Automotive Electrification - Japanese Perspective
SupplierBusiness, February 2011, Pages: 165
Published February 2011 and with over 40 tables and 326 figures, this highly detailed 165 page report includes sections on market forecasts from leading research institutes, analysis of Japanese automakers and the outlook for supercapacitators.
Furthermore the report features mini plant reports and includes details of suppliers by model for Toyota, Honda, Mitsubishi, Nissan, Subaru and Mazda.
Background to this Research
Japanese automakers will be the leaders in hybrid and pure electric vehicles in 2020 for four main reasons - their early start in both segments dating back to the early 1990s, relatively strong balance sheets, skilled suppliers of electronics, batteries, high-tensile steel and other core components, and manufacturing superiority built around the world's leading machine tool industry.
In 2020, depending on three growth scenarios respectively calling for total global vehicle sales of 80 million, 90 million or 100 million units, demand for hybrids including plug-in types will reach 8.8 million, 9.9 million or 11 million units while electric vehicles (EVs) will grow to between 1.6 million and 2 million.
I. SUMMARY
II. MAIN CONCLUSIONS
III. MARKET FORECASTS
a) ASAHI KASEI CORP.
b) BOSCH AUTOMOTIVE SYSTEMS CORP.
c) CLSA ASIA PACIFIC MARKETS
d) DENSO CORP.
e) FORD MOTOR CO.
f) GOLDMAN SACHS JAPAN CO., LTD.
g) HITACHI AUTOMOTIVE SYSTEMS, LTD.
h) HITACHI, LTD.
HITACHI RESEARCH INSTITUTE
i) IHS AUTOMOTIVE
INSTITUTE OF INFORMATION TECHNOLOGY
j) INTERNATIONAL ENERGY AGENCY
k) J.D. POWER & ASSOCIATES
l) J.P. MORGAN SECURITIES CO., LTD.
m) LG CHEM LTD.
n) MITSUBISHI MOTORS CORP.
o) NISSAN MOTOR CO.
p) NOMURA RESEARCH INSTITUTE
q) PANASONIC CORP.
r) SAMSUNG SDI CO., LTD.
s) SANYO ELECTRIC CO., LTD.
t) TOSHIBA CORP.
IV. JAPANESE AUTOMAKERS
IV.1. TOYOTA: HYBRIDS ARE KING
a) EV OFFERINGS
b) MORE HYBRIDS ON THE WAY
c) THIRD GENERATION PRIUS - HYBRID SYSTEM COSTS DOWN 30%
d) 2020 HYBRID SALES TARGET: LIKELY
IV.2. HONDA: WILL REMAIN THE WORLD'S LEADER IN ‘MILD' HYBRIDS
a) ‘MOTOR-ASSIST' STILL HONDA'S WAY, THOUGH SALES DOWN IN 2010
b) THE INSIGHT
c) THE SWITCH TO LITHIUM
d) ‘IDLE STOP' DOWN THE PRIORITY LIST
e) HONDA'S 2020 HYBRID SALES TARGET: LIKELY
IV.3. NISSAN - MAKES BIG COMMITMENT TO EVS
a) LEAF SALES PLAN...
b) THE CASE FOR, THE CASE AGAINST
c) NISSAN'S 2020 EV SALES TARGET: UNLIKELY
d) NISSAN'S REJECTION OF HYBRIDS - A MISTAKE?
e) FUGA HYBRID
IV.4. MITSUBISHI - THE EARLY EV LEADER
a) PLUG-IN HYBRID TECHNOLOGY FOR LARGER VEHICLES
b) 2020 SALES TARGET: VERY UNLIKELY
c) i-MiEV SPECS
IV.5. SUBARU: TOO LITTLE TOO SOON
a) STELLA PLUG-IN EV SPECS & PACKAGING
b) 2020 SALES TARGET: VERY UNLIKELY
IV.6. MAZDA: FOCUS ON IMPROVING IC ENGINES, REDUCING VEHICLE WEIGHT
a) 30% FUEL EFFICIENCY TARGET BY 2015
b) MAZDA HYBRID, BY WAY OF TOYOTA, IN 2013
c) PREMACY HYDROGEN RE HYBRID
V. AT TOYOTA AND HONDA, FUEL CELL VEHICLES COULD COME AFTER PLUG-IN HYBRIDS
a) TOYOTA'S FCHV-ADV COVERS 800 KM
b) HONDA FCX CLARITY
c) NISSAN: FUEL CELL TECHNOLOGY TAKES A BACK SEAT
VI. SUPERCAPACITORS - OUTLOOK PROMISING
VII. PROSPECTS FOR JAPANESE SUPPLIERS
SUPPLIER WINNERS:
VII.1. PANASONIC CORP.
a) PANASONIC ACQUIRES SANYO ELECTRIC
VII.2. PRIMEARTH EV ENERGY CO.
VII.3. DENSO CORP.
VII.4. GS YUASA CORP.
a) PRODUCTION PLANS
b) MISCELLANEOUS
VII.5. NEC CORP.
a) UNANSWERED QUESTIONS
VII.6. HITACHI AUTOMOTIVE SYSTEMS, LTD.
a) NEW LITHIUM BATTERY PLANT
b) NEXT GENERATION BATTERIES
VII.7. TOSHIBA CORP:
VII.8 & 9. YAZAKI CORP. & SUMITOMO WIRING SYSTEMS, LTD.
VII.10. KEIHIN CORP.
VII.11 & 12. NIPPON STEEL CORP. & JFE HOLDINGS INC.
VII.13. AISIN AW CO.
VII.14. CKD CORP.
VIII. SUPPLIERS BY MODEL
VIII.1. TOYOTA PRIUS
VIII.2. TOYOTA CAMRY HYBRID
VIII.3. TOYOTA LEXUS LS600h
VIII.4. TOYOTA LEXUS GS450h
VIII.5. HONDA INSIGHT
VIII.6. MITSUBISHI I-MIEV
VIII.7. NISSAN ALTIMA HYBRID
VIII.8. NISSAN FUGA HYBRID/INFINITI M35
VIII.9. NISSAN LEAF EV
VIII.10. SUBARU STELLA PLUG-IN EV
VIII.11. MAZDA TRIBUTE HYBRID
IX. MINI PLANT REPORTS
IX.1. PEVE'S OMORI NO. 3 PLANT - THE INDUSTRY'S STATE OF THE ART
IX.2. TOYOTA'S TSUTSUMI PLANT
a) OTHER PRIUS ASSEMBLY OPERATIONS
b) OTHER TOYOTA HYBRID ASSEMBLY OPERATIONS
IX.3. TOYOTA'S GEORGETOWN & NISSAN'S SMYRNA PLANTS
IX.4. MITSUBISHI'S MIZUSHIMA PLANT
IX.5. NISSAN'S OPPAMA PLANT
TABLES:
TABLE(1): 2020 GLOBAL HYBRID, EV SALES FORECAST
TABLE(2): JAPANESE CARMAKER 2020 HYBRID & EV SALES FORECAST
TABLE(3): JAPANESE GOVERNMENT SUBSIDIES FOR EVS
TABLE(4): PREFECTURES WHERE EV INCENTIVES ARE BEING OFFERED
TABLE(5): PLUG-IN HYBRID/EV PREFECTURAL PROJECTS
TABLE(6): ZERO EMISSION CARS IN JAPAN IN 2020
TABLE(7): JAPANESE GOVERNMENT HYBRID & EV PENETRATION PLAN
TABLE(8): METI HISTORY OF FINANCIAL SUPPORT FOR LITHIUM BATTERY DEVELOPMENT - FISCAL 1992 - FISCAL 2010
TABLE(9): SALES HISTORY BY MODEL SEGMENT IN JAPAN
TABLE(10): MAIN COMPONENTS ELIMINATED IN EVS
TABLE(11): EV CHARGING STATIONS IN JAPAN - PRESENT & FUTURE PLANS
TABLE(12): FIRST-GENERATION EV SALES HISTORY
TABLE(13): DIESEL HYBRIDS UNDER DEVELOPMENT, ON THE MARKET IN EUROPE
TABLE(14): JAPANESE GOVERNMENT TARGETS FOR EVS & FUEL CELL VEHICLES
TABLE(15): RARE METALS USED IN HYBRIDS
TABLE(16): JAPANESE LITHIUM BATTERY PRODUCTION CAPACITY
TABLE(17): CASHHOLDING TRENDS OF JAPANESE CARMAKERS
TABLE(18): TOYOTA PRIUS PLUG-IN HYBRID LEASE TIMETABLE
TABLE(19): AVERAGE FUEL EFFICIENCY PERFORMANCE OF GASOLINE-POWERED CARS IN JAPAN
TABLE(20): ALTERNATIVE ENERGY VEHICLES IN JAPAN
TABLE(21): ENERGY DEMAND FORECAST BY COUNTRY
TABLE(22): FUEL EFFICIENCY/CO2 REGULATIONS FOR PASSENGER CARS
TABLE(23): LITHIUM BATTERY MATERIAL COSTS
TABLE(24): GLOBAL BATTERY DEMAND FORECAST (IN UNITS)
TABLE(25): GLOBAL BATTERY DEMAND FORECAST (IN YEN)
TABLE(26): UNIT BATTERY PRICE FORECAST (IN YEN)
TABLE(27): JAPANESE HYBRID/EV SALES BY MANUFACTURER & MODEL
TABLE(28): JAPANESE HYBRID/EV SALES BY MANUFACTURER
TABLE(29): PLANTS THAT PRODUCE HYBRID & ELECTRIC VEHICLES FOR JAPANESE CARMAKERS
TABLE(30): ENERGY EFFICIENCY BY MAJOR VEHICLE TYPES
TABLE(31): ELECTRIC POWER GENERATION BY COUNTRY & ENERGY SOURCE
TABLE(32): HONDA FUEL CELL STACK EVOLUTION
TABLE(33): U.S. DEPARTMENT OF ENERGY GRANTS & LOANS
TABLE(34): LITHIUM BATTERY CELL SHARE (2010 FORECAST)
TABLE(35): PEVE BATTERY TYPE BY MODEL
TABLE(36): DC/DC CONVERTER**
TABLE(37): DC-DC CONVERTER FOR ELECTRIC POWER STEERING**
TABLE(38): ELECTRIC AIR-CONDITIONER COMPRESSOR
TABLE(39): POWER CONTROL UNIT DIRECT COOLING DEVICE
TABLE(40): LITHIUM ENERGY JAPAN'S INVESTMENT HISTORY
TABLE(41): NISSAN & RENAULT BATTERY PLANTS RECEIVING GOVERNMENT SUPPORT
TABLE(42): BATTERY-AUTOMAKER TIES
TABLE(43): HIGH-VOLTAGE WIRE HARNESS BY MODEL
TABLE(44): HIGH-TENSILE STEEL PRODUCTION (IN TONS)
Figures
1) Mitsubishi's 660cc i minicar
2) Mitsubishi's i-MiEV electric car
3) Subaru's 660cc Stella minicar
4) Subaru's Stella Plug-In EV
5) Toyota's Highlander SUV
6) Toyota's FCHV-adv fuel cell vehicles
7) Schematic showing downward price curve for electronic toll collection devices; source: Panasonic Corp.
8) Schematic showing Isuzu's electric bus concept
9) Schematic showing Isuzu's electric bus drivetrain concept
10) Daihatsu's Hijet Hybrid
11) Toyota's eCom electric car
12) Honda's City Pal electric car
13) Schematic showing Mitsubishi Heavy Industries' lithium battery cell design
14) Hyundai's Sonata Hybrid
15) Schematic showing Hyundai's Sonata Hybrid drivetrain layout
16) Hyundai's BlueOn EV
17) Toyota Prius Plug-In Hybrid's lithium battery pack
18) Schematic showing Toyota Prius Plug-In Hybrid's powertrain system layout
19) Toyota Prius Plug-In Hybrid's specifications
20) Toyota Prius Plug-In Hybrid, Prius & Prius-sized gasoline car CO2 reduction comparisons
21) Toyota's Prius Plug-In Hybrid
22) Toyota's iQ minicar
23) Schematic showing Toyota's iQ interior packaging and front-mounted differential gear
24) Toyota's iQ interior packaging showing narrowed seat backs
25) Toyota iQ's reverse differential gear
26) Toyota iQ's short steering column design with a center ‘takeoff' steering gear
27) Schematic showing Toyota's iQ engine-front wheel layout
28) Toyota iQ's compact air-conditioner supplied by Denso which reduces size 20% by relocating the blower motor
29) Toyota iQ's compact air-conditioner
30) Schematic showing Toyota iQ's compact air-conditioner design
31) Schematic showing IEA's 2050 global sales targets for clean energy vehicles
32) IEA color code
33) Schematic showing IEA's 2050 sales targets for clean energy vehicles in North America
34) Schematic showing IEA's 2050 sales targets for clean energy vehicles in OECD Europe
35) Schematic showing IEA's 2050 sales targets for clean energy vehicles in OECD Pacific
36) Schematic showing IEA's 2050 sales targets for clean energy vehicles in China
37) Schematic showing IEA's 2050 sales targets for clean energy vehicles in India
38) Schematic showing IEA's 2050 sales targets for clean energy vehicles in other parts of Asia
39) Schematic showing IEA's 2050 sales targets for clearn energy vehicles in the rest of the world
40) Schematic showing Panasonic Corp.'s demand forcasts for rechargeable and lithium batteries
41) Schematic showing Panasonic Corp.'s clean vehicle forecast
42) Toyota's FEV-VII electric car
43) Toyota's Prius C Concept displayed at the 2011 North American International Auto Show
44) Toyota's Prius V
45) Toyota's Prius V
46) Toyota's Prius V with 58% more cargo space
47) Hino's Dutro Hybrid
48) Toyota Prius's drive motor
49) Toyota Prius's drive motor
50) Schematic showing Toyota Prius's drive motor
51) Toyota Prius's nickel-metal hydride battery
52) Schematic showing Toyota Prius's exhaust-heat recovery system
53) Schematic showing Toyota Prius's exhaust-gas recirculation system
54) Toyota Prius's engine-drive motor assembly
55) Toyota Prius's 650-volt motor-generator
56) Toyota Prius's planetary gear assembly
57) Honda's plug-in platform concept unveiled at the Los Angeles Auto Show in November
58) Honda's Fit EV concept unveiled at the Los Angeles Auto Show in November
59) Schematic comparing dimensions of the Honda Insight and the Civic Hybrid inverters
60) GS Yuasa Corp.'s ‘EH6' lithium battery to be used in the new Honda Civic Hybrid due out this spring
61) Nissan's Leaf electric car
62) Schematic showing powertrain of Daimler's Smart ED electric car
63) Renault's Zoe Z.E. electric car
64) Nissan Leaf's 24-kWh lithium battery
65) Nissan Fuga Hybrid, to be sold overseas as the Infiniti M35 Hybrid
66) Nissan Fuga Hybrid's hybrid system
67) Nissan Fuga Hybrid's hybrid system
68) Nissan Fuga Hybrid's lithium battery with power density of 2,550 watts/kg
69) Mitsubishi's i-MiEV Cargo concept
70) Mitsubihi's plug-in hybrid concept, the PX-MiEV
71) Schematic showing Mitsubishi i-MiEV's drivetrain layout
72) Schematic showing Mitsubishi i-MiEV's drivetrain layout
73) Mitsubishi i-MiEV's 16-kWh battery
74) Graph showing Subaru Stella Plug-In EV's mileage performance
75) Subaru R1e's powertrain layout (cutaway)
76) Subaru Stella Plug-In EV specs
77) Schematic showing Subaru Stella Plug-In EV's powertrain layout
78) Mazda's Skyactiv-G engine
79) Mazda Skyactiv-G engine's cavity pistons
80) Graph showing Mazda Skyactive-G engine's ‘4-2-1' exhaust system performance
81) Mazda Skyactiv-D engine
82) Mazda Skyactive-D engine's two-stage turbocharger
83) Schematic showing Mazda Skyactive-D's lower compression ratio due to optimized combustion timing
84) Mazda Skyactiv-Drive 6-speed automatic transmission
85) Mazda's Kiyora concept car
86) High-tensile steel applications for Mazda's new platform lineup
87) Body structural design of Mazda's new platform lineup
88) Chart showing increased usage of above-780 MPa steel for Mazda's new platform lineup
89) Mazda Premacy Hydrogen RE hybrid
90) Mazda RX-8 Hydrogen RE
91) Mazda Premacy Hydrogen RE's hybrid system
92) Schematic showing Mazda Premacy Hydrogen RE's hybrid system layout
93) Schematic showing Mazda Premacy Hydrogen RE's hybrid system layout
94) Mazda's HR-X concept car displayed at the 1991 Tokyo Motor Show
95) Honda's FCX Clarity fuel cell car
96) Image inside Toyota's fuel cell stack in cold conditions
97) Image inside Toyota's fuel cell stack at below freezing temperatures
98) Graph showing low temperature operations of Toyota's fuel cell stack
99) Honda FCX Clarity's fuel cell system layout
100) Honda FCX Clarity's fuel cell stack
101) Honda FCX Clarity's fuel cell system layout
102) Honda FCX Clarity's fuel cell system layout
103) Schematic showing Honda's FCX Clarity fuel cell system layout
104) Schematic showing performance of Honda's V-Flow stack under various load conditions
105) Schematic showing changes in Honda's fuel cell stack design
106) Nissan's X-Trail FCV
107) Schematic showing Nissan X-Trail FCV's fuel cell system layout
108) Schematic showing the ultracapacitor in Honda's FCX fuel cell vehicle, predecessor to the FCX Clarity which adopted to a lithium battery
109) Chevrolet's Volt
110) Chevrolet Volt's platform
111) Ford's Focus EV
112) Daihatsu's Mira EV which covered 1,003 km on a single charge
113) Six-cell module of Primearth EV Energy Co.'s NP2.0 nickel metal hydride battery
114) Primearth EV Energy Co.'s NP2.0 battery modules fitted into a plastic case
115) Schematic showing Primearth EV Energy Co's NP2.0 battery pack construction
116) Eight-cell module of Primearth EV Energy Co.'s NP2.5 nickel metal hydride battery
117) Primearth EV Energy Co.'s NP2.5 battery
118) Schematic showing Primearth EV Energy Co.'s NP2.5 battery cell/module structure
119) Schematic showing Primearth EV Energy Co.'s NP2.5 battery module structure
120) Schematic showing a comparison between Primearth EV Energy Co.'s NP2.0 and NP2.5 module structures
121) Denso Corp.'s hybrid component lineup
122) Toyota industries Corp.'s water-cool type DC-DC converter for the Toyota Prius
123) Toyota Industries Corp.'s DC-DC converter for Lexus HS250h
124) Toyota Industries Corp.'s electric compressor for LS650h
125) Toyota Industries Corp.'s PCU cooling device for the Toyota Prius
126) Schematic showing material properties of LiFePO4 & LiMnPO4; source: GS Yuasa Corp.
127) Schematic showing the effect of the methanol method on the electronic conduction path of LiFePO4/C; source: GS Yuasa
128) Schematic showing the effect of methanol method on utilization of positive electrode with LiFEP04/C
129) Schematic showing LiFEP04 battery; source: GS Yuasa
130) Schematic showing charge characteristics of LiFePO4 cell; source: GS Yuasa
131) Schematic showing charge characteristics of the LiFePO4 cells; source: GS Yuasa
132) Schematic showing charge/discharge curves of LiFePO4 cells; source: GS Yuasa
133) Schematic showing various lithium-ion active materials; source: GS Yuasa
134) Schematic showing life performance of LiFePO4 cells on a 45-degree Celsius cycle test; source: GS Yuasa
135) Schematic showing Nissan and NEC's battery production line at Nissan's Zama plant
136) Hitachi Automotive Systems Ltd.'s power inverter
137) Hitachi Vehicle Energy Co.'s new 300,000 cell/month lithium battery line in Hitachinaka, Ibaraki Prefecture
138) Hitachi Vehicle Energy Co.'s's new 4.5-kW/kg lithium-ion battery for cars
139) Schematic showing temperature performance of Hitachi Vehicle Energy Co.'s new 4.5-kW/kg lithium battery
140) Honda's EV-neo electric scooters on the market since December
141) Toshiba Corp.'s SCiB lithium battery pack
142) Layout of Yazaki Corp's high-voltage power distribution system
143) Layout of Yazaki Corp.'s high-voltage power distribution system
144) Yazaki Corp.'s motor cable
145) Yazaki Corp.'s common connector for the 2003 Prius and fuse director connector for the 2009 Prius
146) Yazaki Corp.'s direct attachment for the 2009 Prius
147) Yazaki Corp.'s individual shield for the 1999 Prius
148) Schematic showing Yazaki Corp.'s 3P connector for hybrid vehicles
149) Schematic showing Yazaki Corp.'s DC power connector for hybrid vehicles
150) Schematic showing Yazaki Corp.'s DC/DC converver connector for hybrid vehicles
151) Schematic showing Sumitomo Wiring Systems Ltd.'s underfloor harness for hybrid vehicles
152) Sumitomo Wiring Systems Ltd.'s high-voltage sealed connectors
153) Sumitomo Wiring Systems Ltd.'s high-voltage wires
154) Sumitomo Wiring Systems Ltd.'s motor and inverter-side connectors
155) Sumitomo Wiring Systems Ltd.'s underfloor harness for hybrid vehicles
156) Sumitomo Wiring Systems Ltd.'s high-voltage shielded wires for hybrid vehicles
157) Sumitomo Wiring Systems Ltd.'s underfloor harness for hybrid vehicles
158) Sumitomo Wiring Systems Ltd.'s high-voltage shielded wire for hybrid vehicles
159) Schematic showing Sumitomo Wiring Systems Ltd.'s heat-resistant wires for hybrid vehicles
160) Keihin Corp.'s battery management ECU for Honda hybrids
161) Keihin Corp.'s engine ECU for Honda hybrids
162) Keihin Corp.'s motor ECU for Honda hybrids
163) Keihin Corp.'s CVT ECU for Honda hybrids
164) Schematic showing JFE Holdings, Ltd.'s ultra-strength steel pillar
165) Schematic showing JFE Holdings, Ltd.'s ultra-strength steel members and reinforcement
166) Toyota Boshoku Corp. ultra-strength steel seat frame
167) Aisin AW Co.'s 2-motor, front-wheel-drive hybrid transmission for Ford cars
168) Aisin AW Co.'s 2-motor, rear-wheel-drive hybrid transmission Toyota luxury cars
169) Schematic showing CKD Corp.'s lithium winding machine in operation
170) Schematic showing CKD Corp.'s lithium winding machine in operation
171) Schematic showing Kaida Manufacturing Co.'s lithium battery manufacturing process
172) Kaida Manufacturing Co.'s lithium battery machine lineup
173) Schematic showing Panasonic EV Energy Co.'s Prius hybrid battery manufacturing process
174) Precisely cut hydrogen-absorbing alloy negative electrode plates
175) Panasonic EV Energy Co. battery module containing stacked negative and positive electrodes
176) Heat-welded upper cover for Panasonic EV Energy Co's nickel metal hydride battery
177) Cells being filled with electrolyte on the battery production line at Panasonic EV Energy Co.'s Kosai plant
178) Cells moving down the line at Panasonic EV Energy Co.'s Kosai plant
179) Battery inspection at Panasonic EV Energy Co.'s Kosai plant
180) Instrument panels fed from a subline to the main Prius assembly line in Toyota's Tsutsumi plant on automated guided pallets
181) Instrument panels fed from a subline to the main Prius assembly line in Toyota's Tsutsumi plant on automated guided pallets
182) Instrument panels fed from a subline to the main Prius assembly line in Toyota's Tsutsumi plant on automated guided pallets
183) Instrument panels fed from a subline to the main Prius assembly line in Toyota's Tsutsumi plant on automated guided pallets
184) Tsutsumi plant workers assembling Prius instrument panels on a subline inside the plant
185) Prius instrument panels waiting to be assembled on a subline in Toyota's Tsutsumi plant
186) Prius instrument panels waiting to be assembled on a subline in Toyota's Tsutsumi plant
187) Tsutsumi plant workers assembling Prius instrument panels on a subline inside the plant
188) Tsutsumi plant workers assembling Prius instrument panels on a subline inside the plant
189) Tsutsumi plant workers preparing the Prius's 1.8L gasoline engine to be machine-lifted into the engine compartment
190) Tsutsumi plant workers preparing the Prius's 1.8L gasoline engine to be machine-lifted into the engine compartment
191) Tsutsumi plant workers tightening the Prius's 1.8L gasoline engine in the engine compartment
192) Tsutsumi plant workers tightening Prius's 1.8L gasoline engine in the engine compartment
193) Tsutsumi plant worker attaching Prius underbody components
194) Tsutsumi plant worker preparing to attach Prius underbody components
195) Tsutsumi plant worker attaching Prius underbody components
196) Tsutsumi plant worker preparing to install the Prius's inverter
197) Tsutsumi plant worker preparing to install the Prius's inverter
198) Tsutsumi plant worker attaching Prius underbody components
199) Tsutsumi plant worker preparing to attach underbody components to another model on the mixed assembly line
200) Tsutsumi plant worker attaching Prius underbody components
201) Tsutsumi plant worker testing the Prius's nickel metal hydride battery
202) Tsutsumi plant worker using a lift-assist device to install the Prius's inverter
203) Tsutsumi plant worker attaching small parts to the Prius's inverter
204) Tsutsumi plant workers installing wiring in the Prius's front-engine compartment
205) Tsutsumi plant worker installing unspecified components in the Prius's front-engine compartment
206) Tsutsumi plant worker installing unspecified components in the Prius's front-engine compartment
207) Tsutsumi plant worker inspecting the Prius's underbody
208) Tsutsumi plant workers attaching front-end and interior components on the Prius's trim line
209) A Tsutsumi plant worker on the main Prius trim line preparing to assemble an unspecified component while seated on a moving chair; the seat concept came from Toyota's Georgetown, KY, plant
210) Three Tsutsumi plant workers - two attaching interior trim parts, one installing engine parts - on the Prius's main assembly line.
211) Tsutsumi plant's main trim line showing workers assembling Prius components from a pre-arranged ‘kit'
212) A Tsutsumi plant worker preparing to attach an engine compartment component; inside the car is can be seen a ‘kit' containing interior parts placed in front of the Prius's nickel metal hydride battery
213) A Tsutsumi plant worker assembling Prius interior components while seated on a moving chair
214) Tsutsumi plant worker attaching interior components to the Prius while seated on a moving chair
215) Tsutsumi plant worker attaching interior trim parts on the main Prius assembly line
216) Fully assembled Priuses moving down the Tsutsumi plant line to the inspection area
217) Inspection area for the Prius's special solar sunroof
218) Inspection area for hybrid electronic checks
219) A Tsutsumi plant worker conducting a final visual inspection of the Prius
220) A Tsutsumi plant worker conducting a final visual inspection of the Prius
221) Tsutsumi plant workers conducting final visual inspections of the Prius
222) Toyota's Estima Hybrid which is produced together with the Prius at the Fujimatsu plant of Toyota Auto Body Co.
223) Cutaway of the hybrid system in the Toyota Estima Hybrid
224) Aided by a lift-assist device, a Georgetown plant worker putting the Camry Hybrid battery into the trunk compartment
225) Aided by a lift-assist device, a Georgetown plant worker putting the Camry Hybrid battery into the trunk compartment
226) A Georgetown plant worker fastening the Camry Hybrid's battery from inside the car
227) A Georgetown plant worker attaching high-voltage cables to the Camry Hybrid's battery from inside the car
228) A Georgetown plant worker preparing to attach the next Camry Hybrid battery to the special lift-assist device
229) A Georgetown plant worker installing the Camry Hybrid's battery into the trunk of the car
230) A Georgetown plant worker preparing the Camry Hybrid's inverter for installation at a so-called ‘bypass' station on the main assembly line
231) A Georgetown plant worker preparing the Camry Hybrid's inverter for installation at a ‘bypass' station on the main assembly line
232) A Georgetown plant worker installing the Camry Hybrid's inverter at a ‘bypass' station on the main assembly line
233) A Georgetown plant worker installing the Camry Hybrid's inverter at a ‘bypass' station on the main assembly line
234) A Georgetown plant worker attaching high-voltage wiring to the Camry Hybrid's inverter
235) A Georgetown plant worker attaching the Camry Hybrid's inverter at a ‘bypass' station on the main assembly line
236) A Georgetown plant worker attaching high-voltage cable to the underbody of the Camry Hybrid
237) A Georgetown plant worker attaching high-voltage cable to the underbody of the Camry Hybrid
238) A Georgetown plant worker attaching unspecified components to the underbody of the Camry Hybrid
239) A Georgetown plant worker assembling the Camry Hybrid's special fuel tank at another ‘bypass' station in the plant
240) A Georgetown plant worker assembling the Camry Hybrid's special fuel tank at another ‘bypass' station in the plant
241) Testing of Camry Hybrid batteries before being transported to the main assembly line at Toyota's Georgetown plant
242) Hybrid components for the Camry Hybrid awaiting shipment to the main assembly line at Toyota's Georgetown plant
243) Hybrid components for the Camry Hybrid awaiting shipment to the main assembly line at Toyota's Georgetown plant
244) The Altima Hybrid's nickel-metal hydride battery attached to an automatic lift device on the main assembly line at Nissan's Smyrna plant
245) A Smyrna plant worker lining up Altima Hybrid's battery for fitment into the car's trunk
246) The automatic lift device putting the Altima Hybrid's battery into the car's truck
247) The automatic lift device putting the Altima Hybrid's battery into the car's truck
248) After fitment of the battery into the Altima Hybrid's trunk, a Smyrna plant worker disconnecting the lift device
249) The Altima Hybrid's battery attached in the trunk compartment
250) The Altima Hybrid's inverter after installation at a dedicated work station on the main Smyrna assembly line
251) The Altima Hybrid's inverter after installation at a dedicated work station on the main Smyrna assembly line
252) Smyrna plant workers attaching high-voltage cables to the underbody of the Altima Hybrid
253) The start of the engine-mounting operation at Nissan's Smyrna plant; Altima Hybrid engines are differentiated by their bright high-voltage cables
254) A Smyrna plant worker putting the Altima Hybrid engine onto a pallet on the plant's main engine line
255) Smyrna plant workers dressing the Altima Hybrid engine on the plant's main engine line
256) Completely dressed Altima Hybrid engine moving down the Smyrna plant's engine line
257) Smyrna plant workers preparing to lift the Altima Hybrid engine into the car's engine compartment
258) Smyrna plant workers preparing to lift Altima Hybrid engine into the car's engine compartment
259) The jig onto which Altima engines, both standard and hybrid, are placed before lifting them into the engine compartment
260) Smyrna plant workers lifting an Altima Hybrid engine into the engine compartment
261) A ‘kit' containing a set of 5-10 engine parts sitting alongside the Altima Hybrid's engine dressing line
262) A ‘kit' containing a set of engine parts moving down the Altima Hybrid's engine dressing line
263) A ‘kit' containing a set of engine parts moving down the Altima Hybrid's engine dressing line
264) Engine dressing area at Nissan North America's Smyrna plant showing virtually no difference between the standard 4-cyl. Altima engine and the 4-cyl. Altima Hybrid engine except for the hybrid's orange high-voltage cables
265) A single worker manning the hybrid battery preparation area at Nissan's Smyrna plant
266) A single worker manning the hybrid battery preparation station at Nissan's Smyrna plant
267) A single worker at Nissan's Smyrna plant putting the hybrid battery assembly onto a pallet for transport to the main line
268) A single worker at Nissan's Smyrna plant putting the hybrid battery assembly onto a pallet for transport to the main line
269) Hybrid batteries stacked on pallets awaiting transport to the main Smyrna assembly line
270) A single worker completing assembly of the Altima Hybrid's inverter and electronic braking modules at a dedicated offline station inside Nissan's Smyrna plant
271) A single worker attaching high-voltage cables to the inverter and electronic braking modules at a dedicated offline station inside Nissan's Smyrna plant
272) A worker attaching high-voltage cables to the inverter and electronic braking modules at a dedicated offline station inside Nissan's Smyrna plant
273) A worker attaching high-voltage cables to the inverter and electronic braking modules at a dedicated offline station inside Nissan's Smyrna plant
274) A worker attaching high-voltage cables to the inverter and electronic braking modules at a dedicated offline station inside Nissan's Smyrna plant
275) An unspecified offline operation at Nissan's Smyrna plant
276) Nissan Smyrna plant worker attaching small parts to the Altima Hybrid's inverter module
277) Interver modules awaiting transport to main Altima assembly line at Nissan North America's Smyrna plant
278) The Altima Hybrid on an in-floor turntable at Nissan North America's Smyrna plant
279) The Altima Hybrid on an in-floor turntable at Nissan North America's Smyrna plant
280) A Nissan associate conducting a series of electronic tests on the Altima Hybrid at the automaker's Smyrna plant
281) A Nissan associate conducting a series of electronic tests on the Altima Hybrid at the automaker's Smyrna plant
282) Large display registering Altima Hybrid test results
283) A Nissan associate showing a safety glove worn by Altima Hybrid inspectors
284) Pallet containing motor-generators next to a dedicated motor module subassembly station at Mitsubishi's Mizushima plant
285) Assembly of the i-MiEV's motor module begins at a dedicated substation along the main assembly line in Mitsubishi's Mizushima plant with a worker attaching the motor-generator to the module's frame
286) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
287) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
288) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
289) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
290) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
291) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
292) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
293) i-MiEV motor module assembly at Mitsubishi's Mizushima plant
294) Completed i-MiEV motor module assembly
295) The motor module being machine-lifted into the i-MiEV's rear compartment
296) The motor module being machine-lifted into the i-MiEV's rear compartment
297) The i-MiEV's motor module being manually tightened
298) The i-MiEV's motor module being manually tightened
299) Hoses and other components being attached to the i's 660cc gasoline engine on the same line as the i-MiEV
300) Hoses and other components being attached to the i's 660cc gasoline engine on the same line as the i-MiEV
301) High-voltage wiring (orange wires) being attached to the underbody of the i-MiEV
302) High-voltage wiring being attached to the underbody of the i-MiEV
303) High-voltage wiring being attached to the underbody of the i-MiEV
304) High-voltage wiring being attached to the underbody of the i-MiEV
305) High-voltage wiring being attached to the underbody of the i-MiEV
306) The underbody of the i-MiEV showing orange high-voltage wiring
307) The i-MiEV's 16-kWh lithium battery pack on a pallet along the Mizushima plant's trim line
308) The i-MieV's lithium battery shown from the rear of the car covered by a plastic sheet
309) The-i-MiEV's lithium battery, covered by a plastic sheet, shown from the front door of the car
310) Leaf shown on Oppama No. 1 plant trim line with other models
311) Leaf seen with another model
312) Leaf motors awaiting installation alongside the line
313) Oppama plant worker attaching underbody components as the car's lithiumion battery awaits installation
314) The Leaf's lithium battery awaiting installation
315) The Leaf's battery being installed
316) Inverter module being readied for installation
317) Inverter-motor assembly being mounted
318) Leaf inspection at the end of Oppama's No. 1 production line
319) Leaf inspection at the end of Oppama's No. 1 production line
320) The Leaf being rolled off the line
321) Completed Leafs lined up for shipment to dealers
322) The Leaf's lithium-ion battery being assembled at AESC's Zama plant
323) The Leaf's lithium-ion battery being assembled at AESC's Zama plant
324) Motor winding station at Nissan's Yokohama engine plant
325) Inverter assembly at AESC's Zama plant
326) Inverter assembly at AESC's Zama plant
Note: Photos 310, 315, 316, 317, 318, 320, 322, 323, 324, 325 & 326 were supplied by Nissan.
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