Tesla is a pure electric car brand that has been committed to accelerating the development of sustainable transportation with the most innovative technologies. A team in China called Youxia Motors has been building pure electric cars. They are very knowledgeable in this area. Previously, they disassembled Tesla's battery pack. Let's take a look at the secrets behind it.
Disassembling a Tesla battery pack
We all know that the battery pack of the 85kW?h version of Tesla MODEL S is composed of nearly 7,000 18650 lithium batteries. But few people have seen the actual situation of the battery pack. Most of the battery analysis published online before was based on Tesla's battery patents. This time we will unveil the last layer of mystery of Tesla batteries for everyone.
Model S has 16 battery packs in total. The bottom one originally had two batteries, which have been removed by Youxia in the picture above. Tesla covers each battery pack with a fiberglass board to provide simple protection for the battery. There is a metal beam separating each two batteries. In the lower left corner of the picture is the fuse of the entire battery pack, and on the right is the battery coolant interface and coolant filling port.
This is Tesla's very high-end lithium battery pack. There are 444 batteries on this board, 74 of which are connected in parallel. The whole battery board is made up of 6 groups of batteries in series. So we can calculate that there are a total of 7104 18650 lithium batteries in this Tesla MODEL S 85.
The wires in the middle of the battery pack are connected to the battery plates on one side and to the battery control module on the other. These wires are used to detect the voltage of the battery pack to ensure the normal operation of the battery pack. If you look closely, you can see that there is a very thin fuse on each battery cell. This is used to protect the entire battery pack. When a single battery cell has an abnormal phenomenon such as overtemperature, the fuse will automatically blow to protect the entire battery pack (each battery cell has a fuse on the positive and negative poles). It is a very large project to weld so many fuses on the circuit board. From a technical point of view, it should be completed by a special robot using ultrasonic welding.
Tesla BMS main control chip
Tesla's battery main control module. Judging from the logo printed on the PCB, this circuit board is completely developed by Tesla itself. A large number of resistors and capacitors are used on the circuit board for signal conditioning. There are 6 sets of electrical signal collection circuits on this side alone.
Since Tesla uses 18650 lithium batteries, which are the batteries used in our laptops, its electronic control technology is very mature. Although I tried many ways and still couldn't see the model of the chip on the motherboard clearly, I can still infer that there are mainly charge and discharge management chips and battery metering management chips on it. Compared with laptop batteries, its complexity should be in the multi-channel battery signal acquisition and control algorithms. After all, the monitoring of hundreds or thousands of batteries in electric vehicles and the monitoring of about 10 batteries in laptops are not on the same order of magnitude.
The batteries used by Tesla are very consistent, and they have also developed a series of liquid cooling solutions to maintain the consistency of battery temperature. In terms of safety and the endurance of electric vehicles, Tesla has always done a good job. From the current design structure, Tesla's protective measures are trustworthy.
Tesla's battery thermal management system
We previously learned that Tesla has a dedicated liquid circulation temperature management system around each single battery, but its specific structure has never been seen. Some media reported that "According to Tesla's patent description, the water inside the isolation plate can be static or flowing, and can be directly stored in the internal tube cavity of the isolation plate, or it can be loaded into a specific water bag. If it is in a flowing state, it can be connected to the cooling system of the battery pack, or a self-contained circulation system can be built."
Tesla's insulation protection
After violent disassembly, we finally saw the internal structure of the battery pack. Inside the lithium battery pack, the heat-conducting aluminum tube filled with water glycol is surrounded in an S shape. The interfaces on the left and right sides of the picture are the circulation interfaces of the water glycol liquid. A layer of orange insulating tape is wrapped around the outside of the aluminum tube. In order to prevent the insulating tape from accidentally rupturing, causing the aluminum tube to contact the lithium battery shell and cause a short circuit, Tesla also added a layer of insulating glue to the outside of the aluminum tube for isolation. A layer of insulating glue is also used to isolate other batteries that do not have aluminum tubes passing through.
When I first saw that Tesla's batteries had so many layers of insulation, I was still very surprised. After thinking for a while, I realized that the 18650 lithium battery used by Tesla is customized. Unlike the lithium batteries we usually see, it has a layer of insulation. The exposed battery shell is the negative electrode of the battery. Once the shell is connected by a conductor, it may cause a short circuit, and in severe cases, it may even cause a fire accident, and the consequences will be disastrous.
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