BorgWarner has secured a contract with an unnamed major North American OEM to supply an 800 V integrated drive module (iDM) and a generator module with a dual inverter. The components will be used in a series of the automaker’s extended-range electric vehicle (EREV) trucks and large-frame SUVs, with production set to begin in 2029.

The iDM is a two-in-one unit combining an induction e-machine with a gearbox. BorgWarner chose an induction motor rather than a permanent magnet design, which the company says eliminates rare-earth magnet dependency and supports a more resilient supply chain. The generator module pairs a permanent magnet electric machine with the dual inverter, mounted directly to the internal combustion engine to extend the vehicle’s electric range.

A key design challenge was fitting the drive components into packaging space shared with the ICE. BorgWarner says it achieved the required power and torque targets in a compact form factor using its torque-dense induction machine for the iDM and its next-generation Viper power module technology in the dual inverter, which the company describes as an “extremely power-dense” design that enabled a smaller, more cost-effective package.

“This business win showcases our breadth in the propulsion space in North America,” said VP Stefan Demmerle, “from platform-based, high-performing and efficient drive units to inverters, e-machines, control boards and more.”

Source: PRNewswire