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

D.7.2 Electrical Power Supply Cost Impact
As shown in Table D-10, the high voltage traction battery subsystem is by far the largest
contributor of cost to the Fusion HEV Electrical Power Supply System – accountable for
$2,084.67 in direct manufacturing costs. This accounts for approximately 61% of the
overall direct manufacturing costs of adding power-split hybrid technology to the baseline
vehicle. The DC-DC converter adds another $152.31 to the HEV direct manufacturing
costs. However, this cost is partially offset by the deletion of the $78.70 conventional
alternator.
The cost make-up of the NiMH traction battery, broken out by major sub-subsystems and
by cost element groups, is shown in Figure D-88. The largest cost contributor is the
Traction Battery Assembly (71.1%) which includes the cost of the 26 sub-modules and
the mounting brackets which secure them together. Additional cost breakdown details
for each of these sub-subsystems can be found in Table D-11 and in Section H, Appendix
A.
Traction Battery Sensing &
Control Modules
$193.21, (9.3%)
Traction Battery Cooling
Module
$83.78, (4.0%)
Brackets, Housing, Covers
$25.04, (1.2%)
Brackets - Battery Interface to
Body
$6.19, (0.3%)
Traction Battery Internal Wire
Harnesses (Low & High
Voltage)
$58.40, (2.8%) Vehicle Wiring - Body Harness
`
$27.00, (1.3%)
Traction Battery (Relays,
Fuses, Disconnects, etc)
$163.52, (7.8%) Assembly of High Voltage
Traction Battery Subsystem
$45.97, (2.2%)
Manufacturing Overhead
$293.87, (14.1%)
Labor
$170.68, (8.2%)
Mark-up
$322.21, (15.5%)
Packaging
$3.44, (0.2%)
Traction Battery Assembly
(Minus Electrical Modules)
$1,481.54, (71.1%)
Material
$1,294.46, (62.1%)
Figure D-88: Ford Fusion 275 Volt, 5.5Ah, NiMH Battery Sub-Subsystem Cost and
Major Cost Element Breakdowns
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