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

B. Introduction
B.1 Objectives
The objective of this work assignment is to determine incremental direct manufacturing
costs for a set of advance light-duty vehicle technologies. The technologies selected are
on the leading edge for reducing future greenhouse gas emissions, primarily in the form
of tailpipe carbon dioxide (CO2). Such reductions generally correspond to fuel economy
improvements. Each technology selected is evaluated against a baseline vehicle
technology configuration representative of the current state of vehicle design and similar
overall driving performance. To obtain cost results across the diverse light-duty vehicle
fleet, application of the new technologies in six (6) vehicle size classes is considered,
though no costing was performed for cases in which a technology is not generally
considered applicable to a vehicle class. The vehicle size classes are:
� Sub-Compact car: a subcompact car typically powered by a small in-line 4 cylinder
engine.
� Small car: a small car typically powered by an in-line 4 cylinder engine
� Large car: a midsize or large passenger car typically powered by a V6 engine
� Minivan: a minivan or large cross-over vehicle with a large frontal area, typically
powered by a V6 engine, capable of carrying ~ 6 or more passengers
� Small truck: a small or mid-sized sports-utility or cross-over vehicle, or a small
pick-up truck, powered by a large V6 or small V8 engine
� Large truck: large sports-utility vehicles and large pickup trucks, typically powered
by a large V8 engine
This report focuses on the incremental costs for two (2) types of advance light-duty
vehicle technologies: power-split and P2 hybrid electric vehicle (HEV) technology.
Because the basis of the costing methodology is founded on having physical hardware to
evaluate, and there were no P2 HEVs available in North America during the time of the
analysis, a large size power-split HEV vehicle was chosen for the lead cost analysis.
From the lead cost analysis, incremental direct manufacturing costs were developed for
other power-split vehicle segments as well as P2 HEV vehicle segments.
For the large size power-split cost analysis (Case Study 0502), a 2010 Ford Fusion HEV
was evaluated for content difference relative to a 2010 Ford Fusion vehicle having a
conventional powertrain. The Fusion HEV powertrain consisted of a 2.5L Atkinson
Cycle I4 engine (156 hp), with two (2) AC synchronous permanent magnet motors (106
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