Yaskawa CIMR-AB4A0018FAA Inverter Teardown

Feature Significance

The Yaskawa A1000 Series, being a relatively recent market offering, represents the latest technology in motor control, and offers a host of features designed to provide superior performance flexibility and efficiency. Many control and interface features not commonly found together in a single device are combined here, including an assortment of networking options and configuration tools.

Design Significance

From a design perspective, the A1000 Series features many characteristics intended to optimize flexibiltity and custom configurability. These include a replaceable display/interface module, several connectivity sub-assembly options, and user-configurable tools.

Yaskawa CIMR-AB4A0018FAA Inverter Main Image

Industrial - Mfg

AC motor drive equipment such as this is typically employed in factory environments, where automated control of motor-driven systems is required.

Released

2010

While specific market release data is unknown, it is evident from the available literature that the A1000 product line was introduced sometime in the 2010 calendar year, making this a relatively new solution.

Yaskawa CIMR-AB4A0018FAA Inverter - Disassembly View 1

Yaskawa CIMR-AB4A0018FAA Inverter - Disassembly View 1

~$1200

Because the manufactuer does not offer any published price lists, and because the wide array of available options make it difficult to specifically identify the cost of the exact configuration of the sample we have analyzed, the exact cost is unknown. However, based on our research and the available data, we estimate a list price of approx. $1200. Typical retail price including a retailer's discount would likley be in the $800 range.

Volume Estimations

24,000 Total Units
5 Total Years

For the purposes of this teardown analysis, we have assumed an Annual Production Volume of 24000 units and a Product Lifetime Volume of 5 year(s).

Teardown volume and production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.

Yaskawa CIMR-AB4A0018FAA Inverter Cost Analysis

Yaskawa CIMR-AB4A0018FAA Inverter Cost Analysis

Listed below are what we have found to be the 10 highest-cost line items in the BOM. These components have the greatest cost-driving effect, and may typically represent the areas where the highest attention might be paid for any potential cost savings.

Total BOM: $204.14
Top Cost Drivers below: $117.56
% of Total BOM 58%

Main Cost Drivers below

Fuji Electric 7MBR25U4P120-50 IGBT Module - 1200V, 25A- (Qty: 1)
Isahaya Electronics VL1130-02R-03 Hybrid IC Power Control Module - IGBT Driver- (Qty: 1)
Enclosure, Main, Center - Die-Cast Aluminium Alloy- (Qty: 1)
Panasonic HE1aN-P-DC15V Relay - SPST, 277VAC, 30A- (Qty: 1)
Current Sensor Module - Hall-Effect Sensor w/ Renesas uPC4570G2 Op Amp- (Qty: 3)
Yamamoto 4-Layer - FR4, Pb-Free- (Qty: 1)
- (Qty: 1)
Liang Dar Technology - (Qty: 1)
Sanwa Electronic Circuit - (Qty: 1)
Renesas R5F72856D100FPV MCU - 32bit, SH-2A CPU, 768Kbyte Flash ROM, 32Kbytes RAM, 12Bit x 8Ch ADC, 89 I/O Ports, UART/USB, 100MHz- (Qty: 1)

Not Included in Analysis

The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.

Manufacturing Notes

Yaskawa is known to have their own manufacturing facilities, rather than use contract manufacturing. Specifically, Yaskawa states that their main AC Drive production facility is located in Fukuoka, Japan.

Country of Origin

For the purposes of this analysis, we are assuming the following country(ies) of origin for each level of assembly, based on a combination of 'Made In' markings, and/or assumptions based on our knowledge of such equipment.

Box Contents - China
Daughter PCB - China
Interface PCB - China
Inverter PCB - China
LED Operator PCB - China
Other - Enclosures / Final Assembly - China
Relay PCB - China

Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies, we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.

Labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.

Design Complexity

Component counts by assembly and the number of assembly are indicators of design complexity and efficeincy.

Component Qty: 502 - Inverter PCB
Component Qty: 81 - Other - Enclosures / Final Assembly
Component Qty: 287 - Interface PCB
Component Qty: 35 - Daughter PCB
Component Qty: 137 - Relay PCB
Component Qty: 72 - LED Operator PCB
Component Qty: 3 - Box Contents
Component Qty: 1117 - Grand Total

Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for China.

Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.

Design Notes

As Yaskawa is a Japanese manufacturer, it would be expected that many Japanese components would be found in the device; and indeed it is evident that Yaskawa has a rather extensive relationship with Renesas, who is by far the greatest source of silicon semiconductor components within the A1000. In fact, even in the major custom IC's it was found that the fabricator of the internal silicon die is Renesas.

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Yaskawa CIMR-AB4A0018FAA Inverter - Box Contents

Yaskawa CIMR-AB4A0018FAA Inverter - Box Contents