Evaluation of electric vehicle production and operating costs

This report presents an analysis of the initial cost of electric vehicles (EVs). The manufacturing and retail cost structure of mature conventional vehicles produced at high volume is analyzed first, and the contributions by various cost categories to vehicle price are estimated. The costs are then allocated to such vehicle component groups as body, chassis, and powertrain. The similarities and differences among various component systems are reviewed. In electric vehicles, an electric drive replaces the conventional powertrain, and a battery pack replaces the fuel system. Three types of traction motors are reviewed, and their cost in high-volume production is analyzed. Various components of the motor and controller package are analyzed, and their representative costs are summarized. Four types of EV batteries are reviewed, and their costs are presented. Various alternatives for the low-, medium-, and high-volume production of EVs are evaluated, and some sample costs are presented. A methodology that estimates initial and operating costs on the basis of this analysis is presented. The methodology also estimates the average lifetime cost of owning and operating an electric vehicle