Swap out of Warp 11 DC motor with a Hyper 9DHV 3 Phase Motor.

When the HyPer 9 initially was introduced by Netgain, it was designed for a voltage range between 60 and 130.  NetGains recent introduction of a higher voltage motor HyPer9-DHV (dual shaft high voltage) allows for operation in the voltage range of 90 to 180 volts.  This higher voltage allows the current Tesla based battery pack (6 cells), with nominal voltage of 144 volts, to be used with either the DC or the AC motor.   One of the goals of the build was to create two separate drive trains that can be swapped out with a minimum amount of effort.  In principle, one might be able to drive DC in the morning (high performance) and AC in the afternoon (in cruising mode).  To that end, each motor has now been attached to its own Getrag 5 speed manual transmission, adapter plate, racing clutch, and motor controller.  Using the components previously described in this blog for the Warp 11 drive train,  the adapter plate (8/31/12), hub adapter (8/24/12), and Stage 2 racing clutch (5/3/13)  were all used without modification when combined with the Hyper 9-DHV.  The controller mounting platform, on the other hand, will need to be different to accommodate the different motor and controller dimensions.

In this build the Warp 11 was configured to use the Soliton1 controller, but other brands of controllers could have been used just as effectively.  In contrast, the HyPer 9-DHV can only operate using the factory supplied AC controller that is matched to the motor. 

DSC06606 showing top view of the HyPer 9 -DHV 3 phase motor (serial number H9DHV000025).

DSC06607 showing the terminal and accessory plate end view.  The motor serial number label is located on the standoff that supports the terminal strip.  In older dual shaft motors (shown) the serial number is sometimes harder to read as it can be obstructed.  updated 8/21/21

In this fresh out of the box picture of a single shaft Hyper9 HV motor, the serial number is much easier to read. updated 8/21/21

IMG1794 Showing motor serial numbers and rating.  The sticker on the encoder (center) is the SME serial number for the motor (9704670001).  The NetGain Motors serial number, for this example of a HyPer9 HV single shaft motor, is H9HV000001.  The maximum mechanical rating for this motor is 8,000 rpm.  The S1 rating (continuous operation rating) is 3,600 rpm. 

A chart that describes the various S Ratings and Duty Cycles of  electric motors can be found here: 

https://endless-sphere.com/forums/viewtopic.php?t=328  

updated 8/23/2021

DSC06605 showing the drive end view.  There are four mounting holes located at 45 degrees and 135 degrees

DSC06608 showing the three phase terminals at the accessory plate end.  These hex head bolts are Zinc plated M10-1.5x15 and the measured outer diameter of the bolts is 9.82 mm (0.3865 inch).  Updated 6/22/2021

Netgain001 Photo of disassembled Hyper 9HV 3 phase motor provided by Hunter at Netgain Motors.

updated 11/16/2019


                             

DSC01913 Showing how the motor windings (red at bottom) are crimp connected (shown exposed on the left) to the W, U, and V terminals shown in picture DSC06608 above.  updated 7/4/2023

Comparison of the HyPer 9 DHV with the Warp 11

                                              HyPer9 DHV                   Warp 11

Voltage Range                       90-180                              48-170
Voltage Nominal                   144                                    144
Current                                   500                                    up to 2000
Efficiency Peak                      95%                                  91.3%
kW Peak                                 100 kW @ 170 volts        340 kW
kW Continuous                       38 kW @ 3600 rpm         32 kW
RPM Peak                               8000                                 5800
RPM Nominal                         3600                                 2200  
Torque                                     162 lb-ft @ 0 rpm            135 lb-ft @ 450 amps
Regen                                       yes                                   none
Motor Diameter (end plate)     9.25"                                11.5"
Motor Diameter (body)            8.66"                                 
Motor Length (face to face)     14.625"                            17.46"
Motor Weight (pounds)            120                                   229
Controller Weight                     7.77                                  33
Shaft                                          double ended                   double ended
Shaft diameter                           1.125  (keyed 0.25")       1.125  (keyed  0.25")
Mounting bolt pattern               B Face (Warp 9)  4 x       B Face (Warp 9)  8 x 3/8-16
Insulation                                  Class H                             Class H
Software                                    Smartview                        Soliton 1
Terminal Studs                          8 mm-1.25
Brushes                                      none                                 Dual Wafer Helwig Carbon
Motor Type                                SRIPM                            Series Wound DC

The HyPer9 DHV data sheet can be found here: 
https://www.go-ev.com/PDFs/HyPer_9HV_Sales_Sheet.pdf  

Hyper9 HV User Manual (as of 5/20/2022)  

https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV09.pdf  

Hyper9 User Manual (as of 5/20/2022)

https://www.go-ev.com/PDFs/HyPer_9_IS_User_Manual_REV09.pdf  

updated 5/20/2022

The Warp 11 data sheet can be found here:
https://www.go-ev.com/PDFs/002_05_06_WarP_11_Sales_Sheet.pdf 

updated 10/27/2019