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

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The traction motor control unit (Figure D-13) contains six (6) Mitsubishi smart Insulated Gate Bipolar Transistor (IGBT) power modules and a control circuit board assembly. Two (2) transfer blocks are built-up of stamped circuit traces and then over-molded to link the IGBT high current leads together. Each of the IGBT’s twelve (12) control leads is soldered to the control circuit board. The IGBT mounting faces consist of coated copper for effective heat transfer to the transaxle case. The cover, circuit board, and base plate are secured together using several threaded fasteners and studs. Figure D-13: Traction Control Unit Components 68
The generator control unit (Figure D-14) is different from the traction motor control unit in that it contains only five (5) Mitsubishi IGBT power modules and an additional aluminum heat sink. Similar to the motor controls section, a circuit board and two (2) transfer blocks connect the various IGBT leads together. All mounting of the power modules and control portions are identical to the motor section. Figure D-14: Generator Control Unit Components The control module (Figure D-15) is assembled to the transmission as a large subassembly. The control module consists of an aluminum frame, two (2) large capacitors, an electrical filter, a ballast resistor, and the CVT control circuit board. Figure D-15: Transmission Control Module 69
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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
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: The traction motor stator (Figure D
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
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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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