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

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Item Table D-10: Net Incremental Direct Manufacturing Cost of Ford Fusion HEV Electrical Power Supply System in Comparison to Ford Fusion Base Electrical Power Supply System 140000 Electrical Power Supply System Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D 1 01 Service Battery Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - 2 02 Generator/Alternator and Regulator Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - 3 03 High Voltage Traction Battery Subsystem $ 1,294.46 $ 170.68 $ 293.87 $ 1,759.01 $ 13.57 $ 119.20 $ 128.32 $ 61.13 $ 322.21 $ 3.44 $ 2,084.65 4 05 Voltage Converter / Inverter Subsystem $ 89.13 $ 20.84 $ 21.83 $ 131.80 $ 0.66 $ 8.56 $ 7.89 $ 3.27 $ 20.38 $ 0.13 $ 152.31 Item 140000 Electrical Power Supply System $ 1,383.60 $ 191.52 $ 315.70 $ 1,890.81 $ 14.22 $ 127.76 $ 136.21 $ 64.40 $ 342.59 $ 3.56 $ 2,236.96 Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D 1 01 Service Battery Subsystem $ 3.00 $ - $ - $ 3.00 $ 0.02 $ 0.20 $ 0.18 $ 0.08 $ 0.47 $ - $ 3.47 2 02 Generator/Alternator and Regulator Subsystem $ 29.50 $ 11.05 $ 27.95 $ 68.50 $ 0.33 $ 4.23 $ 3.90 $ 1.63 $ 10.08 $ 0.13 $ 78.70 3 03 High Voltage Traction Battery Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - 4 05 Voltage Converter / Inverter Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - Item SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description SYSTEM ROLL-UP SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description SYSTEM ROLL-UP 140000 Electrical Power Supply System $ 32.50 $ 11.05 $ 27.95 $ 71.50 $ 0.34 $ 4.42 $ 4.08 $ 1.70 $ 10.54 $ 0.13 $ 82.17 SYSTEM & SUBSYSTEM DESCRIPTION INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE System/Subsystem Description Material Labor Burden 1 01 Service Battery Subsystem $ (3.00) $ - $ - $ (3.00) $ (0.02) $ (0.20) $ (0.18) $ (0.08) $ (0.47) $ - $ (3.47) 2 02 Generator/Alternator and Regulator Subsystem $ (29.50) $ (11.05) $ (27.95) $ (68.50) $ (0.33) $ (4.23) $ (3.90) $ (1.63) $ (10.08) $ (0.13) $ (78.70) 3 03 High Voltage Traction Battery Subsystem $ 1,294.46 $ 170.68 $ 293.87 $ 1,759.01 $ 13.57 $ 119.20 $ 128.32 $ 61.13 $ 322.21 $ 3.44 $ 2,084.65 4 05 Voltage Converter / Inverter Subsystem $ 89.13 $ 20.84 $ 21.83 $ 131.80 $ 0.66 $ 8.56 $ 7.89 $ 3.27 $ 20.38 $ 0.13 $ 152.31 SYSTEM ROLL-UP Manufacturing Manufacturing Manufacturing NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion HEV, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (NiMH Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Total Manufacturing Cost (Component/ Assembly) BASE TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion SE, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft Total Manufacturing Cost (Component/ Assembly) Total Manufacturing Cost (Component/ Assembly) End Item Scrap Total Markup Cost (Component/ Assembly) Markup Total Markup Cost (Component/ SG&A Profit ED&T-R&D Assembly) Total Packaging Cost (Component/ Assembly) Total Packaging Cost (Component/ Assembly) Net Component/ Assembly Cost Impact to OEM Net Component/ Assembly Cost Impact to OEM $ 1,351.10 $ 180.47 $ 287.75 $ 1,819.31 $ 13.88 $ 123.34 $ 132.13 $ 62.70 $ 332.05 $ 3.44 $ 2,154.80 Markup Markup Total Markup Cost (Component/ Assembly) Total Packaging Cost (Component/ Assembly) Net Component/ Assembly Cost Impact to OEM 118
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Table D-11: Net Incremental Direct Manufacturing Cost of Ford Fusion HEV NiMH Battery SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description 140300 High Voltage Traction Battery Subsystem Manufacturing Material Labor 00 Assembly of High Voltage Traction Battery Subsystem $ 9.18 $ 27.42 $ 9.32 $ 45.92 $ 0.00 $ 0.03 $ 0.02 $ - $ 0.05 $ - $ 45.97 01 Traction Battery Assembly (Minus Electrical Modules) $ 921.59 $ 80.45 $ 230.86 $ 1,232.90 $ 11.19 $ 87.68 $ 99.69 $ 49.49 $ 248.05 $ 0.58 $ 1,481.54 02 Traction Battery (Relays, Fuses, Disconnects, etc) $ 117.75 $ 13.84 $ 9.61 $ 141.20 $ 0.71 $ 9.18 $ 8.48 $ 3.53 $ 21.90 $ 0.42 $ 163.52 03 Traction Battery Internal Wire Harnesses (Low & High Voltage) $ 21.96 $ 18.58 $ 9.65 $ 50.19 $ 0.25 $ 3.36 $ 3.06 $ 1.25 $ 7.92 $ 0.29 $ 58.40 04 Traction Battery Sensing & Control Modules $ 150.24 $ 4.03 $ 12.57 $ 166.84 $ 0.83 $ 10.84 $ 10.01 $ 4.17 $ 25.86 $ 0.51 $ 193.21 05 Traction Battery Cooling Module $ 45.82 $ 12.59 $ 13.42 $ 71.83 $ 0.36 $ 4.67 $ 4.31 $ 1.80 $ 11.13 $ 0.81 $ 83.78 75 Brackets, Housing, Covers $ 12.68 $ 5.40 $ 3.73 $ 21.81 $ 0.07 $ 1.35 $ 0.90 $ 0.22 $ 2.53 $ 0.70 $ 25.04 96 Brackets - Battery Interface to Body $ 3.55 $ 0.19 $ 1.19 $ 4.93 $ 0.03 $ 0.57 $ 0.44 $ 0.09 $ 1.13 $ 0.12 $ 6.19 97 Vehicle Wiring - Body Harness $ 11.69 $ 8.18 $ 3.51 $ 23.38 $ 0.12 $ 1.52 $ 1.40 $ 0.58 $ 3.62 $ - $ 27.00 SUBSYSTEM ROLL-UP $ 1,294.46 $ 170.68 NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion HEV, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (NiMH Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Total Markup Total Markup Manufacturing Cost Cost End Item (Component/ Burden (Component/ SG&A Profit ED&T-R&D Scrap Assembly) Assembly) $ 293.87 $ 1,759.01 $ 13.57 $ 119.20 $ 128.32 $ 61.13 $ 322.21 D.8Electrical Distribution and Electronic Control System and Cost Summary D.8.1 Electrical Distribution and Electronic Control Hardware Overview A special high voltage (HV) harness (Figure D-89: ) is required to handle current flow between the bussed electrical center (BEC) in the high voltage traction battery and the eCVT, DC-DC converter and AC compressor. The main circuits in the HV harness are the high voltage high current (HVHC), high voltage low current (HVLC) and high voltage inter-lock (HVI). The HVHC carries the current primarily for traction, generation, and storage. The HVLC is dedicated to the DC-DC converter and electric AC compressor. HVI is a series serial data circuit that is interrupted when an HV connector is loose. HV system shutdown will occur when an HVI event is detected. Three (3) distinct gauges and lengths of wire cable are used in the construction of the HV harness (Figure D-90). Total Packaging Net Component/ Cost Assembly Cost (Component/ Impact to OEM Assembly) $ 3.44 $ 2,084.65 119
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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
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capture additional quote details an
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Project Process Requirement Minimum
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information from both technology co
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and transit lead times. This equate
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study. These vehicles provided a ve
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Table D-1: Vehicle Specification Su
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D.1.2 Direct Manufacturing Cost Dif
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D.2 Engine System and Cost Summary
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D.3 Transmission System and Cost Su
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D.3.1.2 Gear Train Subsystem The po
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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 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: D.7.2 Electrical Power Supply Cost
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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