Michigan, United States- BorgWarner Inc., has won a new contract from a major North American OEM to supply an advanced 800-volt secondary integrated drive module (iDM) and a generator module that uses a dual-inverter system. The technologies will be fitted to the automaker’s upcoming range-extended electric vehicle (REEV) trucks and large-frame SUVs, with production scheduled to start in 2029. The award also marks an important milestone for BorgWarner, bringing its next-generation Viper power module into the program.
The 800-volt iDM is a scalable “two-in-one” unit that combines an induction electric motor and gearbox into a compact drive module suited for hybrid and EV applications. Complementing this, the generator module integrates a permanent-magnet electric machine with a dual inverter mounted directly to the internal combustion engine, enabling the ICE to generate electricity and extend driving range when required. Together, the system is designed to deliver EV-like performance and efficiency, while retaining the backup flexibility of an engine for longer trips or demanding duty cycles.
Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager of BorgWarner PowerDrive Systems, said, “This business win highlights our propulsion breadth in North America and our ability to deliver a complete motor and power electronics portfolio from high-performance drive units to inverters, e-machines and control boards.” He added that the company is looking forward to continuing its long-standing collaboration with the OEM.
A major engineering challenge was meeting the automaker’s performance targets within tight packaging constraints alongside the ICE. BorgWarner addressed this with a torque-dense, highly efficient induction motor in the iDM, which also avoids the use of permanent magnets supporting supply chain resilience. For the generator module, the company developed an optimized dual-inverter layout featuring its new Viper power switch technology, a proprietary, power-dense module designed to reduce size and cost while improving overall system efficiency.
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