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

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Table D-3: Performance Summary Model 2010 Fusion SE 2010 Fusion Hybrid Engine Horsepower 240 hp (179 kW) @ 6,550 156 hp (116 kW) @6,5000 rpm rpm Electric Motor Horsepower N/A 106 hp (79 kW) @ 6,500 rpm Net Horsepower N/A 191 hp (142 kW) @ 6,000 rpm Engine Torque 223 ft-lb (302 Nm) @ 4,300 136 ft-lb (184 Nm) @ 2,250 rpm rpm Electric Motor Torque N/A 166 ft-lb (225 Nm) @ 3,000 rpm 0-60 mph / ¼ mile 7.3 sec. / 15.3 sec. @ 91.8 mph* 8.7 sec. / 16.4 sec. @ 87.8 mph** Power to Weight Ratio 19.5 lb. / hp 14.4 lb. / hp Specific Output 62.4 HP / Liter 80.0 HP / Liter Redline 6,600 rpm 6,550 rpm (Source of information contained in this table is Ford Motor Company sales/service literature except 0-60 mph / ¼ mile data: *Source edmunds.com, **Source Edmunds InsideLine) Left Rear Left Side (LS) Left Front Fusion HEV: 735 lbs Fusion HEV: 1867 lbs Fusion HEV: 1132 lbs Fusion SE: 659 lbs Fusion SE: 1730 lbs Fusion SE: 1071 lbs Delta: 76 lbs Delta: 137 lbs Delta: 61 lbs Rear (R ) Distribution LS/RS (%) Total Distribution F/R (%) Front (F) Fusion HEV: 1460 lbs Fusion HEV: 50.8/49.2 Fusion HEV: 3678 lbs Fusion HEV: 60.3/39.7 Fusion HEV: 2218 lbs Fusion SE: 1310 lbs Fusion SE: 50.3/49.7 Fusion SE: 3438 lbs Fusion SE: 61.9/38.1 Fusion SE: 2128 lbs Delta: 150 lbs Delta: 90 lbs Right Rear Right Side (RS) Right Front Fusion HEV: 725 lbs Fusion HEV: 1811 lbs Fusion HEV: 1086 lbs Fusion SE: 651 lbs Fusion SE: 1708 lbs Fusion SE: 1057 lbs Delta: 74 lbs Delta: 103 lbs Delta: 29 lbs Figure D-2: Fusion HEV and Fusion Base Vehicle Mass Distributions as Measured (Vehicles weighed with 6 gallons of fuel in each tank) 56
D.1.2 Direct Manufacturing Cost Difference for a 2010 Ford Fusion Power-Split HEV compared to a 2010 Ford Fusion SE Baseline Vehicle A summary of the calculated, net incremental, direct manufacturing costs for producing a Ford Fusion Hybrid vehicle over the baseline Ford Fusion SE is presented in Table D-4. The costs, captured only for vehicle differences having an overall positive or negative cost impact, are broken out for each of the major systems in both the Fusion HEV (New Technology Configuration) and Fusion SE (Baseline Technology Configuration). At the bottom of the table, the baseline configuration costs are subtracted from the new technology configuration costs resulting in a net incremental cost From the cost element breakdown within the table, approximately 71% of the incremental direct manufacturing costs (i.e., $2,865.06) are material costs, 14% labor costs, and 15% overhead costs. Relative to the net incremental direct manufacturing cost of $3,435, approximately 83.5% are total manufacturing costs (i.e., material, labor, overhead) and the remaining 16.5% is applicable mark-up. More than 95% of the costs for adding the power-split technology to the baseline configuration originate from the transmission (34%) and electrical power supply (63%) systems. In the sections which follow, additional details on the components evaluated within each vehicle system and their associated costs will be discussed. 57
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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
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: Table D-1: Vehicle Specification Su
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
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The rotor shaft is mounted to an in
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D.7 Electrical Power Supply System
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Circuit connections between packs a
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The traction battery assembly is mo
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During dormant periods the BEC (Fig
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D.7.2 Electrical Power Supply Cost
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Item 1 2 3 4 5 6 7 8 9 10 11 12 13
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The HV connectors (Figure D-91) are
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Item Table D-12: Net Incremental Di
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F. Power-Split Scaling Cost Analysi
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vehicle class was determined. Also
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G. 2010 Hyundai Avante Lithium Poly
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Figure G-3: Li Ion Battery Modules
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Figure G-6: Cell Covers in Module,
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Figure G-9: The Battery Pack Discon
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Table G-2: 2010 Hyundai Avante Lith
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Table H-1: Baseline Powertrain and
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Table H-2: Primary Component Sizing
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Costing Databases: the five (5) cor
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Surrogate part: a part similar in f
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