Long-range EVs is one of those game-changing developments that is shaping the future of our planet and autom0bile sector, and the Model 3 battery pack takes it to a whole new level according to experts.
The Model 3 battery pack uses Tesla’s next-generation 2170 cells (21mm width, 70mm height), which contain 30–33% more energy when compared with previous generation 18650 cells.
Tesla and Panasonic’s joint R&D efforts made the new 2170 battery cell possible. This next generation battery is smaller, more efficient, simpler, and easier to maintain. Tesla Model 3’s battery pack is a true engineering marvel and work of art. This is the BEST, most ADVANCED large-scale lithium battery ever produced on [the] planet and is YEARS ahead of anything currently in work.
Tesla has successfully reduced the wiring harness on the Model 3 to 1,500 meters and is around 2.5″ (64 mm) shorter than a Model S battery pack with the same capacity of 75 kWh.
Tesla has used aluminum high-voltage cables shielded with aluminum foil — aluminum is two times lighter than copper, another innovative move by Tesla.
A key reason for this reduction in wiring length is an integrated hub of multiple Battery Management Systems (BMS), connectors, fuses, contactors, and a high-voltage controller (see figure below).
Tesla has tightly knitted several components in a limited space, presenting the ideal combination of advanced design and expert engineering. The setup of these major components saves well above 1,000 meters (1 km) of cables while providing ease of servicing as well.
In addition, the pyro-fuse or pyro-disconnect (see illustration above) is another breakthrough by Tesla — a completely fail-safe solution in the unlikely event of an anomaly in the electrical system.
Tesla has managed to pack the 4,416 cylinder cells (2170) into four modules that weigh around 1054 lb / 478 kg combined. Also, each module has cells grouped into a brick of 46 cells (cylinders). The shorter modules have 23 bricks and longer ones (center) have 25 bricks of cells each.
Reference- EVTV, Cleantechnica, Tesla website, Evannex