DRIVE UNITS CATALOG TABLE OF CONTENTS

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Gerald Carter
6 years ago
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1 Drive Units Catalog

3 DRIVE UNITS CATALOG TABLE OF CONTENTS OUR SERVICES PG 4 OUR PRODUCTS PG 5 LARGE DRIVE UNITS PG 6 LARGE DRIVE UNITS CONT PG 7 SMALL DRIVE UNITS PG 8 ADD-ONS PG 9 HSR CONTROLLERS PG 10 HSR CONTROLLERS CONT PG W NC Hwy 10, Hickory, NC (844) HSR-4772 hsrmotors.com

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

4 ABOUT US OUR SERVICES 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

5 OUR PRODUCTS 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! HSR Drive Units Catalog Pg 5

COMMON SPECIFICATIONS Input voltage (traction power): 240-404V DC Limits configurable Input voltage

5-16V DC Input current (logic): < 5A (max) (10A fuse suggested) Cooling: Liquid cooled, ¾ ID barbs Flow

pressure: 5 psi (35 kpa) Torque control: 6-wire dual hall-effect throttle input Soft gears: Forward,

6 COMMON SPECIFICATIONS Input voltage (traction power): V DC Limits configurable Input voltage (logic): V DC Input 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 input Soft 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 Pg 6 HSR Drive Units Catalog

LARGE DRIVE UNIT BASE COMMON SPECS Input power (continuous): 35 kw (approximate) Input power (15 minute): 90 kw (approximate) System efficiency (average): Approximately 90% Transmission: Single

73:1, open differential Dry weight: 291 lbs (132 kg) Input current (HV, peak): 950A DC Input power (peak): 335 kw (449 HP)* Motor speed (max): 14,900 RPM Torque (peak output): 450 Nm ( ~ 332

DC Input power (peak): 400 kw (536 HP)* Motor speed (max): 15,200 RPM Torque (peak): 600 Nm ( ~ 443 ft/lb) Torque (regenerative braking, peak): 110 Nm Output power (regenerative braking, peak):

7 LARGE DRIVE UNIT BASE COMMON SPECS 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) Input current (HV, peak): 950A DC Input power (peak): 335 kw (449 HP)* Motor speed (max): 14,900 RPM Torque (peak output): 450 Nm ( ~ 332 ft/lb) Torque (regenerative braking, peak): 105 Nm Output power (regenerative braking, peak): 60 kw Output current (regenerative braking, peak): 225A PERFORMANCE Input current (HV, peak): 1150A DC Input power (peak): 400 kw (536 HP)* Motor speed (max): 15,200 RPM Torque (peak): 600 Nm ( ~ 443 ft/lb) Torque (regenerative braking, peak): 110 Nm Output power (regenerative braking, peak): 70 kw Output current (regenerative braking, peak): 250A HSR PERFORMANCE + Input current (HV, peak): 1400A DC Input power (peak): 475 kw (636 HP)* Motor speed (max): 17,000 RPM Torque (peak): 650 Nm ( ~ 480 ft/lb) Torque (regenerative braking, peak): 140 Nm Output power (regenerative braking, peak): 75 kw Output current (regenerative braking, peak): 250A HSR Drive Units Catalog Pg 7

SMALL DRIVE UNIT COMMON SPECS Input power (continuous): 30 kw (approximate) Input power (15 minute): 75 kw (approximate) System efficiency

34:1, open differential (FROM REAR) Input current (HV, peak): 650A DC (estimate) Input power (peak): 220 kw (294 HP)* Motor speed (max):

kw Output current (regenerative braking, peak): 140A Dry weight: 194lbs (88 kg) (FROM FRONT) Input current (HV, peak): 650A DC (estimate)

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

Input power is dependent on * the voltage of the power source and may vary greatly depending on the type of power source/battery used.

8 SMALL DRIVE UNIT COMMON SPECS 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 (FROM REAR) Input current (HV, peak): 650A DC (estimate) Input power (peak): 220 kw (294 HP)* Motor speed (max): 18,000 RPM Torque (peak): 330 Nm ( ~ 243 ft/lb) Torque (regenerative braking, peak): 115 Nm Output power (regenerative braking, peak): 45 kw Output current (regenerative braking, peak): 140A Dry weight: 194lbs (88 kg) (FROM FRONT) Input current (HV, peak): 650A DC (estimate) Input power (peak): 220 kw (294 HP)* Motor speed (max): 18,000 RPM Torque (peak): 330 Nm ( ~ 243 ft/lb) Torque (regenerative braking, peak): 115 Nm Output power (regenerative braking, peak): 45 kw Output current (regenerative braking, peak): 140A Dry 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. 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. Pg 8 HSR Drive Units Catalog

ADD-ONS FULL REAR SUBCLIP Electric Parking Brake Calipers Half Shafts

Mounting Points (x4) Rear Subframe Brake Rotors (Shown with Small

) Inverter Drive Unit Assembly Mounting Point (Hidden) Inverter

9 ADD-ONS FULL REAR SUBCLIP Electric Parking Brake Calipers Half Shafts Hydraulic Brake Calipers (not pictured) Control Arms Drive Unit Mounting Points (x4) Rear Subframe Brake Rotors (Shown with Small Rear Drive Unit. Also Available for Large Drive Unit.) Inverter Drive Unit Assembly Mounting Point (Hidden) Inverter Cooling Motor Mounting Point Motor Cooling Mounting Point Differential HSR Drive Units Catalog Pg 9

HSR CONTROLLER CONTROLLER SPECS 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.

5A (excluding externally driven loads) In-house filtering design on power input specifically for use in EV drive unit control.

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

10 HSR CONTROLLER CONTROLLER SPECS Weight: 5.3 oz (150 g) Dimensions: Excluding connector: 4.75 (w) 3.75 (L) x (h) inches (12 x 9.5 x 3.5 cm) Including connector: 4.75 (w) 4.75 (L) x (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 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 Pg 10 HSR Drive Units Catalog

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.

11 HSR CONTROLLER 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. HSR Drive Units Catalog Pg 11

POWERTRAIN SOLUTIONS FOR ELECTRIFIED TRUCKS AND BUSES

POWERTRAIN SOLUTIONS FOR ELECTRIFIED TRUCKS AND BUSES PDiM 2017 (Heimo Schreier) Burak Aliefendioglu Fredrik Haag AVL H. Schreier, B Aliefendioglu, F. Haag PDIM 2017 30 November 2017 1 TRUCK & BUS ELECTRIFICATION