BorgWarner announced that it has secured a contract with an undisclosed major North American OEM to supply an 800-volt secondary integrated drive module (iDM) and a generator module incorporating a dual inverter for use in the automaker's range-extended electric vehicle (REEV) trucks and large-frame SUVs, with production scheduled to begin in 2029.
The 800-volt iDM is a scalable, two-in-one unit combining a fully integrated induction e-machine and gearbox, designed for use across hybrid and electric vehicle applications. The generator module pairs a permanent magnet electric machine with a dual inverter mounted directly to an internal combustion engine (ICE), extending the vehicle's range while retaining the on-demand availability of the ICE.
A key design constraint was fitting both solutions into a compact packaging space shared with the ICE. BorgWarner addressed this through its induction e-machine, which eliminates the need for permanent magnets, supporting supply chain resilience — and through a newly developed dual inverter design built around its next-generation Viper power switch technology, described as a proprietary, power-dense module that enabled a smaller and more cost-effective configuration.
"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."
The contract also marks the commercial introduction of BorgWarner's next-generation Viper power module, which the company describes as central to achieving the dual inverter's performance and efficiency targets.