Mach-E High Voltage Connector PALOOZA!!!

In this episode of Munro Live Cory and Sandy introduce and explain to the audience the different electrical connectors used in the vehicle and more importantly the different fasteners.

There are four different fasteners of different sizes and screw head types found throughout the different fastener styles. Sandy goes on to explain why this creates issues from the assembly operator’s perspective and why you should eliminate this in a lean design.

From the DC to DC converter, to the PTC Heater, HVAC Compressor, and so on, Cory walks the viewers through the different devices found within the vehicle and what connectors you will find on them. Sandy then compares these connectors to what is found on the ID.4 and gives high praise for what the design team at Volks Wagen came up with. Sandy is much more impressed with the continuity and simplicity of the connector set on the ID.4. However, he still doesn’t like that there are too many fasteners on VW’s design as well.

Sandy then moves to the Tesla Model Y and compares it’s connector designs to the Mach-E and ID.4 showing how much more simplified their design is compared to the competition.

Sandy takes some time to explain why it is so important to reduce the variety of threaded fasteners and moreover, why to reduce the amount used as much as possible and what kind of difference that will make to a company’s bottom line as well as time savings for the operators assembling these parts.

Delving into the past and “back-to-the-basics” Sandy covers ideas long espoused by Dr. Edward Demming and Eliyahu M. Goldratt in the book “The Goal” as well as others. For an aspiring engineering, this episode is a no-nonsense and to-the-point lesson in why having a lean design is key to good product development.

Click below to watch the full lesson below:

Mach-E: Battery Tray and Battery Cell Features

Mach-E Battery Cells

Is there a revolutionary cooling design in the Ford Mach-E? This episode starts off with Sandy bringing up this very topic, saying that they have found something unique inside this design.

Sandy hands over the reins to Ben as he explains what is found in each battery bay, focusing on the cooling plates and their unique design using a dimpled design pathway for the coolant to flow, similar to the “Plinko Board” from “The Price Is Right” causing the coolant to move in random directions around different areas of the plates and creates a turbulent flow that more effectively transfers heat. All of the coolant is supplied through well designed cooling lines that are attached through quick connects.

Ben also points out that it is actually the battery modules that fix the cooling plates down using the studs that protrude through the cooling plates, which is a great double use of a fastener.

Sandy and Ben then move over to look at the battery modules and cells themselves and where we get a chance to see that the Ford Mach-E and Chevy Bolt batteries are identical which makes sense as they are both supplied by LG. However, Ford made some interested improvements on the rest of the modules, using collector plates that are copper that have been nickel plated with the ends of the battery tabs welded to the plates, but more importantly, Ford chose a smart ribbon cable design for the circuitry to manage the battery cells which prevents breakage during installation and ultimately a cost savings.

From there Ben goes over a great design choice on the Ford Mach-E where Ford has placed bent aluminum strips that aligns up witht the thermal interface compound allowing them to use less compound, saving money, and helping to speed heat transfer. Ben also talks about the foam pads in between the cells which allows for expansion as the cells age.

Finally, Sandy talks about our future “best-of-best” battery tray design that we are coming up with. To catch what he says, watch the full episode below:

Cory and Ben Dive Into The Components Of The Mach-E Thermal System

Mach-E Thermal System Components explained by Cory and Ben

Cory Steuben, President of Munro & Associates, and Ben Lindamood, Account Director and lead on the Ford Mach-E teardown, take our viewers on a tour of their findings of the thermal system of the Ford Mach-E.

Cory first points out that the compressor motor needs quite a bit of power to effectively compress the refrigerant R1234YF gas and that is why in an electric vehicle it requires a high voltage line running to it. From there the refrigerant moves through the hoses into the condenser that then cools the compressed gas by having outside air run through its fins and piping from the grills opening up if the car is moving or the fan if the car is stationary. This process condenses the high pressure, high-temperature gas and dissipates the heat allowing the gas to form into a liquid.

From the condenser, the refrigerant flows through another line and into the chiller which has two functions: 1) the heat exchanger portion cools the ethylene glycol run in a loop that cools the batteries and other electric and vehicle systems and 2) leads up to the thermal expansion valve and then into the evaporator at the front of your dashboard which opens up the volume of the line and allows the compressed liquid refrigerant to revert back to a gas which drops the temperature significantly thus giving you airconditioning.

For heating of the electronics, battery, and cabin, the Ford Mach-E uses a traditional heater core which is a heat exchanger that derives its heat from a PTC (positive temperature coefficient) electric heater.

From here, Cory reviews the HVAC cooling and heating system in a Model Y, which instead uses a heat pump system that effective eliminates the need for a heater core or PTC heater. But to find out it’s advantages, you will have to click on the link below:

“Dirty Tesla” with Chris and Sandy Reveal Tesla FSD Beta 9.0

Chris the President of the Tesla Owners Club of Michigan and YouTube channel Dirty Tesla

In today’s episode of Munro Live, Sandy and Chris, who is the President of the Tesla Owners Club of Michigan and YouTube channel Dirty Tesla, test drive a Tesla Model Y with full self-driving (FSD 9.0).

Chris was lucky enough to get an FSD Beta version 9 Tesla Y, so that he can test it out and was nice enough to let Sandy come for a ride to explain the new feature and get a feel for what it is like. Starting in Munro’s parking lot, Chris gets Sandy to choose a destination on the map and from there the FSD does its magic in navigating to the randomly chosen spot. The first thing that is apparent is that the car can still navigate its way through the parking lot even though there are no lines and it is not a structured street which in and of itself is impressive.

If you want a good feel for what FSD feels like and how it performs, this is the video for you. Also, viewers will get an insight on where Tesla is going in the future with FSD, Sandy’s opinions on radar vs FLIR, and much more. Also, check out Chris’ channel Dirty Tesla here for more great videos from him.

And, of course, click on the video below to watch this exciting episode:

Cory Steuben Speaks On Kettering Podcast “Horsepower to Hyperloops”

Kettering

On July 14th, Cory Steuben, President of Munro & Associates and former graduate of Kettering University (ME 10) was interview by Tim Noonan, author of “GMI/Kettering University at 100,” on the podcast, “Horsepower to Hyperloops.”

Cory talks about his rise from a Co-op student to President of Munro & Associates, starting the popular Munro Live YouTube channel, and his adventures traveling in a Tesla Model 3 with our CEO Sandy Munro to go and meet with Tesla enthusiasts and finally, the man himself, Elon Musk in Boca Chica Texas at SpaceX.

Although the podcast isn’t up yet, it should be soon on Kettering’s official website. Check out this link to see the podcast when it comes out as well as other great previous episodes.

A Detailed Comparison of the Mach-E Thermal System to the Tesla Model Y

Comparing the Mach-E Thermal System To the Tesla Model Y

In this episode of Munro Live, Sandy takes a step back and has Cory Steuben and Ben Lindamood take the audience through a detailed comparison of the Tesla Model Y Thermal System components and the corresponding components on the Ford Mach-E

As Cory points out, the location of the components is very important when it comes to efficiency and cost. Many of the components of the Tesla Model are grouped fairly tightly giving it a smaller footprint in the vehicle. When Ben dumps out all of the hoses for the Mach-E and compares them to the Tesla Model Y, it is overwhelming! There is 35 different hoses on the Mach-E which is a very large number comparatively to what it found on Tesla Model Y (10) or even some of the other EVs we have looked at.

The team goes on to compare the pumps, valves bottles, chillers, eletronics and more. Don’t miss this episode if you are enthusiastic about understanding the thermal systems of these vehicles.

Click below to watch the full episode:

The State of EV’s and Solid State Batteries on Canada Talks Electric Cars

Electric Vehicle Society of Canada Ep 14 Sandy Munro Talks State of EVs and Solid State Batteries

In this exciting new show, Sandy presents to the audience of Canada Talks Electric Cars hosted and created by Tim Burrows of the EV Society in Canada.

Although one of the most interesting things that Sandy covers in this webinar is, of course, solid state batteries, including potential capabilities, trade-offs with other battery technologies, and how close we are to getting these in vehicles including a company that is close, but Sandy goes far beyond just this topic including other bleeding edge technologies for EVs.

In this webinar you will find predictions for where Sandy sees the EV market from now until 2028, the state of the I.C.E. vehicle market and where they will stand in the future, Tesla and it 4680 batteries, China roll in the coming EV market, ADAS, Teledyne FLIR, mega-casting body designs, hydrogen fuel cells, plasma kinetics, and a great Canadian startup – Springpower. This webinar is jam-packed with information, data, charts, technology reveals, and exciting new concepts. If you are an EV enthusiast, you don’t want to miss out!

Click on the link below to watch the full webinar:

Sandy and Ben Look at the Ford Mustang Mach-E Instrument Panel

Sandy Munro and Ben do a Mach-E Instrument Panel review

In this episode of Munro Live, Sandy and Ben explore the Instrument Panel of the Ford Mach-E and point out all of their interesting findings.

Sandy starts off by pointing out the massive magnesium casting for the structure of the instrument panel, explaining that it is his favorite choice of material because the casting will perform excellent in a crash situation and has the benefit of being one of the most sound-absorbing materials, helping to reduce NVH.

Ben goes on to point out the molded-in features in the casting that help with the alignment and positioning of components that are added to it. Ben also likes the mounting features that the magnesium casting has. Ben goes on to point out that the vehicle has a column mounted power stearing motor which is an interesting choice, because while it might have been more efficient to mount the motor on the rack, it would have been more expensive and might have intruded in the space created for the frunk.

Ben and Sandy move on to the features they like and don’t like on the interior of the IP, covering the steering wheel and its ability to be easily adjusted, the vents, infotainment system, glove box, HVAC system and more. But then they move into the cavity area behind the IP and they pick up on some interesting hidden features that are probably meant for an ADAS unit in the future.

Watch the full episode by clicking below:

Mach-E Suspension & High Voltage Wiring Compared to Tesla Model Y

Cory Steuben Gives Thumbs Up on Ford Mach-E Suspension

In this episode of Munro Live, Sandy and Munro’s president Cory Steuben go through the suspension and high voltage wiring of the Ford Mach-E.

Cory, who is an expert in suspensions at Munro, gives us a walkthrough of all of his findings on this Vehicles suspension, giving the rear link suspension an A, but not and A+ for a cost and performance perspective, only for the fact that one of the links is not straight, which means you can’t choose the most efficient cost manufacturing method due to the fact that the bend in the one link requires the operator to have to weld the piece again in order to maintain structural integrity to compensate for the extra loads being exerted on that piece.

From rear to front suspension and the HV wiring surounding it, this is quite an information packed video. So if you are an engineering student looking to get a great insight into how suspension “should” be made as well as some deep insight into the HV wiring and design choices that Ford made on this vehicle, you NEED to watch this whole episode through.

Click on the link below:

Have a Look Inside of the Mach-E Battery Box

Have a look inside the Ford Mach-E battery box with Mark Ellis and Sandy Munro

In this episode of Munro Live, Sandy, Mark Ellis, and Victor Trevino open the Mach-E battery box up and take us on a tour of its insides.

The show starts off with a comparison of the size of the ID.4 vs the Mach-E battery box and then goes into design choices made by each company.

But the real meat of the video begins when Mark starts to explain what he finds with the batteries and the management system itself. From two different sized batteries, to a high wire count for the battery management system, there are some interesting finds within the box.

But to learn more, you will have to watch the video by clicking below: