On EV's, it isn't so much the actual motor (which has fewer moving parts than ICE vehicles,) but all the technology required to make the motors run efficiently.
So there are 3 major “modes” of thought on the drive-train of current production electric cars-
- the Single Motor design - Requires a motor, followed by a single reducer gearbox, followed by a differential. one pair of wheels is left to float, or is hooked through another differential to make a 4WD system. This is Tesla Motor’s current 2WD design.
- The Two motor design - fully 4WD system, with a motor responsible for each pair of wheels. still requires a reducer gearbox and a differential per motor . This is Tesla Motor’s current 4WD design.
- The IWM (In Wheel Motor) - also a fully 4WD system. one motor per wheel, either hooked directly to wheel, or hooked to each wheel through a reducer gearbox. Tesla, Toyota, Mercedes and BMW have all played with the design, to name a few, but no production car uses this yet for a variety of reasons - another story altogether.
In terms of part counts - Electric Motors by themselves have up 4 moving parts - if you count bearings as a single moving part - those would be the rotor, and 2 - 3 bearings between rotor and Sta tor/motor housing.
The reducer gear constitutes 8 - 10 moving parts by the same logic as the motor plus a few spacers, though this can depend on the type of reducer gear they use. Planetary is typical for High RPM electric motors, which would be a large number of moving parts, though I feel like I’ve heard they use a helical spur in Teslas.
Now, adding in a little bit of bad news - Electric motors of this power must have a liquid cooling system, sometimes multiple systems, working on the motors, the VFD electronics (Variable Frequency Drive - what controls the operating speed of the AC motors), and the batteries separately. In addition, the Motors on the Tesla cool the rotor as well as the stator, which introduces a couple union junctions to the mix that add a few more moving parts. for each system you need a separate pump, not coupled to the motor, which can add up to a dozen or so moving parts per pump (depends on the pump), plus a few for the union junctions, plus whatever valves and the like they have in there. all in all, you probably end up with + 20 - 30 parts per car for the cooling systems. so final, VERY ballpark final counts
- Single Motor 2WD, worst case - 80 - 90 moving parts
- Double Motor 4WD, Worst Case - 90–100 moving parts
- IWM 4WD, worst case - 70 - 80 Moving parts
Compared to an ICE?
Several hundreds of moving parts. 1000+ on higher performance motors. the biggest count savings are in the motor and gearbox, obviously. so it’s really no comparison at all. mechanically speaking, electric cars should be dramatically more reliable. electronically speaking? remains to be seen.
in general the widespread use of complex modern electronics is unprecedented in motor vehicles on such a scale so the reliability data over the long haul is really unknown.
There are many expensive components, modules and systems in electric cars each representing a potential point of failure compared to mechanical systems which is a better known entity with a demonstrable reliability history.
With that in mind, we can probably postulate that should the center LC display go bad on the Tesla, for example, or its motor controller, charging system, batteries, and its many potential points of failure in the electrical systems, each of these repairs will prove costly even if they have been reliable so far in its short vehicle history.
Of greater concern is the unknown future availability of OEM replacement parts as there will unlikely be alternate sources.
Source:
Answer (1 of 4): [A2A] Note :EV manufacturers replace whole drive unit which has higher impact on cost than battery packs. Considering the case of TESLA MODEL S . From the words of George Blankenship( Vice president at Tesla motors) Prices are as follows: 1) Cost to REPLACE a "Drive unit" is $2...
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