Thanks gentlemen. As an engingeer it is always fun to have Munro and friends provide us with quality images and explanations of the evolution of Tesla EVs. Congratulaions to the Tesla power electronics team. Yet another set of major advancements in PCS2. From those of us in the path of Helene, my wife and I wish we had PCS2 in her Model S and I in my Y. A neighbor with a Rivian powered their house daily from his Rivian at 5% of full charge per day. I bought more gasoline than we had purchased since I got my Y 3.5 years ago. Just under 20 gallons per day for my 9 KW generator. During the outage, I spent more time in gaslines than I did supercharging my Y twice during the same interval.
The PCB being the transformer coils definitely blew my mind. That is very clever. Avoids a lot of coils windings. You could swap out just the ferrites without changing anything else and you'd have a completely different profile for those coils.
They didn't mention any change to switching frequency, but I'm sure it's increased substantially in this planar transformer (using PCB as part of transformer, which has been around for decades...). Would have to if they don't have big capacitors anymore.
So fun fact - My new 2024 Model Y had a failed PCS module right at the start 500 miles into ownership. When I was at the service center the tech mentioned the part and showed me - PCSv2 - Revision 4 that was failed in my car. My model Y PCS board LOOKED absolutely nothing like this one did in this video and more like the Cybertruck, just FYI. In fact it was so different the service center waited on a engineer coming up to work on a Cybertruck to help diagnose / replace / re-marry this component to my car and get the profile / software reload to take (they were fighting this for a few days). The engineer said that a line change that happen they upgraded a few power modules on the cars that increased efficiency? Nothing else to note. A few memory notes on my board was it was smaller than the Cybertruck and had half those chips - but defiantly had none of the original capacitors shown in this video.. I believe there pushing forward on there new models as they always do...
@@whattheschmidt nope they still have some localized in Fremont (in this case he travels between Texas and CA) and are active in projects. He had experience in Cybertruck since 2020 and prior to that Model 3 / Y. He also knew the sub-systems and firmware related stuff very well - which they were leaning on him to fix why my car wasn't accepting a firmware/part re-marry on the car. Talking to him made my day - love to nerd out haha :)
@@AustinFerguson Absolutely wild! Tesla continues to amaze. No legacy auto manufacturer would ever even think of doing this. They make the identical part for the life of the vehicle lineup. Tesla eats the upfront cost, flying engineers around so they can continually upgrade major modules like this.
@@philtrubey7480 they definitely don't stop. When I look at my 2018 model 3 and my new model Y, it's just insane the little changes that make for bigger things. My biggest wonder on my model Y is the charge port and support for power output with an adapter like Hyundai does. It would be one the most ultimate hidden by the way software updates.
@@AustinFerguson Gawd that would be nice. I’ve been annoyed at Tesla for years for not allowing decent power output from their vehicles. A2Z makes adapters for J1772 vehicles to get 120V 20A out from Kia vehicles. Would be nice to see from Tesla. If their new PCSv2 is bidirectional just like the Cybertruck’s is (and I don’t see why it wouldn’t be), then Tesla could actually offer PCS upgrades for such functionality and I’ll bet a lot of people would take them up on that offer.
Using the printed circuit board for ferrite winding is genius. Having worked on wire wound devices like speakers, and induction coils for 50+ years I have found the wire coating to be the most common point of failure. Have to resolder the connections. Just did the tweeter on a 70 year old KLH and a pair of 20 year old Alesis speakers.
Probably using Silicon Carbide Mosfets so they can run at higher frequencies which will use lower value inductors which can be PCB layers that will be plated up to at least 2oz copper.
Tesla is just adopting to what is state of the art in power electronics. The true innovation is coming from the elctronic companies that produce the parts used here.
@@davidbeppler3032 There's no reason at all they cannot do it tomorrow. But different applications have different requirements and the cybertruck is special regarding this.
That is an amazing PCB and they seem to have mixed high current paths with fairly fine pitch SMT components, and it’s also rather large as well. The layer stack for this board would be very interesting on its own with the planar magnetics and lots of higher frequency switching. Fantastic work by the engineering team at Tesla ❤👍
Acronym of the day: 1:51 DFMEA (design failure mode and effect analysis) is a systematic approach to recognize and evaluate potential failures of systems, products, or processes.
I think the original PCS-1 board design and build was very, very good (way more than a textbook design and focused directly on the power needs of the vehicles). However, this new PCS-2 design really seems, IMO, to take things to the next level (and provide redundancy in the same footprint)! The idea of printing planar (on CB) inductors is not totally new, but to get all that to work elegantly in real applications, seems state-of-art to me. Congratulations to the Tesla engineering and circuit board design teams that created both of these solutions.
Small but insightful to see how some daps of RTV on tops of the caps would improve vibe resistance. Love when problems have simple solutions like that!
Halfway through the video, they are comparing parts that do completely different jobs. The big white toroidal looks like common mode choke to stop the switching noise propagating out of the convertor, and the transformers look like they are missing. The new design with the ferrite brick transformers in the middle are clever, but a concept I saw in a Metrohm power supply 20 years ago. Still great engineering.
I wish they turned the new board over so we could see the backside and how it interfaces with the cooling plate. There must be conducting pedastles or something?
The "Clever" bit here is the almost complete reduction in damping / smoothing capacitance. Ok, a fundamental frequency uplift enabled by SiC switches is going to help, but the amount of work required to optimise leakage (primarily inductance leakage) paths at a pcb level is significant!
One of the major advantages of 48V system is higher voltage and lower current. For a conventional DCDC in EV usually rated between 3-6kw (250A to 500A), it is a little surprising the 48V system is rated 400A, is that the short duration peak current capability?
Supposedly it is also supplying the base 48V to the inverters in the bed supplying 120/240. Still, 400A @ 48V is 20kW... that's a lot of power, so they might just be talking burst or bus bar specs and not continuous conversion specs. That said, DC-DC buck conversion is very efficient... they should be hitting 98% to 99% efficiency so there is no particular reason why a board like that couldn't do it. At 99% efficiency it would have to dissipate about 200W worth of heat.
I wouldn't refer to those as "power transformers" they're actually planar transformers (because all the windings are contained in the plane of the PCB). A transformer meant for power can take any form.
It will be interested to see how/if/when these techniques will be applied to solar PV inverters. Getting rid of through-hole components and electrolytic capacitors seems like a big win for durability.
@@philtrubey7480 see PC motherboards... They all switched to Aluminum Electrolytic, Tantalum capacitors or a hybrid of the two. They are expensive, which is probably why they are compensating with impedance. They probably did it for safety over 20 years... But Im hoping they did it because super capacitors are known to fail in space and there will be a Lunar CyberTruck.
My modestly educated guess is that they moved to a higher switching frequency, spreading that otherwise higher thermal hysteresis load over a larger lower saturation driven core. Those smaller current cycles would allow for a drastically smaller cap volume.
@@eelcohoogendoorn8044 That's what it looks like to me too, particularly given how few PCB trace windings are going through the ferrite core pairs. They could have gone as high as 2 MHz. Anywhere from a 200 KHz to 2 MHz switching frequency.
I can't say whether or not the average passenger vehicle consumer would use a power out but it'd be a great add on option for the tailgate party goer that wants to power an induction cooktop, a DJ set-up, recharge electric tool's or a bicycle or just plain act as a back up "power-wheels" like the f150 to light up your house in a blackout.
What a video! Thanks for the insight! I remember In the very first Munro video with 5 Tesla chief engineers just after cybertruck was released, they did mention that the HV/48V DCDC converter is still 3kW. So I am just wondering two questions: 1) For the redundant design, is it 3kW each or 3kW together? will both part work together in normal operation to provide half of the required power each, or only one work and the other one take over only when the first one fails. 2) If the maximum current is 400A this is definetely not a 3kW DCDC converter😅So what is exactly the nominal power of HV/48V DCDC converter
When one board provide multiple functions, can it provide all simultaneously? E.g. power 240 V outlet while driving? When car is charging from AC will it pass the power to the outlets?
All kidding aside those people who have the old board in their cars will be replacing their boards in due time. Capacitors only last so long before they fail. Usually in pretty cool ways. Do you think Tesla will charge you $60 parts plus an hour labor to solder new capacitors in place? Or will they charge you $4,000 and three hours labor to swap the board?
@@ReluctantLuddite the new inductor heavy, electrolytic capacitor free design, should last forever. Safety was clearly the main reason for the redesign... The old design may have a high failure rate after 20 years of use... Also, Supercapacitors don't work on the Moon. (HP discovered this in failing SSDs aboard the ISS)
@@HWKier nothing last forever and the inside of a truck is a very hostile environment for electronics, heat, vibration etc. That’s way too much technology for a personal transportation vehicle. Maybe not for a space capsule, but a car? And just where are we going to find technicians to repair all this tech? Oh, that’s right we will just keep going to Tesla for insanely expensive repair costs. Tesla is the reason your non EV auto insurance has gone up so much in recent years.
I give a thumbs up to Tesla for the engineering of the 2nd generation power converter. The planar transformers are a smart way to improve reliability. Eliminating the large electrolytic capacitors is also a big gain by eliminating components which are shock and temperature sensitive. The downside is that the semiconductors are probably more expensive. It is good to see the redundant 48 Volt supplies. I would have expected no less because the vehicle has catastrophic loss of control if the DC power fails. It is pretty bold of Tesla to have gone completely steer by wire. I prefer the Nissan Q50 approach of a clutched intermediate shaft which allows steering in the case of lost power. The Tesla steering rack is doubly redundant with a third sensor as a backup vote. The gain by going strictly by-wire is that it enhances the flexibility of arranging the interior space by eliminating the intermediate shaft. Tesla fans point out that Airbus has a glass cockpit with fly by wire, but the aircraft system is triply redundant with the third circuit not having a computer. Each circuit is also multiply redundant within the circuit. Of course an aircraft malfunction can affect the safety of hundreds of occupants while a vehicle crash typically only affects a few people.
It would be nice to have more 'layman' explanation as to what and/or how the components worked. Like the ferrites and coils and chips. That is what made these videos great in the past. Knowing that a large number of viewers do not have the technical knowledge.
So the old transformer has a coil of copper wire that is fed through the center of the circular ferrite, so you need a machine that can do that wrapping efficiently. Then the wrapped ferrite copper wires have connectors to make the connection to the printed wiring in the pcb. All expensive operations. Compare that to the wide copper traces inside the pcb which do the wiring and the ferrite rectangles which have a top part which mates with a bottom part on the back of the pcb, so that the ferrite "box" encloses the copper wiring within the pcb. Much cheaper to produce. In addition, as the control electronics get faster the higher frequencies mean you can use smaller inductors and capacitors for the same power conversion capability. Bottom line is that Tesla is using state of the art power electronics design to reduce costs and improve efficiency.
@@morrisg I get that. And it is pretty clear the simplicity in the new board versus the old. But prior to Corey leaving they were much better at explaining in layman's terms what and how things work. In this video they say here's the coil. But then they don't explain really what the coil does, or what the ferrites do. So its not just the how is it better, it is also, what do all the better parts actually do. I'm sure insiders got all of it and understand a lot. But Munro was better at getting regular people educated.
my 2014 honda crv which i can pick up engines for 1,000 or less and transmissions for 1,000 or less disagrees even consumer reports says my car is more reliable than modern vehicles based on DATA. add a transmission cooler and trailer brake controller to my honda crv tow 3,500 lb trailer for longer distances than a cybertruck lol what a joke.
It’s pretty cool but I still think it’s a miss not including 2 of them (as well as 2 charge ports). They already split the battery, so it would literally double the charge rate both for DC and AC charging, maybe less on the DC depending on cooling. It would also let me charge and export power at the same time, which would be nice for RV’s passing power through from the post.
This is not that unusual in telecom. But I am curious. Ferrite tends to be brittle. Are those cores mounted in some way that they are isolated from vibration? (shock and vibe)
@@MunroLive Question? What about doing reviews on the TACOMA RANGER, COLORADO and FRONTIER? I'd rather visit in person, should be easy I know MICHIGAN....
Probably just a conformal coating, which is very typical for PC boards that operate in these environments (actually just generally now, most PC boards have conformal coatings). Probably 4-layer or 6-layer board depending... I'm guessing 6-layer.
@@junkerzn7312 Your better then me I couldn't tell or notice, it would be semi clear. I was thinking about dirt, water or anything that could get on there.
200 A at 48 V seems like quite a lot of power for the DC-DC converters, even with the added demand from steer-by-wire. I suspect that both DC-DC are not used together to get 400 A. Instead the DFMEA probably called for full DC-DC output in the event of a failure, and the max demand from the 48 V loads is never more than 200 A.
I was wondering what the total number of individual board soldered components reduction there was. Not even the types of individual components reduced, i can't buy your reports, but just knowing how many less solder joints between the iterations.
Planar transformers as used in your TV a decade ago to make a low profile power supply, nice to see them scaled up to these power levels, but what's the cost, there's always a cost in engineering and I would have thought traditional transformers are more efficient?
No. PowerShare can provide 48 A at 240 V. It is using the 48 V on-vehicle charger in reverse, as this new one is bi-directional. The 400 A is the output of the two redundant 800 V to 48 V DC-DC converters, 200 A each. This was explained in a brief caption near the beginning of the video.
@@georgepelton5645 False: "It is using the 48 V on-vehicle charger in reverse, as this new one is bi-directional." Correct: "It is using the 48 A on-vehicle charger in reverse, as this new one is bi-directional."
Why do you keep saying DC-DC when the board clearly says DC-AC? These converters bi-directionally convert the battery DC to and from utilities' AC. In other words, DC-AC converters.
Got rid of those electrolytic capacitor's, great they are a life limiting device. When they run hot they degrade and cause the DC/DC converter to fail.
One of the worst presentations, not to mention you are talking about DC-DC and you show the AC-DC convertor, then you present the planar transformer and you compare with a common mode choke from previous version....also on this latest pcb CMC is a discrete component and NOT planar, where did you find this engineer? In a repair shop?
That board is clearly a DC-DC, not an AC-DC. It is providing base 48VDC to the vehicle and apparently also providing 48VDC to the AC inverters in the bed for the 120/240VAC outlets.
@@CATA20034 There is no AC inverter on that board that I can see, cat. It's a twin DC-DC buck converter. Not necessarily even for redundancy, just so it can operate efficiently over a large current range. I don't see any rectification, EMC management, EMI filters, or power factor correction, and the inductor configuration doesn't look right for AC. It looks perfect for a DC-DC buck, though. There are also severe limitations to the switching frequency if the input is 60Hz AC, but it's obviously running at a high frequency. What part of the board is supposed to be AC? -Matt
Yep, this video lost all credibility for me when they were showing the toroid common mode choke and saying it was a converter transformer. Also the obvious change from big aluminum electrolytics (needed with the lower switching frequency converter on the old boards) to much smaller caps that can be used on the new higher frequency converter design. That should have been mentioned right at the start instead of their misguided dancing around discussion. This is all very basic stuff for anyone involved with current state of the art power conversion, even on small scale power supplies.
Nvm, I see what they could be doing. They must be chopping the AC directly and combining the chopper and the rectifier together with a synchronous rectification design. So the input stage is basically just a current pump. Which makes sense because it has a battery pack's extremely low impedance that it can push against. We need to be able to peek under the plastic on that input stage before the planar magnetic elements. There is still a lot of EMC missing that has to be there somewhere. Plus whether there are diodes or [*]FETs Its supposed to be bidirectional so... might not have diodes. -Matt
Dear youtube.com/@MunroLive, sorry to say, but what you are saying at minute 7:00 is simply wrong! You are talking about the redundant DC/DC converters, but it is the AC to DC stage. It is even marked as DC/AC 1 & 2. Actually the orange connector is the 3 phase + N AC input. I hope this is correct in your pricy report ;-) I guess the white connector is the HV DC output and the blue connector is the LV (48V) output. The big planar transformers are part of the conversion stage (AC to DC). BTW: Planar transformers are nothing new to automotive. A similar concept was already used in the DC/DC converter of an ID.3 (MEB).
At this point you would think Tesla is way more valuable at designing and engineering parts than they are at building cars but I guess you can't have one without the other and original OEMs would probably never jump at this if Tesla were selling it, it's only once they see the success that they want in.
You guys are good but Sandy really makes the videos. More Sandy please!!! I'm speaking for everyone when I say we like his insight and color commentary!!
Strange that they didn't borrow their solar inverters to convert 800VDC to 240AC. They have a 19KW budget and 11KW are dedicated to AC outlets. I guess it would be additional single function hardware. What if I want to run two welders? A three-phase water pump? An electric barge? A hovercraft? A submarine? An anti-drone laser? An anti-tank railgun?
I can think of a reason. Keeping the power outlets in the bed on while connected to an AC charger. Say you have a box in there for keeping food cold, and you stop over night at a camp ground/hotel/grandma's house?
Devices designed for static installations in one orientation don't survive random vibe of vehicles in motion. Lessons Learned: Peacekeeper Rail Garrison.
For me it's a big problem the V2Load functionality is not on every Tesla model already. I cant buy such a piece of hardware and not being able to power any device or tool whenever and wherever I need it. V2L needs to arrive asap to every Tesla model. Im not buying a Tesla until its implemented
Yeah i understand but your coverage is far away from your old videos and insights.. i like you guys but as an engineer this was more a sales video than anything else sadly
@@MunroLive carls latest video was a really nice deep dive into new areas for me especially when he showed the effect of shrinkage! Top notch video which gets shared a lot!
@@steinmar2 If @MunroLive discovers cutting-edge technology or processes known only to Tesla (or any other vendor teardown), as a business employing many experienced engineers, they cannot afford to give that 'secret sauce' away for free. This is the reason that the new $$$ reports are only affordable to OEMs playing catch-up or financial houses with deep pockets. Carl's content is excellent but is widely known in the industry.
They already said they are going to support powershare on all teslas in 2025 so expect this to be rolled out to all of them. I doubt if they will include 240v outlets in a model Y or 3, but certainly to run your house for 2 or 3 days, a huge benefit of owning an electric car.
Yes, I enjoy Sandy's presentations as well. However, for a software-defined vehicle, there is a huge amount of highly specialized knowledge in electrical engineering; power and control management; and software design, coding, and implementation that goes way beyond ordinary ICE cars. Sandy has a multi-disciplinary team to help him disassemble and reverse engineer all of that. Tesla has fantastic multi- and inter-disciplinary design and engineering teams who create all of this essentially from scratch and first principles. In fact, this is the major reason, IMO, for the difficulties that legacy auto-makers encounter when trying to compete with Tesla or the Chinese EV start-ups.
Just the fact that bidirectional charging has been ADDED whilst at the same time reducing size and weight is definitely interesting. Also, the removal of the electrolytic capacitors (can shapes on the older boards) means a large improvement in reliability and a huge improvement in board lifespan. That's interesting! And you can be sure that those improvements will be added to the millions of cars of the other Tesla car models that are going to be made. "Well may I ask what you expected to see out of a Torquay hotel bedroom window? The Hanging Gardens of Babylon? Herds of wildebeest sweeping majestically across the plain" - Basil Fawlty, Fawlty Towers
@@johnpublicprofile6261 Eliminating the capacitors which are temperature and shock sensitive is pretty interesting to me too. There is likely some cost to making the change because the semiconductors are probably going to be more expensive. There may be some engineering by lawyers hiding in the background. The redundant 48 Volt supplies are an absolute necessity because loss of the 48 Volt power results in being unable to steer the vehicle. I wouldn’t want to be one of the engineers on the receiving end of a lawsuit resulting from a crash due to loss of DC power.
Too bad Elon is a douche 🇷🇺 Half of us cancelled our Tesla’s. Every timeline he projects is false, can you imagine the short cuts just to get it to production! I took one look at mine & walked! It’s a POS
I bet you your opinion is based because of him supporting Trump 😂 Go cry to Biden/Kamala they will bring some illegals in your neighborhood. Truthseeker my a$$
Thanks gentlemen.
As an engingeer it is always fun to have Munro and friends provide us with quality images and explanations of the evolution of Tesla EVs.
Congratulaions to the Tesla power electronics team. Yet another set of major advancements in PCS2. From those of us in the path of Helene, my wife and I wish we had PCS2 in her Model S and I in my Y. A neighbor with a Rivian powered their house daily from his Rivian at 5% of full charge per day. I bought more gasoline than we had purchased since I got my Y 3.5 years ago. Just under 20 gallons per day for my 9 KW generator. During the outage, I spent more time in gaslines than I did supercharging my Y twice during the same interval.
I reluctantly clicked on this video and found it fascinating that the architecture can be so different within a few months of production.
I got the impression PCS2 was what the Cybertruck started with, and the older one is in S/3/X/Y, but maybe I misheard something.
Fascinating indeed but I clicked immediately.
wow the difference between old and new is stunning
The PCB being the transformer coils definitely blew my mind. That is very clever. Avoids a lot of coils windings. You could swap out just the ferrites without changing anything else and you'd have a completely different profile for those coils.
True ... though traditional transformers are very reliable in my own experience, whereas PCB board tracks not so much!
@@MrAdopado These are fat boy tracks, not tiny traces.
They didn't mention any change to switching frequency, but I'm sure it's increased substantially in this planar transformer (using PCB as part of transformer, which has been around for decades...).
Would have to if they don't have big capacitors anymore.
So fun fact - My new 2024 Model Y had a failed PCS module right at the start 500 miles into ownership.
When I was at the service center the tech mentioned the part and showed me - PCSv2 - Revision 4 that was failed in my car. My model Y PCS board LOOKED absolutely nothing like this one did in this video and more like the Cybertruck, just FYI. In fact it was so different the service center waited on a engineer coming up to work on a Cybertruck to help diagnose / replace / re-marry this component to my car and get the profile / software reload to take (they were fighting this for a few days). The engineer said that a line change that happen they upgraded a few power modules on the cars that increased efficiency? Nothing else to note.
A few memory notes on my board was it was smaller than the Cybertruck and had half those chips - but defiantly had none of the original capacitors shown in this video.. I believe there pushing forward on there new models as they always do...
They had an engineer at your service center? I take it you are in Austin...interesting
@@whattheschmidt nope they still have some localized in Fremont (in this case he travels between Texas and CA) and are active in projects. He had experience in Cybertruck since 2020 and prior to that Model 3 / Y. He also knew the sub-systems and firmware related stuff very well - which they were leaning on him to fix why my car wasn't accepting a firmware/part re-marry on the car.
Talking to him made my day - love to nerd out haha :)
@@AustinFerguson Absolutely wild! Tesla continues to amaze. No legacy auto manufacturer would ever even think of doing this. They make the identical part for the life of the vehicle lineup. Tesla eats the upfront cost, flying engineers around so they can continually upgrade major modules like this.
@@philtrubey7480 they definitely don't stop. When I look at my 2018 model 3 and my new model Y, it's just insane the little changes that make for bigger things.
My biggest wonder on my model Y is the charge port and support for power output with an adapter like Hyundai does. It would be one the most ultimate hidden by the way software updates.
@@AustinFerguson Gawd that would be nice. I’ve been annoyed at Tesla for years for not allowing decent power output from their vehicles. A2Z makes adapters for J1772 vehicles to get 120V 20A out from Kia vehicles. Would be nice to see from Tesla. If their new PCSv2 is bidirectional just like the Cybertruck’s is (and I don’t see why it wouldn’t be), then Tesla could actually offer PCS upgrades for such functionality and I’ll bet a lot of people would take them up on that offer.
Using the printed circuit board for ferrite winding is genius. Having worked on wire wound devices like speakers, and induction coils for 50+ years I have found the wire coating to be the most common point of failure. Have to resolder the connections. Just did the tweeter on a 70 year old KLH and a pair of 20 year old Alesis speakers.
AFAIK it is not a new technique.
But using it in automobiles probably is, as probably is such high ampage and production volume.
Probably using Silicon Carbide Mosfets so they can run at higher frequencies which will use lower value inductors which can be PCB layers that will be plated up to at least 2oz copper.
Awesome! been looking forward to videos on the 48 volt/electrical system since Munro bought the cybertruck!
Tesla just keeps innovating.
Tesla is just adopting to what is state of the art in power electronics. The true innovation is coming from the elctronic companies that produce the parts used here.
Non stop. Hard to see how anyone could catchup to them.
@@EinzigfreierNamelegacy auto will do the same thing, in 10 years.
@@davidbeppler3032 There's no reason at all they cannot do it tomorrow. But different applications have different requirements and the cybertruck is special regarding this.
Whole world does, it's just some car companies that seem to have a problem
That is an amazing PCB and they seem to have mixed high current paths with fairly fine pitch SMT components, and it’s also rather large as well.
The layer stack for this board would be very interesting on its own with the planar magnetics and lots of higher frequency switching. Fantastic work by the engineering team at Tesla ❤👍
Acronym of the day:
1:51 DFMEA (design failure mode and effect analysis) is a systematic approach to recognize and evaluate potential failures of systems, products, or processes.
I think the original PCS-1 board design and build was very, very good (way more than a textbook design and focused directly on the power needs of the vehicles). However, this new PCS-2 design really seems, IMO, to take things to the next level (and provide redundancy in the same footprint)! The idea of printing planar (on CB) inductors is not totally new, but to get all that to work elegantly in real applications, seems state-of-art to me. Congratulations to the Tesla engineering and circuit board design teams that created both of these solutions.
Small but insightful to see how some daps of RTV on tops of the caps would improve vibe resistance. Love when problems have simple solutions like that!
Halfway through the video, they are comparing parts that do completely different jobs. The big white toroidal looks like common mode choke to stop the switching noise propagating out of the convertor, and the transformers look like they are missing. The new design with the ferrite brick transformers in the middle are clever, but a concept I saw in a Metrohm power supply 20 years ago. Still great engineering.
Most of Tesla's "genius" is applying already existing technology in unique ways, especially for the automotive industry.
How is that not genius???why reinvent the wheel. The steel from the cyber truck being handed down for a different use is the most obvious success
@@nickford5549 Did I say it wasn't?
Higher freqs, maybe in resonant mode so they need those chokes.
I wish they turned the new board over so we could see the backside and how it interfaces with the cooling plate. There must be conducting pedastles or something?
Interesting presentation showing the awesome advances in electronics in the new 48V architecture.
No
Great talk through Gents. The bi-directional capabilities are huge.
The "Clever" bit here is the almost complete reduction in damping / smoothing capacitance. Ok, a fundamental frequency uplift enabled by SiC switches is going to help, but the amount of work required to optimise leakage (primarily inductance leakage) paths at a pcb level is significant!
love this video very well done!!
Thank you so much!!
One of the major advantages of 48V system is higher voltage and lower current. For a conventional DCDC in EV usually rated between 3-6kw (250A to 500A), it is a little surprising the 48V system is rated 400A, is that the short duration peak current capability?
its because the Tesla needs so much 48V for power for the electronic steering system
Supposedly it is also supplying the base 48V to the inverters in the bed supplying 120/240. Still, 400A @ 48V is 20kW... that's a lot of power, so they might just be talking burst or bus bar specs and not continuous conversion specs. That said, DC-DC buck conversion is very efficient... they should be hitting 98% to 99% efficiency so there is no particular reason why a board like that couldn't do it. At 99% efficiency it would have to dissipate about 200W worth of heat.
I wouldn't refer to those as "power transformers" they're actually planar transformers (because all the windings are contained in the plane of the PCB). A transformer meant for power can take any form.
Knows exactly what he’s talking about more videos he’ll be right on track congratulations
THANK YOU for the t3ch talk. Really interesting. Cheers
It will be interested to see how/if/when these techniques will be applied to solar PV inverters. Getting rid of through-hole components and electrolytic capacitors seems like a big win for durability.
Good video! Very informative and interesting. Cheers!
So how’d they get rid of the bulky electrolytic capacitors?
@@philtrubey7480 see PC motherboards... They all switched to Aluminum Electrolytic, Tantalum capacitors or a hybrid of the two. They are expensive, which is probably why they are compensating with impedance.
They probably did it for safety over 20 years... But Im hoping they did it because super capacitors are known to fail in space and there will be a Lunar CyberTruck.
@@ch4.hayabusausing a topology with cancelling ripple currents
And using small MLCC capacitor
@@ch4.hayabusa I can assure you they weren't concerned about operation in space, after all the cybetruck is air cooled.
My modestly educated guess is that they moved to a higher switching frequency, spreading that otherwise higher thermal hysteresis load over a larger lower saturation driven core. Those smaller current cycles would allow for a drastically smaller cap volume.
@@eelcohoogendoorn8044 That's what it looks like to me too, particularly given how few PCB trace windings are going through the ferrite core pairs. They could have gone as high as 2 MHz. Anywhere from a 200 KHz to 2 MHz switching frequency.
Great stuff.
Thanks!
Major change is power control for sure!
Munro et al. make a happy Friday into a fascinating Friday! Thanks.
I can't say whether or not the average passenger vehicle consumer would use a power out but it'd be a great add on option for the tailgate party goer that wants to power an induction cooktop, a DJ set-up, recharge electric tool's or a bicycle or just plain act as a back up "power-wheels" like the f150 to light up your house in a blackout.
Thanks so much
World Peace
Tom is the best
What a video! Thanks for the insight! I remember In the very first Munro video with 5 Tesla chief engineers just after cybertruck was released, they did mention that the HV/48V DCDC converter is still 3kW. So I am just wondering two questions: 1) For the redundant design, is it 3kW each or 3kW together? will both part work together in normal operation to provide half of the required power each, or only one work and the other one take over only when the first one fails. 2) If the maximum current is 400A this is definetely not a 3kW DCDC converter😅So what is exactly the nominal power of HV/48V DCDC converter
Those green boards look like a drone shot of oil refineries
Nice
. looks like previous version unit is thermally conductive plastics and electrically insulative to extract heat
When one board provide multiple functions, can it provide all simultaneously? E.g. power 240 V outlet while driving? When car is charging from AC will it pass the power to the outlets?
What would it cost to replace a power conversion system or traction inverter board should one fry?
Come on electronics never fail. Remember EVs are made
From Pixie dust. They have no maintenance cost…😂
All kidding aside those people who have the old board in their cars will be replacing their boards in due time. Capacitors only last so long before they fail. Usually in pretty cool ways. Do you think Tesla will charge you $60 parts plus an hour labor to solder new capacitors in place? Or will they charge you $4,000 and three hours labor to swap the board?
@@ReluctantLuddite the new inductor heavy, electrolytic capacitor free design, should last forever. Safety was clearly the main reason for the redesign... The old design may have a high failure rate after 20 years of use... Also, Supercapacitors don't work on the Moon. (HP discovered this in failing SSDs aboard the ISS)
Switching to 48V is enabler for this.
@@HWKier nothing last forever and the inside of a truck is a very hostile environment for electronics, heat, vibration etc. That’s way too much technology for a personal transportation vehicle. Maybe not for a space capsule, but a car? And just where are we going to find technicians to repair all this tech? Oh, that’s right we will just keep going to Tesla for insanely expensive repair costs. Tesla is the reason your non EV auto insurance has gone up so much in recent years.
I give a thumbs up to Tesla for the engineering of the 2nd generation power converter. The planar transformers are a smart way to improve reliability. Eliminating the large electrolytic capacitors is also a big gain by eliminating components which are shock and temperature sensitive. The downside is that the semiconductors are probably more expensive. It is good to see the redundant 48 Volt supplies. I would have expected no less because the vehicle has catastrophic loss of control if the DC power fails.
It is pretty bold of Tesla to have gone completely steer by wire. I prefer the Nissan Q50 approach of a clutched intermediate shaft which allows steering in the case of lost power. The Tesla steering rack is doubly redundant with a third sensor as a backup vote. The gain by going strictly by-wire is that it enhances the flexibility of arranging the interior space by eliminating the intermediate shaft.
Tesla fans point out that Airbus has a glass cockpit with fly by wire, but the aircraft system is triply redundant with the third circuit not having a computer. Each circuit is also multiply redundant within the circuit. Of course an aircraft malfunction can affect the safety of hundreds of occupants while a vehicle crash typically only affects a few people.
Blablabla crap
AWESOME
I see the 240w as a new option for Tesla.
Reminds me of SpaceX Raptor 1 vs. 2 vs. 3 designs. Each version is both more capable and streamlined/beautiful than the last; it’s so fun to see.
No! And they still burn fossil fuels
It would be nice to have more 'layman' explanation as to what and/or how the components worked. Like the ferrites and coils and chips. That is what made these videos great in the past. Knowing that a large number of viewers do not have the technical knowledge.
So the old transformer has a coil of copper wire that is fed through the center of the circular ferrite, so you need a machine that can do that wrapping efficiently. Then the wrapped ferrite copper wires have connectors to make the connection to the printed wiring in the pcb. All expensive operations. Compare that to the wide copper traces inside the pcb which do the wiring and the ferrite rectangles which have a top part which mates with a bottom part on the back of the pcb, so that the ferrite "box" encloses the copper wiring within the pcb. Much cheaper to produce. In addition, as the control electronics get faster the higher frequencies mean you can use smaller inductors and capacitors for the same power conversion capability. Bottom line is that Tesla is using state of the art power electronics design to reduce costs and improve efficiency.
@@morrisg I get that. And it is pretty clear the simplicity in the new board versus the old. But prior to Corey leaving they were much better at explaining in layman's terms what and how things work. In this video they say here's the coil. But then they don't explain really what the coil does, or what the ferrites do. So its not just the how is it better, it is also, what do all the better parts actually do. I'm sure insiders got all of it and understand a lot. But Munro was better at getting regular people educated.
@@vr4042 Just trying to help. I miss Corey too.
@morrisg thank you very much for the very interesting information 👏👏
@@deltajohnny You're welcome.
Such a big improvement.
my 2014 honda crv which i can pick up engines for 1,000 or less and transmissions for 1,000 or less disagrees even consumer reports says my car is more reliable than modern vehicles based on DATA. add a transmission cooler and trailer brake controller to my honda crv tow 3,500 lb trailer for longer distances than a cybertruck lol what a joke.
It’s pretty cool but I still think it’s a miss not including 2 of them (as well as 2 charge ports). They already split the battery, so it would literally double the charge rate both for DC and AC charging, maybe less on the DC depending on cooling. It would also let me charge and export power at the same time, which would be nice for RV’s passing power through from the post.
Wait, where are the magnetics for the model 3 and S boards you are showing of the PCS one as you call it!
This is not that unusual in telecom. But I am curious. Ferrite tends to be brittle. Are those cores mounted in some way that they are isolated from vibration? (shock and vibe)
Question?
Is the NEW board coated?
Whats the THICKNESS of the board?
Is TESLA making the NEW boards in house?
Buy our report! 😉
@@MunroLive Question?
What about doing reviews on the TACOMA RANGER, COLORADO and FRONTIER?
I'd rather visit in person, should be easy I know MICHIGAN....
Probably just a conformal coating, which is very typical for PC boards that operate in these environments (actually just generally now, most PC boards have conformal coatings). Probably 4-layer or 6-layer board depending... I'm guessing 6-layer.
@@junkerzn7312 Your better then me I couldn't tell or notice, it would be semi clear. I was thinking about dirt, water or anything that could get on there.
@@marshalllapenta7656 They could also be using heavier-weight copper layers for the PCB, but I suspect not. I like the design.
200 A at 48 V seems like quite a lot of power for the DC-DC converters, even with the added demand from steer-by-wire. I suspect that both DC-DC are not used together to get 400 A. Instead the DFMEA probably called for full DC-DC output in the event of a failure, and the max demand from the 48 V loads is never more than 200 A.
It would be great if Tesla would use the redesigned power system to upgrade the S and X, but probably not economical to do.
We want to see the bottom of the PCB !!
I was wondering what the total number of individual board soldered components reduction there was. Not even the types of individual components reduced, i can't buy your reports, but just knowing how many less solder joints between the iterations.
time to look at a BYD?
Planar transformers as used in your TV a decade ago to make a low profile power supply, nice to see them scaled up to these power levels, but what's the cost, there's always a cost in engineering and I would have thought traditional transformers are more efficient?
How did they replace those big electrolytic capacitors in the new version? Did they use something like active capacitor?
Silicon Carbide Mosfets, higher frequency, smaller caps and inductors.
I would not be surprised if the same power conversion system is found in a SpaceX rocket. It is redundant, as well as vibration and shock resistant.
So how do I do v2h?
A trivial observation perhaps, but how unusual to see components mounted askew instead of in the usual north/south - east/west orientation.
PCB designer gets board with the North/South stuff.
So does this mean the PowerShare can do 400amps? Crazy.
No. PowerShare can provide 48 A at 240 V. It is using the 48 V on-vehicle charger in reverse, as this new one is bi-directional. The 400 A is the output of the two redundant 800 V to 48 V DC-DC converters, 200 A each. This was explained in a brief caption near the beginning of the video.
@@georgepelton5645 False: "It is using the 48 V on-vehicle charger in reverse, as this new one is bi-directional." Correct: "It is using the 48 A on-vehicle charger in reverse, as this new one is bi-directional."
#Monro Live: Can you do the same with Tesla Semitruck, semi teardown❓️ Just as you do with Zybertruck... I love this Teardown videos. Lurn alot.😅
Where is Sandy?
He's currently in a meeting.
Who cares. As long as he doesn’t feature in any video I am happy.
Why do you keep saying DC-DC when the board clearly says DC-AC? These converters bi-directionally convert the battery DC to and from utilities' AC. In other words, DC-AC converters.
Got rid of those electrolytic capacitor's, great they are a life limiting device. When they run hot they degrade and cause the DC/DC converter to fail.
👍👍
One of the worst presentations, not to mention you are talking about DC-DC and you show the AC-DC convertor, then you present the planar transformer and you compare with a common mode choke from previous version....also on this latest pcb CMC is a discrete component and NOT planar, where did you find this engineer? In a repair shop?
That board is clearly a DC-DC, not an AC-DC. It is providing base 48VDC to the vehicle and apparently also providing 48VDC to the AC inverters in the bed for the 120/240VAC outlets.
@@junkerzn7312 watch again, dcdc is the small part with the two transformers.
@@CATA20034 There is no AC inverter on that board that I can see, cat. It's a twin DC-DC buck converter. Not necessarily even for redundancy, just so it can operate efficiently over a large current range.
I don't see any rectification, EMC management, EMI filters, or power factor correction, and the inductor configuration doesn't look right for AC. It looks perfect for a DC-DC buck, though. There are also severe limitations to the switching frequency if the input is 60Hz AC, but it's obviously running at a high frequency.
What part of the board is supposed to be AC?
-Matt
Yep, this video lost all credibility for me when they were showing the toroid common mode choke and saying it was a converter transformer. Also the obvious change from big aluminum electrolytics (needed with the lower switching frequency converter on the old boards) to much smaller caps that can be used on the new higher frequency converter design. That should have been mentioned right at the start instead of their misguided dancing around discussion. This is all very basic stuff for anyone involved with current state of the art power conversion, even on small scale power supplies.
Nvm, I see what they could be doing. They must be chopping the AC directly and combining the chopper and the rectifier together with a synchronous rectification design. So the input stage is basically just a current pump. Which makes sense because it has a battery pack's extremely low impedance that it can push against.
We need to be able to peek under the plastic on that input stage before the planar magnetic elements. There is still a lot of EMC missing that has to be there somewhere. Plus whether there are diodes or [*]FETs Its supposed to be bidirectional so... might not have diodes.
-Matt
Dear youtube.com/@MunroLive, sorry to say, but what you are saying at minute 7:00 is simply wrong! You are talking about the redundant DC/DC converters, but it is the AC to DC stage. It is even marked as DC/AC 1 & 2. Actually the orange connector is the 3 phase + N AC input. I hope this is correct in your pricy report ;-) I guess the white connector is the HV DC output and the blue connector is the LV (48V) output. The big planar transformers are part of the conversion stage (AC to DC). BTW: Planar transformers are nothing new to automotive. A similar concept was already used in the DC/DC converter of an ID.3 (MEB).
seem you are valeo guy ?
At this point you would think Tesla is way more valuable at designing and engineering parts than they are at building cars but I guess you can't have one without the other and original OEMs would probably never jump at this if Tesla were selling it, it's only once they see the success that they want in.
You guys are good but Sandy really makes the videos. More Sandy please!!! I'm speaking for everyone when I say we like his insight and color commentary!!
Sandy is busy and can’t be in EVERY video!
Strange that they didn't borrow their solar inverters to convert 800VDC to 240AC. They have a 19KW budget and 11KW are dedicated to AC outlets.
I guess it would be additional single function hardware. What if I want to run two welders? A three-phase water pump? An electric barge? A hovercraft? A submarine? An anti-drone laser? An anti-tank railgun?
what about turning the lights out…. and…. like which happened with lightning… or not…🎉
I can think of a reason. Keeping the power outlets in the bed on while connected to an AC charger. Say you have a box in there for keeping food cold, and you stop over night at a camp ground/hotel/grandma's house?
Devices designed for static installations in one orientation don't survive random vibe of vehicles in motion. Lessons Learned: Peacekeeper Rail Garrison.
Well this just shows how car industry got obsolete and FAR behind. Planar inductors are used in railways industry for about 20 years!
I don’t see any components or conductors that can handle 400 amps.
For me it's a big problem the V2Load functionality is not on every Tesla model already. I cant buy such a piece of hardware and not being able to power any device or tool whenever and wherever I need it. V2L needs to arrive asap to every Tesla model. Im not buying a Tesla until its implemented
I think their day in the sun has passed
Tesla is by far the best power electronics company, yet noone talks about it.
One of the most interesting systems shown as lame as possible no real close ups or real information
All the information is in our reports!
Yeah i understand but your coverage is far away from your old videos and insights.. i like you guys but as an engineer this was more a sales video than anything else sadly
@@MunroLive carls latest video was a really nice deep dive into new areas for me especially when he showed the effect of shrinkage! Top notch video which gets shared a lot!
@@steinmar2 If @MunroLive discovers cutting-edge technology or processes known only to Tesla (or any other vendor teardown), as a business employing many experienced engineers, they cannot afford to give that 'secret sauce' away for free. This is the reason that the new $$$ reports are only affordable to OEMs playing catch-up or financial houses with deep pockets.
Carl's content is excellent but is widely known in the industry.
Because this is a sales video for our reports.
They already said they are going to support powershare on all teslas in 2025 so expect this to be rolled out to all of them. I doubt if they will include 240v outlets in a model Y or 3, but certainly to run your house for 2 or 3 days, a huge benefit of owning an electric car.
Something very odd about this new employee
I miss the initial model 3 tear down series. Much closer together videos, much more videos and most of all, much more informative. Here is just an ad.
pity he would say what he knows or have done his home work and red his crib sheet
I used to watch these videos when it was Sandy presenting
Sandy is a busy man.
@@MunroLive I enjoy all Munro videos, regardless of who's hosting
Yes, I enjoy Sandy's presentations as well. However, for a software-defined vehicle, there is a huge amount of highly specialized knowledge in electrical engineering; power and control management; and software design, coding, and implementation that goes way beyond ordinary ICE cars. Sandy has a multi-disciplinary team to help him disassemble and reverse engineer all of that. Tesla has fantastic multi- and inter-disciplinary design and engineering teams who create all of this essentially from scratch and first principles. In fact, this is the major reason, IMO, for the difficulties that legacy auto-makers encounter when trying to compete with Tesla or the Chinese EV start-ups.
Thank you!
Good talking. Just no key information.
That’s because it’s in our reports!
First😁
🏆
🙋♂️THANKS TOM,SAM AND MUNRO FOR SHARING 📐📐📐
The investor analysts on Wall Street just don’t get it. Tesla is way ahead, period. And their patents are open!
The most boring silly old farts, just not Sandy
If you guys don't find anything interesting you don't have to fake like it is
Lots of interesting findings in our report!
Just the fact that bidirectional charging has been ADDED whilst at the same time reducing size and weight is definitely interesting.
Also, the removal of the electrolytic capacitors (can shapes on the older boards) means a large improvement in reliability and a huge improvement in board lifespan. That's interesting!
And you can be sure that those improvements will be added to the millions of cars of the other Tesla car models that are going to be made.
"Well may I ask what you expected to see out of a Torquay hotel bedroom window? The Hanging Gardens of Babylon? Herds of wildebeest sweeping majestically across the plain" - Basil Fawlty, Fawlty Towers
@@johnpublicprofile6261 Eliminating the capacitors which are temperature and shock sensitive is pretty interesting to me too. There is likely some cost to making the change because the semiconductors are probably going to be more expensive. There may be some engineering by lawyers hiding in the background. The redundant 48 Volt supplies are an absolute necessity because loss of the 48 Volt power results in being unable to steer the vehicle. I wouldn’t want to be one of the engineers on the receiving end of a lawsuit resulting from a crash due to loss of DC power.
@@MunroLive I felt like there was an appropriate level of disclosure here to lead people who need to know detail to obtain the report.
Sounds like you’re bitter about Tesla. You probably want your Kia or whatever it is you want to have the spotlight lol
Great technology, but a product which will not help to stop the experiment we do with our atmosphere. Tesla, go learn from Fiat Topolino and such
Too bad Elon is a douche 🇷🇺
Half of us cancelled our Tesla’s. Every timeline he projects is false, can you imagine the short cuts just to get it to production! I took one look at mine & walked! It’s a POS
How’s bankruptcy coming along at your fossil car stealership ?
I bet you your opinion is based because of him supporting Trump 😂 Go cry to Biden/Kamala they will bring some illegals in your neighborhood. Truthseeker my a$$
Why does every one of your statements sound like the opposite of truth seeking?
Alien technology!
The cost cutting, innovation and thinking outside the box mentality never stops at Tesla. They employ some brilliant engineers.
Lol!! You mean making vehicles less and less repairable right! That single board fails and the vehicle is not operational.