From interview with Tesla CTO, JB Straubel (discussed here:
Tesla Motors CTO talks future batteries and charging protocols) one number struck me: JB mentioned that batteries have improved from 2008 Roadster to 2012 Model S by 40%, and he projects a similar improvement for Gen III.
So I came up with a spread sheet, feeding in the only other fuzzy number we know about Gen III: it will be 25% smaller than Model S.
I arrived at
46kWh pack size for the entry model Gen III, giving a range of
200 miles (EPA), and a top level model Gen III with
70kWh pack and
273 miles of range.
I will list my steps below, perhaps there is a fundamental flaw in there.
The Roadster has a pack of ~900lbs or around 450kg, and hold 53kWh of energy. The pack energy density is 123Wh/kg.
Model S
85kWh pack is said to be around 485kg (1070lbs) which is a fair part of total curb weight 4647lbs. There are 7104 cells in the 85kWh pack weighing 330kg, so an overhead of 50% for pack structure and cooling seems OK. This gives an energy density of 175Wh/kg, an improvement of 34% over the Roadster. They managed to stay close to the 40% improvement at cell level - an incredible feat!
Model S efficiency I calculate by 85kWh/265 miles (EPA) = 321Wh/mi.
For Model S 60kWh pack I arrive at 363kg (800lbs) pack weight and an energy density of 165Wh/kg. The 85kWh pack is more densely packed. But I will use this number for the pack density of an entry level model. Efficiency is 288 Wh/mi.
Model S without a pack weighs 1624kg, then.
My assumptions going from Model S-60 to GenIII are as follows:
- Tesla will improve pack energy density by another 30%, arriving at 215Wh/kg
- a minimum range of 200 miles (EPA) is targeted for the entry model.
- the net vehicle mass (excluding the pack) is reduced by 85%. A 25% size reduction means less metal in body panels, chassis, and other parts scaling with car dimensions. Other parts e.g. seats don't scale, however.
- reduction of frontal area by 10% and reduction of rolling resistance of lighter vehicle decrease energy consumption by 20%. The Gen III efficiency hence is 231Wh/mi.
From that follows a pack capacity of 46kWh, pack weight of 215kg (473lbs) and total vehicle weight of 1595kg (3514lbs).
Next step would be a top level Model S with similar improvement in pack energy density due to denser packaging (227Wh/kg). Efficiency would take a similar hit like Model S 60 to 85 kWh, I calculate 257Wh/mi. Finally I chose a pack capacity of 70kWh, and arrive at 273 miles of range (EPA) and a total vehicle weight of 1688kg (3719 lbs).
That is a slick car!