Welcome back to Monroe Live, everybody. Today we have the Lucid Air Rear Drive Unit and we have Walker with us. This is the first time you've been in a video. You've been at Monroe and Associates for a couple years now, right? And you're one of our rising engineering stars. So we're going to run through what you found.
A lot of the intricacies that we see on the table and let's hop right in. So where are we going to start with maybe one of the planetary sets, maybe the general layout? Sure. Those do general layout.
Okay. So we have a shaft over here and I'll roll this this way. And this is right in the center of the unit and explain how the laminates for the rotor are sleeved on here, explain where the little differential is. Actually, I'll check that. So we have this tiny little differential in the center, correct? And it interfaces with the center of the shaft with these small pins. There's four pins and you see how it slides in here.
But in order to actually assemble it, we have this like loosely bolted together just to show how it works. But what's unique for the Lucid is that this is in the center and oftentimes when there's a planetary set in an electric drive motor, they'll put the differential in the planetary set and then they'll have a shaft that runs inside up here. They're not doing that.
They're sending the power from the stator to the rotor. They're spinning the rotor. The pins spin the center of this and if the wheels are moving in the same speed, this thing stays essentially locked. And as you go around the corner, one spins slightly faster than the other and it rotates. And then it's going to interface with the sun gear of the planetary set right here.
Exactly. Yeah, so they're placing their differential pre-gear reduction, which is one of the reasons that we see it so small here for those. Now why is that the torque demands are a lot less? Because you're not seeing the torque at the wheels. You're seeing the torque at the motor before the gear reduction.
Exactly. Yeah, they're running this at motor speed, not output speed. So this is seen far less torque than it would after it goes through this planetary set, which is a seven to one gear reduction. So the overall load that this sees is far less than that that we would see on like a Tesla, which we could bring over here. Additionally, they have four pinion gears as opposed to just two that we would typically see.
Oh yeah, cool. And then we have one of the planetary sets kind of taken apart here. So you have the sun gear and then you have three planets and then they react to a ring gear. Is that correct? Yes. And then as the carrier spins, this would be wheel speed.
Exactly. So the speed of the carrier is wheel speed. And one thing I noticed that was kind of different is the OD of the seal, sealing surface and the bearing surface. And we have the seal actually installed on this one. Now we were talking about this the other day. This is going to be a higher speed, right? So the further out you are, the higher the speed is.
So it would be kind of interesting to see if they have any service issues with this, you know, late in life. But typically you want these seals. This is a pretty standard design. It's what I see on like the slipy oak of a transfer case. I had a 2500 diesel truck along in another life. And it was slightly smaller than this, but it was pretty much the exact same design.
But what's really nice about this drive unit is that it's centered. So you have the motor in the middle. You have two identical planetary sets, one on each side. So this planetary set is only taking the power of half of the motor, right? So one of the wheels. And if you think of a Rivian, which has a quad motor, they'll have one motor driving. Do they have a planetary set? Do they have offset gear? Rivian was using offset at the bottom. So they have one set of gear train handling all the power from one motor and then another motor driving the other.
This, it's really refined. And I know that Peter Robinson, they did that really nice video. And they talked about how dense this thing is. And it's so small. And it's quite amazing that they're able to get this much horsepower in this unit.
So it's 669 horsepower. Yeah, it's capable up to 669 horsepower. This particular vehicle had a front, in rear, drive unit. But yeah, a lot of people walked by this one that was coming apart. And I think that was the first thing everyone said was just looking at the size and knowing the performance characteristics of the vehicles to see something that's small was pretty impressive.
Talk about the magnets. What did you see on the magnets? Yeah, so the magnets themselves. So the rotor, you can see there has key ways. So this slots over the rotor shaft after the differential is installed.
So they have two of these laminate stacks with magnets. You can see that there's epoxy down the magnet slots to hold these in place. And these are actually segmented magnets. So the original Tesla has utilized these segmented magnets as opposed to they have since transitioned to just one piece magnets. The segmented magnets, you have some efficiency benefits of not having the eddy current losses. So there might be some marginal efficiency benefits to doing this.
But overall, it's a pretty simple rotor design. There's two of these laminate stacks that get slotted over the rotor shaft. Yeah, right here. You can see the slot. Then they use some die cast end caps to cap off either end of these. And it's actually a pin assembly. So due to kind of the nature of how this gets built up with the diff having to be installed first, they actually have this be able to build up as a sub assembly separate from the rotor shaft using those die cast end caps.
We can bring over. Yeah. The idea behind why the shaft itself had these broach marks. And it looked like little broach marks. Do you know why that is? Is that for the electrical conductivity doesn't go down here? Why is that? Do you know? We don't have any definitive reason. Overall, I think it's just going to help them have some retention on these. You can see this isn't a neural surface per se, but overall, this splined fitting is definitely going to provide some additional securing of the rotor stack.
And the end caps, these are aluminum and they're common. Besides the drilling they do for the rotor. Yeah, which so after the entire thing is assembled with the differential and then they would do this additional machining afterwards to just ensure that the overall rotor assembly is perfectly balanced. Yeah. And then here for a position of the rotor, you have a pretty standard, was this a resolver one? But the target ring is really kind of unique. It's integrated into the shaft. Yeah.
We've never seen anything quite like that. Yeah. So, based on the shape of this, this is how they're figuring out what position the rotor is in. It's kind of unique that it's not a separate part. If we walk over here, Eric will actually show you what these target rings look like on a couple of other motors. So we have a rivion shaft right here, a modelless plaid, sorry. The modelless plaid, you see it's a similar shape. It's like this trilobal shape. And this target ring is made up of a stack of thin laminates.
And then on the rivion, you have this quad lube on the end, much smaller. So from a material perspective, this is pretty small and here's another example of one. You know what this is? Up the lightning. Up the lightning. So, it's very common for them to use these stack laminates. So seeing it integrated as a piece of, as a part of the machining of the shaft, it really reduces part count, but not necessarily weight because the rivion with this little tiny target ring there, that's kind of probably your lowest weight right there.
And as that also drives, this drives the size of your resolver ring, your sensor, because you can have a much smaller one if you're trying to sense a smaller target, doesn't need to be as big. They may be able to get some increased accuracy. Most likely the bigger you are, the more sensors, the more spots you have to sense, maybe you can get some more accuracy. I'm not sure.
And I know we were talking about the differential earlier, but here's a differential from a Model S plaid. And this has got to be from the front motor because the rear has a motor that drives each. But here, it can show you the difference in size. And each one of these, right here, that's spinning, is connected essentially to an output shaft to a wheel.
我知道我们之前在谈论差速器,但是这里是一辆Model S plaid的差速器。它应该是来自前驱动器,因为后驱动器每个轮胎都有一个电机驱动。但是这个差速器可以向你展示它的大小差异。每个正在旋转的部件都与一个输出轴连接到车轮上。
So imagine you're driving your vehicle down an icy road and you transition from ice to dry pavement and you have a huge shock load of a tire grabbing. This differential has to handle that shock, particularly when you have one wheel spinning at a different speed and then they both grip or grab. Or all of the torque when you're accelerating is essentially being applied through this pin, these two gears, and moving the whole vehicle forward. And so you can get this huge reduction in size and weight if you have it at the motor instead of at the output shaft.
Let's go look at the laminates for the stator because this was pretty cool. Do you explain how many they have and what they're used for? Yeah, so this is a stator assembly. So we're missing about half of it that we've taken off. There was roughly 462 laminates, I believe, making up the overall stack itself. They have four discrete laminate styles they use, so we have some various ones laid out here. And they're doing something pretty novel with their cooling strategy for this.
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So similar to Tesla, which we can speak to in a second, they're actually routing oil through the laminate stack to cool the conductor ends. So if we turn it here, you can see this little hole here basically creates a nozzle for the oil to spray out onto these conductor ends to cool it. This is one of the areas of the stator. It gets pretty hot and you need to maintain this at a proper operating temperature.
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The laminates themselves, if you want to look at how they create that nozzle, basically the various laminate styles come together. And at the very outmost laminate, they stack one another on top of each other to create a tiny little orifice for that oil. And then it also creates a channel. So as you see the different shapes and sizes, as they're stacked up, you can see they form a channel where the oil actually flow through and get down very low in between these conductor bars.
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Yeah. We can bring over a Tesla. So Tesla does a similar approach of routing oil through their laminate stack, but in comparison to how the Tesla does it versus how Lucid's doing it, you can just see how much closer that they are bringing their oil actually to the conductor themselves as opposed to being far out on the other side.
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Yeah. And this shows you a comparison of how much copper is being used. This is an 800 volt architecture, right? So you have a stack of 1, 2, 3, 4, 5, 6, 7, 8 airpins right here. The Tesla motor is used a wire wound method, which you get a lot of inefficiencies in your fill factor. It's incredible that this small motor, with this small amount of fill factor in copper is able to produce so much power. And that's something that's really kind of blown us away with the Lucid is its efficiency.
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And also how this stator is manufactured with the, who is it called a continuous wire wound? Continuous wave winding. Yeah. Explain what that means. So yeah, we're typically used to seeing a lot of hairpin or coil wound stators like we see on the Ford products we've examined as well as the Tesla products. And maybe we can walk over here and show you this. This is a perfect example of the difference.
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Yeah. So typically with a hairpin you would have on one end the, look like that. Hairpins would be preformed to look similar to this. But on the opposing end you would have all these ends that need to be welded together to meet all the conductors to one another. So you're looking at hundreds of welds that need to take place on the end of a hairpin stator. As opposed to if you look at this, both ends are just folded over. So this actually, this with the continuous wave winding technology, they actually just continually create the conductors in a large mat, fold it over on one another. If you actually follow this you'd see that this is just one giant circle.
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And so what you get with that is the high slot fill like a hairpin. But you eliminate so much of the welding operations. So in total this thing had 24 welds as opposed to 200 welds. Yeah. And you can see right here where they're welding too, right? Yeah. Now, I don't know exactly where these went. But you have one, two, three, so you have your three phases which will connect to probably six each, right? If there's 24.
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I don't know. They double something up I think, don't they? Yeah. And this is quite impressive from a manufacturing perspective because every time you weld here, any inconsistency in a weld from weld to weld, you can build up some variance in the resistance and the amount of copper in that path. So by eliminating all these, you can more carefully control your welds here and even spend a little more time and effort honing this process so that you can get your peak operating performance. Yeah. And each one of these hairpin needs to be discreetly manufactured, bent, and then they need to insert them, re-bend them, clean the surface. There's a lot of steps that go into getting those welds accurate.
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Yeah. We did a whole cost analysis on this motor. Yeah, we did. We're going to sell. It's actually for sale now. So all of these manufacturing steps are captured. You worked on that, right? I did, yeah.
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Yeah. And so we not only captured manufacturing steps, we put a cost to everything. So something that's real interesting, we'll have a cost per kilowatt of power. And I think this thing is probably the best. It's pretty dense. It's pretty dense.
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So that was essentially the basic layout, you got a rotor in the center with a little baby differential in the middle going out equal lengths to two planetary sets for your gear reduction, that gear reduction is what? Seven to one. Seven to one.
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And let's see what else. So there was this large plastic oil reservoir. It also holds the pump and the filter. So serviceable filter. So this is something that we see the Tesla going to in their fourth gen drive unit where they're going to go to an insert filter, but it won't be serviceable without splitting the case.
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This still has some serviceable nature where you could come in here and remove these three screws to get to it. Light weight. I like the fact that it's integrated. They're not using the spin on. It's what you see on the earlier Teslas.
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And then the pump, very similar to what we see on the low lightening, the rivion, I think the Hummer and the Tesla products where you have a low voltage pump that's going to circulate your gear oil fluid. This is important that it's not mechanically attached to the gear train because like for an internal combustion engine, your oil pump is part, it's connected to the rotation of the actual engine.
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So if you have start stop technology and you shut your engine off, your oil system stops pumping. This is important where you can circulate that fluid from a thermal perspective and you have this plate heat exchanger which interfaces with the glide call.
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So if you have a high heat soak environment, maybe you just were driving really fast and you pull up and stop, your motor stops, you can still be running this at full speed to circulate that and interface with the glide call to get it cool. So that's important. It's a relatively expensive part of an electric drive system and how the pump works is almost identical to what you would see in an internal combustion engine vehicle.
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Man, it's so small. How small this thing is. And lastly, these ring gears are what the planetary set will react to. So as that differential which we showed earlier will spin the sun. And if these planet gears don't have anything to react to, your carrier won't move. So essentially once your ring gear is, I'll probably just do it.
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So close. There. So this will be fixed. So hold this, Walker. As I spin this, this is the speed of your wheel. So essentially your tire is attached to the carrier on the other side. And that's essentially how you get your 7-1 gear ratio.
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Now notice the ball bearing. This is a question we get all the time. We'll do paid calls and people will assume that an electric motor has very few or one moving part. Guess how many moving parts this has? I asked Walker to count before we got here. Just tell us. So we have 360 relative moving parts.
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So not even including all the, like, tree in the rotor as one moving part essentially made up of 400 laminates, but relative moving parts, we have 361. And this is how we get there. So this right here, we count as one moving part, the shaft that runs the sun. Each of the ball bearings roll relative to everything else separately.
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And the cage itself is separate from the balls. Each planet spins separate from everything else. And then all of the roller bearings and the cage for the roller bearing are separate parts. So when we count all that up, we get 111 moving parts just in each planetary set. Or not differential. Each planetary set.
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Then the differential has probably another dozen or so parts plus the bearings in the differential, which typically are not moving relative to the motor unless you're turning. So that whole assembly is usually moving in concert with the rotor if you're just driving straight.
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And it only moves when you turn. But we're still counting every moving part relative to each other. So it's an incredible amount. And for other OEMs, you have a similar number, probably a little less. If you don't have a planetary set, it's much less, you're essentially counting the balls in the ball bearing and the carriers. That's where you're going to get the most of your separate moving parts.
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But when comparing that to an internal combustion engine, you have that many pieces in just the timing chain alone. Typically, if you have a long timing chain on a high-feature V6, probably has like a couple hundred lengths there, and then you're valvetrain with tapets and lifters and valvets springs, you easily get to 2, 3, 400 very quickly.
So, guys, we've been looking at a phenomenon that we're seeing in Tesla that we think nobody else is noticing. We think nobody else understands. And we wanted to share that with you today. We're also looking at this phenomenon as it relates to the big guys. As it relates to Volkswagen, General Motors, and some of the other big players that are trying to get into this electric vehicle business.
So what we're talking about here is range. We're talking about how much can an electric vehicle go on a single charge. And what we've looked at is, we've looked at the fact that Tesla's range is growing faster than anyone else. Their range is now over 400 miles. Nobody else is even close to that. And what that's doing, is it's causing a gap. A range gap. Between Tesla and the others that we think is not going to be easily overcome.
And when we're talking about range, we're talking about not just having a 100-mile range car, or a 200-mile range car, or a 300-mile range car. We're talking about a car that has such long range that people are no longer worried about "range anxiety". And it turns out that Tesla is the only company that's been able to achieve that kind of range, and they've done it at a faster pace than anyone else.
Now, we've been tracking this since 2012, and it's just amazing what's happened. We've seen Tesla's range going up, up, and up, at levels that nobody really anticipated. And the gap between Tesla and the other OEMs is increasing. In fact, we plot this on a graph and if we draw a trendline through that graph, we can actually see when the other OEMs are likely to catch up to Tesla's current 400 mile range. And it's not a very pretty picture.
All right, so let's talk a little bit about how we got here. Tesla started out with the Roadster. They had that car for a number of years. It was a Lotus-based vehicle. It had a range of about 200 miles, and people were thrilled with that. And then they came out with the Model S. And the Model S, right away, had a 265-mile range. That was 2012.
Now, at the time, we were looking at the Model S and we thought "wow, this is amazing! This is going to change the industry forever." And we checked around with people at the OEMs, and they said "oh no, no, no. That's a short-term thing. They can't sustain that." And we said, "you guys don't understand. This is a game-changer. They're going to keep pushing this. They're going to gain economies of scale. They're going to expand what they're doing here."
And sure enough, that's exactly what happened. The Model S got up to 300 miles, and then 350 miles, and now it's really over 400 miles. And this has happened in less than 10 years. And we're seeing nobody else really advancing at that kind of pace. It's just amazing.
果然如此,这正是发生的事情。Model S 的续航里程已经达到了300英里,然后是350英里,并且现在已经达到了400英里以上。而且这发生在不到10年的时间里。我们看到没有其他公司能够以这种速度取得进展。这真是令人惊叹。
Now, when we look at the other OEMs, they make mistakes. They make mistakes with their chemistry. They make mistakes with their thermal management. They have to do a lot of testing. They have to do a lot of validation. And that just slows everything down. And because they're not getting the scale, they can't get the costs down. And that's really hurting them.
So, when we compare Tesla's range with others, the gap is growing. It's not shrinking. Nobody else is getting it. Nobody else is beginning to understand how they can catch up with this. Tesla's competitors are actually falling behind. And this is a big deal.
Now, when we look at competition among electric vehicles, there are a lot of things that are important. And in many cases, Tesla hasn't been the leader in all those categories. But when it comes to range, Tesla is annihilating the competition. There's nobody else even close.
Now, for customers, range is a big issue. They don't like to be tethered to a charger, and that's what's happening with other EVs. They have to be close to the wall, they have to charge up. It's a pain, it's a hassle, and it's not convenient. And by the way, if you're talking about long distances - taking a long road trip - it's not even possible with those cars.
So, as we look forward, we think that Tesla is going to continue to maintain this lead in range. They're going to use economies of scale, they're going to continue to improve their chemistry, they're going to continue to improve their thermal management. And they're going to be just so far ahead of the other OEMs that it's going to be really tough for them to catch up.
Now, we know a lot of people are working on this. We know there are a lot of people trying to come up with new chemistry, trying to come up with new thermal management, trying to validate, trying to do all these things. But we think, at this point, nobody's really close.
So, what does this mean for the industry? Well, we think it means that it's going to be very difficult for anyone to really compete with Tesla. We think that their lead in range is going to give them so much market power that they're going to be almost in a category by themselves.
In fact, if you look at some of the numbers, some of the data, you see that the other EVs really can't compete with Tesla, even on things like charging speed, or quality of service, or anything like that. People are looking for range, and Tesla has it. They say "I don't care about the others. I don't care about things like quality of service or charging speed, because that's not an issue for me. I want range."
So, we think that the gap is going to continue. We think that Tesla is going to be very difficult to catch up with. They're already over 400 miles in range, and the others are really struggling to even get over 200 miles. And in some cases, they're not even close. It's a big deal, and we think it's going to be a market-changer.