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

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Table F-2: Primary Component Sizing for a Range of Power-Split Hybrid Electric Vehicles Classes Class 1 2 3 4 Vehicle Classification New Technology Configuration: Power-split HEV, ICE, Electric Motor, Electric Generator, eCVT, and NiMH Battery Vehicle Class Passenger Description Capacity Subcompact Passenger Vehicle Compact/Small Size Passenger Vehicle Mid/Large Size Passenger Vehicle (Ford Fusion Cost Analysis) Mini Van/Large Size Passenger Vehicle Passenger (2-4) Passenger (2-5) Passenger (4-6) Passenger (6-8) System Power Max (ICE+E-Motors) "kW" System Power Reduction "kW" F.3 System Scaling Overview ICE Power Max Engine Config. ICE: System Power Ratio Traction Motor Power Max "kW" Traction Motor: System Power Ratio Generator Motor Power Max "kW" Generator Motor: System Power Ratio Nominal Pack Voltage Nominal Pack Amp Hours Nominal Battery Pack Supply Energy Operation Time Battery Pack Size Relative to Baseline "V" "Ah" kWhr Hours Minutes Percent Addition/ Reduction In Battery Cells Required Quantity of D-Cell Batteries (Ave. 1.35V) 75.5 0.79 61.7 I3 0.82 32.22 0.43 16.11 0.21 148 5.5 0.81 0.0168 1.0083 0.54 94 91.1 0.79 74.4 I4-DS 0.82 38.87 0.43 19.43 0.21 178 5.5 0.98 0.0168 1.0083 0.65 72 140.6 0.79 114.8 I4 0.82 60 0.43 30 0.21 275 5.5 1.51 0.0168 1.0083 NA NA 137.4 0.79 112.2 V6-DS 0.82 58.65 0.43 29.32 0.21 269 5.5 1.48 0.0168 1.0083 0.98 5 In Table A-1, the net incremental direct manufacturing costs to add power-split HEV technology to a range of vehicle segments are presented. The mid- to large-size passenger vehicle costs are represented by the Ford Fusion cost analysis (case study #0502). The incremental costs for the subcompact size, compact-small size, and minivanlarge size passenger vehicle segments, are calculated using the scaling methodology discussed in sections F.1 and F.2. In the power-split scaling analysis, the application of scaling factors range in complexity from system to system. In simpler cases, a scaling factor was applied to the total component cost. In more complex cases, similar to the electrical AC compressor discussed above, the scaling factor was only applied to the relevant components within the assembly, and/or the scaling factor was only applied against selected cost elements (i.e. material, labor, manufacturing overhead). 128
G. 2010 Hyundai Avante Lithium Polymer Battery Cost Anaylsis In addition to evaluating the NiMH battery found in the Ford Fusion, a lithium polymer battery packaged in the 2010 Hyundai Avante and sold domestically in South Korea, was also evaluated (Figure G-1). The analysis provided a good comparison of the manufacturing costs between the NiMH and lithium polymer battery, as well as some of the physical attributes of the batteries, namely size and weight. In addition the results from the lithium polymer battery analysis were used in the P2 HEV cost analysis. The EPA team felt the lithium polymer, high voltage battery was a better long-term solution (versus the NiMH battery) for P2 HEV applications. The Ford Fusion NiMH battery is a larger capacity battery (275 V, 5.5Ah, 1.51kWh, 26 modules approximately, 10.6 volts/module) in comparison to the Hyundai Avante lithium polymer battery (180V, 5.3Ah, 0.954kWh, 6 modules, 30 volts/module). Not accounting for the state of charge (SOC) swing differences between the NiMH and lithium polymer batteries, a size and weight comparison was made by scaling the lithium polymer battery pack up to an equivalent NiMH size by adding three (3) additional modules (30 Volts/Module x 9 = 270 Volts). Table G-1 below provides the comparison results. Table G-1: NiMH versus Lithium Polymer High Voltage Battery Attribute Comparison NiMH High Voltage Traction Battery Lithium Polymer High Voltage Traction Battery Cost/kWh $1,378 $1,270 Percent Weight Difference Baseline 46% Reduction Over NiMH Percent Volume Difference Baseline 20% Reduction Over NiMH G.1.1.1 Lithium Polymer High Voltage Traction Battery Subsystem Overview The High Voltage Traction Battery (as delivered) is comprised of six (6) modules connected in series (Figure G-2). Each module contains eight (8) lithium ion polymer battery (LIB) pouch-cells that are connected in series (Figure G-3). The battery packs have molded features to facilitate assembly, promote airflow, and fixture temperature sensors. 129
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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)
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The traction motor stator (Figure D
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The generator control unit (Figure
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The CVT control circuit board (Figu
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The speed sensor for the traction m
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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 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: vehicle class was determined. Also
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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