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� All manufacturing process and operations are based on standard/mainstream industrial practices. � All material, labor and manufacturing overhead costs are based on 2009/2010 economics. � All OEM mark-up will be applied using indirect cost (IC) multipliers. These are not within the scope of this analysis, but should be separately determined and applied to the results of this analysis to obtain the total (direct + indirect) manufacturing costs. Since the manufacturing costs presented in this report are based on current automotive and/or surrogate industry manufacturing operations and processes, it is acknowledged that a reduction to the costs presented is very likely based on both product and manufacturing learning. Projected technology cost reductions, as a result of learning, are not covered as part of this analysis. In addition, no attempt was made in the analyses to forecast the impact of material, labor, and/or manufacturing overhead rate changes. However, a sensitivity analysis has been added to predict the impact of changes in any of the costs. The report begins by providing an overview of the costing methodology used to conduct the various analyses contained within this report. Additional details on the costing methodology can be found in EPA published report EPA-420-R-09-020 “Light-Duty Technology Cost Analysis Pilot Study” (http://www.epa.gov/OMS/climate/420r09020. pdf). Following the costing methodology overview, the incremental cost impact of adding power-split hybrid electric vehicle (HEV) technology to a conventional baseline vehicle is discussed. The analysis is based on the detail teardown and costing of the hardware difference, applicable to the adaptation of power-split HEV technology found between the 2010 Ford Fusion HEV and an equivalent equipped 2010 Ford Fusion conventional powertrain vehicle. A description of the hardware required to create the power-split technology is highlighted and details on the costs are captured at various levels. Figure A-1 is a simple illustration of the power-split technology analyzed highlighting key components within the power-split system boundary as well as those systems which impacted the net incremental direct manufacturing cost. Components within other vehicle systems (e.g., suspension, driveline, electrical feature) were also modified, however their differences were assessed to have no significant cost impact. 2
Internal Combustion Engine (ICE) Other Systems with a Net Incremental Direct Manufactuing Cost Impact Body System Brake System Climate Control System Power-split System Boundary Electronic Continuous Variable Transmission Power Electonics, Motor, and Gear Cooling Subsystem Flywheel Main Transfer Gear Ass'y High Voltage Distribution Planetary Set Relays, Fuses, Disconnect Generator Differential Traction Motor Power Electonics/Inverter & Controls High Voltage Traction Battery Control Electronics, Sensors, Switches Battery Cells/Modules Battery Cooling Module Figure A-1: Power-split System Diagram Illustrating Basic Concept 3
Page 1 and 2: Light Duty Technology Cost Analysis
Page 3 and 4: Contents A. EXECUTIVE SUMMARY......
Page 5 and 6: Figures FIGURE A-1: POWER-SPLIT SYS
Page 7 and 8: FIGURE D-90: HIGH VOLTAGE HARNESS C
Page 9: A. Executive Summary Light-Duty Tec
Page 13 and 14: Table A-1: Net Incremental, Direct
Page 15 and 16: Table A-2: P2 Vehicle Segment Mass
Page 17 and 18: Table A-4 and Table A-5 provide add
Page 19 and 20: B. Introduction B.1 Objectives The
Page 21 and 22: B.2 Process Flow and Key Supporting
Page 23 and 24: Step 6: Phase 2 (component/assembly
Page 25 and 26: Table B-1: Summary of Universal Cos
Page 27 and 28: C. Costing Methodology C.1 Teardown
Page 29 and 30: An example of a custom complex mode
Page 31 and 32: For a component which has a serial
Page 33 and 34: C.2 Cost Model Overview The cost pa
Page 35 and 36: Lastly, the “Net Incremental Dire
Page 37 and 38: considered. For example, forged com
Page 39 and 40: part, while “buy” indicates an
Page 41 and 42: C.4.3.3 Contributors to Labor Rate
Page 43 and 44: sided part, CNC turning, auto bar f
Page 45 and 46: The Primary Process Equipment secti
Page 47 and 48: 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
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The electric pump (Figure D-30 ) is
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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
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ase to the body. The seat cover is
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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 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
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Figure D-67: Main Housing and Elect
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The rotor shaft is mounted to an in
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D.7 Electrical Power Supply System
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Circuit connections between packs a
Page 121 and 122:
The traction battery assembly is mo
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During dormant periods the BEC (Fig
Page 125 and 126:
D.7.2 Electrical Power Supply Cost
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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
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vehicle class was determined. Also
Page 137 and 138:
G. 2010 Hyundai Avante Lithium Poly
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Figure G-3: Li Ion Battery Modules
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Figure G-6: Cell Covers in Module,
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Figure G-9: The Battery Pack Discon
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Table G-2: 2010 Hyundai Avante Lith
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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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