BorgWarner has unveiled a major expansion to its electric drive motor portfolio, focusing on high-efficiency, scalable technologies that cater to the growing demand for next-generation electric and hybrid mobility. These new developments aim to increase power density, boost efficiency, and offer greater flexibility across various vehicle types—from compact EVs to high-performance luxury models.
Integrated Drive Modules (iDMs): Scalable Solutions for EVs and Hybrids
BorgWarner’s Integrated Drive Modules (iDMs) now feature modular, adaptable designs tailored for original equipment manufacturers (OEMs). These iDMs support both parallel countershaft and coaxial gearbox configurations, giving automakers more control over cost, performance, and energy efficiency.
- iDM146: Built for compact vehicles
- iDM220: Engineered for high-performance EVs (up to 350 kW output)
Each module supports various motor types, including:
- Permanent Magnet Synchronous Motors (PMSM)
- Induction Motors (IM)
- Externally Excited Synchronous Machines (EESM)
This level of customization ensures compliance with global regulatory needs while optimizing for performance and cost.
Hairpin Winding Technology: Setting New Efficiency Standards
At the core of BorgWarner’s innovation is its high-voltage hairpin (HVH) winding technology. This method delivers up to 97% peak efficiency, setting a new benchmark for EV motors.
- HVH146: 90 kW output, ideal for light-duty vehicles
- HVH264: Up to 450 kW, for performance EVs
- HVH320 (2024 Launch): Delivers 1280–1650 Nm torque and up to 575 kW power
These motors are available in various lengths, cooling options, and winding configurations, ensuring wide-ranging use—from commuter cars to heavy-duty fleet vehicles.
S-Winding Tech for Smarter Hybrid Integration
The third generation of BorgWarner’s S-winding technology is advancing hybrid powertrain efficiency. Already in use across many P2 and 48V P3 hybrid architectures, this design improves packaging and simplifies manufacturing.
Key advantages include:
- Shorter winding head lengths
- Fewer components
- Elimination of welded pin connections
As a result, hybrid systems can now be smaller, easier to produce, and more reliable—especially useful in space-constrained vehicle designs.
Eco-Friendly, Rare Earth-Reduced Motor Development
Alongside high-performance gains, BorgWarner is investing in sustainability. New developments in Interior Permanent Magnet (IPM) motors aim to reduce rare earth material usage. This is made possible by advanced motor control systems and innovative cooling methods that maintain power without sacrificing efficiency.
The company is also creating a next-gen compact drive module. This includes a high-speed differential gearbox directly on the rotor shaft, optimizing torque control while saving space.
Driving the Future of Electrification
With this expanded portfolio, BorgWarner is helping automakers meet the increasing demand for electric mobility. Its focus on scalable, sustainable, and high-efficiency drive solutions places it at the forefront of EV and hybrid innovation.
Whether it’s compact EVs, luxury sedans, or commercial vehicles, BorgWarner is equipping the future of mobility—efficiently and sustainably.
