Yeah the smell was atrocious, fair play they came out and fixed it the next day and it was fine afterwards but if I wasn’t working from home it could have been nasty.
When mine did similar it was a loose socket to the board and or the wire was not torqued down enough. They never confirmed, just refunded the money for the unit.
High amp stuff like power showers connections or car chargers if not torqued down enough can get very hot.
They never said. I was doing work for chargemaster at the time so it was all done via back channels (although with the correct documentation) I suspect it was, as stated, something not properly tightened.
The main things I enjoyed was the use of castings to eliminate a ton of complex welded sub-assembly; and the rationalisation of number of complete body assembly permutations (my goal at BMS was to get down to <10 from 100’s).
The bit that struck a chord was the separation of body structures from the outer skin. Quite apart from the design opportunities of being able to modify the outer design without changing all the tooling for something like an integrated monoside, the fact that you can then service and repair these without the need for rejigging etc and expensive cut out and weld processes, or even happing to scrap the vehicle.
The road that Tesla haven’t gone down yet in terms of production appears to be the use of composite skins/ closures which I was developing for BMW when I was in Body Concepts Engineering. Given how they’ve managed to make castings work in terms of investment cost and takt time then they would seem to be heading in a direction that might make these viable and then that opens up a whole host of opportunities.