By ATN Editorial Team
Summary: BorgWarner has secured a 2029 production contract with a major North American OEM to supply an 800-volt secondary integrated drive module (iDM) and a generator module with a dual inverter for REEV trucks and large SUVs. The award marks the debut of BorgWarner’s next-generation Viper power module in a production program.
Key engineering takeaway:
The 800-V iDM integrates a torque-dense induction e-machine and gearbox into a compact two-in-one unit, eliminating the need for permanent magnets and improving supply chain resilience. The accompanying generator module combines a permanent magnet machine with a dual inverter mounted directly to the ICE, enabling efficient range extension. The dual inverter leverages BorgWarner’s Viper power switch technology to increase power density while reducing size and cost in a constrained packaging environment.
Why it matters:
The solution highlights the growing importance of high-voltage architectures and integrated propulsion systems in REEV platforms, particularly for large trucks and SUVs where packaging and performance demands are significant. By combining magnet-free traction drives with advanced inverter technology, BorgWarner strengthens its position in scalable, high-efficiency electrified powertrains that balance EV performance with ICE-backed range assurance.
BorgWarner develops a 800-volt secondary integrated drive module (iDM) and a generator module incorporating a dual inverter.
BorgWarner, a global product leader in delivering innovative and sustainable mobility solutions, has secured a contract with a major North American original equipment manufacturer (OEM) to provide a powerful and efficient 800-volt secondary integrated drive module (iDM) and a generator module incorporating a dual inverter. The BorgWarner solutions will be integrated into a series of the automaker’s REEV trucks and large-frame SUV models, with production set to begin in 2029. This significant business award achieves several company milestones, including the introduction of its next-generation Viper power module.
BorgWarner’s 800-volt iDM is a scalable, two-in-one drive module featuring a fully integrated induction e-machine and gearbox for use in hybrid or electric vehicle (EV) applications. The generator module features a permanent magnet electric machine and a dual inverter mounted directly to an internal combustion engine (ICE), extending the range of the vehicle platforms. The combination enables the vehicle to realize the performance capabilities and benefits of an EV with the no-compromise availability of the ICE when needed.
“This business win showcases our breadth in the propulsion space in North America, accentuating our innovative design and manufacturing capabilities to deliver a full motor portfolio from platform-based, high performing and efficient drive units to inverters, e-machines, control boards and more,” said Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager of BorgWarner PowerDrive Systems. “We’re grateful for the opportunity to carry on our strong, collaborative relationship with this highly respected OEM.”
A key factor in designing these custom products was achieving the automaker’s high performance needs in a challenging packaging space shared with the ICE. The BorgWarner team achieved a high-performance, compact solution with the use of its highly efficient and torque-dense induction electric machine in the iDM. The induction e-machine eliminates the need for permanent magnets, supporting a resilient supply chain. In the generator module, the BorgWarner team developed an optimized dual inverter design featuring its next-generation Viper power switch technology. This proprietary, extremely power-dense power module helped deliver a smaller, more cost-effective design with optimized system efficiency.
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