BorgWarner Unveils Plans for Next-Generation Drive Modules
This 800-volt integrated drive module will be used in next-generation electric pickup trucks and SUVs. Photo courtesy BorgWarner Inc.
AUBURN HILLS, MI—BorgWarner Inc. has secured a contract with a major North American automaker to provide an 800-volt secondary integrated drive module (iDM) and a generator module incorporating a dual inverter. The devices will be integrated into a series of range-extended electric pickup trucks and large-frame sport utility vehicles, with production set to begin in 2029.
“This showcases our breadth in the propulsion space in North America, accentuating our innovative design and manufacturing capabilities to deliver a full motor portfolio from platform-based, high performing and efficient drive units to inverters, e-machines, control boards and more,” says Stefan Demmerle, Ph.D., president and general manager of BorgWarner PowerDrive Systems. “[It] achieves several company milestones, including the introduction of [our] next-generation Viper power module.”
BorgWarner’s 800-volt iDM is a scalable, two-in-one drive module featuring a fully integrated induction e-machine and gearbox for use in hybrid or EV applications. The generator module features a permanent magnet electric machine and a dual inverter mounted directly to an internal combustion engine, extending the range of the vehicle platforms. The combination will enable vehicles to realize the performance capabilities and benefits of an EV with the availability of the ICE when needed.
According to Demmerle, a key challenge in designing these products was achieving the automaker’s high performance needs in a tight packaging space shared with the ICE. The BorgWarner engineers solved this by using a highly efficient and torque-dense induction electric machine in the iDM, which eliminates the need for permanent magnets.
For the generator module, the engineers developed an optimized dual inverter design featuring Viper power switch technology. This proprietary, extremely power-dense module delivers a smaller, more cost-effective design with optimized system efficiency.
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