don't think they started Project i only to terminate the program before they bring EV's to the market for sale. I do hope they see the amount of interest the Mini E program is generating and realize most us in the trial lease program understand it will be a difficult process to develop the necessary infrastructure to make BEV's a viable option for the masses. Just like the manufacturers will have hurdles, the people that buy the first round of EV's available for sale in the next few years will have difficulty finding palaces to charge. That being said, I think there are enough people willing to deal with the inconveniences that will exist to provide the demand for these vehicles that the manufacturers need to have to continue to invest in them. Just about everyone I meet and talk to about the car asks me when will they be able to buy an EV. I'm certain there is a tremendous market for EV's out there just waiting for some manufacturer to mass produce them and offer them for sale (no more closed end leases!). The infrastructure problems will be sorted out in time and BMW will have a head start from the information gathered from the Mini E program. I just hope it doesn't take too long. After my short while driving this car I know I don't want to go back to an ICE, and I won't if there is an electric option when my time with the Mini E is up. I'll deal with the lack of available chargers, just sell me the car.