The battery technology

behind the wheel

Kurt Kelty
Tesla Motors

Founded in 2003
>350 employees STORES
Los Angeles, CA
Menlo Park, CA
2 stores opened, 9 more
stores planned for 2009 In Process:
New York, NY
Miami, FL
Seattle, WA
Chicago, IL
Washington, D.C.
Munich, Germany
London, UK
Monaco
Zurich, Switzerland

FACILITIES TAIPEI, TAIWAN SAN CARLOS, CA AUBURN HILLS, MI HETHEL, UK

Motor Manufacture Corporate HQ Engineering Office EU Sales
Battery Manufacture Glider Manufacture

LOS ANGELES, CA
Styling Studio
Best-in-Class – The 2008 Roadster

Zero-emissions electric powertrain

0-60 mph acceleration: 3.9s
Quarter mile acceleration: 12.7s
EPA driving range: 244 miles
Carbon fiber body, aluminum chassis
Full Federal Motor Vehicle Safety Standards (FMVSS) compliant
2009 model price:
– US: $109,000 (Base model)
– EU: €99,000 (Special Signature Edition)
– UK: £82,000 (excluding VAT)
Industry Leading EV Powertrain

Controls and Software Proprietary

53 kWh Lithium Ion
Battery Pack

Power Electronics
Module
Proprietary 250hp AC (DC-AC Inverter, Charger)
Induction Motor and
Gearbox
 Manufacturing Strategy

Tesla Roadster
Glider in UK; Final assembly in Menlo Park, CA

HETHEL, UK
Glider Manufacture
BAY AREA
TAIPEI, TAIWAN
Final Assembly
Motor Manufacture
Battery Pack Assembly
Powertrain Integration
 Key Components
Tesla’s proprietary technology has several key components
Detail follows

BATTERY POWER ELECTRONICS MODULE

„ Battery Pack: 6,831 cells „ 200 kW 3-phase IGBT-based bi-
„ 53 kWh directional inverter
„ Battery system safety „ Integral 70-amp 120V/240V
„ Battery system durability charging circuitry
„ Worldwide approval for
transport and use „ Approx. 3.5 hours for normal
„ Pampered battery charging (Roadster battery)
environment

MOTOR CONTROLS AND SOFTWARE

„ Proprietary, 3-phase motor „ Fully integrated vehicle and
design with copper rotor powertrain control system
„ 87% average efficiency over „ Digital motor control
operating range
„ Charge control
„ Max torque available instantly
„ Battery state of charge, state of
from start; 14,000 rpm redline
heath and balancing monitoring;
battery pack control
 Battery Development Detail

CELLS SHEET BATTERY

„ Lithium ion cells „ Sheet: 621 Cells „ Battery Pack: 6,831 cells
„ Built IP around 18650 form „ Modular, scalable design „ 53 kWh
factor „ IP in charge balancing and „ Battery system safety
„ Internal cell evaluation lab cooling „ Battery system durability
„ Leverage industry battery „ Battery longevity (cycle & „ Scalable, automated
chemistry investments calendar life) assembly
„ Worldwide approval for
transport and use
Roadster Battery Pack

Total 18650 cells: 6831

Usable Energy Storage: 53 kWh

Capacity: 150Ah

Total weight 450 kg

Energy Density 120 Wh/kg

Continuous output: 53kW

Nominal OCV 366 volts

– (297V min, 411V max)
Auxiliary power available 12 volts@ 200
amps
Normal charge time 3-5 hours
Battery Production
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
 1. Start with a safe, reliable cell: Li-ion 18650

Internal PTC element CID device in every

in every cell cell

Pressure vent High-temperature

separator shutdown

Must Meet Dimensionally stable

steel case
UL 1642
“Standard for Lithium Ion
Batteries”
1. Start with a safe, reliable cell:
Accelerating Rate Calorimeter (ARC) Test Results

ARC measures cell

internal heat
release at high
temperatures,
giving an indication
of thermal stability
under failure
1. Start with a safe, reliable cell:
Nail Penetration Test

3 mm diameter steel nail

1. Start with a safe, reliable cell:
Impact Test
1. Start with a safe, reliable cell:
Single cell vibration testing

Characterize cells
Perform Vibration Test
USABC Battery Test Procedures
Manual, Procedure #10 - Battery
Vibration Test / SAEJ2380
The vibration envelopes of this
procedure correspond to
approximately 100 000 miles of
usage at the 90th percentile.

Re-characterize cells
1. Start with a safe, reliable cell
Final cell selection

Battery cell vendors chosen based on:

– Safety performance in Tesla tests
– Reputation: safety & reliability
– Experience and capacity
• Billions of cells produced to date

– Quality:
• automated production
• controlled environment

– Reasonable price
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
3. Prevent propagation of thermal runaway

Assume any cell will spontaneously go into thermal runaway

– passive & active safety features to prevent propagation
– passive systems alone prevent propagation

confirmed in repeated tests

3. Prevent propagation of thermal runaway

800
Cell 0
700 Cell 1
Cell 2
Cell 3
600
Cell 4
Cell 5
500 Cell 6
Cell 7
400

300

200

100

0
0 500 1000 1500
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
4. Redundant monitoring & protection

Battery pack sensors

– Multiple temperature sensors
– Accelerometer
Leads to
– Tilt sensor appropriate safety
– Humidity sensor response
such as contactors opening
– Immersion sensor
– Under/Over voltage
– Over current
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
5. Physically protect the battery pack
Roadster wrecked at 100kph
Tesla Approach to Battery Safety/Reliability

1. Start with a safe, reliable cell

2. Prevent thermal runaway
3. Prevent propagation of thermal runaway
4. Redundant monitoring & protection
5. Physically protect the battery pack
6. Extensive testing and validation
Cell Test Data Results
 6. Extensive Testing and Validation

Approval received from DoT to ship Tesla 53kWh mass production battery pack by
boat, truck or air.
 6. Extensive Testing and Validation
Pack level test

Vibration Testing using USABC Test procedure #10 (same as SAE J2380)

• Suggested test for “traction batteries hard mounted to a chassis of an EV”.

• 38 hours simulate 100,000 miles of driving.
6. Extensive Testing and Validation
Vehicle durability – 40K km PAVE – 1K km

Each test
equivalent to 100K
miles driving
 6. Extensive Testing and Validation
Corrosion
Salt splash (part of 40,000km mixed durability)
76 times throughout test
enter 30 km/h
exit 55km/h

The ESS must be able to

withstand the salt spray test
specified in the Vehicle
Technical Specification as well
as SAEJ1211 sections 4.3 and
ASTM B 117-73.
Tesla Roadmap
Tesla confirms smart EV battery supply deal

Posted Jan 13th 2009

by Sam Abuelsamid, AutoblogGreen
“The rumors were true. At the Society
of Automotive Analysts outlook
conference this morning, Tesla CEO
Elon Musk announced that his
company will supply lithium ion battery
packs and charging systems to
Daimler AG. The components will be
used to power the second-generation
smart ed. Daimler will build 1,000 of
the electric smarts for field testing
beginning this year. Some of those will
be coming to the US in 2010. Tesla
and Daimler are collaborating on
development of the batteries. Musk
told ABG that the program began in
November 2007 and the first prototype
was ready in 40 days.”
Foundation of Revolutionary Vehicles

Tesla Roadster
250+ produced
1,000+ reservations
100% Electric Powertrains

Tesla Model S
Luxury Sports Sedan
Market intro: March 26th
Production starts: 2011
ƒ High performance
ƒ Zero emissions
ƒ 200+ mile range
ƒ Proprietary technology

OEM powertrains
Model S Sedan Product Overview
Leverages zero-emissions electric powertrain
In advanced development, production targeted for late 2011
Designed for exceptional performance, aesthetics and functionality
– 7 passengers: 5 adults + two child seats
– 4 doors + hatchback Æ Best in class cargo space
– All wheel drive options
– World class design; unrivaled user interface

Target Performance
– 0-60 mph acceleration: 5.7s (standard), 4.4s (sport)
– EPA driving range: 160 miles, 230 miles, 300 miles

Advanced range capabilities

– Usage of multiple advanced cell chemistries
– 45 minute charge capability
– 5 minute battery pack swap capability

Base price $49,900 after Federal Tax Credit

Introducing the Model S Sport Sedan
Model S Sport Sedan
Model S Sport Sedan
Model S Sport Sedan
Model S Sport Sedan
 Thank
Thank You!
You!

Kurt
Kurt Kelty
Kelty
[email protected]
[email protected]