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Pics/Info: Inside the Tesla 100 kWh Battery Pack

Discussion in 'Model S: Battery & Charging' started by wk057, Jan 24, 2017.

  1. wk057

    wk057 Senior Tinkerer

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    I originally posted this on my projects site, but will also post here.

    All rights reserved. Images may not be copied or used without my express permission.

    Pics and Info: Inside the Tesla 100kWh Battery Pack | wk057's SkieNET

    Jason Hughes on Twitter

    ---

    So I recently purchased the first known salvage auction Tesla with the new 100kWh battery pack, a P100D VIN 159k.



    [​IMG]



    There have been tons of rumors flying around how what changes Tesla had made to increase the capacity so drastically. Rumors of new cooling patents, increased voltage, new cell double bond wiring, incompatible with older cars, and all sorts of things.



    Personally, I figured Tesla wouldn't reinvent the wheel just yet and go with a whole new pack design, but who knows. Not me, so that had to be corrected. [​IMG]



    Without further ado, here is a shot of a module from the 100 kWh pack.



    [​IMG]



    So, immediately with one picture we have a lot of answers.





    • They're 18650s
    • There are more of them (12 more per group to be exact)
    • Single cell fuse/bond wires
    • Still six cell groups (no voltage change)

    Awesome. 516 cells per module. That's 8,256 cells per pack, a ~16% increase vs the 85/90 packs.

    A comparison with an older module makes the added cells more clear:
    [​IMG]


    Basically they crammed a couple more rows of cells into the module.



    But what about the rumors around cooling? Well, they did modify the cooling, but not in any exotic way. The new modules simply have two shorter and thinner cooling loops per module. This way the coolant doesnt have to run past so many cells before exiting.



    [​IMG]



    What about compatibility with other/older cars? Well, the pack itself has the same high-voltage connection, the same low voltages connectors, and the same cooling connector. However, the pack has the newer ring around the high-voltage connector. So, it's plug-and-play (for the most part, firmware and config changes needed) on the Model X and refreshed Model S, however it would require a different spacer ring on the high voltage connector. Tesla even has a part number for it, so it should be pretty simple to put into any Model S/X.



    [​IMG]



    The six screws on the orange HV connector can be removed to replace the ring with one compatible with older Model S. [​IMG]



    As for real capacity, the BMS reports usable capacity at a whopping 98.4 kWh. It also reports a 4 kWh unusable bottom charge, so that's 102.4 kWh total pack capacity! Congratulations, Tesla. A high capacity pack that meets its nameplate rating!



    Also, the BMS reports a max discharge current of 1,760A for the P100D Ludicrous pack. The normal Ludicrous P90D/P85D packs report 1,520A. This makes perfect sense with scaling, since it's 74 vs 86 cells per group.



    Additionally, the pyro fuse in the 100 kWh is labeled differently. I couldn't find any physical differences between the normal ones, but it is labeled "DISCONNECT,PYROTECHNIC,HYBRID,100kWh", which suggests it has a different setting for the higher current. It also still has the two non-rechargeable lithium ion cells in the case, suggesting it will need replacement at some point like the rest of them.



    It's great to put rumors about this pack to rest. No exotic cooling, is compatible with older cars (physically), no new cell type, etc. Just a new module design that packs more cells into each one.



    Enjoy.



    -wk
     
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  2. stopcrazypp

    stopcrazypp Well-Known Member

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    Interesting stuff. Looks like it's still a single bond wire. The main change is a denser packing and it looks like the cutouts are rectangular instead of round. Any speculation why the change in shape? Is it solely for packing more cells?
     
  3. Andyw2100

    Andyw2100 Supporting Member

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    Awesome work. Great information. As usual!

    Thanks!
     
  4. gaswalla

    gaswalla P4201/85/airsusp/pano/19i

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    Wow...great research and information. Thank you
     
  5. callmesam

    callmesam Member

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    Great info as always. Glad to see someone with the heart of an engineer cracking open their cars.

    Can I ask what you paid for the wrecked vehicle and did you buy at auction/eBay/private sale?
     
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  6. Bighorn

    Bighorn Top Supercharger

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    Awesome--thanks!
     
  7. AWDtsla

    AWDtsla Active Member

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    Did anyone ever physically confirm a double cell bond? IMHO sounds like an engineering nightmare anyway, tiny differences between the bonds can skew current to one or the other, and if one bond fails, you're sure the other one will too.
     
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  8. AWDtsla

    AWDtsla Active Member

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    @wk057 Did you weigh the packs?
     
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  9. Bheuring

    Bheuring Member

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    So now let's hook it up to (mine )or your p85 and see how far it goes
    Great work as always
     
  10. tga

    tga Supporting Member

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    Awesome. What are your plans for the pack/rest of the car?
     
  11. CarlK

    CarlK Member

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    Thanks for the great info. Tesla did say current P90DL could be upgraded to P100D for a "mere" $20K. Wonder if anyone actually has done that.
     
  12. MP3Mike

    MP3Mike Active Member

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    @Ingineer I think you are the one that first reported the double bonding wires, is that something you saw for yourself?
     
  13. BestRadar

    BestRadar Member

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    Thanks for the time you put into this. So the 100kWh is really a 100kWh pack and that is good news for those that have one. Makes me feel more cheated with my 90kWh pack being only 81KWh usable.
     
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  14. lunitiks

    lunitiks Memba

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    Thumbs up!
     
  15. Andyw2100

    Andyw2100 Supporting Member

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    So, Jason, this thread and your work motivated me to finally undertake a "project" I've been putting off. It's not quite on the same level of difficulty of the projects you undertake, but even so...

    I just changed the CR2032 on the system board on the computer that I run Visible Tesla on.

    (That system, when it lost power and restarted, would get to an error screen about low voltage, so with no one around to move on from that screen, Visible Tesla would not be running at times. Finally replacing the battery should solve this problem for me!)
     
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  16. HankLloydRight

    HankLloydRight Fluxing

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    Wow. There's no stopping you now!
     
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  17. scaesare

    scaesare Active Member

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    Cool beans.

    So... although the existing cooling connectors are compatible with the new pack design, I wonder if there's any change to the newer in-car chilling systems to handle the greater load that a 100kW pack might produce...
     
  18. AWDtsla

    AWDtsla Active Member

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    It should produce less heat, not more, given equal power demands.
     
  19. Matias

    Matias Active Member

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    So no heat pipes, no flexible PCB, no double wires.
     
  20. Vitold

    Vitold Active Member

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    Much better heating/cooling in the new pack appears to be it's biggest advantage, aside from 15% increase in capacity. Is the heat exchanger larger (new part number?) compared compared to P90D?
     

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