We’ve heard a lot about the Tesla Model S over the last few years, it’s a vehicle with a habit of being newsworthy. And as a fast luxury electric saloon car with a range of over 300 miles per charge depending on the model, its publicity is deserved, and that’s before we’ve even mentioned autonomous driving driver-assist. Even the best of the competing mass-produced electric cars of the moment look inferior beside it.
Tesla famously build their battery packs from standard 18650 lithium-ion cells, but it’s safe to say that the pack in the Model S has little in common with your laptop battery. Fortunately for those of a curious nature, [Jehu Garcia] has posted a video showing the folks at EV West tearing down a Model S pack from a scrap car, so we can follow them through its construction.
The most obvious thing about this pack is its sheer size, this is a large item that takes up most of the space under the car. We’re shown a previous generation Tesla pack for comparison, that is much smaller. Eye-watering performance and range come at a price, and we’re seeing it here in front of us.
The standard of construction appears to be very high indeed, which makes sense as this is not merely a performance part but a safety critical one. Owners of mobile phones beset by fires will testify to this, and the Tesla’s capacity for conflagration or electrical hazard is proportionately larger. The chassis and outer cover are held together by a huge array of bolts and Torx screws, and as they comment, each one is marked as having been tightened to a particular torque setting.
Under the cover is a second cover that is glued down, this needs to be carefully pried off to reveal the modules and their cells. The coolant is drained, and the modules disconnected. This last task is particularly hazardous, as the pack delivers hundreds of volts DC at a very low impedance. Then each of the sixteen packs can be carefully removed. The packs each contain 444 cells, the pack voltage is 24 V, and the energy stored is 5.3 kWh.
The video is below the break. We can’t help noticing some of the rather tasty automotive objects of desire in their lot.
This places no blame on Tesla because the system was simply not designed to handle obstacles travelling at 90 degrees to the car. Because the truck that the Tesla plowed into was sideways to the car, “the target image (side of a tractor trailer) … would not be a “true” target in the EyeQ3 vision system dataset.” Other situations that are outside of the scope of the current state of technology include cut-ins, cut-outs, and crossing path collisions. In short, the Tesla helps prevent rear-end collisions with the car in front of it, but has limited side vision. The driver should have known this.
The basic components behind the build are a current transformer, a NeoPixel LED strip, and an ATtiny44 to run the show. But the quality of the build is where [ch00f]’s project really shines. The writeup is top notch — [ch00f] goes to great lengths showing every detail of the build. The project log covers the challenges of finding appropriate wiring & enclosures for the high power AC build, how to interface the current-sense transformer to the microcontroller, and shares [ch00f]’s techniques for testing the fit of components to ensure the best chance of getting the build right the first time. If you’ve ever gotten a breadboarded prototype humming along sweetly, only to suffer as you try to cram all the pieces into a tiny plastic box, you’ll definitely pick something up here.
