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D.5 Brake System and <strong>Cost</strong> Summary Overview D.5.1 Brake Hardware Overview A brake-by-wire brake system replaces the conventional brake system found on the baseline Ford Fusion vehicle. In the brake-by-wire system the traditional brake pedal module is replaced with an actuation unit consisting of a pedal feel simulator and rotary position sensor to pick-up driver commands. Signals from the actuation sensor, along with various other sensors directly related to vehicle braking, are delivered electrically to an electronic control unit. Under normal braking conditions, the electric generator is “turned on,” converting vehicle braking energy into electric power which is stored in the high voltage traction battery. When the generator-provided deceleration is insufficient, the electronic control unit will activate the hydraulic control unit, and potentially the vacuum pump, which in turn builds up the necessary hydraulic pressure to operate the conventional wheel brakes. In addition to a unique pedal actuation mechanism and the added vacuum pump, an enhanced booster containing a vacuum control solenoid and position sensor were required. The hydraulic systems on both vehicles, from the master cylinders to the wheels, were considered cost neutral. It is acknowledged that the brake-by-wire system provided by Continental Automotive for the Fusion HEV is one of many available brake system options that may be used in an HEV or EV application. The system is perhaps more expensive than others in the market that are not considered true brake-by-wire. However, based on the stated advantages of the brake-by-wire (Figure D-49), and the growing industry trend toward increased electronic actuation and controls (e.g., drive-by-wire, electronic power steering), the team felt the technology configuration was a good choice for the application. More details regarding the difference between the two (2) brake systems and associated costs are captured in the following discussion. 92
Figure D-49: Key Components of Brake-By-Wire System (Source of information contained in this figure - Continental Automotive Web page “Regenerative Brake System” http://www.conti-online.com/generator/www/de/en/continental/automotive/themes/passenger_cars/ D.5.1.1 Brake Actuation Subsystem chassis_safety/ebs/extended_functions/brems_systeme_en.html D.5.1.1.1 Brake Actuation Subsystem (Base Fusion) The pedal and bracket assembly – brake (Figure D-50) on the base vehicle consists of a conventional multi-piece stamped steel bracket, stamped pedal arm, pedal plate, and pedal pivot hub. A pivot shaft secures the pedal arm assembly to the bracket. There is an added switch bracket and flag for mounting and actuating the brake on/off switch, respectively. The pedal arm has a stamped clevis hole which provides the mechanical connection to the brake booster. Figure D-50: Brake Pedal Assembly (Base Fusion) 93
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Light Duty Technology Cost Analysis
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Contents A. EXECUTIVE SUMMARY......
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Figures FIGURE A-1: POWER-SPLIT SYS
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FIGURE D-90: HIGH VOLTAGE HARNESS C
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A. Executive Summary Light-Duty Tec
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Internal Combustion Engine (ICE) Ot
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Table A-1: Net Incremental, Direct
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Table A-2: P2 Vehicle Segment Mass
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Table A-4 and Table A-5 provide add
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B. Introduction B.1 Objectives The
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B.2 Process Flow and Key Supporting
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Step 6: Phase 2 (component/assembly
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Table B-1: Summary of Universal Cos
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C. Costing Methodology C.1 Teardown
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An example of a custom complex mode
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For a component which has a serial
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C.2 Cost Model Overview The cost pa
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Lastly, the “Net Incremental Dire
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considered. For example, forged com
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part, while “buy” indicates an
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C.4.3.3 Contributors to Labor Rate
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sided part, CNC turning, auto bar f
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The Primary Process Equipment secti
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For this cost analysis study, four
Page 49 and 50: very difficult to predict and are v
Page 51 and 52: C.4.6.2 Types of Packaging and Sele
Page 53 and 54: capture additional quote details an
Page 55 and 56: Project Process Requirement Minimum
Page 57 and 58: information from both technology co
Page 59 and 60: and transit lead times. This equate
Page 61 and 62: study. These vehicles provided a ve
Page 63 and 64: Table D-1: Vehicle Specification Su
Page 65 and 66: D.1.2 Direct Manufacturing Cost Dif
Page 67 and 68: D.2 Engine System and Cost Summary
Page 69 and 70: D.3 Transmission System and Cost Su
Page 71 and 72: D.3.1.2 Gear Train Subsystem The po
Page 73 and 74: The generator stator (Figure D-10)
Page 75 and 76: The traction motor stator (Figure D
Page 77 and 78: The generator control unit (Figure
Page 79 and 80: The CVT control circuit board (Figu
Page 81 and 82: The speed sensor for the traction m
Page 83 and 84: D.3.1.4 Transmission Cooling System
Page 85 and 86: The electric pump (Figure D-30 ) is
Page 87 and 88: technology adaptation (i.e., driven
Page 89 and 90: Item Table D-5: Net Incremental Dir
Page 91 and 92: Item Table D-6: eCVT Motor and Cont
Page 93 and 94: Figure D-34: HEV Fusion, Under Engi
Page 95 and 96: ase to the body. The seat cover is
Page 97 and 98: Figure D-43: Expanded Polypropylene
Page 99: D.4.2 Body System Cost Impact As sh
Page 103 and 104: D.5.1.2 Power Brake Subsystem D.5.1
Page 105 and 106: Figure D-56: Actuator Solenoid and
Page 107 and 108: Table D-8: Net Incremental Direct M
Page 109 and 110: D.6.1.2 Refrigeration/Air Condition
Page 111 and 112: The two (2) main housings and both
Page 113 and 114: Figure D-67: Main Housing and Elect
Page 115 and 116: The rotor shaft is mounted to an in
Page 117 and 118: D.7 Electrical Power Supply System
Page 119 and 120: Circuit connections between packs a
Page 121 and 122: The traction battery assembly is mo
Page 123 and 124: During dormant periods the BEC (Fig
Page 125 and 126: D.7.2 Electrical Power Supply Cost
Page 127 and 128: Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Page 129 and 130: The HV connectors (Figure D-91) are
Page 131 and 132: Item Table D-12: Net Incremental Di
Page 133 and 134: F. Power-Split Scaling Cost Analysi
Page 135 and 136: vehicle class was determined. Also
Page 137 and 138: G. 2010 Hyundai Avante Lithium Poly
Page 139 and 140: Figure G-3: Li Ion Battery Modules
Page 141 and 142: Figure G-6: Cell Covers in Module,
Page 143 and 144: Figure G-9: The Battery Pack Discon
Page 145 and 146: Table G-2: 2010 Hyundai Avante Lith
Page 147 and 148: Table H-1: Baseline Powertrain and
Page 149 and 150: Table H-2: Primary Component Sizing
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Costing Databases: the five (5) cor
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Surrogate part: a part similar in f
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