BorgWarner has secured a contract with a major North American OEM to supply an 800-volt secondary integrated drive module (iDM) and a generator module incorporating a dual inverter for use in range-extended electric vehicle (REEV) trucks and large-frame SUV platforms.
Production is scheduled to begin in 2029. The 800-volt iDM is a scalable drive unit integrating an induction electric machine and gearbox within a compact assembly. Designed for hybrid and electric vehicle applications, the system supports high-voltage architectures increasingly adopted in electrified platforms to improve efficiency and reduce current loads.
The generator module incorporates a permanent magnet electric machine paired with a dual inverter mounted to an internal combustion engine. In REEV configurations, this module functions as a range extender, supplying electrical energy to the battery and propulsion system while maintaining electric drive capability.
The combined architecture enables electric propulsion under most operating conditions, with the combustion engine used primarily for energy generation. This configuration supports extended driving range while preserving key EV performance characteristics.
A primary engineering constraint in the program was packaging within vehicle platforms that also house an internal combustion engine. The integrated drive module uses a torque-dense induction machine, eliminating the need for permanent magnets and reducing exposure to rare-earth material supply constraints. The compact architecture supports integration within shared drivetrain spaces.
The generator module incorporates a dual inverter design using BorgWarner’s next-generation Viper power module technology. The high power-density switching architecture contributes to reduced inverter size while maintaining system efficiency within the 800-volt platform.
The award expands BorgWarner’s electrified propulsion portfolio in North America and reflects continued development of high-voltage integrated drive systems for electric and range-extended vehicle applications.
Filed Under: Technology News