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

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The battery management control board (Figure G-10) has a chip set for each individual cell of the battery pack. The chip set controls the charge and discharge rates of each individual cell and monitors charge values to maintain balance of the cells in each individual module. Each of the modules has a master control chip that controls the balance of charge for each module to maintain balance in the overall battery pack. G.1.1.2 Lithium Polymer Electrical Power Supply Cost Impact For the lithium polymer high voltage traction battery (LIB) analysis, four (4) main subsubsystems were evaluated for cost: � Traction Battery Modules ( i.e., 6 - 30V modules) � Traction Battery Relays, Fuses, Disconnects, etc. � Traction Battery Sensing & Control Modules � Assembly of High Voltage Traction Battery Subsystem The costs for the sub-subsystems listed above can be found in Table G-2. To compensate for missing sub-subsystems not included with the evaluated service parts, the Ford Fusion HEV vehicle cost analysis results were utilized. These surrogate subsystem costs, which included costs for components such as the battery cooling module, energy control module, low voltage battery wire harness connections, and assembly of the battery to the vehicle were scaled primarily by battery capacity. The results of the scaling can be found in Table A-5, under System ID H.3. 136
Table G-2: 2010 Hyundai Avante Lithium Polymer High Voltage Traction Battery Cost Analysis Technology Level: Lithium Polymer High Voltage Traction Battery Vehicle Class: Small Size Passenger Vehicle, 2-4 Passengers Study Case#: N0501 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class) NEW TECHNOLOGY PACKAGE COST INFORMATION Lithium Polymer High Voltage Traction Battery - 2010 Hyundai Avante (180V, 5.3Ah, 0.954kWh, 6 modules, 30 volts/module) NEW TECHNOLOGY PACKAGE QUOTE PARAMETERS NEW TECHNOLOGY PACKAGE COST INFORMATION Lithium Polymer High Voltage Traction Battery - 2010 Hyundai Avante (180V, 5.3Ah, 0.954kWh, 6 modules, 30 volts/module) Net Component/ Assembly Cost Impact to OEM Total Packaging Cost (Component/ Assembly) Markup Total Markup Cost (Component/ Assembly) SG&A Profit ED&T-R&D End Item Scrap Manufacturing Total Manufacturing Cost Material Labor Burden (Component/ Assembly) Notes Scaling Factor (Default =1) Full, Modification, Differential, or Not Applicable Quote Level Q T Y / S u b s y s te m Part Number Name/Description C o m p o n e n t S u b a s s e m b ly A s s e m b ly S u b -S u b s y s t e m S u b s y s t e m I t e m 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - 140300 High Voltage Traction Battery Subsystem 1 00 Assembly of High Voltage Traction Battery Subsystem $ 5.67 $ 6.83 $ 12.99 $ 25.49 $ 0.21 $ 3.19 $ 2.59 $ 0.70 $ 32.17 $ - $ 32.17 A Hy Battery Assembly (Assembly of Modules into Final Battery Pack) 14 03 00 - N0502 01 1 Full 1 2010 Hyundai Avante h/w $ 5.67 $ 6.83 $ 12.99 $ 25.49 $ 0.21 $ 3.19 $ 2.59 $ 0.70 $ 32.17 $ - $ 32.17 2 01 Traction Battery Modules 1 $ 284.68 $ 179.28 $ 153.96 $ 617.92 $ 14.30 $ 44.88 $ 50.13 $ 24.49 $ 133.79 $ 0.75 $ 752.47 A Hy Cell Asm, Cell Module (8 cells/module) 14 03 01 - N0502 01 6 Full 1 2010 Hyundai Avante h/w $ 24.71 $ 9.68 $ 10.36 $ 44.75 $ 0.28 $ 4.06 $ 3.48 $ 1.16 $ 8.99 $ - $ 53.75 A.1 HV Battery, 30 volt modules 14 03 01 - N0502 02 6 2010 Hyundai Avante h/w $ 259.97 $ 169.60 $ 143.60 $ 573.17 $ 14.01 $ 40.82 $ 46.65 $ 23.32 $ 124.80 $ 0.75 $ 698.72 3 02 Traction Battery Relays, Fuses, Disconnects, etc. $ 59.22 $ 10.08 $ 10.86 $ 80.17 $ 0.52 $ 7.32 $ 6.35 $ 2.13 $ 16.32 $ - $ 96.49 B Battery Disconnect Module (BDM) 14 03 04 - N0502 03 1 Full 1 2010 Hyundai Avante h/w $ 53.61 $ 8.65 $ 6.08 $ 68.34 $ 0.43 $ 6.09 $ 5.24 $ 1.77 $ 13.53 $ - $ 81.87 B.1 Current Sensor, BDM 14 03 04 - N0502 04 1 Full 1 2010 Hyundai Avante h/w $ 0.40 $ 0.57 $ 1.16 $ 2.13 $ 0.02 $ 0.27 $ 0.22 $ 0.06 $ 0.57 $ - $ 2.69 B1.1. 1PCB Asm, Current Sensor 14 03 04 - N0502 05 1 Full 1 2010 Hyundai Avante h/w $ 5.22 $ 0.86 $ 3.62 $ 9.70 $ 0.07 $ 0.96 $ 0.89 $ 0.30 $ 2.23 $ - $ 11.92 5 04 Traction Battery Sensing & Control Modules 1 $ 164.89 $ 1.53 $ 3.62 $ 170.05 $ 0.88 $ 11.47 $ 10.55 $ 4.30 $ 27.20 $ - $ 197.25 A Battery Management Module (BMM) 14 03 04 - N0502 01 1 Full 1 2010 Hyundai Avante h/w $ 1.54 $ 0.72 $ 0.94 $ 3.19 $ 0.02 $ 0.36 $ 0.30 $ 0.09 $ 0.77 $ - $ 3.96 A.1 PCB Asm, Populated, BMM 14 03 04 - N0502 02 1 Full 1 2010 Hyundai Avante h/w $ 163.35 $ 0.82 $ 2.69 $ 166.85 $ 0.85 $ 11.11 $ 10.25 $ 4.22 $ 26.43 $ - $ 193.28 $ 514.46 $ 197.72 $ 181.44 $ 893.62 $ 15.90 $ 66.86 $ 69.62 $ 31.62 $ 209.49 $ 0.75 $ 1,078.37 No Complete Subsystem Quote (Yes/No) 137
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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
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The electric pump (Figure D-30 ) is
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technology adaptation (i.e., driven
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Item Table D-5: Net Incremental Dir
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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 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: Figure G-9: The Battery Pack Discon
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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