WHAT’S IN THE BOX? – BYD’s 8-in-1 electrification system at a glance – Part 2

Twice a month, Yole SystemPlus analysts share the noteworthy points from their automotive Teardown Tracks. Today, Benjamin Pussat, Technology & Cost Analysts at Yole SystemPlus, part of Yole Group, takes us to the heart of BYD’s all-in-one high-voltage powertrain, the most integrated electrification system on the market.

BYD claims that its 8-in-1 system is 16% more compact, 10% lighter, and saves on BOM and assembly costs compared to their former generation stand-alone systems. A few weeks after Yole SystemPlus’ first revelations (1) about the system architecture, let’s see what their experts have found out about the subject when each sub-function of BYD powertrain (excluding the e-motor and reducer) is compared to a sampling of non-Chinese stand-alone systems.

Yole SystemPlus is a Yole Group company.

Yole SystemPlus conducted volume, weight and cost comparative analyses considering six of the eight functions: inverter, OBC, DC-DC, BMS, VCU and PDU. The estimated savings stand at a significant 25%, 20%, and 18%, respectively. These gains offer substantial benefits, including increased space for passengers or the integration of additional functionalities, and enhanced autonomy due to a lower energy consumption. However, there are notable drawbacks to this ultra-integration approach: complex vehicle layout with one bulky component, challenging thermal management and EMI (electromagnetic interference), and a higher overall failure rate. Nevertheless, this is not slowing down the ongoing trend towards greater integration, as evident in the 7-in-1 systems from Chang’an and Leapmotor, alongside the recently announced Valeo 6-in-1 eAxle.

Concurrently, the Chinese OEM has embraced a self-sufficiency strategy, sourcing at least 40% of the total cost of materials from in-house manufactured or assembled parts. Chinese players constitute 79% of total material costs (including BYD), with companies like Sinofuse and Chnbel contributing to mechanical and key parts, and Faratronic and Sun & Lynn Circuits supplying electronic parts.

Yole SystemPlus remains committed to following up this evolution trend by planning more teardown tracks to enrich the technology and cost comparison tool available online.

Stay tuned for our next What’s in the box? review!

Yole SystemPlus Automotive Teardown Tracks are the result of detailed physical and costing analyses. They are carried out by experts with academic and industrial backgrounds in the semiconductor domain. Yole SystemPlus Automotive Teardown Tracks offer a clear and fruitful understanding of the technical choices made by the leading manufacturers. It also reveals accurate insights related to manufacturing costs.

The company covers the overall supply chain from the components to the system. Based on daily technical and industrial monitoring, Yole SystemPlus has significant expertise to support innovation.

Benjamin Pussat is a Technology & Cost Analyst at Yole SystemPlus, part of Yole Group. With solid expertise in electronic systems and with a specific focus on automotive systems, Benjamin produces reverse engineering & costing analyses while also working on custom projects for the electronic systems teams. Benjamin identifies and analyzes the overall manufacturing process and determines the technical choices made for the system components. The objectives of this analysis are to understand the structure of the device, identify all the relevant components and determine the final manufacturing cost.

In addition, Benjamin updates internal tools and runs custom training sessions and demos with industrial organizations. He has also published some articles in the press.

Prior to Yole SystemPlus, Benjamin worked as an Engineering Technician at SEIA.

Benjamin holds a University Diploma in Technology in Electrical Engineering and Industrial Computing (Université de Nantes, France).

This article has been developed in collaboration with Yu Yang, Senior Technology & Market Analyst, from Power and Wireless Division at Yole Intelligence, and Amine Allouche, Technology & Cost Analyst from Yole SystemPlus.

Source: www.yolegroup.com