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Anyone have more insight into this? An overheating contactor doesn't sound like something that can be fixed with software (except to ignore it).

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They control the heat input, too. Software fixes:

* limit max current (dumbest) * limit max current based on moving average of current over last N seconds * limit max current based on experimentally validated thermal model of contactors (cleverest)

This might even be possible without a significant/noticeable performance hit, if the overheating is only experienced in extreme conditions.

The contactors might have active cooling controlled by software. The battery packs do.

I'm not aware of any contactor design that has active cooling. It would be foolish to have that. It's possible they're doing something incorrect with the pre-charge circuitry, though which could cause overheating.

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