Tesla Model S electric car: Manufacturing Process

The Tesla Model S body is 98% aluminum. A robot transfers aluminum sheets or blanks into the draw died of a stamping process. The effort I plus more than 1,400 tons of downward force while the lower section exerts about a hundred and thirty tons. This for stretches the black aluminum sheet over the form in the center of the lowered. Robots move apart from station to station. Each panel undergoes a series of procedures before emerging on the other side of this gigantic structure. The Structure is called the mechanical line.

Tesla Model S electric car: Manufacturing Process

Comic for process of Tesla Model S Electric car manufaturing in Tesla Factory

Workers inspect each finished panel to ensure there are no flaws and all epenings have been cut.

The chance to impress and is capable of exerting more than 11,000 tons of force and creates 5,000 parts every day.

Tesla will use his state of the art technology to build the Model S is under tested. Here a robot brings the car’s front, center and rear 4 panels to the phrases. A Team of robots uses CNT or hold metal transfer wielding to join the parts. With the 4 panels in place, the underbody moves forward on the line and apparel robots install the body sides.

The body sides at the complete sides of the Model S. They feature high strength steel reinforced be pillars. Next the sides are joining the top by a pair of patterns that can span the width. These will complete the basic structure of the car.

Tesla uses several methods to join the car’s body components, including cold metal transfer welding, conventional spot welding, structure and self piercing rivets.

A worker now attaches the door panels. They each have 2 hinges attached with 4 bolts. Like most of the car, the lightweight doors are made of aluminum. The total weight to the aluminum used in the Model S is just over 410 pounds.

The front fenders go on before workers install the hood. Since there’s no engine the front hood is really just a cover for the front trunk space.

The body of the car is now completely assembled. It’s what manufacturers call a body.

A technic than gives the body in white a thorough inspection, checking all 12 points in structural adhesive joins as well as the overall fit and finish.

In the paint department, the car body goes through a pretreatment process. It’s essentially a bath for the car in the giant dishwasher.

Once clean, the body receives a corrosion resistant electrolytic coaching: a primer, a base coach and a clear coach. When the six-hour process is complete, 3 separate teams of inspectors examine the surface to ensure its quality.

Tesla Motors builds most of its car components in house, including the AC or alternating current motors. This step in the production process is called the stator wire line. A machine unexposed wire over half a mile of copper wire for each motor. An electric motor consists of the stator and rotor. Here a machine begins building a stator by pulling the copper coils into structure called the staff. This is a three-phase motor scooter or three separate coils of copper. When in used, a current will pulse through each coil creating a temporary magnet. The rotor will turn because its magnum follows the stators magnetic field.

This worker carefully lengthens and straightens the ends of each bundle of wires. This is something insert the hydraulic lift needed to move the stator to the next phase of production.

For the motor to work properly, the bundles must be insulated so the phases don’t touch each other.

A technician insulates the copper wire by carefully keeping each one in a  protected sleeve.

While much of the production process at Tesla was completed by high-tech machinery, this step is so important that it best done by hand. For all its futuristic qualities the Model S has a few old school elements to motor, for instance it is a direct descendant of the 100 year old motor developed by Nikola Tesla himself.

A worker slips the ends of the copper bundles to prepare them for the next step. These components are called love. A worker slides them over the wires where they will be credit, form the attachment points for the motors three phases.

You may be surprised to see a soda machine on the production line for an electric motor, but that’s exactly what this is.

Tesla uses this highly specialized device to find a coil securely in place. To more tightly bound the wires are the more efficiently the motor are. This binding process also prepares the stator to be encapsulated in a two-part epoxy. Blocking everything in place.

The two-part epoxy provides an extra layer of insulation evenly distributing the motor heat.

The completed stator easily slips inside a heated metal casing as the casing calls. It contracts firmly in place. Next, a technician uses a system to insert the rotor inside the stators opening.

The completed AC motor moves down the production line to another station where a worker installs the differential. The three legs that are attached to the stators three phases for truth from the top of the motor. Now the worker attaches other sections of the gearbox in place. Thanks to its well-designed motor inverter, the Tesla Model S can rely on simple gearbox rather than a complex transmission.

Not only use the gearbox more efficient than a transmission, it’s far smaller leaving more room for storage space. A technician conduction early testes on the motor and gearbox before the next day.

A worker now prepare another crucial component of a drive. To three-phase tripolar burger. The Model S motor requires an inverter to convert the batteries direct current electricity into alternating current power. Every Tesla Model S drivers must undergo a dyno test. In this test, two components of the dyno machine plugged into the drive. The dyno tool the test every branch of the drive unit to ensure it meets all design criterial. This test takes just 4 minutes. Every 4,5 minutes a new drive unit comes off the production line. From here the drive units head to the general assembly area.

Battery-operated cars guided by magnetic strips in the floor area carry the cars through assembly. Technicians install tunes on the underside of the car that will carry cool into the battery. This will prevent the battery cells from overheating. The technicians also install the high-voltage cables that power the motor. Then a worker lowers the car with a hydraulic lift preparing it for the next step in production.

A robot installs the car’s roof. Customers can choose a panoramic roof for their Model S. This all glass top is constructed of lightweight safety glass that blocks 80% of the sun’s heat and 100% of UV rays. A technician begins building the frame for the instrument panel. The frame is one of the few components made of steel and aluminum body car. The instrument panel needs to be single because it’s the main interface between car and passenger. The panel requires a more dependable structural integrity than an aluminum provides it holds everything from the radio tuner amplifier to the airbags and touch-screen controls.

This touchscreen is central to the Model S driving experience. It’s like an on-board table computer that allows the driver to control all aspects of the car’s performance.

Using the touchscreen you can access the rearview camera, raise and lower car; open and close the roof adjust the brakes; choose the car’s performance mode; monitor energy consumption and fine-tune the sound system. Maps, music in the internet can also be accessed all in a single device.

The touch screen is always up today automatically downloading the latest browsers when one becomes available. In the general assembly area a technician store the instrument cluster screen and touch screen in the instrument panel. It’s upholstered with synthetic leather. Next, they add their banks and other components. The instrument cluster above the steering wheel shows Steven power use the driver can also choose to monitor other functions on the display including energy used, sound system and phone info.

Workers used hydraulic hoist system to install the completed instrument pound. The hoist help prevent worker injuries and minimizes the chances of a damage being done to the panel during assemble.

Driver can access many of the touchscreen functions directly from the steering wheel.

A worker raises the Model S is driving up under the car and secures it in place. The tribune it fits into the rear axle assembly. It provides power directly to the wheels so there’s no need for the usual drive shaft.

Finally, it’s time to install one of the cars most unique features – the battery. Since Tesla designed a model from the ground up, they were able to turn the challenge of battery storage into an asset.

The lithium-ion battery weights almost 1,200 pounds running the length and weight of the car.

The battery has strength and rigidity to the car and lowers its center of gravity. This improves the model S traction and handling as well as its safety rating.

Thank to incredibly efficient of electric motor, the drive efficiency of Tesla Model is nearly 90%. The Tesla Model S is now nearly ready to drive.

The Model S may look like luxury sedan from the outside, but there are certain details that reveal how different this electric car really is.

Since there’s no hot engine to cool down, Tesla Model has new kind of grill instead of a traditional front grill. Also there is no tailpipe gas cap.

Technicians now begin to give the Model S a complete inspection inside and outside. They test every aspect of the cars functionally and thoroughly example fit and finish.

One it passes inspection, a driver takes the car for its first drive.

Tesla builds all of its Model S cars to order this particular cars destined for an overseas customer so the steering wheels on the right hand side. At its next stage, a worker performs roll tests. During this five-minute test, the technician brings the car up to speed checks the brakes and set the alignment. Most cars would also get an emissions test. But since the Tesla Model doesn’t have any emissions, there’s no need to conduct this test.

Next, the car undergoes a water test. As high pressure water grinches the car, the inspector examines the interior for any signs of leakage.

The cars low center of gravity helps maintain traction in wet weather. The electric drivetrain and his low inertia allow you to adjust quickly to changing road condition.

In cold weather, drivers can use an app to preheat the car before stepping in,

Finally, the Model S is let loose on the Tesla test track to ensure the car meet its design parameters. The driver gives it a thorough road test. Here complex it’s electric muscles. Despite the compact size of the cars, they can accelerate from 0 – 60 mph in just 5.2 seconds with a top speed of 120 miles per hour.

For a sedan, Model S has a remarkable amount of space, with the seats folded flat, it has over 63 cubic feet of total storage space. Using the touch screen, the driver can customize the car’s performance right raise down to its ride height and steering. On board map show the closets supercharging stations and the car keeps close track of its energy usage.

With a drag coefficient 2.2 for the Model S is one of the most aerodynamic car in the world.

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