Light Duty Technology Cost Analysis, Power - US Environmental ...

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D.5.1.1.2 Brake Actuation Subsystem (Hybrid Fusion) The hybrid brake pedal and sensor assembly – brake (Figure D-51), by nature of its added function, is more complex than the base pedal and bracket assembly. The pedal bracket is a cast aluminum design containing traditional features (e.g., switch bracket mounting, pedal arm mounting) as well as new features required for brake-by-wire (e.g., rotary position sensor mounting, brake actuator solenoid mounting). The brake arm contains a modified clevis attachment, a travel stop, and a feature to drive the brake simulator and position sensor. The position sensor provides the driver commanded brake signal. The simulator provides the reactionary load to the driver simulating traditional brake system efforts as would be experienced in a mechanical system. The actuator provides the fail-safe function allowing the brake actuation system to revert back to a conventional mechanical system. The rotary position sensor, actuator, and simulator are shown in Figure D-52. Figure D-51: Brake Pedal Assembly (HEV Fusion) 1. Rotary Position Sensor 2. Actuator 3. Simulator Figure D-52: Additional Components Added to the Pedal & Bracket Assembly – Brake for a Brake-By-Wire System 94
D.5.1.2 <strong>Power</strong> Brake Subsystem D.5.1.2.1 Vacuum Booster (Base Fusion) The base vehicle utilizes a typical single diaphragm vacuum booster (Figure D-53). This booster consists of two (2) stamped shells front and rear. The forward face provides features for attaching the master cylinder and vacuum supply port. The rear shell mounts to the dash panel and is secured to the pedal housing on the opposing side of the dash panel. The booster pushrod is secured to pedal arm using a clevis pin and clip arrangement. The two (2) housings together enclose all of the booster components. Figure D-53: Base Brake Booster with Master Cylinder D.5.1.2.2 Vacuum Booster (HEV Fusion) A dual diaphragm active booster (Figure D-54) is utilized on the Fusion hybrid. The booster, in like manner to the base Fusion, uses a vacuum supply, master cylinder mounting, and pedal attachment features. The dual diaphragm design is typical of current automotive boosters. The electronic components that are added to the base vehicle brake booster include a position sensor, pressure sensor, and actuation solenoid (Reference Figure D-55 and Figure D-56). 95
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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
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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 and 100: D.4.2 Body System Cost Impact As sh
Page 101: Figure D-49: Key Components of Brak
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
Page 151 and 152: Costing Databases: the five (5) cor
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Surrogate part: a part similar in f
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