BorgWarner has secured a significant contract to supply advanced propulsion components for a major North American original equipment manufacturer (OEM). The agreement will see the automotive supplier provide 800-volt integrated drive modules (iDM) and a dual-inverter generator module for a new series of extended-range electric vehicle (EREV) trucks and large-frame SUVs. Production is slated to commence in 2029.
Advanced Propulsion Components for EREVs
The integrated drive module (iDM) developed by BorgWarner is a sophisticated two-in-one system, combining an electric machine with a gearbox. Notably, the company has opted for an induction motor in the iDM, a design choice that bypasses the need for rare-earth magnets, thereby enhancing supply chain resilience. Complementing the iDM, the generator module features a permanent magnet electric machine coupled with a dual inverter. This unit is designed to mount directly onto the internal combustion engine, effectively extending the vehicle’s electric driving range.
Engineering Challenges and Solutions
A primary engineering hurdle involved integrating these powerful drive components within the confined packaging space allocated alongside the internal combustion engine. BorgWarner reports successfully meeting the required power and torque specifications within a compact design. This was achieved through the use of its torque-dense induction machine for the iDM and its next-generation Viper power module technology for the dual inverter. The Viper module is characterized as an “extremely power-dense” design, which facilitated a smaller and more cost-effective overall package.
Strategic Importance of the Contract
Stefan Demmerle, BorgWarner’s Vice President, highlighted the strategic significance of this business award. “This business win showcases our breadth in the propulsion space in North America,” Demmerle stated, emphasizing the company’s capabilities ranging from “platform-based, high-performing and efficient drive units to inverters, e-machines, control boards and more.” This contract underscores BorgWarner’s expanding role in the electrification of commercial vehicles and larger automotive segments.
