The Hybrid and Electric Vehicle Components Report

Foreword

Glossary

Introduction

Methodology and scope

Forecast Horizon

Advanced energy storage – a complementary report

Executive Summary

Technology Developments

Discussion of Key Issues

Market Drivers

Component Requirements of Electrified Drivelines

Component Performance Requirements

Future vehicle component requirements

Micro Hybrids

Mild Hybrids

Full hybrids

Plug-in Range Hybrids (PHEV)

Extended Range Electric Vehicles (EREV)

Electric Vehicles (EV)

Production Costs and Targets

Components

Battery Management Systems

BMS Topology

Chargers

Gearboxes

Nissan LEAF

Chevrolet Volt

Toyota Prius

EV Gearboxes

Solid State Components Technology

Inverters

Vehicle/Powertrain Control Unit

Denso

Major Component Suppliers

The OEMs’ position

BMW

Fiat Chrysler

Daimler

Ford

General Motors

Honda

Hyundai-Kia

Mitsubishi

PSA Peugeot Citroën

Renault-Nissan

Toyota

Volkswagen

FHI

Tata

Volvo

Other manufacturers

Chinese Manufacturers

Market Forecast

Strategic Issues

Risks Sharing

Investment Requirements and R&D Costs

Supply Limitations

Standardisation

Intellectual Property Rights

Disruptive Technology

Supply Chain Development

Risk and Liability

Safety

The Value Chain

Rationalisation and Consolidation

Appendix 1 – CURRENT AVAILABILITY OF EV and HEV SYSTEMS IN EUROPE,

NORTH AMERICA, JAPAN AND KOREA 2011

List of Figures

Figure 1 Scenario for 2015 EV HEV Market Penetration Source: KGP Estimates

Figure 2: Component System Market Forecast 2015 (USUSD bn) Source: KGP Estimates

Figure 3: Component System Market Forecast 2025 (USUSD bn) Source: KGP Estimates

Figure 4 IEA ‘Blue Map’ Scenario

Figure 5: Major industry drivers and stakeholders

Figure 6: Global Short Term CO2 and Fuel Economy targets Source: ICCT 22

Figure 7: Tank/Well-to-wheels analysis (TTW/WTW) Source: Magna 22

Figure 8: Well-to-wheels CO2 on the Japanese 10-15 mode cycle (Total CO2 per km driving) Source: JHFC – Based on average Japanese energy generation

Figure 9: Energy requirement kWh per km for various test cycles for small/medium EVs

Figure 10: Overall efficiency of conventional powertrain vs. electric Source: Various

Figure 11: Fuel specific and gravimetric energy density Source: Various

Figure 12: Contribution of Alternative Technologies to meet EU CO2 targets 2015/2025 (%) Source: KGP Analysis

Figure 13 EV and HEV Comparison Summary Table Source: FEV

Figure 14 FreedomCar Power Requirements for Electric Propulsion System for EVs and HEVs

Figure 15 FreedomCar Power Requirements for Electric Propulsion System for a HEV

Figure 16: Examples of vehicles with stop/start 2011 in Europe

Figure 17: Functions of Various Drivelines

Figure 18: Component Specifications Current and Near Future Hybrids and EVs 2009-2011 models

Figure 19: Current and Future Micro Hybrids, HEV, PHEV, EVs 2008-2010/11 Source: KGP Analysis

Figure 20: Component Usage by Vehicle Type Source: Various, KGP Analysis

Figure 21: US DOE FreedomCar Technical Targets for Electric Traction Systems

Figure 22: US DOE FreedomCar Technical Targets for a 3kW DC/DC converter Source: US DOE FreedomCar

Figure 23: US DOE FreedomCar Technical Targets for Motors

Figure 24: FreedomCar Technical Targets for Power Electronics

Figure 25: Oak Ridge National Laboratory Summary of DOE Advanced Power

Electronics Research Source: ORNL

Figure 26: EV Cost Breakdown Source: TATA

Figure 27: HEV Component On-Costs Split Source: GM

Figure 28: - Brusa EVB1-400-40 Battery with integrated BMS

Figure 29: SB LiMotive BMS Schematic Source: Bosch

Figure 30: BMS Key Functions Source: Compact Power

Figure 31: Hybrid/EV Transmissions

Figure 32 GM Chevrolet Volt Hybrid Architecture Source: GM

Figure 33 Chevrolet Volt Transmission

Figure 34 Toyota Prius transmission layout (2009 LHS vs. 2010 RHS)

Figure 35 BorgWarner eGearDrive Transmission

Figure 36 Bosch eAxle Specification

Figure 37 Bosch eAxles Source: Bosch

Figure 38 ZF Sachs 8 Speed AT – 8HP

Figure 39 Aisin AW Hybrid Transmissions HD10, HD20, HR-10F

Figure 40 Strigear Hybrid Powertrain (Stridsberg Powertrain AB)

Figure 41 ROHM SiC Devices Summary

Figure 42: Azure Dynamics DC-DC converter

Figure 43: TDK-EPC DC-DC converter

Figure 44 Power Electronic Benchmarks

Figure 45 Toyota Industries Electric Air-conditioning Compressor

Figure 46 Tesla Roadster AC Induction Motor Source: Tesla

Figure 47 Yaskawa Electric QMET Drive System

Figure 48: Tier One Component Developments

Figure 49 AC Propulsion Drive System

Figure 50 Ansaldo’s Motor Product Range Source: Ansaldo

Figure 51 Ansaldo Inverter Source: Ansaldo

Figure 52 Ansaldo Inverter Specifications Source: Ansaldo

Figure 53 eGearDrive Specifications

Figure 54 DC-DC converter ISG applications Source: Bosch

Figure 55 Bosch Components for PSA’s Hybrid3008

Figure 56 Continental-Hybrid Components Source: Continental

Figure 57 Continental Side-Mounted Electric Motors Source: Continental

Figure 58 Continental Axle Drive System Source: Continental

Figure 59 Daesung Electric DC-DC converter (ISG and EV/HEV) Specifications

Figure 60 Remy NV250/410 HVH Efficiency

Figure 61 Remy NV250 HVH Specifications

Figure 62 Remy Performance Results

Figure 63 Delphi DC-DC converter Source: Delphi

Figure 64 Delphi Inverter for Mild Hybrids

Figure 65 Denso Products for HEVs Source: Denso

Figure 66 Denso DC-DC converter

Figure 67 Denso DC-DC converter Specifications

Figure 68 Denso Aircon Compressor

Figure 69 Electric Compressor Structure Source: Denso

Figure 70 Denso Specifications for Nickel Metal Hydride Battery Management System

Figure 71 Evo Electric Motor Specifications

Figure 72 GKN eAxle for Hybrid AWD, eTransmissions Source: GKN

Figure 73 Jatco JR712E Hybrid Transmission

Figure 74 iMiev DC-DC converter/Charger Source: Nichicon

Figure 75 LEAF Onboard Charger Source: Nichicon

Figure 76 Nichicon DC-DC converter (RHS), Inverter (LHS)

Figure 77 Nichicon Charger Specifications Source: Nichicon

Figure 78 Punch Powertrain Hybrid HT1 Source: Punch Powertrain

Figure 79 Via Motor’s EV Powertrain

Figure 80 Sevcon/TechOps Motor Controller Source: Sevcon

Figure 81 TM4 Motive Motors and Inverters

Figure 82 TM4 MФTIVE™ System Performance

Figure 83 TM4 INVERTER/MOTOR Specifications

Figure 84 Toshiba Motor and Invert for Hybrid Vehicles

Figure 85 Toshiba’s ‘SCiB’ lithium-ion batteries

Figure 86 Enova Electric Vehicle Power Systems PowerPhase Propulsion Systems

Figure 87 Enova Hybrid Powertrain Systems

Figure 88 Zytek Motor Source: Zytek

Figure 89 Zytek Integrated 55kW Electric Engine Technical Specification Source: Zytek

Figure 90: Major Component OEM Relationships

Figure 91 Maxwell Super-capacitors Supplied to PSA Source: Maxwell

Figure 92: Market penetration scenarios 2015

Figure 93: Market penetration scenarios 2025

Figure 94: Component System Market Forecast 2015 (USUSD bn)

Figure 95: Component System Market Forecast 2025 (USUSD bn)

Figure 96: Risks for OEMs

Figure 97: Component Alliances (Non-Exhaustive)

Figure 98 Rare Earth Supply Trends

Figure 99: EV HEV Components Value chain

Figure 100: Key model availability in Europe, North America, Japan and Korea