Tag Archives: Tesla

Elon Musk Calls Munro’s Analysis of Tesla Engineering Accurate

The recent CNET.com article “Tesla Cybertruck’s engineering and design might be genius — here’s why” offers an initial analysis of the Cybertruck by Munro & Associates CEO Sandy Munro. According to the author, Sandy “paints a pretty picture for Tesla.”

Elon Musk, co-founder and CEO at Tesla, noticed the article on Twitter and responded with his thoughts on Sandy’s analysis: “Munro’s analysis of Tesla engineering is accurate, both pro & con. I think he will appreciate some elements of the Model Y body design.”

So what did Sandy have to say about Tesla’s engineering?

Here’s one interesting tidbit: “Munro thinks the capital expenditure would be about $30 million … to build a pickup truck. That’s a downright incredible figure. An F-150 at 50,000 units per year is more like $210 million.”

Interested in more Tesla engineering insight? It has never been more affordable to get access to all of the Tesla Model 3 teardown secrets!  To get the latest prices and descriptions of the teardown and benchmarking report click here: https://leandesign.com/pdf/Tesla-3-Analysis-Sales-Information.pdf.

Tesla Model 3 Considered “Car of the Decade”

Wheels 24 recently posted an article discussing why the Tesla Model 3 is the absolute ‘car of the decade.’ According to author Lance Branquinho, “it is a vehicle of strange contradictions. By the time Tesla had finally managed to deliver its Model 3 to customers in late 2017, the market for mid-size sedan cars had shrunk dramatically. Despite this, Tesla’s Model 3 has proven boundlessly popular, with surging global demand.”

According to Branquinho, its popularity is due to the vehicle’s “unrivalled” fundamental engineering. “Not even the most technically regarded German brands have managed to produce something with comparable performance or originality of design in terms of powertrain. Tesla’s batteries might be Panasonic’s doing, as part of a joint venture, but the electric motors are their own design and absolute genius.”

The article goes on to use Munro’s assessment of the Model 3 to further his assertion: “Engineers who have dissembled the Model 3, most notably American powertrain specialist, Sandy Munro, quickly discovered that although the bodywork design was poor, everything else is decades ahead. Much like a smartphone, almost any issue with a Model 3 can be diagnosed and remedied by over-the-air updates, which completely revolutionizes the convenience of ownership. You don’t need to seek a dealership to plug-in for diagnostics or wait for an afternoon to hear what the fault code is.”

Check out the full article here: https://www.wheels24.co.za/News/Guides_and_Lists/heres-why-this-is-the-absolute-car-of-the-decade-20191231

Tearing Down Tesla Segment 2: Tesla Model 3 vs. BMW i3 with REx System

What costs more? An electric vehicle with an extended range system or a full electric vehicle? How does OEM assembly time factor in?

Background: The supplier component costs for a full battery electric vehicle, like the Tesla Model 3, are often more expensive than an electric vehicle with a range extender, like the BMW i3. However, for the OEM, an electric vehicle with a range extender (or any type of hybrid vehicle) will drive more OEM assembly costs. Additional assembly workstations are required to build a range extender system (often in a spur line), then more stations must be added to the main final assembly line in the vehicle assembly plant.

Side note: this does not include the cost to assemble the engine, which could be supplier or OEM assembly costs.

Data: The BMW i3 REx system can be estimated to drive approximately $45.61 in OEM assembly costs for installation and assembly of the system components into the REx module. This drives the need for approximately 35-40 more workstations in the assembly plant.

Methodology: Munro’s Design Profit® software has a built-in scoring system that allows users to analyze handling and interaction times when assembling parts. Munro uses this scoring system, along with a library of industry standard fastening and operation times, to generate an estimated time and motion study for the assembled parts and work cells that are required. Then, in order to generate assembly costs, that assembly time is matched with a work cell rate for the require operator and equipment.

Munro Talks Tesla Cybertruck, SpaceX Tech, Bulletproof Windows, Crash Safety and Battery Magic with All Things EV

All Things EV’s Sean Mitchell was back at Munro & Associates for a great discussion with CEO Sandy Munro. Check out the in-depth discussion that covers a variety of topics, including:

  • What do you think about the Cybertruck and did you order one? 00:30
  • Does the Cybertruck have stealth properties? 03:01
  • Is there a difference between a uni-body and exoskeleton? 04:07
  • Why is body-on-frame such a popular way to build trucks? 06:56
  • What type of chassis did the DeLorean have? 09:15
  • How can Tesla pull from SpaceX technology? 10:12
  • Will the Cybertruck be more cost effective to produce than their other vehicles? 19:43
  • How will the Cybertruck do in a crash? 22:05
  • Does this new manufacturing approach address some of your Tesla build quality concerns? 24:12
  • Is there some magic behind a $40,000 Cybertruck? 27:26
  • What are some things that appeal to you about the off-road capabilities? 34:21
  • What are Ford, GM, and Chrysler saying about the Cybertruck in their boardrooms? 37:03

Sandy brings a lot to the discussion – including bullets! – when discussing the skin of the Cybertruck. Here’s a link to the full video: https://youtu.be/koNaFUuIjk4.

Sandy Munro Discussed the Tesla Cybertruck with E for Electric

Munro & Associates CEO Sandy Munro recently shared his first impression of Tesla’s Cybertruck with E for Electric after watching the abridged version of it’s unveiling in the following video: https://www.youtube.com/watch?v=zLwjAj53PL0.

Check out the 15-minute segment for interesting insights about the Cybertruck, including:

  1. His first impression of the vehicle;
  2. Why it should be easy to manufacture;
  3. The feasibility of making it actually bulletproof;
  4. How bulletproofing will impact the vehicle’s weight;
  5. If Tesla is ready with its battery technology; and
  6. Will he tear one down?

The video also announces that Sandy has committed to being a once-a-month guest speaker for E for Electric. Stay tuned for future segments!

Tearing Down Tesla: Comparing Secrets of Tesla and Other Leading EVs

Calling all automotive engineers looking for objective technical information about today’s leading electric vehicles (EVs).

This post kicks off a series of articles that will compare notable aspects of leading EVs. From OEM assembly time to suspension and from battery cooling systems to HVAC ducting and venting, this series will cover a lot of ground. Most importantly, it aims to offer knowledge that’s interesting and valuable to today’s engineers … with data points that support our findings.

We used our proprietary Design Profit software for all of our teardown analysis. It enables the teardown team to document each part, how it is installed in the vehicle, as well as how it’s assembled in each subassembly. With this data, we’re able to reverse engineer the assembly process for the given vehicle. More information about the software can be found here: https://designprofit.com/

With that said, here’s the first post ….

Did you know that the BMW i3 has a serviceable battery pack while the Tesla Model 3 doesn’t?

Background: The BMW i3 has a serviceable battery that can be lowered from the vehicle by removing the pack’s mount bolts located on the exterior of vehicle. Individual sub-packs can be replaced after removal of the cover and sub-pack fasteners.

The Tesla Model 3 battery pack was designed not to be serviced. It requires the removal of bolts in the interior and exterior of the vehicle to drop out the battery pack, as well as the removal of the vehicle’s seats and carpeting (to access bolts). The battery pack uses structural adhesives to seal and mount its cover and sub-packs, which does not allow service to open and easily remove modules for repair.

Insight: The advantage of the Tesla Model 3 non-serviceable battery pack is that it reduces the final assembly cost of the battery pack. The disadvantage is that if significant cell damage happens in the pack, then it requires a full swap of the battery pack.

Side note: based on the range for the Tesla Model 3 battery pack vs the BMW i3, in order to equalize, the BMW i3 assembly costs would be considerably higher than the current cost analysis.

Data:  The Tesla Model 3 uses three lines of structure adhesive bead and 78 fasteners, with a final assembly cost of $36.87 to mount the sub-packs and install the battery pack cover. The BMW i3 battery pack uses 120 fasteners, with a final assembly cost of $41.39.

Munro on Tesla’s Motors: “They’ve Got Magic!”

After watching numerous interviews of Munro, it is apparent that it takes a lot to impress him, and Tesla does exactly that. When talking about Tesla’s innovation, he is as happy as a kid in a candy store. Like anyone, Munro wants to make money, but like many engineers, he is intrinsically obsessed with his work and you can tell he really loves this technology.”Kurt Lowder, CleanTechnica

Does anyone else remember when Sandy Munro said that Tesla’s motors have magic? If you missed it, this CleanTechnica article offers a nice recap of how Sandy explains Tesla’s motor magic.

According to the article, Tesla’s newer permanent magnet motors are superior to the competition for a number of reasons. This article focused on one of those reasons: magnets. Per the article:

“Tesla was able to take advantage of what is referred to as the Halbach array. Tesla’s new permanent magnet motors are an improved design that first appeared in the Model 3. Only recently have the Model S and Model X been upgraded to this new technology.

Magnets within these motors are engineered to create a more optimal magnetic field. Four carefully designed, small magnets that oppose each other are actually glued together to create a stronger — or rather, a more optimized — magnetic field that makes the permanent magnet motor more powerful and more efficient. There are several of these magnets within the motor.

This crucial aspect of the motor is one of the main reasons why Tesla vehicles get more range than competing vehicles that have the same size battery packs.”

Interested in learning more? Then head over to the full article with more details: https://cleantechnica.com/2019/04/28/industry-expert-on-teslas-motors-theyve-got-magic/

Munro’s ‘Tesla Motor Mouths’ Featured in IndustryWeek

In a recent IndustryWeek article, Munro & Associates CEO Sandy Munro and Mark Ellis, senior lead design consultant, have a spirited discussion on electric vehicle drives.

Sandy also shared that, unasked, he also sent Elon Musk 230 ideas on how he could improve the build of the Model 3 and make it more realistic to manufacture. “I have no clue if he implemented any of it.” His motive was avuncular, he says—he wants Tesla to succeed because it’s the only automaker doing anything innovative.

Here are some other key takeaways from their interview:

  • If Sandy had to pick only one thing that distinguishes the Model 3 motor, which is the lightest of the four and has the most output, it would be the casing.
  • The magnets in the Tesla motor are “vastly different” than the other contenders.
  • The Tesla motor is also the cheapest … they think.
  • For car detectives, the Model 3 is the gift that keeps on giving.
  • When his colleague discovered the magnet configuration in the motor, Sandy got curious, took it over to a vice and gave it a tap with a hammer to see if he could break a magnet free. The whole thing exploded.
  • The BMW motor is the heaviest and most expensive, and it has the least amount of power.
  • Telsa’s invertor/convertor—the device that takes the battery power, and supplies that power to the electric motor—is very advanced.
  • Telsa’s the only automaker that uses silicon carbide on the integrated circuit (power supply) invertors.
  • Overall, Tesla’s motor is considerably smaller and more high-tech than the others.
  • The Tesla body, “looks like a kids’ high school project,” says Sandy.
  • The Model 3 battery design is “brilliant” in its circuitry design and how simple and lightweight it is compared to competitors, but there are issues with its manufacturing.
  • Overall, Tesla’s electronics team is “like a whole bunch of Sheldon Coopers that actually get along with people and don’t insult each other.”

Check out the full article for more details: http://bit.ly/2JaJjRB

ICYMI: Sandy Munro Talks Tesla in China

Munro & Associates CEO Sandy Munro has talked about the Tesla Model 3 and his findings several times in the past, particularly when he’s featured as a guest on Autoline After Hours.

During his April Autoline appearance recapped here by Teslarati, Sandy discusses the Tesla’s China opportunities for the Model 3, as well as the rapid progress of large-scale construction projects such as Gigafactory 3. Munro also shared his frustration with some of analysts’ assumptions about Tesla.

“I found a new source of pain. Analysts, talking about things. Holy mackerel, where these guys get their ideas from, or where they get their information from is beyond me, but I can tell you one thing for sure. I know they didn’t tear apart one of these cars. I know they don’t really look at what it is that’s going on. I’m sure they’re good readers. Readers are leaders, but sometimes, they’re liars,” Munro noted.

Munro has experience with bad data. Emphasizing his point, the teardown expert stated that some of the assumptions being thrown about the company are flat-out untrue.

“Quite frankly, I’ve been on a few of these little shows and somebody says, ‘Well, you know, such-and-such from wherever says this.’ And I’m sitting there and going, ‘Ah, that’s not true.’ ‘Well, he said it was.’ I said ‘Oh, it’s not true.’ And then I’ll reach over like, I’ve got my books right over here. Somebody says something that I know is not true, I’ve got pictures, I’ve got numbers, I got data up the yin-yang. There’s nobody gonna argue with me, that’s for sure. And if I don’t know the answer, I got a whole 90 guys that’ll (be) happy to tell you which ends up. These other guys, I don’t know, I think it’s web searches and blogs and who knows, I don’t know. But it’s not for real,” Munro said.

Check out the April Autoline segment where Sandy shares more insight on Tesla: http://www.autoline.tv/journal/?p=61130