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

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Table A-3: Net Incremental, Direct Manufacturing Costs for Adding P2 HEV Technology to a Range of Vehicle Segments System ID System Description Sub-Compact Vehicle Segment Passenger 2-4 Calculated Incremental Manufacturing Cost - P2 HEV Technology Small/ Compact Vehicle Segment Passenger 2-5 Vehicle Example Ford Fiesta Ford Focus Large Size/Vehicle Segment Passenger 4-6 Ford Fusion and Taurus Mini Van Vehicle Segment Passenger 6-8 Small Truck 010000-A Internal Combustion Engine (ICE) System $ - $ $ $ $ $ Engine technology - selection and - downsizing outsid - e of analysis - scope 010000-B Integrated Electric Motor/Generator and Clutch Assembly System Large Truck Ford Flex Ford Ranger Ford Explorer $ 1,038.80 $ 1,091.51 $ 1,269.82 $ 1,190.83 $ 1,159.44 $ 1,274.14 020000 Transmission System $ Transm - ission $ technolo - gy $ selection - and $ downsizing - outside $ of analysis - $ scope - 030000 Body System $ 6.13 $ 6.25 $ 6.30 $ 6.39 $ 6.25 $ 6.39 060000 Brake System - BBW $ 225.84 $ 230.74 $ 234.42 $ 235.07 $ 232.78 $ 240.99 120000 Climate Control System $ 190.72 $ 202.51 $ 217.77 $ 271.48 $ 249.05 $ 239.85 140000 Electric Power Supply System $ 1,253.72 $ 1,391.21 $ 1,512.44 $ 1,518.78 $ 1,474.39 $ 1,702.71 180000 Power Distribution and Control System $ 197.11 $ 201.22 $ 203.28 $ 203.97 $ 201.22 $ 212.20 Net Incremental Direct Manufacturing Cost $ 2,912.32 $ 3,123.43 $ 3,444.03 $ 3,426.52 $ 3,323.13 $ 3,676.28 - 8
Table A-4 and Table A-5 provide additional cost analysis details for the two major P2 HEV contributing systems (Integrated Electric Motor/Generator and Clutch Assembly System and Electric Power Supply System, respectively). Table A-4: P2 HEV Integrated Motor/Generator and Clutch Assembly System, Subsystem Cost Analysis Breakdown System ID 010000-B System Description Sub-Compact Vehicle Segment Passenger 2-4 Calculated Incremental Manufacturing Cost - P2 HEV Technology Small/Compact Vehicle Segment Passenger 2-5 Vehicle Example Ford Fiesta Ford Focus Integrated Electric Motor/Generator and Clutch Assembly System (Sum of Subsystems B.1 - B.13) Large Size/Vehicle Segment Passenger 4-6 Ford Fusion and Taurus Mini Van Vehicle Segment Passenger 6-8 Small Truck Large Truck Ford Flex Ford Ranger Ford Explorer $ 1,038.80 $ 1,091.51 $ 1,269.82 $ 1,190.83 $ 1,159.44 $ 1,274.14 B.1 Case Subsystem $ 121.22 $ 129.22 $ 156.84 $ 144.79 $ 138.65 $ 161.75 B.2 Launch Clutch Subsystem $ 84.87 $ 89.40 $ 104.61 $ 98.86 $ 99.30 $ 114.75 B.3 Oil Pump and Filter Subsystem $ 29.97 $ 31.71 $ 37.61 $ 35.25 $ 33.97 $ 40.44 B.4 Traction Motor - Generator Subsystem $ 231.95 $ 242.92 $ 278.58 $ 262.12 $ 253.89 $ 273.09 B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) $ 78.52 $ 82.86 $ 96.99 $ 90.47 $ 87.21 $ 94.82 B.6 Power Electronics/Inverter & Controls Subsystem $ 262.03 $ 271.65 $ 302.91 $ 288.49 $ 281.27 $ 298.11 B.7 Traction Motor-Generator Sensor Subsystem $ 38.55 $ 38.55 $ 38.55 $ 38.55 $ 38.55 $ 38.55 B.8 Internal Electrical Connection Subsystem $ 42.11 $ 42.11 $ 42.11 $ 42.11 $ 42.11 $ 42.11 B.9 Switch Subsystem $ 3.04 $ 3.04 $ 3.04 $ 3.04 $ 3.04 $ 3.04 B.10 Electrical Housing/Support Structure Subsystem $ 45.40 $ 53.65 $ 80.48 $ 68.10 $ 61.91 $ 76.35 B.11 Electric Motor/Generator & Clutch Cooling Subsystem $ 46.76 $ 51.80 $ 72.82 $ 64.09 $ 64.73 $ 75.95 B.12 Other Misc (e.g. brackets, sealing, etc) $ 3.05 $ 3.26 $ 3.96 $ 3.64 $ 3.47 $ 3.85 B.13 OE Electric Motor/Generator Clutch System Assembly $ 51.33 $ 51.33 $ 51.33 $ 51.33 $ 51.33 $ 51.33 9
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: Table A-2: P2 Vehicle Segment Mass
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 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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