DIY Electric Car Forums banner

A look at the new Tesla cells

11902 Views 124 Replies 14 Participants Last post by  Kevin Sharpe
2170 cells replaces 18650 standard at the Gigafactory.

Doubtful they will be available to DIY community, though. The big boys will probably contract full production.
41 - 60 of 125 Posts
His dyno # was 588hp, not kW. And wheel power is measured the same regardless of the power plant; engine (ICE) or electric motor or steam engine. hp or kW are just units. Power is the same .

major
Ahh ... thanks for the correction. That is a lot better.

My point is that the dyno, made for the sports and muscle car market, will tend to overrate things. I have seen that in a slightly different context, that power by ICE is discounted when compared to electric power. By as much as a factor of 1.4. See for example Torqeedo.com. So power is not the same if marketing says so.
Dual (or even triple) 'parallel' reduction is the way to go. Should make the gearheads happy.
take a look at the graph I posted in #30
http://www.diyelectriccar.com/forums/showthread.php?p=885953#post885953

it stays within 15% of 588 hp from ~45mph to 110mph!

parallel clutch paths need multiple gear reductions and efficiency hits, and you are adding a high wear item in a very demanding application, so a driveline that would have lasted a million miles now needs service every 20k miles.

a lower gearing won't help anything (unless tire smoke is a thing), and it doesn't have any problems that need fixing at 150+mph on the high end, and a 10 second 1/4 mile! holds peak torque from 0 to near 60mph in 2.27 seconds, what more do you want?!? dual clutch whatsit is not gonna last or help (noise, lol).

It could use a diet @ 5,000 lbs, and an appropriately lower ratio at the same time, that's about it.

they tried the dual speed transmission, it didn't hold up, and didn't really buy them much except headache and expense. They are hitting all the high profile performance metrics without it. And you have like 2 moving parts...

http://www.autoblog.com/2008/01/23/breaking-tesla-has-a-solution-for-their-transmission-woes-get/
See less See more
...
In the chart, look at 55 mph. R_Tq for the L is 255 (whatever unit) and at 75 mph 163 and at 90 mph is 130.
55*255 = 14,025
75*163 = 12,225
90*130 = 11,700
Whatever the unit may be. You can see the power to the wheels decreasing, even though power input is almost constant. Between 55 mph and 90 mph, power input drops 3.4% while power output drops 16.6%...
That's the approach which I was suggesting.
The problem with these values is that the output (based on torque and road speed) is for only the rear motor of this two-motor AWD vehicle, while the electrical power input is for both motors.
So power is not the same if marketing says so.
I don't care much about marketing. Never have believed a car salesman.
With a higher drive reduction ratio, they can get more torque for less power at the start...
They can get more torque at the wheels below the current threshold speed - which they don't need - but not necessarily for less electrical power per unit of mechanical power.
...
A dual clutch gearbox with only two gears can be designed by their engineers in their sleep. I fail to see the challenge in shifting gears with a dual dry clutch. They will kill two birds with one shot. I am certain electric supercars will all be multi-gear.
I agree that a dual-clutch design is the obvious solution for automated shifting of a two-speed gearbox, and especially for multiple gearboxes (due to multiple motors). The Rimac Concept_One (more of a technology demonstrator than a production car, but a more-than-million-dollar extreme performance exotic) has this type of transmission for each rear drive motor (one per wheel).

On the other hand, most electric drive motors, even in megadollar hybrids and electric concepts, drive through single-speed gearboxes. Even the Concept_One only had two-speed gearboxes at the rear, not the front. The two-speed seems easy, but manufacturers are not consistently finding it worthwhile.
It should be noted that according to the chart, the vehicle is drawing almost 40 kW at standstill. Compare this to a Leaf's 0.5 kW base load. I would guess that this may be the result of entering Ludicrous mode and the cooling system is feverishly pre-engaged to cool down the systems and the pack, prior to the sprint.
It could be that the cooling system is running, but that wouldn't take anything close to 40 kW and my guess - since the chart shows substantial torque output at zero speed - is that the motors are being driven and the car is being held by the mechanical brakes. This is the electric version of the classic run-up before launching, and should be expected of a current automated launch system (which would not be expected in a Leaf). Unlike other current production EVs and hybrids, Teslas have induction motors, so the stator field is rotating (at the slip speed) with the motors stalled - it seems to me that could take substantial power.

(I see now that Karter2 already explained the launch mode, but I'll leave my longer version.)

Maybe they're running the motors at stall in part to do the pre-heating that Karter2 mentioned.
The two-speed seems easy, but manufacturers are not consistently finding it worthwhile.
sure, just take a bulletproof existing design and throw in a couple clutches and gears that can handle the 1000 odd foot pounds and 16,000 rpm, for an imperceptible change in performance and efficiency, what could go wrong?
Wow - at this ratio, the motor RPM is about 21,000 at 95 mph assuming 245/45R19 tires. Does this reduction include the differential?
The Tesla gearbox is the most common layout for production EVs, which is a two-stage helical spur gear train. The final gear is the ring gear around the differential, just like a typical transverse front-wheel-drive transaxle, so yes... that quoted reduction ratio is the motor to wheel speed ratio.

At 21,000 RPM you are smoking a lot of things, and the noise is certainly not so pleasant (if you can hear that frequency!).
I haven't had a ride in a Tesla, so I have no idea what it sounds like, but I don't know why anyone would assume "at 21,000 RPM you are smoking a lot of things". Lots of machines run much faster than that, including gear trains and electric motors.
major, thanks for the charts - they are very helpful.

Does the inefficiency also reduce the torque, or just the output power?

The first chart, running at 4000 rpm with 90 Nm of torque requires about 38 kW. Let's say this is an electric Smart car. With a tire circumference of 1.1 m and a reduction ratio of 7:1, you get 37 kph. The efficiency is 92%. At 35 kW power, you will be accelerating quite a bit. So you accelerate to 74 kph and the rpm is 8000. Your efficiency is about 93%. Now you are approaching 111 kph which is 12,000 rpm. From the chart you see that the efficiency is quickly being pushed down to 80, 70, and then 60%. The faster you go, efficiency drops dramatically.

What is causing this sudden drop in efficiency?

It goes to show that depending on the motor and load conditions, the motor can become so inefficient that if we just increase the power without accelerating, we will actually be using less power, per unit of work.

BTW. my calculation for RPM was amiss. Karter2 has the correct speed.
See less See more
sure, just take a bulletproof existing design and throw in a couple clutches and gears that can handle the 1000 odd foot pounds and 16,000 rpm, for an imperceptible change in performance and efficiency, what could go wrong?
The gears are no problem, but yeah... with the clutches, the two-speed only seems easy. The design is actually straightforward, but dual-clutch transmissions in conventional cars have had varying success with durability of the clutches... although most work fine, even while shifting much more frequently than a 2-speed would require and slipping to get started (which the electric drive would not). It can certainly work, but most manufacturers think the risk or cost or weight or bulk or something is not worth the improvement in efficiency or available power.
Lithium cells have reduced IR at certain temperatures..depending on the exact chemisty...but generally in the 30-50 deg C range.
Your heat figures are way off.
With each cell discharging 15 A @ 40mohm IR...it will generate approx 9 watts of heat.
With 8000 cells that means a total of 72kW of heat....for 10 secs !!
Do some heat theory maths and see what that means in a 600kg battery pack
...not a melt down situation.
EDIT....to save having to correct any mistakes you may make on that heat calculation, you can look up battery cell tests for this type of cell.
At a constant 15A discharge the cell increases in temp by les than 5 degC after one minute !
BUT.. The power electronics in the inverter controls may not take so well to dealing with the 500+ KW they are handling .
Teslas pack "cooling" system is dual function..cooling and heating.
Apparently it is more often used to coolthe pack during supercharging (30+ minutes at 1-2C) especially in hot climates after a high speed run.
...and also for preheating the pack in cold climates..again particularly before charging.
See less See more
The first chart, running at 4000 rpm with 90 Nm of torque requires about 38 kW. Let's say this is an electric Smart car. With a tire circumference of 1.1 m...
The standard rear tires for a smart are 185/60R15, which have a rolling circumference of 1.83 m. 1.1 m would be ridiculously small - 350 mm or 13.8" diameter, which is much smaller than the tires on 10" wheels of an original Austin Mini. It doesn't matter to the Telsa battery, but if you're working out examples, they won't produce realistic speeds with the wrong tire size.
fwiw I do think that a clutchless 2 speed shifting is gonna be a thing at some point. With hi resolution control over motor speed or even gear tooth position (yes, possibly the return of sliding mesh, it is simpler mechanically and more efficient) it will be able to snick it up or down no problem. but it will be for lower powered commuters, or Bonneville.

I really don't see where it helps looking in the graph in post #30, you drop the ratio by 10% the rpm drops to a point with %10 more motor torque (no change in wheel torque), and the power is basically flat anyway., and the performance is more than adequate as is for a road car.
Im not a motor technology guy, but there was a comment on the Tesla forum suggesting that the profile of the Torque plot on that graph , ...in particular the flat constant value for the first several thousand rpm....suggests that the maximum torque available is being limited by the control systems (current limiting ?).
Implying that even more torque is potentially available via software and or harware alterations...One of which may well be a higher power capacity battery.
Major, ?..Brian ?...anyone,...any view on this ?
yep, flat top means you are at the limit of the controller.

i.e. the flat part of the torque curve is the controller limiting motor current, and a flat top on the power curve is probably the controller limiting battery current.

i.e: http://media3.ev-tv.me/Azure300VDC-400Acurve.pdf a serious flat top.

when at the power limit, the motor behaves like a CVT, which is nice.
Does the inefficiency also reduce the torque, or just the output power?

What is causing this sudden drop in efficiency?

It goes to show that depending on the motor and load conditions, the motor can become so inefficient that if we just increase the power without accelerating, we will actually be using less power, per unit of work.
Hi Sol,

Doesn't seem the place to answer those two questions and you really need a study in motor design and a look at the particular one in question. The only "sudden" drops in efficiency which I see are near zero torque or zero speed, areas where the motor spends little duration and/or are of such low power that poor efficiency accounts for little loss. Obviously if you push any motor beyond its intended application you can encounter consequences.

You seem to imply that multiple ratios can buy performance at the top end, high speed & high power. I fail to follow that logic. When you have sufficient motor properly geared to handle the top end, you'll have plenty for the entire operational region in most applications. Even the drag race is better handled with one ratio.

I realize there are those who disagree. One in particular is John Metric. He occasionally visits this board. You might look at his efforts in the electric 1/4 mile. Lonestar Racing IIRC. NEDRA.com

Regards,

major

Edit:

It goes to show that depending on the motor and load conditions, the motor can become so inefficient that if we just increase the power without accelerating, we will actually be using less power, per unit of work.
I reread the above statement and can't make any sense out of it. But I think it is academic anyway because nobody would operate a motor at such a condition.
See less See more
yep, flat top means you are at the limit of the controller.
...
Well sure, but that limit is set to prevent exceeding or closely approaching breakdown torque in the case of the induction motor. Beyond BDT, more motor current doesn't produce more torque, less in fact.

Edit: attachment from: http://what-when-how.com/induction-...-control-constant-voltshertz-induction-motor/

Attachments

See less See more
the neat thing about that graph is how much the peaks resemble a series motor torque curve.

but yah, you can't overload it on the low end like a series, cuz you are just saturating a shorted transformer at some point.



edit, it could be a controller limit (switch rating) or pre-determined motor limit enforced by the controller.

edit2, I don't even understand armature reaction fully, so take it w/a grain of salt.
See less See more
Here is a little wild "internet rumour"....
http://www.teslarati.com/tesla-4416-lithium-battery-cell-model-3-next-gen-s-x/
..tesla using a "44160" format cell in the new model 3 ! :rolleyes:
41 - 60 of 125 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top