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

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attery and air flow, and (3) addition of body weld studs and nuts for mounting unique HEV components (e.g., DC-DC converter module, high voltage wire harness, and High Voltage Battery). All other portions of the body system were found to be essentially identical. Note: In some cases, where components are added to a vehicle system to support the mounting or function of a component within another system, costs are generally captured in the system driving the need for the component. For example, weld studs and nuts are added to the body system to support the mounting of the high voltage wire harness to the vehicle. In the cost analysis, the costs of the weld studs and nuts are included in the Electrical Distribution and Electronic Control System, Traction and High Voltage <strong>Power</strong> Distribution Subsystem. D.4.1.1 Body Closures Subsystem D.4.1.1.1 Body Closures Subsystem The under engine splash shield on the base Fusion deadens sound, insulates, and protects the lower engine bay and powertrain (Figure D-33). The hybrid Fusion’s under engine splash shield (Figure D-34) is identical in construction and purpose to the base model. The difference between the shields in size and number of access holes which are driven by the powertrain package. Figure D-33: Base Fusion, Under Engine Splash Shield 84
Figure D-34: HEV Fusion, Under Engine Splash Shield D.4.1.2 Interior Trim and Ornamentation Subsystem A molded trim panel is utilized in the HEV Fusion’s luggage compartment to cover the traction battery. Provisions are made for warm air to exit the plenum as it is exhausted from the cooling system of the battery (Figure D-35). Figure D-35: Luggage Compartment Liner D.4.1.3 Sound and Heat Control Subsystem Due to traction battery heat at the rear seat backs, heat shielding is inserted into the rear seat back covers. This heat shield consists of double layer bubble wrap captured between a top and bottom aluminum foil layer (Figure D-36). 85
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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
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: Item Table D-6: eCVT Motor and Cont
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,
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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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