Version 1

Ricardo 2015
INTRODUCTION

Disclaimer

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.

EVanalysis@Ricardo.com +01-734-394-3939

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INTRODUCTION

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

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Table of Contents

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

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VEHICLE

Benchmarked Vehicle Overview

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

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

Model S Range per UDDS ZEV
ZEV credits/ vehicle
Variant (in miles) Classification
S1 160 Type III ZEV 4
Vehicle teardown
S2 230 Type IV ZEV 5 conducted on the S2
S3 300 Type V ZEV 7 (60kWh) vehicle)

* 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

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VEHICLE

Vehicle HV Electrical Equipment Schematic

1 2 3 4 5

6 7 8 9

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

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VEHICLE

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.

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

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 BATTERY PACK

Battery Pack Attachment to Vehicle: (34)x Fasteners

Front Pack Corner to Center Pack to Side Pack to Vehicle Front Pack to Vehicle
Vehicle Bolts Vehicle Bolts Bolts Bolts
Qty: 2 Qty: 12 Qty: 16 Qty: 4

1 2 3 4
Vehicle Front

Vehicle Rear

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BATTERY PACK

Battery Pack Section (2/2)

Blanket
(uncompressed) RTV Weather
(compressed) Seal
(compressed)

12
X
1
X

X5

XX.5
X7

X5
7

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BATTERY PACK

Battery Pack Electrical Power Distribution System

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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 + Terminal

cell bottom

- Terminal

CAD model available on

Ricardos eStore
EVanalysis@Ricardo.com

(1) of (X) current

collectors per
Close up view of XXX module
current collector
manufactured by XXX

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

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BATTERY MANAGEMENT SYSTEM

Master PCB Major Components

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TRACTION MOTOR & INVERTER

Stage 3 Coolant Flow: Inverter Housing

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TRACTION MOTOR & INVERTER

Rotor Geometry

1XX

1XX

1XX

XX4

XX4

XX3

50

Lamination material area (net

after stamping) = 1XX.5 cm2 ea.
XXXX w/ CX coating
Total rotor lamination mass
est.=1X,X00g

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DC/DC CONVERTER

DC-DC Converter Construction (in mm)

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 APPENDIX

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 Ricardos significant work in the xEV sector product development and strategy consulting with
A2Mac1, the industrys 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:

2014 VW e-Golf 2013 Ford C-Max Energi

2014 BMW i3 w/ Range Extender 2013 Chevrolet Malibu Eco
2014 VW Jetta Hybrid 2012 Toyota Prius Plug-in Hybrid
2014 Chevrolet Spark EV 2011 Chevrolet Volt
2013 Tesla Model S 60 (60kWh) 2011 Nissan Leaf
2013 Ford Fusion Hybrid 2011 Mitsubishi i-MiEV

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

Workshops EV/Hybrid Analysis CAD Models

EVanalysis@Ricardo.com http://estore.ricardo.com/

+01-734-394-3939 Ricardo Benchmarking

CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITES

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