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

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Figure D-54: Dual Diaphragm Booster The additional components increases sealing requirements for the front cover since they pass through their own individual ports. A position sensor provides feedback on stroke/travel of the diaphragm. It is pressed into the front cover and retained with a plastic adapter. This sensor is spring loaded and requires no direct attachment to the diaphragm. A pressure sensor used to determine if the vacuum pump needs to be run during engine off modes is also pressed in place with a snap fit. Figure D-55: Diaphragm Position & Pressure Sensor The solenoid is added to actuate the input rod to the master cylinder, and requires an extra jumper harness. It provides connection from inside the booster to the engine harness through the cover. The solenoid is set directly over the input shaft to the master cylinder and integrated into the center valve design of a typical conventional booster. 96
Figure D-56: Actuator Solenoid and Additional Harness The last unique feature on the hybrid Fusion’s booster is a slotted clevis (Figure D-57). The slotted clevis eliminates the traditional mechanical link between the brake pedal arm and booster under normal braking conditions. During certain system failure modes the clevis pin in the brake arm will travel to the bottom of the clevis slot, permitting mechanical actuation of the brake system similar to a conventional brake system. Figure D-57: Slotted Clevis with Over Molded Slide D.5.1.2.3 Vacuum Pump and Motor The Fusion hybrid utilizes an electric vacuum pump (Figure D-58) to maintain vacuum pressure while the gasoline engine is not running. The pump allows the vehicle to sustain sufficient vacuum pressure to the brake booster. It is secured to the lower left side of the engine with an aluminum bracket. A sensor on the brake booster indicates whether or not the pump should be activated. Air is drawn into the pump through the end opposite the pump’s case. The pump uses a combination of reed valves on each end to build vacuum pressure via a dual chamber, dual piston design. The vacuum pump has a singular outlet which is split into two (2) separate lines running directly to the intake manifold. The majority of the case components are die cast aluminum parts that bolt together. 97
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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
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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 and 102: Figure D-49: Key Components of Brak
Page 103: D.5.1.2 Power Brake Subsystem D.5.1
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
Page 153: Surrogate part: a part similar in f
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