An Overview of Parameter and Cost for Battery Electric Vehicles

König, Adrian; Nicoletti, Lorenzo; Schröder, Daniel; Wolff, Sebastian; Waclaw, Adam; Lienkamp, Markus · 2021 · OpenAlex-citations

DOI: 10.3390/wevj12010021

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Summary

This review paper addresses the evolving cost structures and technical parameters of battery electric vehicles (BEVs) and autonomous vehicles (AVs), driven by the automotive industry’s shift toward electrification and automation. The authors aim to provide manufacturers and researchers with a comprehensive overview of relevant design parameters and costs to facilitate the development and optimization of future vehicle concepts. The study is motivated by the need to understand how new technologies, such as traction batteries and autonomous driving sensors, alter vehicle weight, purchase price, and overall feasibility compared to internal combustion engine vehicles (ICEVs). The methodology consists of an extensive literature review, supplemented by data from technical experts and internet sources. The authors standardized their cost assessments by applying a fixed 2019 exchange rate ($1.13 to €1) and adjusting for inflation, assuming all component costs apply to manufacturers. The analysis categorizes findings into vehicle parameters, mobility, infrastructure, and energy, with a primary focus on the BEV powertrain, including the traction battery, electric machine, gearbox, and power electronics. Key findings highlight that battery costs currently account for up to one-third of total BEV costs, though falling prices are projected to reduce the price gap between BEVs and ICEVs to 9% by 2030. The paper details trends in lithium-ion battery technology, noting that gravimetric energy density is expected to reach practical limits of 350–370 Wh/kg by 2030, while volumetric density may approach 1000 Wh/L for all cell types. The authors derive a regression model indicating that usable net battery energy is approximately 92% of gross installed energy. Battery pack costs vary significantly with production volume, ranging from 157 €/kWh for high-volume models to nearly 400 €/kWh for low-volume vehicles, with an economic parity threshold with ICEVs estimated at 91 €/kWh. Regarding electric machines, permanent magnet synchronous machines are priced at 10 €/kW and induction motors at 8 €/kW, with manufacturers targeting gravimetric power densities of 5 kW/kg. Gearbox efficiencies for BEVs are reported between 92% and 97%. The significance of this work lies in its provision of updated, standardized benchmarks for BEV development. By synthesizing disparate data sources into a coherent framework, the paper enables engineers to assess the trade-offs between technical performance and cost. It underscores that while battery technology is approaching physical limits in energy density, cost reductions through economies of scale and manufacturing optimization remain critical for market competitiveness. The overview serves as a foundational reference for planning future vehicle concepts that balance technical suitability with economic viability.

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