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Munro Talks Tesla Model 3 Manufacturing, Model Y Wiring, and EV Competition with All Things EVs

Munro & Associates CEO Sandy Munro and Mark Ellis, senior lead design consultant, recently sat down with Sean Mitchell of All Things EV to discuss the Tesla Model 3, EV technology and manufacturing, and the upcoming Tesla Model Y.

The discussion covers a variety of topics, nicely outlined by Sean here:

  • What does Munro & Associates do? 1:06
  • What is your technical background? 3:03
  • What are traditional automakers doing well with EVs? 5:13
  • What pending EV are you most excited about? 11:38
  • Why are we not seeing more competitive range EVs from traditional OEMs? 13:57
  • Do EV makers need to create their own cells to be competitive? 16:22
  • Will Tesla get into the battery raw materials business? 22:01
  • Why is the Model 3 over-manufactured? 26:44
  • Is a 204 mile e-tron and 235 mile I-Pace viable for the luxury EV market? 31:25
  • What do you make of Rivian’s product and will Ford take advantage of their tech? 36:41
  • What did you discover between how Tesla and others approached overall design and manufacturing? 45:36
  • You’ve compared Tesla’s hardware tech to what you see in fighter jets, can you expound on that? 52:50

Interestingly, Sandy shares that Munro has plans to acquire and tear down an early Model Y. He’s most interested to see what changes Tesla has made to the body, as well as what the wiring looks as it’s reduced from over a kilometer to a few hundred meters.

Check out the full video here: https://youtu.be/i93VJ1PEp6o

Sandy Munro Shares Thoughts on Structural Adhesives in Automotive Engineering Article

In the recent Automotive Engineering article “Stuck on Structural Adhesives” from Automotive Engineering, Munro & Associates CEO Sandy Munro shares “We’ve used adhesives forever. It’s just that the amount of confidence in them has drastically changed [in recent years].”

According to the article, as the need for lighter materials and enhanced body performance intensifies, structural adhesives are flourishing as a materials-joining solution. The widening reliance on high- and ultrahigh-strength steels and aluminum for body structures, particularly unitized bodies-in-white (BIW), to cut weight without sacrificing crash-mitigating strength or handling degrading rigidity, is the prime factor driving the expanding use of structural adhesives.

Sandy references his firm’s findings from the BMW i3 teardown and adds, “Anything you can possibly imagine, they glued together. The polyurethanes they are using are unreal.”

To read the full article, visit: http://bit.ly/2pHYsRS.

Munro & Associates Partners with Centrepolis Accelerator for Manufacturing; Celebrates Grand Opening at Lawrence Technological University

On October 4, Munro & Associates will join the Centrepolis Accelerator in celebrating the grand opening of its new manufacturing business accelerator space at Lawrence Technological University. The new Centrepolis Accelerator facility is a 6,300 square-foot, state-of-the-art business assistance center for physical product developers and manufacturing companies.

Centrepolis Accelerator clients will include manufacturing startups and existing companies looking to move up to the next level in product innovation. Services will include access to office space, co-working space, workshops, mentors, business planning services, and laboratories and equipment for digital product design and prototyping, as well as virtual reality and mixed reality labs.

Munro is offering Centrepolis Accelerator clients its Design Profit software to support product design and cost planning. Munro has previously provided formal Lean Product Design Assessments to Centrepolis Accelerator clients, which has reduced the complexity of products, reduced part count, and improved design for manufacturability and total product cost before going to market.

The Centrepolis Accelerator and Munro have also previously partnered on a series of events at Munro’s facility called “Leaning Your Product Design,” which has attracted many physical product developers and improved their product designs as a result.

For more information on the Centrepolis Accelerator, visit: http://www.centrepolisaccelerator.com/.

Munro’s Cory Steuben Shares Secrets of Tesla and Other Leading EVs at The Battery Show

Presenting to a standing room only crowd, Munro & Associates’ Cory Steuben, account director, offered automotive engineers objective technical information about today’s leading EVs during two sessions at The Battery Show North America recently held in Novi, Mich.

During two presentations, Steuben compared EV systems integrations across car companies/vehicles and demonstrated why a vertically integrated company, such as Tesla, is leading the way and why the domestics must rethink their designs if they want to catch up.

Steuben first presented “Tesla Model 3 vs. Jaguar I-PACE Motor Insights” where he showcased two disassembled electric motors: one Tesla Model 3 internal permanent magnet (IPM); and one Jaguar I-PACE IPM.

“When it comes to motors, we see many different attempts across many manufacturers—particularly with the geometry of how they put the magnets into their internal permanent magnet motors,” said Steuben. “When you look at the ideal shape is actually very expensive to manufacture—it would be three or four sets of parabolic magnets. There is no common orientation. With the Jaguar, we see three stacked magnets, all neodymium-ferrite-born magnets which is similar to others in the magnet material. Tesla does a simple single V. We have seen six or seven variations in various forms.”

For more Steuben’s insights on Jaguar I-PACE and Tesla Model 3 motor configurations, check out this Design News article: Motors Are as Important as Batteries In The World Of EVs

Steuben also presented “Electric Vehicle System-Level Integration Trends & Thermal-Electrical Management Synergies,” where he provided a detailed report on the system-level integration advancements that are impacting the OEM-level development of thermal and electrical systems. He highlighted system integration trends from the past and present, with a focus on the Tesla Model 3 Superbottle and integrated system.

Revealing the Secrets of the Tesla Model 3, BMW i3, Chevy Bolt, and Jaguar I PACE – An Exclusive Event hosted by Munro & Associates

Get Your Tickets Now Online!

Munro is hosting an intimate Electric Vehicle conference at its headquarters in Auburn Hills, Michigan on June 21st 2019. Attendees will get a closer look at the parts and structure of these vehicles, all while being educated by Munro’s staff on their inner workings.

During the event, the Munro team will present an engineering comparison of four leading EVs: the Tesla Model 3; the BMW i3, the Chevy Bolt; and the Jaguar I-PACE.

The tour of the Munro Benchmarking Investigation, Innovation & Implementation Center will provide an Engineering deep dive of the most advanced electric vehicles and technologies in the market today. Munro will also provide an in-depth view into how we analyze products and perform Costing and Reverse Engineering.

The main focus will be on the EV “Big 3”: Motors, Batteries and Electronics; however, there will be a new technology review with insight into the engineering and designs of some of the other innovative vehicles on the road today. All the Powertrains will be compared side-by-side to highlight their strengths and weaknesses.

Unlike many “Power Point Conferences” the parts will be laid out on tables or hanging on “A Frames” with knowledgeable Munro Engineers to provide detailed description of the key take-ways along with answering all your questions.

For the Jaguar I-PACE, there will be a hoist review to discuss the I-PACE and its electric motor.

EXTRA! Munro has also invited an independent investigator from Tesloop who will share important aspects of EVs that are rarely discussed; life expectancy and maintenance of an EV. Tesloop has ALL the documentation on the durability of the Tesla product.

This is a must attend event for all EV Engineers!

$199 which includes:

  • An overview of “EV Big 3:” motors; batteries; and electronics;
  • A technology review with insight into the engineering and designs of some of the other innovative vehicles on the road today;
  • A tour of Munro’s Benchmarking Investigation, Innovation & Implementation Center
  • The opportunity to participate in an engineering deep dive of today’s most advanced EVs and technologies; and
  • An in-depth view into how Munro analyzes products and performs reverse engineering.

Timing, Location & Agenda:

Friday, June 21st, 2019

Munro & Associates
1140 Centre Road Auburn Hills, MI 48326

8:30 a.m.Registration, Coffee & Donuts
9:00 to 9:15Welcome and logistics
9:15 to 9:45Who is Munro? How do we get our Numbers?
9:45 to 10:15Battery Debrief  
10:15 to 10:45Electronics Debrief
10:45 to 11:15Electric Motor Debrief
11:15 to 12:00Long Range Tesla Data; Full data on Tesla vehicles some with 380,000 MILES! BTW No Maintenance Issues!!!
12:00 to 1:00Lunch
13:00 to 15:30On-The-Floor, Group Breakout, Around the Parts; I PACE Hoist Review, Side by Side discussions at 5 teardown stations to discuss all the vehicle components
15:30 to 16:30Social Hour, Tours of Other Vehicles at Munro and Networking

Tickets limited to 100 guests. Purchase your tickets now by clicking here:

http://bit.ly/2HJF8dr

New FedDev Money for Canadian Manufacturing Including the Agro-Food Processing Sector

The Conservative federal government is injecting $190-million until March 31, 2014 for Investing in Business Innovation in southern Ontario.   FedDev Ontario is focused on helping early-stage and small to medium businesses that are recognized as having the potential for high growth and a net long-term economic benefit for southern Ontario.

Unlike previous years, FedDev has decided to put a further emphasis on initiatives Agricultural and Agro Food Processing sectors to identify where operational improvement and capital equipment investment can increase and strengthen local markets for not just increased import export, but also local job creation.  Lean Design Canada was instrumental in carrying out the initial pilot benchmarking assessments which have so far received very positive reviews from the participating companies.

Up to $5,950,000 is also being provided through FedDev Ontario’s Prosperity Initiative to support three projects that contribute to building an economic advantage in southern Ontario. The projects will include upgrades in technology and expansion of food processing capacity, as well as mentoring and support for students and recent graduates developing and commercializing digital media for mobile devices. FedDev Ontario funding for these projects have been leveraged to attract up to $19,400,000 in private sector investment.

For start-up businesses, approximately $9,438,833 will be invested in 16 projects to support product development and commercialization through FedDev Ontario’s “Investing in Business Innovation” initiative.  An additional leveraging of the FedDev funding  is looking to Angel and Venture capital to attract up to $33,941,667 for additional projects financing.

Ontario’s Youth “STEM” initiative will support development and delivery, for 2 projects aimed at encouraging young people to pursue education and future careers in the engineering, science, technology and math fields.  Funding up to $1,795,000 will reach up to 28,350 students across southern Ontario included for in field mentorships, in-school programs, and online initiatives.

The Nation Research Council (NRC) IRAP (Industrial Research Assistance Program) grant which is aimed at helping small to medium companies develop new technology and products that have the potential to materially increase the firm’s sales or employment.  IRAP offers up to $100,000 of matching funds (50/50) for furthering innovative programs and products.

The Nation Research Council also has another program entitled DTAPP (Digital Technology Adoption Pilot Program) which is aimed at companies furthering or adopting best practices programs such as Design Profit and Munro MAP3.  Although it does not pay for the capital investment in software, it will pay for training in new software and customization costs of adopting these new technologies for companies to become competitive in the market place.

Beyond this, Canada has a healthy ongoing tax program that helps companies of any size, in any sector, to receive tax credits to conduct research and development (R&D) in Canada called the SR&ED tax credit program.  The SR&ED program is administered by the Canada Revenue Agency (CRA) and is up to 50% – the highest tax credit program of its type in the world.

Lean Design Canada and Munro & Associates have been involved with grant programs in Canada since 2008/2009 and have had many success stories come of it.