From Specifications to Vehicle Demonstrator: System Optimization and Validation Process of an Integrated e-Drive Module

Authors

Dr. Gabriel Domingues, Tua Högnäs, M. Sc. Eng., Dr. Ali Rabiei, BorgWarner, Landskrona, Sweden;
Dr. Tausif Husain, BorgWarner, Noblesville, USA; 
Joe Tyckowski, M. Sc. Eng. BorgWarner, Auburn Hills, USA

Summary

BorgWarner has undertaken the development of its new platform of integrated electric drive modules targeted to B and C segment passenger vehicles. This paper provides a detailed description of the overall system optimization process, from the definition of the vehicle performance targets, powertrain and cooling concept, down to the simulation and optimization of the electrical machine, winding technology selection, power electronics specification and transmission design. Moreover, the possibility of adapting the performance of the unit by means of minor changes of the design or material selection has been studied as a mean of covering a wider range of customer needs. Additionally, a prototype of the developed iDM has been mounted on a C-Segment crossover SUV.

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