In January 2019, following the mass production of the eDM electric drive module, BorgWarner launched a fully integrated electric drive (iDM, integrated Drive Module) suitable for pure electric drives and P4 hybrids. solution.
BorgWarner’s iDM electric drive module is one of the key driving engines in the electrification process of the automotive industry. It fully demonstrates BorgWarner’s all-round strength – the development of future solutions and cooperation with global automakers. Close collaboration and a deep understanding of customer needs.
Reducing emissions and providing cleaner mobility solutions are key challenges for OEMs and suppliers. BorgWarner's compact, lightweight and efficient iDM products help electric vehicles reduce energy consumption and drive longer distances with the same battery. This advanced all-in-one electric drive system solution also has excellent NVH performance and can meet cutting-edge electric vehicle and hybrid vehicle transmission requirements, helping OEMs design powerful, clean and efficient vehicles.
The iDM series products have the excellent characteristics of high integration, high efficiency and lightweight. They are available in three models - iDM200? and iDM220. They can be easily integrated into passenger cars and passenger cars according to the design architecture and different applications. On the front or rear axle of a light commercial vehicle. In addition to pure electric vehicles, iDM is also suitable for P4 hybrid vehicles, where the electric motor is located on the rear axle of a front-wheel drive vehicle.
The main advantage of the iDM series is its scalable and modular architecture, which supports a variety of gear ratios and motor sizes. The working voltage of iDM is 220-480V DC voltage (VDC). Depending on the customer's different vehicle voltage platforms, this series of products can provide peak power of up to 160kW and peak torque of 3800N.m. This advanced electric drive product ensures smooth and quiet motor operation, while its hairpin flat wire stator winding motor technology provides outstanding performance and excellent noise, vibration and harshness.
By 2025, BorgWarner’s iDM electric drive system will also provide products with a peak power of 300kW and a peak torque of 4500N.m.
It is worth mentioning that all components used in the iDM module are mature technologies independently developed by BorgWarner, and can be used as highly integrated modules or independent new energy vehicle drive system solutions. In addition, this product supports various software functional requirements of the entire vehicle platform, and provides an advanced version of the controller that supports vehicle dynamics and energy management. Its software architecture meets current market demand, is easy to integrate into common platforms such as AUTOSAR, and can meet ASIL D safety level requirements.
To cope with the increasing data exchange needs in modern vehicle systems, BorgWarner's advanced controllers can also be used with CAN, CAN? FD bus and flexray.
The iDM electric drive system is mainly composed of eight modules: high-performance motor, transmission system cooling module, motor control module, signal connection interface, high-voltage power interface, transmission shaft interface and parking lock system.
The core components of iDM - permanent magnet synchronous motor, high-performance electronic control module and high-efficiency reduction mechanism are integrated together to reduce the layout space as much as possible and facilitate the layout of the entire vehicle by the OEM.
The three main modules of BorgWarner’s iDM:
(1) High-speed motor: The motor in BorgWarner’s iDM system is a permanent magnet synchronous motor with a maximum speed of 16,000 rpm. . It can support higher speed ratio to increase wheel end torque output and reduce motor size. The motor also uses hairpin stator winding technology to significantly increase the motor's power density.
With this patented technology, BorgWarner’s high-speed motors have excellent performance in terms of noise, vibration and acoustic harshness. A German competitor just acquired a motor winding equipment supplier in early 2019 and began to absorb its winding equipment and key technologies. In this regard, BorgWarner is one step ahead and masters the core technology of high-efficiency motor manufacturing. In the future, motors will develop in a direction of smaller size and higher power density.
(2) Power electronics: Different from eDM products that have been mass-produced, BorgWarner's iDM eAxle system integrates electronic control devices.
BorgWarner's iDM eAxle electronic control device currently uses mainstream IGBT (Insulated Gate Bipolar Transistor) insulated gate bipolar transistor technology.
(3) Gear transmission mechanism: The ability to provide flexible reduction ratios to adapt to various customer needs is one of the key indicators when considering an electric drive system. BorgWarner's iDM system uses a fixed speed ratio and currently can provide customers with a reduction ratio of 12.5, which basically covers the power transmission needs of most customers for various models. Looking at market conditions, BorgWarner's gear ratio is above average.
New functions of BorgWarner iDM
(1) Electronic vector control system; in order to ensure the stability of electric vehicles when passing corners, BorgWarner developed a coaxial vector control system Control the motor. This system can simultaneously control the torque output of the left and right axles, allowing electric vehicles to have the electronic stability program (ESP) capabilities of fuel engine vehicles. BorgWarner's current iDM integrates an open differential, which can easily realize motor torque vector control. In order to prevent one side of the wheel from slipping (50% of the torque) and the other side losing power (50% of the torque is not enough to drive the vehicle away), BorgWarner can also install an electronic differential lock to prevent one side of the wheel from slipping. Set the torque on the slipping side to zero and give 100% torque to the other side to drive the vehicle away from the slipping area.
(2) Electronic parking function: BorgWarner provides customers with an optional parking system. If the customer's vehicle is not equipped with an electronic handbrake system, you can choose to install an electronic parking system on the iDM drive system, which can ensure that the electric vehicle will not roll away on slopes and save the cost of electronic handbrakes.
Software functions of BorgWarner iDM
(1) BorgWarner’s iDM supports various software functions and provides advanced versions that support vehicle dynamics and energy management. Its software architecture meets current market demand, is easy to integrate into common platforms such as AUTOSAR, and can achieve safety performance such as ASIL?D.
(2) To meet the increasing data exchange needs in modern vehicle systems, BorgWarner's advanced power electronics equipment can also be used with the CAN or CAN?FD bus.
This article comes from the author of Autohome Chejiahao and does not represent the views and positions of Autohome.