Drive Units Catalog - HSR Motors Motors - Drive Unit...LARGE DRIVE UNITS PG 6 LARGE DRIVE UNITS CONT...

D r i v e U n i t s C a t a l o g

T A B L E O F C O N T E N T S

O U R S E R V I C E S P G 4

O U R P R O D U C T S P G 5

L A R G E D R I V E U N I T S P G 6

L A R G E D R I V E U N I T S C O N T P G 7

S M A L L D R I V E U N I T S P G 8

A D D - O N S P G 9

H S R C O N T R O L L E R S P G 1 0

H S R C O N T R O L L E R S C O N T P G 1 1

D R I V E U N I T S C A T A L O G

5277 W NC Hwy 10, Hickory, NC 28602 w (844) HSR-4772 w hsrmotors.com

Pg 4 | HSR Drive Units Catalog

A B O U T U SO U R S E R V I C E S

HSR Motors LLC specializes in the refurbishing and repurposing of components from various electric vehicles. The most popular of which are the many variants of Drive Units from the Tesla Model S and Model X. At HSR, we have developed custom control systems that allow these units to be utilized for other projects outside of a Tesla vehicle, such as an electric vehicle conversion project, custom electric vehicle, or any other application where a high power density, high voltage, and fully integrated electric motor system would be useful.

Our approach is unique, as we keep the original Tesla hardware completely intact with no modification to it. This ensures that you get the full efficiency, power, and features that these units are capable of providing. HSR Motors’ propriety controller hardware allows the user to utilize commands for manipulating cruise control, torque limiting, power limiting, basic traction control, regenerative braking, and many additional settings to configure the system for your specific application.

Pg 4 | HSR Drive Units Catalog HSR Drive Units Catalog | Pg 5

Tesla Drive Units offered by HSR are complete systems that include a three phase AC Induction Motor, a High Voltage DC to AC Inverter, and a Differential, all in a single package (see Drive Unit Assembly on pg 9).

HSR Motors can also provide several additional components for use with the Tesla Drive Units, including a Full Rear Subclip. This setup would include the Drive Unit, along with the majority of the suspension components normally found in a Tesla Model S (as shown on pg 9). This is a complete system which, when combined with shocks appropriate for your application, can be placed into a vehicle with just four mountings points. If you’re doing an electric vehicle conversion where your vehicle can accommodate the same wheel base as a Tesla Model S, then using a Full Rear Subclip can be a major time saver!

Whatever your intended application, the power and versatility of our Tesla Drive Unit Packages makes them the best electric powertrain product available. Contact us for more info!

O U R P R O D U C T S


C O M M O N S P E C I F I C A T I O N S

Input voltage (traction power): 240-404V DC Limits configurableInput voltage (logic): 10.5-16V DCInput current (logic): < 5A (max) (10A fuse suggested)Cooling: Liquid cooled, ¾” ID barbs Flow required during operation Max coolant temp: 85C / 185F Max coolant pressure: 19 psi (130 kPa) Min coolant pressure: 5 psi (35 kPa)Torque control: 6-wire dual hall-effect throttle inputSoft gears: Forward, Neutral, Reverse

No mechanical gear changes. Reverse is achieved by reversing the motor’s direction. Neutral achieved by cutting power to the stator.

Motor type: 3-phase AC induction


Input power (continuous): 35 kW (approximate)Input power (15 minute): 90 kW (approximate)

System efficiency (average): Approximately 90%Transmission: Single speed, 9.73:1, open differential

Dry weight: 291 lbs (132 kg)

COMMON SPECS

L A R G E D R I V E U N I T

Input current (HV, peak): 950A DCInput power (peak): 335 kW (449 HP)*Motor speed (max): 14,900 RPMTorque (peak output): 450 Nm (~332 ft/lb)Torque (regenerative braking, peak): 105 NmOutput power (regenerative braking, peak): 60 kWOutput current (regenerative braking, peak): 225A

BASE

Input current (HV, peak): 1150A DCInput power (peak): 400 kW (536 HP)*Motor speed (max): 15,200 RPMTorque (peak): 600 Nm (~443 ft/lb)Torque (regenerative braking, peak): 110 NmOutput power (regenerative braking, peak): 70 kWOutput current (regenerative braking, peak): 250A

PERFORMANCE

Input current (HV, peak): 1400A DCInput power (peak): 475 kW (636 HP)*Motor speed (max): 17,000 RPMTorque (peak): 650 Nm (~480 ft/lb)Torque (regenerative braking, peak): 140 NmOutput power (regenerative braking, peak): 75 kWOutput current (regenerative braking, peak): 250A

HSR PERFORMANCE +


Input power (continuous): 30 kW (approximate)Input power (15 minute): 75 kW (approximate)System efficiency (average): Approximately 92%Transmission: Single speed, 9.34:1, open differential

COMMON SPECS

Input current (HV, peak): 650A DC (estimate)Input power (peak): 220 kW (294 HP)*Motor speed (max): 18,000 RPMTorque (peak): 330 Nm (~243 ft/lb)

Torque (regenerative braking, peak): 115 NmOutput power (regenerative braking, peak): 45 kW

Output current (regenerative braking, peak): 140ADry weight: 194lbs (88 kg)

(FROM REAR)

Input current (HV, peak): 650A DC (estimate)Input power (peak): 220 kW (294 HP)*Motor speed (max): 18,000 RPMTorque (peak): 330 Nm (~243 ft/lb)Torque (regenerative braking, peak): 115 NmOutput power (regenerative braking, peak): 45 kWOutput current (regenerative braking, peak): 140ADry weight: 205 lbs (93 kg)

Note: This drive unit has no direct control torque input. Torque is controlled digitally through the HSR Motor Control Module.

(FROM FRONT)

S M A L L D R I V E U N I T

* Input power can be configured up to this value. Input power is dependent on the voltage of the power source and may vary greatly depending on the type of power source/battery used. Generally, a fully charged battery pack with a low internal resistance (high C discharge capable) is required to reach peak values. Input power is not mechanical output power.


A D D - O N S

FULL REAR SUBCLIP

(Shown with Small Rear Drive Unit. Also Available for Large Drive Unit.)

Electric Parking Brake CalipersHydraulic Brake Calipers

(not pictured)

Brake RotorsMounting Points

(x4)

Control Arms

Half Shafts

Drive Unit

Rear Subframe

Drive Unit Assembly

Motor

Mounting Point (Hidden)

Inverter Cooling

Mounting PointMounting Point

Differential

Motor Cooling

Inverter


H S R C O N T R O L L E R

Weight: 5.3 oz (150 g)

Dimensions: – Excluding connector: 4.75 (w) 3.75 (L) x 1.375 (h) inches (12 x 9.5 x 3.5 cm) – Including connector: 4.75 (w) 4.75 (L) x 1.375 (h) inches (12 x 12 x 3.5 cm) – 4-hole or strap mounting capable

Power Input: – 9V to 22V DC, max 0.5A (excluding externally driven loads) – In-house filtering design on power input specifically for use in EV

drive unit control.

Core Components/Features:– 32-bit RISC microcontroller @ 48MHz– Dual high-speed CAN interfaces– Hardware and software based control safety protection– Secure firmware upgrade capable via auxiliary CAN or diagnostic serial– All components rated for use in an automotive environment

External connections– Water resistant connector housings– 12V Power input– Configurable relay control outputs (4)– Brake signal outputs (to drive unit, 2)– Configurable isolated 12V inputs (6)– Diagnostic serial connection– CAN connections (powertrain control and auxiliary CAN)– High-voltage Interlock Loop (HVIL) generator output– General purpose peripheral inputs (3)

• For possible future feature expansion

CONTROLLER SPECS


Our Drive Unit control system has been designed and built from the ground up using high quality automotive grade components. It is not based on low quality hobbyist hardware (such as the Ardunio) that is in no way suitable for use in a safety critical system in an automotive environment. When performance is critical, you need a well validated design that is right for the job. No corners are cut when it comes to hardware from HSR. Every Drive Unit controller is fully tested in-house to ensure it meets all specifications so that you can trust that our systems will perform appropriately and safely.

An improper or incomplete control system could lead to unexpected, and sometimes unsafe, results. It may just be an inconvenience like a power output limit, but such poor control can end up being extremely unsafe, resulting in improper torque control or acceleration, excess high-voltage current usage, excess regenerative braking causing battery overcharge, and more.

At HSR, we have put in the time and research needed to ensure that Drive Unit packages from us will perform as well or better than they would have in their original vehicle. We have full control over all variants of the Tesla Drive Unit. We’re also not limited by the Drive Unit’s build date or software version in any way. Additionally, full features are available—including cruise control capability. No safety or performance compromises have been made with our design. We’ve kept our products in development for a long time to be sure we were satisfied that everything functioned perfectly and safely. As a result, with our products, you get the full functionality you deserve from these amazing devices.

H S R C O N T R O L L E R

Drive Units Catalog - HSR Motors Motors - Drive Unit...LARGE DRIVE UNITS PG 6 LARGE DRIVE UNITS CONT...

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