The iDM e-axle integrates state-of-the-art transmission, electric motor and power electronics by offering a modular solution to customers with exceptional flexibility, along with the benefits of lightweight and higher efficiency.
Globally, manufacturers of passenger cars and commercial vehicles need electric traction and transmission systems that support their development of modern vehicles with efficient propulsion. The main goal and challenge at the same time is to meet ever stricter emission and sustainability standards.
For OEMs, one solution in this quest is the innovative iDM technology by BorgWarner. The fully integrated drive module (iDM) has been developed for pure electric and hybrid vehicles. It integrates power electronics into common architecture. This enables manufacturers to design primary and secondary propulsion applications for today’s demands and is also a basis for future development.
Integrated Drive Module Enhances Efficiency
Both of today’s electrification requirements as well as future innovations can be easily realized with the company’s fully integrated drive modules. Thanks to the combination of transmission technology, electric motor and power electronics in a compact eAxle unit, the all-in-one solution achieves higher efficiency and benefits from lower weight. It allows for optimized battery size and reduced energy consumption, resulting in the extension of the pure electric driving range per battery charge. The iDM, either integrated in the front or the rear axle, is deployed as primary propulsion in pure electric vehicles. In P4 hybrid systems, for example, it can be used as a secondary drive unit.
Due to the modular and scalable architecture, a wide range of gear ratios and the flexibility in power options, various manufacturer’s requirements can be fulfilled. Available peak power densities are 90 kW, 120 kW and 160 kW at a nominal level of 330 VDC (operating range: 230 to 450 VDC), peak torque outputs lie between 2,500 Nm and 3,500 Nm.
Performance Power
One of the iDM’s key components is the patented electric motor technology, which is complemented by transmission technology based on the eGearDrive®. In addition, specially developed integrated power electronics offer full software functionality. They allow for high-level control of vehicle dynamics and energy management.
Instead of conventional round wire windings BorgWarner uses rectangular windings within the electric motor. Manufacturers benefit from a high-voltage hairpin configuration, which significantly improves space requirements as well as power density and efficiency. Compared to conventional motors with similar performance the setup with rectangular windings needs 20 % less room and 10 % less mass than round wires.
Moreover, the iDM technology offers smooth and quiet operation. It delivers exceptional performance and optimized NVH characteristics.
Conclusion
As mentioned above, the challenge for manufacturers is to design cleaner and more efficient vehicles. BorgWarner supplies them with a holistic propulsion solution: The iDM is an efficient and compact lightweight that minimizes HEV’s power consumption resulting in a longer pure electric driving range on a single battery charge. The state-of-the-art transmission, electric motor and power electronics in one package is easy to integrate, completely tested and validated. It meets OEM requirements for both hybrid and pure electric vehicles.
