If lightweight and miniaturized drive and transmission systems can add to the efficiency and performance of internal combustion engine vehicles, it is an essential attribute for hybrid vehicles, plug-in hybrid vehicles, and pure electric vehicles. .
In view of the limitations of current power battery technology, automakers cannot completely eliminate users' mileage anxiety. At present, the most direct way to increase battery life is to use a larger number of batteries. The problem that this brings is that the weight of the car and the volume of the battery pack also increase, which is not a favorable factor for the efficiency of the vehicle and the creation of the interior space.
At this Beijing Auto Show, auto parts supplier Borgwarner (Borgwarner) launched a new set of fully integrated electric drive solutions suitable for pure electric drive and P4 hybrid-iDM integrated electric drive module.
This system was born based on the demand for compact and miniaturized parts of electric vehicles.
Reducing emissions and providing cleaner travel solutions are the main challenges faced by OEMs and suppliers. BorgWarner's compact, lightweight and high-efficiency iDM products help electric vehicles reduce energy consumption and drive longer distances with the same battery.
This all-in-one electric drive system solution also has excellent NVH performance, which can meet the current transmission requirements of electric vehicles and hybrid electric vehicles, and help OEM customers design powerful, clean and efficient electric vehicles.
It is understood that the iDM integrated electric drive module includes two models-iDM200 and iDM220, which can be integrated on the front or rear axles of passenger cars and light commercial vehicles according to the design architecture and different applications.
In addition to pure electric vehicles, iDM is also suitable for P4 hybrid vehicles, where the motor is located on the rear axle of the front-wheel drive vehicle.
According to Gong Youxing of BorgWarner’s PDS China Division, the iDM electric drive system is mainly composed of eight modules: high-performance motor, drive system cooling module, motor control module, signal connection interface, high voltage power interface, drive shaft interface and parking Lock the system.
Gong Youxing said that the main advantages of the iDM series products are their scalable and modular architecture, and support various gear ratios and motor sizes. According to customers' different vehicle voltage platforms, this series of products can provide up to 160kW peak power and 3800N.m peak torque. It can ensure that the motor runs smoothly and quietly, and its hairpin flat-wire stator winding motor technology provides excellent NVH performance.
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.
Not only that, thanks to the unique driving mode of electric vehicles, iDM can also optimize the control performance of electric vehicles.
The current iDM integrates an open differential, which can 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 slip side to zero and give the other side 100% torque to drive the vehicle away from the slip area.
In addition, 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 slip on the slope and save the cost of the electronic handbrake.
Another new technology related to it is the innovative torque vectoring dual clutch system. The system can replace the traditional dual-motor drive system commonly found in electric vehicles with only one motor. It also has the characteristics of compact structure.
This torque vectoring system can change the torque allocated to each wheel to achieve all-wheel drive. The solution has a wide range of adaptability.
In order to replace the traditional differential on the electric drive transmission system, the device is equipped with two clutches, an inner clutch and an outer clutch. The traditional torque vectoring system requires two rear electric motors, which is expensive and bulky. BorgWarner’s technology can help improve the overall efficiency of the vehicle while reducing the weight and space occupation of the powertrain.
The total weight of the system is about 21 kg, and each clutch has a torque capacity of 2600 Nm. In addition, it also has the function of disconnecting the rear axle when all-wheel drive is not required, so that the vehicle enters the front-wheel drive mode to reduce the cost of electric vehicles. Energy consumption increases the cruising range.
"Our new torque vectoring dual clutch system minimizes wasted torque, not only saves energy, but also requires fewer components," said Stefan Demmerle, president and general manager of the BorgWarner Power Drive Systems Division.
In addition to the two new systems mentioned above, BorgWarner also owns various key components of electric vehicles, including motors, gearboxes, power electronics and thermal management systems.