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Tesla Megapack Safety Overview


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Publication Title | Tesla Megapack Safety Overview

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Tesla’s commitment to safety and 15+ years of experience in battery module design and manufacturing for both vehicle and energy storage applications guides every Megapack design decision. Megapack is designed from the ground up with safety as the top priority, including features that make the product safe throughout the entire product lifecycle – during transit, installation, commissioning, operation, maintenance and decommissioning.
Tesla’s approach to safety involves comprehensive design and testing at each level of the Megapack. Vertical integration across design, manufacturing, and testing ensures that safety features of the cell, battery module, inverter, thermal system, and overall system-level components are closely linked and not decoupled.
Tesla uses the highest quality lithium-ion cells, but recognizes that in rare instances a cell can be flawed. For this reason, each cell in Tesla products is individually inspected and tested prior to module assembly. Flawed cells are discarded and used to drive further cell manufacturing improvements.
Each Megapack battery module includes individually-fused cells and dedicated power electronics that electrically and galvanically isolate the batteries from the common DC bus, similar to the
Pod architecture in Powerpack. Unlike racked battery systems, the battery modules arrive pre-installed without the need to connect live high voltage DC elements on site. Each battery module includes a built-in isolated DC- DC converter and an active fuse that provides an added layer of protection in case of hazardous conditions, allowing for multiple levels of isolation. All of these features are controlled by the module’s dedicated Battery Management System (BMS), which ensures that the cells are operated within approved limits.
Non walk-in IP66 Enclosure
Touch-Safe Customer Interface Bay
Thermal Roof with passive deflagration vents
Isolated DC-DC converter electrically and galvanically isolates batteries from the common DC bus
Separated Battery Bay Sections
Individually fused Battery Modules

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