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

More documents

Recommendations

Info

The HV disconnect (Figure D-92) is a manual plug that interrupts the traction battery current path. It is useful for service personnel and emergency rescue teams when an HV system power down is required. A one hundred (100) amp fuse is housed inside the HV disconnect. Figure D-92: Battery Disconnect and Main Fuse D.8.2 Electrical Distribution and Electronic Control Cost Impact The electrical distribution and electronic control system contains both low and high voltage wiring and controls subsystems for the entire vehicle. For this analysis, when new HEV devices were added to the vehicle, which drove the need for additional wiring and/or controls, the cost of the wiring and/or controls was captured in the added device subsystem or system as opposed to grouping together in a wiring and controls system. The same methodology held true for the deletion of conventional devices. Therefore, the only direct manufacturing costs captured in the electrical distribution and electronic controls system are for the high voltage wire harness found in the Traction and High Voltage Power Distribution Subsystem. As shown in Table D-12, the net incremental, direct manufacturing cost impact of the adding the high voltage wire harness is $201.50. Additional details on the high voltage wire harness can be found in Section H, Appendix A. 122
Item Table D-12: Net Incremental Direct Manufacturing Cost of Ford Fusion HEV Electrical Distribution and Electronic Control System in Comparison to Ford Fusion Base Electrical Distribution and Electronic Control System SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description Material Labor 180000 Electrical Distribution and Electronic Control System 1 06 Traction And High Voltage Power Distribution Subsystem Item SYSTEM ROLL-UP SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description Manufacturing $ 127.00 $ 32.43 Material Labor 180000 Electrical Distribution and Electronic Control System 1 06 Traction And High Voltage Power Distribution Subsystem $ - Item SYSTEM ROLL-UP SYSTEM & SUBSYSTEM DESCRIPTION System/Subsystem Description 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) Burden Total Manufacturing Cost (Component/ Assembly) End Item Scrap Markup Total Markup Cost (Component/ SG&A Profit ED&T-R&D Assembly) BASE TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion SE, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft Total Packaging Cost (Component/ Assembly) $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ Material Labor 180000 Electrical Distribution and Electronic Control System 1 06 Traction And High Voltage Power Distribution Subsystem $ 127.00 $ 32.43 SYSTEM ROLL-UP $ 127.00 $ 32.43 Burden Total Manufacturing Cost (Component/ Assembly) End Item Scrap Markup SG&A Profit ED&T-R&D Total Markup Cost (Component/ Assembly) Total Packaging Cost (Component/ Assembly) $ - $ - $ - $ - $ - $ - $ - $ - $ - - $ - $ - $ - $ - $ - $ - $ - $ - $ - Manufacturing INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Burden Total Manufacturing Cost (Component/ Assembly) End Item Scrap Markup Total Markup Cost (Component/ SG&A Profit ED&T-R&D Assembly) Total Packaging Cost (Component/ Assembly) $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 Net Component/ Assembly Cost Impact to OEM $ $ 201.50 201.50 Net Component/ Assembly Cost Impact to OEM $ $ $ $ 123 Net Component/ Assembly Cost Impact to OEM - - 201.50 201.50
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 and 10:
A. Executive Summary Light-Duty Tec
Page 11 and 12:
Internal Combustion Engine (ICE) Ot
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
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 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: The HV connectors (Figure D-91) are
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
show all

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

Create successful ePaper yourself

Delete template?

Save as template?