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Components for Hybrid Electric VehiclesPublished by: BCC Research Published: Jan. 31, 2006 - 186 Pages Table of ContentsINTRODUCTION STUDY GOAL AND OBJECTIVES REASONS FOR DOING THE STUDY CONTRIBUTIONS OF THE STUDY AND FOR WHOM SCOPE AND FORMAT METHODOLOGY INFORMATION SOURCES RELATED BCC WORK CREDENTIALS RELATED BCC PUBLICATIONS BCC ONLINE SERVICES DISCLAIMER SUMMARY Summary Table: GLOBAL MARKET FOR NEW COMPONENTS USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Summary Figure: GLOBAL MARKET BREAKUP FOR NEW COMPONENTS USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS), 2003-2010 ($ MILLIONS) OVERVIEW INTRODUCTION BENEFITS OF HYBRID ELECTRIC TECHNOLOGY DEFINITIONS HISTORY HYBRID CLASSIFICATION DEGREES OF HYBRIDIZATION Table 1 HYBRID CLASSIFICATION IDLE-OFF CAPABILITY REGENERATIVE BRAKING CAPACITY ENGINE DOWNSIZING EXTENDED BATTERY-ELECTRIC RANGE Table 2 GLOBAL MARKET FOR THIRTEEN NEW COMPONENTS BY HYBRID ELECTRIC VEHICLE CLASSIFICATION, THROUGH 2010 ($ MILLIONS) POWER TRAIN CONFIGURATIONS HYBRID ELECTRIC DRIVETRAINS SERIES PARALLEL COMBINATION FULL HYBRID KEY SUPPLIERS OF FULL HYBRID ELECTRIC VEHICLES DRIVING DYNAMICS OF A FULL HYBRID CAR (TOYOTA PRIUS) ENGINE MOTOR-GENERATOR BATTERY INVERTER Table 3 GLOBAL MARKET FOR THIRTEEN NEW COMPONENTS USED IN FULL HYBRID ELECTRIC VEHICLES (CARS ONLY), THROUGH 2010 ($ MILLIONS) DRIVING DYNAMICS OF A FULL HYBRID SPORTS UTILITY VEHICLE (FORD ESCAPE) ENGINE MOTOR-GENERATOR BATTERY DRIVING DYNAMICS OF A FULL HYBRID SPORTS UTILITY VEHICLE (LEXUS RX 400H) ENGINE MOTOR-GENERATOR BATTERY DRIVING DYNAMICS OF THE TOYOTA HIGHLANDER FULL HYBRID SUV DRIVING DYNAMICS OF THE FORD MERCURY MARINER FULL SUV Table 4 GLOBAL MARKET FOR THIRTEEN NEW COMPONENTS USED IN FULL HYBRID ELECTRIC VEHICLES (SUVs ONLY), THROUGH 2010 ($ MILLIONS) MILD HYBRIDS BELT ALTERNATOR STATOR DRIVING DYNAMICS OF A MILD HYBRID CAR (HONDA CIVIC) ENGINE MOTOR GENERATOR BATTERY DRIVING DYNAMICS OF A MILD HYBRID CAR (HONDA INSIGHT) ENGINE MOTOR GENERATOR BATTERY Table 5 GLOBAL MARKET FOR THIRTEEN NEW COMPONENTS USED IN MILD HYBRID ELECTRIC VEHICLES (CARS ONLY), THROUGH 2010 ($ MILLIONS) DRIVING DYNAMICS OF A MILD HYBRID SPORTS UTILITY VEHICLE (HONDA ACCORD) ENGINE MOTOR GENERATOR BATTERY DRIVING DYNAMICS OF THE CHEVROLET SILVERADO MILD HYBRID SUV DRIVING DYNAMICS OF A MERCEDES-BENZ S-CLASS HYBRID SUV DRIVING DYNAMICS OF AN AUDI-Q7 MILD HYBRID SUV DRIVING DYNAMICS OF A NISSAN ALTIMA HYBRID Table 6 GLOBAL MARKET FOR THIRTEEN NEW COMPONENTS USED IN MILD HYBRID ELECTRIC VEHICLES (SUVS ONLY), THROUGH 2010 ($ MILLIONS) IMPACT OF HIGH COSTS ON HYBRID CAR SALES RATE OF HYBRIDIZATION (ROH) ORDER OF HYBRIDIZATION ELECTRIC HYBRIDIZATION RATE (HER) COMBUSTION HYBRIDIZATION RATE (CHR) HYBRID ELECTRIC VEHICLE ENERGY CONCEPT HYBRID ELECTRIC VEHICLE COMPONENT ANALYSIS KEY POINTS COMPONENT SUPPLY CHAIN FOR TOYOTA HYBRIDS IN-HOUSE COMPONENT PRODUCTION Denso Panasonic EV Energy Co. Aisin AW Co. Toshiba Corp. Koyo Seiko, NSK, Ltd. and ADVICS Hitachi Related Activities COMPONENT SUPPLY CHAIN FOR FORD HYBRIDS COMPONENT SUPPLY CHAIN FOR HONDA HYBRIDS ENGINE TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES ENERGY RECOVERY AND BATTERY STORAGE ENGINE SHUT-OFF WHEN STOPPED USE OF AN ATKINSON ENGINE (GASOLINE) Table 7 SUMMARY OF ENGINE TYPES USED IN HYBRID ELECTRIC VEHICLES IN 2005 BATTERY TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES BATTERY CAPACITY Table 8 BATTERIES USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES IN 2005 UNITED STATES ADVANCED BATTERY CONSORTIUM (USABC) Table 9 USABC SECONDARY CRITERIA FOR ADVANCED BATTERY TECHNOLOGIES OTHER CRITERIA Table 10 HYBRID BATTERY MARKET DATA Table 11 SECONDARY BATTERY TECHNOLOGY COMPARISON ELECTRIC MOTOR TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES Table 12 COMPARISON OF DIFFERENT MOTOR TYPES USED FOR HYBRID ELECTRIC VEHICLES Table 13 2005 MOTOR RATING DATA FOR HYBRID ELECTRIC VEHICLES Table 14 TYPES OF CVTS USED IN HYBRID ELECTRIC VEHICLES IN 2005 REGENERATIVE BRAKING TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES INVERTER TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES INVERTER (ELECTRICAL) CASE STUDY: 2005 TOYOTA PRIUS INTEGRAL POWER UNIT (IPU) TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES IGBT TRANSISTOR ELECTRONIC CONTROL UNIT (ECU) TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES ULTRACAPACITOR TECHNOLOLGY USED IN HYBRID ELECTRIC VEHICLES Table 15 COMPARISON OF ULTRACAPACITOR AND BATTERY CHARACTERISTICS HIGH-VOLTAGE CONNECTOR AND CABLE TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES TWO-POLE INVERTER CONNECTOR POLE INVERTER CONNECTOR SERVICE PLUG HEV BATTERY BUS BAR MODULE HIGH-VOLTAGE JUNCTION BOX SHIELDED EV-HEV CABLE ELECTRIC COMPRESSOR TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES ELECTRIC POWER STEERING TECHNOLOGY USED IN HYBRID ELECTRIC VEHICLES TECHNICAL ISSUES RELATED TO ELECTRICAL AND ELECTRONIC COMPONENTS USED IN HYBRID ELECTRIC VEHICLES HYBRID COMPUTER CONTROL SYSTEMS MULTIPLE SYSTEM CONTROLLERSS POWER MANAGEMENT ELECTRONICS CHALLENGES COSTS POWER CONSUMPTION OPERATING ENVIRONMENTS RELIABILITY AND DURABILITY SAFETY AND SECURITY REGULATIONS THERMAL MANAGEMENT Thermal Management and System Integration MOTOR GENERATOR DETAILS Material Challenges BATTERY DETAILS Specific Energy Specific Power Battery Life Energy Efficiency Specific Costs COSTS ULTRACAPACITOR DETAILS KEY POINTS FOR EVALUATING PERFORMANCE AND COST OF ULTRACAPACITORS FOR HYBRID ELECTRIC VEHICLE PROPULSION INVERTERS, IPU MODULES AND OTHER ELECTRONICS Case Study: 2005 Toyota Prius Hybrid Synergy Drive GROWTH DRIVERS REGIONAL GROWTH PRICE COMPETITION AMONG COMPONENTS COMPETING WITH TOYOTA MARKET SIZE OF THIRTEEN COMPONENTS FOR HYBRID ELECTRIC VEHICLES INTRODUCTION METHODOLOGY KEY ASSUMPTIONS IN ESTIMATING THE DOLLAR MARKET OF COMPONENTS FOR HYBRID ELECTRIC VEHICLES IN 2005 AND 2010 Dollar Market Projections for Thirteen New Components for Hybrid Electric Vehicles in 2005 GROWTH RATE JUSTIFICATION BATTERIES MOTORS OTHER ITEMS TOTAL MARKET SIZE HYBRID CARS AND SUVS Table 16 GLOBAL MARKET FOR 13 NEW COMPONENTS FOR HYBRID ELECTRIC VEHICLES BY CLASSIFICATION, THROUGH 2010 ($ MILLIONS) Figure 1 GLOBAL MARKET OF 13 NEW COMPONENTS BY CLASSIFICATION OF HYBRID ELECTRIC VEHICLE, 2005 AND 2010 ($ MILLIONS) COMPONENT TYPES Table 17 GLOBAL MARKET FOR 13 NEW COMPONENTS USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Justification for the Battery Aftermarket Strategic Conclusions Motors Generators CVTs Ultracapacitors IGBT Interters ECUs Integrated Power Control Units High-Voltage Wiring Electric Power Steering Electric Compressors for HVAC Regenerative Braking Figure 2 GLOBAL MARKET OF 13 NEW COMPONENTS USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS), 2005 AND 2010 (%) Engines Market Size: High Power-density and High-efficiency Combustion Engines Table 18 UNIT COSTS OF ENGINES FOR HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ THOUSANDS) Table 19 GLOBAL MARKET FOR ENGINES USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 20 PERCENT SHARE OF WORLD MARKET FOR MAJOR COMPANIES MANUFACTURING ATKINSON ENGINES FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Batteries Table 21 UNIT COSTS OF BATTERIES USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS) 2003-2010 ($ THOUSANDS) Table 22 GLOBAL MARKET FOR BATTERIES USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 23 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING AUTOMOTIVE GRADE BATTERIES FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Motors Table 24 GLOBAL MARKET FOR ELECTRIC MOTORS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 25 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING MOTORS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Generators Table 26 GLOBAL MARKET FOR GENERATORS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 27 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING ELECTRIC GENERATORS FOR HYBRID ELECTRIC VEHICLES Market Size: Power Splitters (Continuously Variable Transmissions - CVTs) Table 28 GLOBAL MARKET FOR POWER SPLITTERS (CONTINEOUSLY VARIABLE TRANSMISSIONS-CVTS) USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 29 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING CONTINUOUSLY VARIABLE TRANSMISSIONS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Regenerative Braking Table 30 GLOBAL MARKET FOR REGENERATIVE BRAKING USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 31 PERCENT SHARE OF THE WORLD MARKET FOR TOP COMPANIES MANUFACTURING REGENERATIVE BRAKING FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Inverters Table 32 GLOBAL MARKET FOR IGBT INVERTERS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 33 PERCENT SHARE OF WORLD MARKET FOR TOP FIVE COMPANIES MANUFACTURING IGBT INVERTERS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Integrated Power Units (IPUs or Controllers) Table 34 GLOBAL MARKET FOR INTEGRATED POWER UNITS (IPUS) USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 35 PERCENT SHARE OF WORLD MARKET FOR TOP FIVE COMPANIES MANUFACTURING IPUS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Electronic Control Units Table 36 GLOBAL MARKET FOR ELECTRONIC CONTROL UNITS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 37 PERCENT SHARE OF THE WORLD MARKET FOR TOP FIVE COMPANIES MANUFACTURING IPUS FOR HYBRID ELECTRIC VEHICLES, 2005 Ultracapacitors Market Size Table 38 GLOBAL MARKET FOR ULTRACAPACITORS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 39 PERCENT SHARE OF WORLD MARKET HELD BY TOP FIVE COMPANIES MANUFACTURING ULTRACAPACITORS FOR HYBRIDE ELECTRIC VEHICLES, 2005 Market Size: High-voltage Wiring Table 40 GLOBAL MARKET FOR HIGH-VOLTAGE WIRING USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 41 PERCENT SHARE OF WORLD MARKET FOR TOP FIVE COMPANIES MANUFACTURING ULTRACAPACITORS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Electric Compressors Table 42 GLOBAL MARKET FOR ELECTRIC COMPRESSORS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS) THROUGH 2010 ($ MILLIONS) Market Players Table 43 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING ELECTRIC COMPRESSORS FOR HYBRID ELECTRIC VEHICLES, 2005 Market Size: Electric Power Steering Table 44 GLOBAL MARKET FOR ELECTRIC POWER STEERING USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 ($ MILLIONS) Market Players Table 45 PERCENT SHARE OF WORLD MARKET FOR TOP COMPANIES MANUFACTURING ELECTRIC POWER STEERING FOR HYBRID ELECTRIC VEHICLES, 2005 INDUSTRY STRUCTURE OVERVIEW INDUSTRY CHARACTERSTICS MARKET Table 46 GLOBAL MARKET FOR HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 (NUMBER OF CARS) Table 47 U.S. AND JAPANESE MARKETS FOR HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 (THOUSANDS OF UNITS) Table 48 EUROPEAN AND OTHER COUNTRY MARKETS FOR HYBRID ELECTRIC VEHICLES (CARS AND SUVS), THROUGH 2010 (THOUSANDS OF UNITS) Suppliers Hybrid Vehicle Manufacturing REGIONAL MARKET SHARES OF THE 13 COMPONENTS FOR HYBRID ELECTRIC VEHICLES Figure 3 REGIONAL PERCENT OF MARKET SHARE OF THIRTEEN NEW COMPONENTS USED IN MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS), 2005 AND 2010 (%) JOINT ALLIANCES AND LICENSE AGREEMENTS FOR HYBRID TECHNOLOGY SHARING AMONG HEV COMPONENTS SUPPLIERS MERGERS AND ACQUISITIONS Table 49 JOINT VENTURES, DEALS, LICENSING AGREEMENTS, ACQUISITIONS AND MERGERS AMONG HYBRID COMPONENT SUPPLIERS, 2000 TO 2005 JOINT ALLIANCES AND LICENSING AGREEMENTS FOR HYBRID TECHNOLOGY SHARING AMONG HYBRID ELECTRIC VEHICLE OEMS GENERAL MOTORS TWO-MODE HYBRID SYSTEM Table 50 JOINT VENTURES, LICENSING ARRANGEMENTS, ACQUISITIONS AND MERGERS AMONG HYBRID ELECTRIC VEHICLE MANUFACTURERS, FROM 2000 TO 2005 COMPETITION AND MARKET DYNAMICS KEIRETSU RELATIONSHIPS: THE JAPANESE NETWORK OF AFFILIATED COMPANIES CUSTOMER DIVERSIFICATION NEW SUPPLIERS PATENTS AND PATENT ANALYSIS LIST OF PATENTS PATENT ANALYSIS PATENTS BY COMPONENT TYPE Table 51 NUMBER OF PATENTS GRANTED FOR NEW HEV COMPONENTS BY TYPE, JANUARY 2001 TO SEPTEMBER 2005 Table 52 FIRST THROUGH 26TH COMPANIES BY NUMBER OF PATENTS GRANTED FOR NEW HEV COMPONENTS, FROM 2001 TO SEPTEMBER 2005 Table 53 NUMBER OF PATENTS GRANTED BY ASSIGNED COUNTRY/REGION FOR COMPONENT GROUPS USED IN HEVS (CARS AND SUVS) FROM 2001 TO SEPTEMBER 2005 Figure 4 NUMBER OF PATENTS GRANTED BY ASSIGNED COUNTRY/REGION FOR DESIGNATED COMPONENT GROUPS USED IN HEVS (CARS AND SUVS) FROM 2001 TO SEPTEMBER 2005 HYBRID COMPONENT PATENT ACTIVITY INTERNATIONAL OVERVIEW OF NEW HYBRID COMPONENT PATENT ACTIVITY Table 54 NUMBER OF PATENTS GRANTED BY ASSIGNED COUNTRY/REGION FOR NEW COMPONENTS USED IN HYBRID ELECTRIC VEHICLES (CARS AND SUVS) FROM 2001 TO SEPTEMBER 2005 Table 55 HYBRID ELECTRIC VEHICLE-RELATED PARTS SUPPLIERS PRODUCT LINE REFERENCE COMPANY PROFILES AISIN AW CO., LTD. ADVICS CO., LTD. AZURE DYNAMICS, INC. COBASYS (OVONIC BATTERY CO., INC.) CONTINENTAL ISAD ELECTRONIC SYSTEMS GMBH & CO. DENSO CORP. FAVESS FUJI ELECTRIC DEVICE TECHNOLOGY HITACHI PRODUCT STRATEGIES FOR 2010 Electric Powertrain Systems Drive Control Systems Engine Management Systems JAPAN STORAGE BATTERY CO., LTD. (JSB) JATCO, LTD. JOHNSON CONTROLS AUTOMOTIVE GROUP GLOBAL CAPABILITIES IN AUTOMOTIVE BATTERIES United States and Canada Europe Mexico South America KEIHIN CORP. KOYO SEIKO CO., LTD. LuK GROUP LuK GROUP (CONTINUD) MAXWELL TECHNOLOGIES MITSUBISHI ELECTRIC NEC ELECTRONICS AMERICA, INC. NESSCAP CO., LTD. NSK STEERING SYSTEMS AMERICA, INC. PANASONIC EV ENERGY CO., LTD. PIE TECHNOLOGY SAFT AMERICA, INC. SANYO ELECTRIC CO., LTD. SHIN-KOBE ELECTRIC MACHINERY CO., LTD. SUMITOMO WIRING SYSTEMS, LTD. TDK CORP. TOCHIGI FUJI SANGYO KABUSHIKI KAISHA TOSHIBA CORP. SEMICONDUCTOR CO. TOYOTA INDUSTRIES CORP. UQM TECHNOLOGIES, INC. VISTEON CORP. YAZAKI BUHIN K.K. ZF FRIEDRICHSHAFEN AG Table 56 DATA COMPARISON FROM THREE SOURCES RELATING TO GLOBAL PRODUCTION OF MILD AND FULL HYBRID ELECTRIC VEHICLES (CARS AND SUVS) 2005 AND 2010 (NUMBER OF UNITS) APPENDIX Table 57 SUMMARY OF VEHICLE COST DATA: PRIUS AND CIVIC HYBRIDS, 2003 ($ THOUSANDS) Table 58 MODELS OF HYBRID ELECTRIC VEHICLES NOW AVAILABLE OR EXPECTED TO BE AVAILABLE ON GLOBAL MARKETS BETWEEN 2005 AND 2010 AbstractThe report contains:
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