Design and cost optimization, automotive companies in the direction of electric vehicle platforms
In recent times, many have come across news about accidents involving autonomous vehicles, particularly those from Uber and Tesla’s Model X. When it comes to the development of new technologies, it's easy to spot the weaknesses of electric vehicles (EVs) and self-driving systems. However, progress is inevitable—it follows a path of survival of the fittest, where problems are solved one by one as they arise.
Today, I came across an insightful article from McKinsey titled “What a teardown of the latest electric vehicles reveals about the future of mass-market EVs.†It was quite encouraging to see how far the industry has come. With ongoing improvements in design and cost efficiency, automakers have made significant strides in electric vehicle development. They’ve achieved partial breakthroughs in their own vehicle configurations. By enhancing design efficiency or reducing manufacturing costs, the overall price of EVs is gradually decreasing, making them more accessible to a broader range of consumers.
As shown in Figure 1, once the benchmark EV achieves an average range of over 300 kilometers (or 185 miles), OEMs seem ready to target the low-price segment while still offering sufficient driving range. The long-awaited mass-market electric vehicle—“a medium-sized electric car designed for the average consumerâ€â€”may soon become a reality.
Electric vehicle platforms are also evolving. Although the initial investment is higher (in terms of engineering time and new molds), these new platforms outperform modified models in every aspect. Designed entirely around the electric vehicle concept, they eliminate the need for engines and gearboxes, allowing for greater flexibility and fewer compromises at the engineering level.
Thanks to these new platforms, energy losses are being reduced, especially in the architecture and body structure. This allows for larger battery packs, resulting in longer driving ranges. On average, the battery pack volume has increased by 25%. The body structure can be built around the battery, without needing to integrate with existing designs. This engineering freedom often means that a larger battery can be installed.
Other potential advantages include higher discharge power and faster charging speeds. As battery technology continues to advance, the range limitations of EVs are steadily being overcome. We’re seeing electric vehicles move toward the early stages of development seen in fuel-powered cars. The flexibility of the new platform plays a key role in this shift. For example, battery packs can be configured with different capacities and numbers while maintaining the same form factor. Variable transmission system technology allows automakers to produce rear-wheel, front-wheel, and four-wheel drive electric vehicles on a single pure-electric platform.
From a disassembly perspective, the electric vehicle powertrain is moving toward greater integration. Many power electronics components are now physically integrated into fewer modules. While there isn’t a universal integration plan among automakers, the overall trend shows a rapid decline in the number of core components and connected cables.
The next focus is on the efficient integration of thermal management systems, aiming for better energy control. Looking at the layout of electric vehicles, we can see a simplification of components, which doesn't take up more space than traditional platforms. That’s a major advantage.
To boost appeal, electric vehicles are increasingly integrating more intelligent functions and cockpit electronics. At this stage, EVs need more selling points beyond just range and charging speed—they must also offer advanced automotive electronics. These new features help break away from old perceptions.
Profitability for pure electric vehicles is largely dependent on cost. Achieving profitability remains a challenge, especially due to the high cost of batteries. While current subsidies may make some models profitable, stricter cost controls will become even more critical for further EV development and market entry. Finding a way to offer attractive pricing without compromising company profits will be key. Cost control and continuous cost reduction will be central to competition in the industry.
In summary, the road for pure electric vehicles is challenging, but it's a crucial one. It lays the foundation for autonomous driving and car electronics. First, we need a car to have functions.
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