- Volvo’s EX60 uses electric “shark-fin” door handles but addresses safety concerns about power loss.
- The interior handle combines electronic opening with a mechanical backup in the same pull motion.
- Redundant power systems help ensure doors unlock even if the 12-volt battery is dead after a crash.
Regulators and consumers have grown increasingly skeptical of power door handles, as safety concerns have mounted. Yet Volvo, a company known for its relentless focus on safety advancements, is still fitting its most important new electric vehicle with shark-fin-shaped electronic door handles.
The reason, according to one executive, is simple: design them right and there shouldn’t be a safety issue.
“We’re launching with our shark fin door handles in the middle of an ongoing debate on door handle safety, which is a kind of a bit of a misguided point, because it’s about system safety, not our door handles, really,” Anders Bell, Volvo’s chief technology officer, told reporters at the EX60 crossover’s launch event on Wednesday.
The EX60 uses a “shark fin” door handle, with a little rubber button on the back side actuating the door mechanism. I still prefer a mechanical handle, but at least these can still be opened in one fluid motion, unlike the setup on the Tesla Cybertruck.
Photo by: Volvo
“The reason I say it’s a bit misguided is because it’s not really about door handles, it’s about redundancy. It’s all about being able to quickly exit the car in a reliable way if you’re in the crash, but also, if you’re unconscious, that somebody else can get you out,” he said.
Regulatory scrutiny on power door handles is all based on the extraction problem. Electronic door handles require power to function, unlike traditional manual latches. When a vehicle crashes or loses power, the handles often can’t function. In the vast majority of cars, there are mechanical releases to address that issue. But the mere presence of a backup isn’t enough if you don’t know how to use it.
One illustrative if horrible example involved a 2007 Chevrolet Corvette, which featured power door releases inside. In 2015, a 72-year-old man and his dog were in the vehicle when its 12-volt battery died. The Corvette had a mechanical backup handle, but presumably unaware of the floor-mounted release, he tried in vain to get out. On a hot sunny day in Texas, his time ran out. The man and his dog died in the incident.
Volkswagen had to stop selling the ID.4 for the better part of 2024, after issues with its door handles prompted a worldwide scramble to fix it.
They were not the last victims of poorly designed power door handles. The family of a Tesla Cybertruck owner who died in a fiery crash has alleged in a lawsuit that he was unable to exit the vehicle due to the difficulty of locating the hidden mechanical door release. But even the designs that include intuitive mechanical releases on the inside may suffer from a separate, but also potentially fatal, flaw.
While a passenger may theoretically be able to get out of a Tesla Model S with a dead battery, if they are incapacitated, there is no easy way for first responders or bystanders to open the doors from the outside, as another fiery, fatal incident demonstrated. The same issue afflicts the Xiaomi SU7. An owner in China got trapped inside a burning SU7 and died, kicking off the first big regulatory push to ban dangerous door handle designs.
The Xiaomi SU7 was one of the hottest EV launches of all time. But in one incident, after a crash incapacitated the driver and started a fire, bystanders say they were unable to save the driver’s life because they couldn’t open the doors. The incident prompted regulators to push for safer designs.
So you can understand why some people are concerned. The U.S. National Highway Traffic Safety Administration (NHTSA) is currently investigating whether Tesla’s door handles have inherent safety issuesand one member of Congress has proposed a federal law mandating that door handles be designed to opened quickly and intuitively in emergencies.
Volvo isn’t expecting consumers to have any problems with its design, though, because it has solved the biggest issue with electronic door handles. Both the shark-fin style exterior doorhandles —with little buttons on the inner side that pop the door—and the interior power-operated door latch should function even if a crash destroys the car’s battery, Bell claims.
The solution for the interior is obvious, and has been adopted by a few other EVs, including the original Model S. In the EX60, Bell says, the mechanical interior door release and the electronic release are activated by the same handle.
The electronic door release is integrated into the armrest, ahead of the window controls. But the mechanical release is mounted to the same handle. Pull gently, and the electronics pop the door. Pull hard and the cable triggers a mechanical release.
Photo by: Volvo
“So you pull a little, you open them electrically. You pull more, you open mechanically,” he said. This way, when you frantically panic and yank on the door handle, you’ll get exactly what you want. It’s no wonder that many automakers are using similar designs. But the trickier issue is having a safe way to open the car from the outside in the case of an accident. Volvos, Bell notes, already unlock their doors automatically when crashed. And when someone pulls the handle, it’ll open, even with a completely dead or destroyed 12-volt battery.
“We have redundancy for that, too,” Bell says. In an EV, low-voltage power is typically supplied by a component called a DC-to-DC converter. It takes high-voltage power from the main battery pack, steps it down, and uses it to charge the 12-volt battery and/or run electronics directly.
But the EX60 doesn’t have one DC-to-DC converter, it has two, with one on each side. The systems are interlinked, so as long as one converter is functioning, the car can get 12-volt power for its emergency systems. Because they are each located inboard and under the rear seats, it would take an extraordinarily disastrous crash to knock both out.
“What happens if you knock both out? Well, frankly speaking, at that point you can’t [tell] what kind of car it was. It’s a very protected area,” he said.
Contact the author: [email protected]
Why where Volvo electric door handles freezing up?
Table of Contents
- 1. Why where Volvo electric door handles freezing up?
- 2. the Clever Way Volvo Solved The Biggest Issue With electric Door Handles
- 3. The Problem: Why Were Handles Freezing Up?
- 4. Volvo’s Initial Response & The Recall
- 5. The Innovative Solution: A Redesigned Cable Routing System
- 6. Benefits of the Redesign
- 7. What Volvo owners Need to Know
- 8. Beyond the Fix: Volvo’s Commitment to Quality
the Clever Way Volvo Solved The Biggest Issue With electric Door Handles
Electric door handles – a hallmark of modern car design, promising sleek aesthetics and a futuristic feel. But for early adopters of vehicles featuring this technology, notably with Volvo’s recent models, a frustrating problem quickly emerged: handles failing in cold weather. It wasn’t a matter of the motors freezing, but a surprisingly simple issue with the cable mechanisms. Volvo’s solution, tho, was anything but simple, and demonstrates a remarkable commitment to customer satisfaction and engineering ingenuity.
The Problem: Why Were Handles Freezing Up?
The issue wasn’t the electric motors themselves, which are generally well-protected. Instead, the problem resided within the cable system connecting the interior door handle to the exterior latch. Water ingress, combined with sub-zero temperatures, caused the cables to freeze and become stiff, preventing the handles from operating smoothly – or at all.
This was particularly prevalent in regions experiencing harsh winters, and affected models like the XC60 Recharge, C40 Recharge, and S90 Recharge. Owners reported being stranded, requiring roadside assistance to manually unlock doors. The frustration was compounded by the fact that the cars were otherwise functioning perfectly. Early discussions on Volvo owner forums highlighted the inconvenience and safety concerns, quickly escalating the issue’s visibility.
Volvo’s Initial Response & The Recall
Volvo quickly acknowledged the problem and initiated a voluntary recall in late 2023 and throughout 2024, impacting hundreds of thousands of vehicles globally. However, the initial fix – applying a water-repellent coating to the cables – proved to be a temporary solution. While it offered some improvement, the problem persisted for many owners, especially after repeated exposure to winter conditions.
This led Volvo to pursue a more permanent and elegant solution.They realized a coating wasn’t enough; the entire system needed a redesign.
The Innovative Solution: A Redesigned Cable Routing System
Volvo’s engineers didn’t just patch the existing system; they fundamentally re-engineered the door handle mechanism.The core of the fix involved:
* Relocating the Cables: The cable routing was completely altered to move the vulnerable sections inside the heated cabin habitat. This drastically reduces the cables’ exposure to freezing temperatures and moisture.
* Improved Cable Insulation: New, more robust insulation was applied to the cables, providing an additional layer of protection against water ingress and ice formation.
* Drainage Enhancements: Improved drainage pathways were incorporated into the door structure to prevent water from accumulating around the cable mechanisms in the first place.
* Modified Handle Linkage: Subtle changes were made to the linkage connecting the handle to the latch,reducing friction and ensuring smoother operation even in colder temperatures.
This wasn’t a speedy fix. It required significant retooling of production lines and a ample investment in engineering resources. But Volvo prioritized a lasting solution over a temporary band-aid.
Benefits of the Redesign
The redesigned system offers several key benefits:
* Reliability in Cold Weather: The primary benefit is, of course, consistent and reliable operation of the electric door handles, even in extremely cold temperatures.
* Reduced Risk of Stranding: Eliminates the risk of being locked out of your vehicle due to frozen handles.
* Enhanced Customer Satisfaction: Addresses a major pain point for owners of affected Volvo models,restoring confidence in the brand’s quality and reliability.
* Long-Term Durability: The improved design is expected to be considerably more durable and resistant to the elements, reducing the likelihood of future issues.
What Volvo owners Need to Know
If your Volvo is part of the recall, it’s crucial to schedule the repair as soon as possible. Volvo dealerships are equipped to perform the redesigned cable routing and insulation upgrade. The process typically takes several hours, as it involves disassembling parts of the door.
Checking Recall Status: owners can check if their vehicle is affected by visiting the Volvo Cars website and entering their Vehicle Identification Number (VIN).
Beyond the Fix: Volvo’s Commitment to Quality
The electric door handle saga highlights Volvo’s commitment to addressing issues proactively and investing in long-term solutions. While the initial problem was frustrating for owners, the company’s response demonstrates a dedication to quality and customer satisfaction that sets it apart. This willingness to thoroughly re-engineer a system, rather than simply applying a temporary fix, speaks volumes about Volvo’s engineering philosophy and its focus on building vehicles that are both innovative and reliable. The incident serves as a valuable case study in automotive engineering and the importance of anticipating potential issues in real-world conditions.
