Hairpin and S-winding technologies aim to contribute to efficiency and power density improvements in electric and hybrid vehicle motors.
30 Apr 2025 | 647 Views | By Shruti Shiraguppi
BorgWarner is expanding its electric drive motor portfolio with advanced technologies designed for various automotive segments. The company offers Integrated Drive Modules (iDMs) compatible with both 400V and 800V systems, spanning from compact city cars to high-performance luxury vehicles. These modules feature innovative cooling systems, advanced winding technologies, and modular ...
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BorgWarner is expanding its electric drive motor portfolio with advanced technologies designed for various automotive segments. The company offers Integrated Drive Modules (iDMs) compatible with both 400V and 800V systems, spanning from compact city cars to high-performance luxury vehicles. These modules feature innovative cooling systems, advanced winding technologies, and modular designs that enable customization according to market requirements.
The company's mechanical drive configurations include both parallel countershaft and coaxial gearbox architectures, with parallel countershaft arrangements preferred for cost and efficiency advantages. The product range extends from the iDM146 for compact cars to the iDM220 for systems delivering up to 350 kW of power. All systems can be configured as Permanent Magnet Synchronous Motors (PMSM), Induction Motors (IM), or Externally Excited Synchronous Machines (EESM).
BorgWarner's high-voltage hairpin technology has achieved power density and maximum efficiency exceeding 97%. The HVH motor series comes in multiple versions with different configurations, lengths, cooling methods, and winding options. The portfolio begins with the HVH146 model (90 kW peak power) and extends to the HVH264 (450 kW peak power) for high-performance applications. A new HVH320 platform launching in 2024 will offer versions with maximum torque/power ratings ranging from 1280 Nm/485 kW to 1650 Nm/575 kW.
For hybrid applications, BorgWarner has advanced its S-winding technology, which offers packaging advantages due to shorter winding head lengths and eliminates the need for welding individual pins. The second generation (S-Wind Gen2) is widely used in P2 drive modules for hybrid vehicles, while the latest generation (S-Wind Gen3) is utilized in 48V P3 modules.
Looking forward, BorgWarner is developing a next-generation drive module with an ultra-compact design that incorporates a high-speed differential gearbox on the rotor shaft. The company claims to be focusing on sustainability improvements for interior permanent magnet (IPM) technology, aiming to reduce dependency on heavy rare earth elements through enhanced cooling systems and optimized motor control techniques.