Category Archives: Automotive

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’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

Competitive Benchmarking at Its Highest

A few months ago, Fusion TV sent the crew from their new show, “Car VS America” to investigate what they called, “One of the stealthiest little known operations in the Detroit area” to uncover one of the best kept secrets of the automotive industry – Munro’s Benchmarking Innovation Center (BIC) to see just how deep the “Competitive Benchmarking” rabbit hole goes.

Munro & Associates has been in the business of Competitive Benchmarking and Reverse Engineering for decades, tearing apart and analyzing anything from cars to tanks, consumer electronics to heavy industrial machines.  They now currently have a materials, process and new technology base rivaled by very few in the Manufacturing industry.

The presenters Michael Ballaban and Raphael Orlove, car-obsessed editors from Jalopnik, now team up in their new show to explore all the inner workings, tricks of the trade, and, in general, experience how people in the Auto Industry take their craft to the next level.

Both presenters of this show were dazzled by the secrets they got to check out and play around with at Munro & Associates.  But to find out what they saw, you will have to watch the episode.

Follow this link to watch a short clip of the program on Munro and find out for yourself.

Munro & Associates (USA) Announces Strategic Benchmarking Agreement with MarkLines (Japan)

Munro & Associates Inc. USA announced today that it has reached an agreement with MarkLines Co. Ltd. to be their first Strategic Benchmarking Data Supplier. Munro & Associates will contribute benchmarking and quality data to the MarkLines web portal to add value and unique data to its existing services.

We are very excited about becoming the first benchmarking center supplying data to industry leader MarkLines,” said Sandy Munro, CEO of Munro & Associates. “We look forward to developing our relationship with MarkLines and supporting their subscribers with the unique Munro insights and data from our benchmarking process.”

MarkLines President & CEO, Makoto Sakai, said “We believe this alliance offers major synergies between our companies and will bring great benefits to our expanding client base by adding value to our website and by giving out customers in the Japanese automotive industry access to data from a renowned benchmarking organization.”

Unlocking the Secrets Of BMW’s Car Of The Future

Joann Muller of Forbes fame recently visited Munro & Associates with her camera crew for an exclusive tour of the BMW i3 teardown and reverse engineering project.  For the last several months the team at Munro have slaved away tearing down and analyzing this high-tech vehicle, uncovering one new technology after another.

Joann describes the scene as, “…a nondescript industrial building in suburban Detroit, (where) a $50,000 BMW is lying in pieces. The place looks like an illegal chop shop, where stolen vehicles are disassembled to be sold as parts.”  Muller goes on to explain though, “But A. Sandy Munro is no car thief: he paid full price for the BMW i3 he subsequently tore apart. Nor is he selling it for parts. He is, however, selling information about this remarkable car to anyone who is interested. And rest assured, a lot of people in the auto industry want to know its secrets.”

Amongst many of the new technologies and process uncovered in this teardown, Muller emphasized the overall importance of these breakthroughs, “to cope with a confluence of troubling trends — global congestion, pollution and, yes, high fuel costs — that threaten the long-term viability of the automotive industry.”

To see the video and article click here.

Or to download the BMW i3 Report Prospectus click here.

The Future of Cars Looks Very Different

The last few months have seen a flurry of activity at Munro & Associates as the team has been undertaking the massive task of dismantling, recording, and analyzing the BMW i3 in minutia for one of the largest and most comprehensive teardown benchmarking and reverse engineering studies the company has ever seen.  This has attracted a lot of media attention, including from the prestigious Wall Street Journal.  Journalist Joseph B. White was one of the visitors who got the full tour of what innovations and secrets this breakthrough vehicle holds.

“Seeing the battery-powered i3 in pieces puts into perspective how far this industry has come over the past quarter century…” , remarks Joseph White in his article.  “The i3 combines some of the auto industry’s oldest ideas with some of its newest”, White reminisces, impressed with the idea of the classic “body-on-frame” concept adapted using the latest carbon fiber technology to achieve a lightweight yet strong structure that is leading the industry.  “BMW’s carbon-fiber city car is an important marker for anyone trying to figure out the future of an industry that is still a centerpiece of the global economy after more than a century.”

White describes Munro as a place where the team “…takes apart cars, seeking clues to design and manufacturing tricks he can sell to manufacturers eager for a cram course on their competition.”

Click here for a link to the original article.

Or to download the BMW i3 Report Prospectus click here.