The integrated system can coordinate power delivery through a single electric machine, enabling efficient operation for REEVs, advanced hybrids, and all-wheel-drive vehicles.
BorgWarner has developed an 800V Integrated Drive Module (iDM) designed for Range Extended Electric Vehicle (REEV) applications, combining generator and drive functionality in a single electric machine. The module simplifies hybrid powertrain architecture while reducing system complexity.
The iDM integrates multiple components, including an inverter, two clutches, and a dual-mass flywheel, paired at the system level with the internal combustion engine. It delivers energy-efficient generator operation and can provide all-wheel-drive mode when required. By combining two major functions into a single module, the system supports compact vehicle layouts and streamlined assembly.
At the heart of the module is a single-electric-machine design that enables coordinated generator and drive operations, balancing performance, efficiency, and packaging. The inverter incorporates next-generation Viper power switches and dual-side cooled power module technology, supporting high-voltage and high-current operation while maintaining robust thermal management. This ensures reliability and efficiency under demanding powertrain conditions.
The system-level integration offers multiple advantages. It allows smoother power delivery, optimized energy management, and efficient coordination between generator and drive functions. By combining key functions, the iDM supports flexible hybrid vehicle layouts and adaptable control strategies. These advantages enable applications in high-performance REEVs, advanced hybrid vehicles, and all-wheel-drive configurations where compact packaging and thermal stability are critical.
Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager, PowerDrive Systems, says, “Our integrated drive module demonstrates how combining generator and propulsion functions into a single unit can optimize performance, efficiency, and packaging in hybrid powertrains.”
