We found various anomalies in the first round of Model 3.1 data analysis led by Dr. Malcolm, Dr. Ojala, and our lead electrical engineer, Mr. Mark Chang. The performance and load data collected were instrumental in identifying the issues.  

To confirm the suspected interference and drag caused by the brake system, Omar Garcia, our resident Texan contributor at the UL test site, conducted a “chalk test” on the disk. This test confirmed interference with the brake disc and calipers, possibly due to the 27,000-pound rotor assembly and supporting tower settling about 2-3mm.

Our solution is to adjust the caliper placement, redo the motor-drag test and normalize our existing data by the amount of drag caused by the rubbing issue. We can then quickly reestablish the power performance curve. We will share with you the increase in energy output that results. 

The cyclical brake drag issue has also affected how the ABB drive responds to torque and power quality from the Soga variable speed motor/generator. The interaction between the ABB drive and the Soga generator has not been as efficient and easy to control as it should be, primarily due to the calibration offset caused by the brake drag.

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