tesla model s 60_benchmarking overview_v2 - preview

Version 1

©Ricardo 2015

2013 MY TESLA MODEL S60 - 60 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 2

Ricardo Inc. has taken all reasonable care in compiling the analyses and recommendations provided in this report. Information contained in this report is based on limited data available to Ricardo believed correct

on the date of publication. Ricardo does not assume any liability, provide any warranty to activities based on the contents of this report.

This report is restricted and may not be distributed, re-published, sold or exchanged outside use by purchased companies.

Disclaimer

INTRODUCTION

[email protected] +01-734-394-3939


Executive Summary

• In 2014, Ricardo and partner A2Mac1 conducted a benchmarking teardown and

analysis review of a 2013MY Tesla Model S 60 (60 kWh) vehicle

• This report provides an over view of:

– Selected vehicle features

– High voltage battery pack design

• Enclosures

• Thermal system

• Battery module

• Battery cell

• Battery management system

– High voltage junction box

– Motor and motor controller (inverter) module

– Charging system & DC-DC converter

• Most imagery is courtesy of A2Mac1 and Ricardo and is available through

A2Mac1.com subscription services and may be purchased by contacting

A2Mac1.com or EVanalysis@ Ricardo.com. This report provides a review of selected

vehicle and component features, suppliers and patents

• Additional information is provided in the Appendix of this document including

publicly available US governmental agency reports, patent files and component

specification sheets where known

INTRODUCTION


1. Vehicle………………………………………………………………………….…..4

2. Battery Pack……………………………………………………………….……12

3. Battery Module………..…………………………………………..…………37

4. Battery Management System…………………………..………………45

5. Traction Motor & Inverter……..……………………..…………………53

6. High Voltage Junction Box………………..………..……………………76

7. DC/DC Converter…………………..…………………..……………………79

8. Charging System…………………………………..…..………………......82

9. Appendix……………………………………………...………………………..94

Table of Contents


Benchmarked Vehicle Overview

Note — Per February 1st 2012 letter from TESLA to EPA:

Model S Variant

Range per UDDS(in miles)

ZEV Classification

ZEV credits/ vehicle

S1 160 Type III ZEV 4

S2 230 Type IV ZEV 5

S3 300 Type V ZEV 7

* Source: http://iaspub.epa.gov/otaqpub/display_file.jsp?docid=28443&flag=1

As Published Tesla Lithium Ion Battery Emergency Response Guide As Measured (via Benchmark)

Specifications Units Pack Module Pack Module

Nominal Voltage VDC 310-360* 22 3XX 2X

Max. Voltage VDC 360-410* 26 - -

Weight kg 400-600* 16-26* XXX 2X

Dimensions

Length cm 270 70 2XX XX

Width cm 152 30 1XX XX

Height cm 20 8 2X X

Values vary w/ pack and module model

Tesla ‘Lithium-Ion Battery Emergency Response Guide, Model S’. Release Date:17 April 2013

Electric Architecture Battery electric vehicle Vehicle Model Year 2013

Battery Location Under vehicle floor Vehicle Market North America

Battery Cooling Ethylene glycol Vehicle Price as Purchased $73,070

Battery Configuration XXXX All Electric Range (label) 208 miles (EPA)

Battery, Number of Cells X,XXX6 Plug-In Charging Voltage 120V, 240V & Supercharging

Battery Capacity 6X kWh Vehicle Mass (as weighed) 1.955kg

Battery Voltage (label) 3XXVDC Seating (as purchased) 5 adults

Battery Cell Type Cylindrical (18650) Motor Architecture3-phase, 4-pole AC induction

motor (per service manual)

Battery Cathode Chemistry XXXX Motor Max Speed 14,800rpm

Electric Motor Peak Torque XXX Nm Gearbox Single speed fixed gear

Electric Motor Peak Power XX5kW Final Drive Ratio 9.73:1

VEHICLE

Vehicle teardown

conducted on the S2

(60kWh) vehicle)


Vehicle HV Electrical Equipment Schematic

Index Explanation

1 XXXXX

2 XXXXX

3 Junction Box

4 XXXXX

5 Motor/Gearbox/Inverter Module

6 XXXXX

7 Battery Pack

8 XXXXX

9 Charging Port

VEHICLE

6

1

7

5

98

32 4


Key System and Component Suppliers

Battery Pack Tesla (Fremont, CA)

Traction Motor Tesla (Fremont, CA)

On-Board Charger System Tesla (Fremont, CA)

Battery Tray (Lower) XXXX

Battery Cell Panasonic

Battery Module Current Collector XXXX

DC-DC Converter XXXX

AC-DC Inverter Capacitors XXXX

AC-DC Inverter IGBT Devices XXXX

Electric Cabin Heat XXXX

Battery Pack LV Wire Harnesses XXXX

Battery, 12V XXXX

Traction Motor – Rotor (fig. 1) Tesla, Freemont, CA

Traction Motor – Stator Tesla, Freemont, CA

From Blanco, Sebastian. AUTOBLOG Green.

“Tesla questions if Chevy is first OEM building electric vehicle motors in US?”. 17 Apr. 2013:

“Tesla told AutoblogGreen:

‘We manufacture all parts of Model S motors here at the factory in Fremont, California. We have a winding

line at the factory where we wind our own stators off of spools. We also manufacture the rotors and other

components to the unit”.

VEHICLE

Source: http://green.autoblog.com/2013/04/17/tesla-questions-chevy-first-oem-building-electric-ev-motors-us/


Battery Pack Attachment to Vehicle: (34)x Fasteners

Ve

hic

le F

ron

t

Ve

hic

le R

ea

r

Front Pack Corner to

Vehicle Bolts

Qty: 2

Center Pack to

Vehicle Bolts

Qty: 12

Side Pack to Vehicle

Bolts

Qty: 16

Front Pack to Vehicle

Bolts

Qty: 4

BATTERY PACK

2 3 41


Battery Pack Section (2/2)

X7

X5

X

X

X5

XX.5

7

12

1

X

RTV

(compressed)

Weather

Seal

(compressed)

Blanket

(uncompressed)

BATTERY PACK


Battery Pack Electrical Power Distribution System

BATTERY PACK


60 kWh (S2) Battery Module – Cell to Cell Interconnect Architecture

Fusible link from cell to

current collector

1 ea. on cell top and

cell bottom

(1) of (X) current

collectors per

module

- Terminal

+ Terminal

Close up view of XXX

current collector

manufactured by XXX

BATTERY PACK

• For the S2 modules: (X)x current collectors are epoxied to (X)x ‘sub-modules’ each of (XX)x cells

& (XX)x empty shapes

• Fusible links connect each cell to the current collector

CAD model available on

Ricardo’s eStore

[email protected]


Master PCB Major Components

BATTERY MANAGEMENT SYSTEM


Stage 3 Coolant Flow: Inverter Housing

TRACTION MOTOR & INVERTER


Rotor Geometry

TRACTION MOTOR & INVERTER

50

XX4

XX4

XX3

1XX

1XX

1XX

• Lamination material area (net

after stamping) = 1XX.5 cm2 ea.

• XXXX w/ CX coating

• Total rotor lamination mass

est.=1X,X00g


DC-DC Converter Construction (in mm)

DC/DC CONVERTER


Contact Information

Ricardo Strategic Consulting (RSC) is the global management consulting subsidiary of Ricardo PLC and is a

natural extension of Ricardo's high value-added engineering services. We serve a broad range of clients in

both the Automotive & Transportation sectors.

Coupling Ricardo’s significant work in the xEV sector product development and strategy consulting with

A2Mac1, the industry’s most recognized provider of web-accessible automotive benchmarking services,

provides an unique toolset that supports companies efforts to deliver innovative, high-value services to their

global automotive clients.

The following vehicles have be benchmarked:

Hands-on workshops, interactive benchmarking tools, and battery CAD models are available for purchase.

[email protected]

+01-734-394-3939

http://estore.ricardo.com/

Ricardo Benchmarking

CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITES

APPENDIX

Workshops CAD ModelsEV/Hybrid Analysis

• 2014 VW e-Golf

• 2014 BMW i3 w/ Range Extender

• 2014 VW Jetta Hybrid

• 2014 Chevrolet Spark EV

• 2013 Tesla Model S 60 (60kWh)

• 2013 Ford Fusion Hybrid

• 2013 Ford C-Max Energi

• 2013 Chevrolet Malibu Eco

• 2012 Toyota Prius Plug-in Hybrid

• 2011 Chevrolet Volt

• 2011 Nissan Leaf

• 2011 Mitsubishi i-MiEV

tesla model s 60_benchmarking overview_v2 - preview

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