BorgWarner has secured a new contract to supply dual inverters to a major Chinese original equipment manufacturer (OEM) for use in hybrid electric vehicles. The project is set to enter mass production by the end of 2025, marking a continuation of the companies’ collaboration in the new energy vehicle (NEV) sector that began with a previous dual inverter agreement in 2021.
The dual inverter technology supplied by BorgWarner features a highly integrated structural design, enabling synchronous control of two electric motors through a single controller. This integration is intended to improve packaging efficiency and simplify installation. The system utilizes proprietary packaging methods that allow for flexible configuration of power modules within a compact footprint, aiming to reduce both weight and manufacturing costs.
According to the company, the power module design reduces thermal resistance by up to 50% compared to single-sided cooling solutions, contributing to higher power density. The modular architecture also supports the integration of different semiconductor die types within standardized module sizes, helping vehicle manufacturers meet China’s light-duty vehicle test cycle (CLTC) efficiency requirements.
Additional features include adaptive battery voltage regulation, which extends the motor’s constant power range and high-efficiency operating zone, potentially improving overall system performance.
BorgWarner’s dual inverter technology has undergone successive generations of development. The third-generation model incorporates a high-performance single chip capable of managing both DC-DC conversion and dual motor control, with optional high-voltage auxiliary interfaces available based on customer specifications. The fourth-generation design integrates a boost converter alongside dual inverters and offers an optional DC-DC module, providing flexibility for various hybrid vehicle architectures.
Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager of PowerDrive Systems, stated that the new award reflects ongoing collaboration with the OEM and underscores the company's role in delivering electrification solutions amid the evolving NEV market in China.
BorgWarner, a global supplier of automotive systems and components, has operated for over 130 years, with a current focus on sustainable mobility technologies, including electrified powertrain solutions.