Leading technology company delivering innovative and sustainable mobility solutions for the vehicle market, BorgWarner has secured contracts from several OEMs for it EV product portfolio.
Generator Inverter
The company has secured a contract with a major global OEM to supply high voltage generator inverters to be used in an innovative electrified architecture to charge the main batteries.
According to the company, the silicon carbide (SiC) based inverter is designed to provide high levels of continuous current and advanced cooling strategies to manage the application's challenging thermal demands.
The power-dense inverters use its Viper family of scalable power modules, coupled with enhanced thermal designs, to allow continuous operation at 70% of peak current. The typical applications provide only 40-50% of peak current continuously. Additionally, using SiC power switches helps make these inverters more efficient than traditional silicon-based inverters.
BorgWarner's inverter performance, robustness, scalable design, overall value, customer relationship and global manufacturing footprint are all factors that led to the business win. The inverter's production is slated for 2024.
First High Voltage eFan System Win
A major European Commercial Vehicle OEM has selected the company to provide its eFan system for battery-powered long-haul road transport vehicles. This is the company's first business win for the high-voltage (HV) eFan system, which is tailored to the customer's individual needs. It will be implemented on vehicles for the European market. Production is expected to commence in late 2024.
New generations of fully-electric heavy-duty trucks will require dedicated high-voltage thermal management solutions like the eFan system to cool components such as the e-motor, battery and electronics. Using computational fluid dynamics, the company has specifically optimised its fan design for performance and efficiency. The HV eFan is driven by a robust e-motor powered by the vehicle's electrical system via an inverter. The power density of the motor is rated at 40kW output with compact dimensions and is optimised for speeds below 3,000 rpm. In addition, the liquid-cooled electric motor is completely encapsulated for reliable long-term operation. The system has a wide operating range from less than 650 volts to 850 volts, ensuring compatibility with various high-voltage commercial vehicle electrical systems.
Hydrogen Injection System
The technology company is expanding its efforts into hydrogen combustion and was recently awarded its first hydrogen injection system production programme for an off-road application by a European construction equipment manufacturer. The technology supports CO2-free mobility and offers an appealing total cost of ownership due to optimised energy efficiency and payload capacity, and short refuelling time.
Hydrogen technology is a quick-to-market propulsion solution that requires only slight adjustments to the traditional internal combustion engine. As hydrogen has a substantially lower density than gasoline and diesel, the engine's injection system needs a new solution to meet fueling and packaging requirements.
800V SiC Inverters
The company has received an order from a leading Chinese OEM to launch a new, high-end battery electric vehicle (BEV) platform by providing its 800V silicon carbide (SiC) inverters. The inverters will be featured on two of the company's subsidiary brands targeted at mid-and high-end segments in the global market. The first vehicle model using the platform is expected to roll out in the first quarter of 2023, the company said.
The new platform is equipped with a broad range of cutting-edge drivetrain technologies, including an 800V SiC-based power module and an optional dual-motor system for torque vectoring control. The modular design concept used in the project allows higher flexibility to meet the various vehicle requirements. BorgWarner will develop three inverters for the platform, including a front single with an actuator control unit, a rear single, and a rear dual. All three inverters will be applied to two all-wheel-drive vehicle models, the company added.