Nissan LEAF Teardown: Comparison of the Gen1 and New EV electric units (with photos)

Comparison of the 2010 and 2017 Nissan Leaf’s EV Powertrain System major components

2019/08/14

Summary

 At the Electric Vehicle Teardown Training session (on July 11, 2019) conducted by Shizuoka prefecture’s Hamamatsu Industrial Technology Support Center and the Hamamatsu Agency for Industrial Innovation’s Next-Generation Automotive Center, components were exhibited and lectures explained how the 2010 first generation and new 2017 Nissan Leaf have evolved.

 This report explains the differences between the main components of the EV powertrain system electric units of the 2010 Leaf and the 2017 Leaf (e.g. inverter, DC/DC converter, on-board charger, drive motor) using accompanying photo images.

 

Comparison of key differences between Nissan’s Gen1 and the New Leaf

Vehicle/Specifications ZAA-ZE1
(MY 2017)
ZAA-AZEO
(MY 2012)
ZAA-ZEO
(MY 2010)
Length×Width×Height 4480×1790×1540mm 4445×1770×1550mm 4445×1770×1545mm
Wheelbase 2700mm 2700mm 2700mm
Curb weight 1490kg 1450kg 1520kg
Seating capacity 5 5 5
AC Power consumption (JC08) 120Wh/km 117Wh/km 124Wh/km
Single charge range (JC08) 400km 280km 200km
Drive battery type Lithium ion battery Lithium ion battery Lithium ion battery
Total voltage 350V 360V 360V
Total capacity 40kWh 30kWh 24kWh
Motor type EM57 EM57 EM61
Max. output kW (PS)/rpm 110(150)/3283~9795 80(109)/3008~10000 80(109)/2730~9800
Max. torque N・m (kgf・m)/rpm 320(32.6)/0~3283 254(25.9)/0~3008 280(28.6)/0~2730
Power transmission final drive ratio 8.193 8.1938 7.9337
Drive system Front-wheel drive Front-wheel drive Front-wheel drive

Source: Nissan Motor Co., Ltd. website

 

Technical assistance system for companies in Shizuoka prefecture

 In terms of the amount of goods manufactured by prefecture, Shizuoka prefecture’s output is on par with that of Osaka, and is ranked third, following Aichi prefecture, which ranks first in terms of manufactured goods shipped by prefecture, and Kanagawa prefecture, which ranks second. The largest industry sector in the prefecture is related to transportation equipment, accounting for 25% of the total value of goods shipped, which is about twice as large as that for the electrical equipment sector (from an industrial statistics bulletin issued by the Japanese government in 2018). In addition, the city of Hamamatsu has the largest population in the prefecture, and when combined with the neighboring cities of Iwata and Kosai, accounts for about 1/3 of the total value of manufactured goods shipped by the entire prefecture of Shizuoka. In light of this industrial climate, Shizuoka prefecture’s Hamamatsu Industrial Technology Support Center and its Economy and Industry Department’s regional Hamamatsu Agency for Industrial Innovation’s Next-Generation Automobile Center, who co-sponsored the latest Electric Vehicle Teardown Training session, are both key organizations that bear a heavy responsibility for guiding prefectural companies in developing products for the automotive industry of the future.

EV車両分解研修の講演
Presentation during the EV vehicle teardown training session

 The Hamamatsu Industrial Technology Support Center, which was the site of the training session, is one of four locations (i.e. the cities of Shizuoka, Numazu, Fuji, and Hamamatsu) as part of Shizuoka prefecture’s Industrial Technology Research Institute. The organization, as a core agency promoting the creation of new industries and the advancement of technologies, is based on a collaboration between associated industry, academia and government entities and responsible for providing local manufacturing companies with comprehensive support, such as technical consultations, use of equipment, testing services, joint research, and commissioned research.

 In this training session, in addition to providing support for facilities personnel, the Hamamatsu Industrial Technology Support Center played a central role in collaborating with the Next-Generation Automotive Center, to provide support such as technical commentary (for students), teardown operations, and management of the components.


 The center coordinates support by industry experts in advanced measurement and testing equipment, and expertise and experience in the following five technological areas to support companies in the resolution of issues in areas such as research and development, commercialization, and market development.

  • Optical: Focused on optical measurement technology. Recently, the center has been focusing on applications related to laser manufacturing technology.
  • Electronics: Specializes in EMC (electromagnetic compatibility) technology. The center has recently installed new testing equipment for applications such as in-vehicle and IoT devices.
  • Machinery: Specializes in the areas of precision measurement technologies and quality engineering. The center is engaged in numerous development activities related to next-generation vehicles.
  • Materials: Specializes in materials related areas such as testing, analysis, and failure analysis. The center is also focusing on processing and surface treatment technologies for weight reduction.
  • Fiber reinforced polymer materials: Specializes in the support and development of applications for numerous textile companies in the prefecture. The center has extensive expertise the measurement of the properties of plastics and rubber as well as the evaluation of deterioration.

 The training was attended by participants from approximately 50 companies with major business operations in the prefecture, seeking to refine their company’s technologies based on knowledge obtained through participation in the training session with the aim of enabling their companies to submit new business proposals to OEMs and major parts suppliers. In addition, the training session gave participants the opportunity to borrow the teardown components so that each specialty supplier could conduct their own in-depth benchmarking surveys. As part of the program, the results of those independently conducted surveys will be compiled by the event organizer into a report, which will then be distributed to all of the companies who participated in the training session.

 

Related reports:
Nissan LEAF Teardown: Powertrain with electromechanical structure, and drive system (Nov. 2018)
Nissan LEAF Teardown: Lithium-ion battery pack structure (Dec. 2018)
Nissan LEAF Teardown: By-wire technologies for driving, braking, and stopping (Jan. 2019)