Tag Archives: Tesla

Tearing Down Tesla Segment 4: Battery Cooling System Comparison on Tesla Model 3 vs. BMW i3

The Munro engineering team also spent some time analyzing the battery cooling systems for Tesla (coolant) and the BMW i3 (AC fluid).

Background: Outside of the battery pack, the primary cost difference seen between the Tesla Model 3 and BMW i3 is the cooling system. The Model 3 (similar to other coolant cooled battery packs, such as the Bolt) requires an auxiliary water pump to push coolant through the battery cooling circuit. Since the BMW i3, which uses AC fluid, has to move much less fluid, the compressor does not require an additional pumping mechanism, but may require a slight upsizing of the AC compressor to compensate for increased demand.

Further, an added benefit that the Tesla battery pack cooling gives to its functionality is that each battery cell in the pack has full contact along the side of the coolant tube. This differs from the BMW (and the Bolt), which have only module level contact to the coolant system (at the bottom of the battery module). This enables the Model 3’s cells to cool more evenly, as well as more efficient control of pack temperatures.

Data: Within the battery pack, the Tesla cooling system costs approx. $270 for a 75 kWh pack, which translates to $3.60/kWh in cooling cost vs. the BMW, which costs approximately $84 for a 22 kWh pack translating to $3.80/kWh. 

Methodology: All coolant system components were removed from the vehicles. Install to vehicle and battery pack were captured in Design Profit to develop assembly costs. Next, the fabrication of each part within the cooling racks in each battery pack was analyzed to develop cost for the parts. These costs are then totaled and analyzed via Design Profit to better understand the differences between the vehicles.

Critics Miss Crucial Point About the Cybertruck

While Munro & Associates CEO Sandy Munro loved it, according to a recent WardAuto article, “critics had a field day ripping into the design” of Tesla’s new Cybertruck. However, according to auto expert John McElroy, they missed a critical point: the design enables Tesla to eliminate most of the tooling costs.

According to McElroy, “The body is an exoskeleton, which is to say, the body panels are welded together to form the structure of the truck. This is not body-on-frame construction like a conventional pickup truck, nor a collection of panels bolted and welded into a unitized body shell like a typical car or crossover. Instead, it’s a different way of constructing a vehicle, which no other major automaker has ever done.”

This approach, according to Munro, will save Tesla $60 million (for a 50,000 unit-a-year run) by eliminating blanking and stamping dies compared with traditional ways of making trucks.

And that’s just the start! For more insight into the cost saving opportunities the Cybertruck affords, check out the full article here: https://www.wardsauto.com/technology/cybertruck-s-low-costs-will-save-tesla-millions

Tesla Takes the Lead: Becomes Most Valuable US Car Maker of All Time

According to a recent Auto Express article, Tesla’s market capitalization of $81.39 billion sees it surpass Ford’s record from 1999. This growth makes Tesla worth nearly as much as Ford and GM combined … and the most valuable American carmaker of all time.

Author Hugo Griffiths said, “… as a dedicated maker of electric vehicles, Tesla has forged a path for mainstream manufacturers to follow, leaving giants like Volkswagen and Toyota to play catchup as consumer tastes and legislation increasingly favor electric vehicles rather than those powered by fossil fuels.”

According to Munro & Associates CEO Sandy Munro, “Tesla’s electronics are also said to be significantly more advanced than some car makers.” In a recent Autoline After Hours podcast, Sandy said that the Tesla Model 3’s circuit board design is highly sophisticated, and “like nobody has got.”

“This is cellphone technology,” Sandy said. “The technology we would see in really high-end computers…spectacular…the same kind of technology you would see on the flight controller for an F35. Everything here smacks of cellphone technology and defense technology.”

For more insight on how Tesla has taken the lead, please review: Tesla is the most valuable US car maker of all time

Tesla Cybertruck: No Paint Makes it Profitable

According to a recent BGR article: “For years, the big knock against Tesla is that the company didn’t know how to turn a profit. Over the past two years, however, Tesla has turned things around. With demand still staggeringly high, production has become more efficient and the company posting a profit can no longer be characterized as a mere fluke.”

Munro & Associates CEO Sandy Munro reports that the Cybertruck could be an especially profitable vehicle for the company.

According to BGR, one interesting reason Munro mentions is that the Cybertruck production process will not require a paint job.

“I think that we’re going to be looking at press brakes and simple stamping,” Munro notes. “I don’t see a reason for a paint job, and when painted parts are needed, I think what they’re gonna do is they’re going to come in painted by the supplier.”

Full article details can be found here: Top auto consultant explains why Tesla’s Cybertruck could be incredibly profitable

Sandy Munro Talks Cybertruck’s Novel Body Technology

The Cybertruck novel body tech has caught Munro & Associates CEO Sandy Munro’s interest.

Going off what Tesla has revealed about the upcoming electric pickup truck, the “Cybertruck is built with an exterior shell made for ultimate durability and passenger protection. Starting with a nearly impenetrable exoskeleton, every component is designed for superior strength and endurance, from Ultra-Hard 30X Cold-Rolled stainless-steel structural skin to Tesla armor glass.”

An electrek article reports that Sandy estimates “that combining the body with the platform and the lack of paint should result in a significant reduction in capital expenditure to bring the vehicle to production.”

For more insight – including some numbers Sandy has “thrown around” check out the full article here: Tesla Cybertruck is ‘incredibly cheap’ to bring to production, says manufacturing expert

Munro on What the Tesla Cybertruck Will Really Cost to Build

Motor Trend Technical Director Frank Markus recently shared some insights on the Tesla Cybertruck’s eventual production. Markus was recently on the Autoline After Hours panel discussion with Munro & Associates CEO Sandy Munro and recapped some of the highlights.

For example, when discussing the tooling cost for 50,000 Cybertruck bodies per year: “Sandy sees stainless-steel blanks entering the facility in a couple of sizes, from which they are cut either via water jet or laser (water would be his preference, so as not to risk altering the steel’s heat treatment). The blanks will then be handled manually and formed on press breaks or very simple stamp operations (using manual load, clamp, break, and possibly manual tack welding) and then structurally fastened via robotic TIG welding. There would be no major paint shop, as chassis and other non Class-A surface parts that require paint or other corrosion protection would arrive painted or powder-coated by the supplier.

Forecast capital expense for 50,000 trucks: $30 million. Assuming five years of tooling amortization, that’s less than $200/truck—a fraction of what Sandy claims mainstream manufacturers assume for marketing ($800/vehicle) and legacy costs ($600/vehicle).”

The article also discusses the comparative tooling costs for 50,000 conventional (F-150-type) truck bodies/year: “Tools to handle rolls of steel coil stock, blanking dies, stamping presses and dies: $25 million; body shop with partial automation and multiple spot welders: $35 million; paint shop: $150 million. Total: $210 million.”

Curious how these figures change for 600,000 bodies per year? Then head over to the Motor Trend article here:  https://www.motortrend.com/news/tesla-cybertruck-electric-pickup-will-cost-build/

Sandy Munro and the Tesla Cybertruck

According to AutoBeat journalist Gary Vasilash, Elon Musk is a clever man.

In a recent article, based on a recent Autoline After Hours interview, Vasilash writes, “although according to the portion of the Tesla website where you can place an order for the Tesla Cybertruck (all you need is a $100 refundable deposit) indicates that ‘production nears in late 2021,’ the amount of speculation regarding the vehicle since unveiled at the Tesla Design Studio in LA on November 21, 2019, has been so great that it would take multiple years for any other pickup truck to accumulate that degree of interest.”

Clever, according to Vasilash.

The Cybertruck certainly got Munro & Associates CEO Sandy Munro’s interest. He says when it saw it, “it was love at first sight.” He loved it even more when he ran the numbers.

According to Sandy, the CAPEX to product 50,000 units per year would be $30 million … a “mere fraction of the cost that is required by any other truck on the market.”

Clever, according to Vasilash.

Further, according to Sandy, the Cybertruck uses a remarkable engineering approach: “rather than a body-on-frame (typical of pickups) or a unibody construction (most cars and crossovers), the Cybertruck construction is an exoskeleton. With the exception of closure panels, which are added on, the rest of the vehicle—as in the front and rear fenders—is structural.”

For more on Musk’s clever engineering – and Sandy’s thoughtful analysis – you can click here: https://www.autobeatonline.com/articles/sandy-munro-and-the-tesla-cybertruck

Back by Popular Demand: Sandy Munro Discusses Tesla Cybertruck on Autoline

It was “love at first sight,” according to Munro & Associates CEO Sandy Munro. As an avid off-roading and hunting enthusiast, when Sandy first saw the Tesla Cybertruck he was love-struck.

Sandy recently discussed his thoughts on the Cybertruck on Autoline After Hours. Joining him on the panel was Host John McElroy, Frank Markus of Motor Trend and Gary Vasilash of AutoBeat.

During the almost 1.5 hour segment (side note: a number of fans commented there should be no broadcast time limit when Sandy is on!), Sandy discussed a number of topics pertaining to the tooling cost of the Tesla Cybertruck. And, according to his analysis, it can be manufactured at a mere fraction of the cost that is required by any other truck on the market.

Check out Sandy’s full analysis here: https://www.youtube.com/watch?v=_uRwZRPQ8RE and his follow-up comments and clarification regarding the paper instrument panel, which can be found here http://www.autoline.tv/journal/?p=65721.

P.S. Ever wondered what Elon Musk, co-founder and CEO at Tesla, thinks of Munro’s analysis? Well, wonder no more!

In a recent tweet, Musk shared “Munro’s analysis of Tesla engineering is accurate, both pro & con. I think he will appreciate some elements of the Model Y body design.”

Even though Model Y shares most of its parts with Model 3, the design is still supposed to feature some interesting manufacturing improvements, and it will go into production before the Tesla Cybertruck.

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