BorgWarner said it has secured a contract from a premium European automaker to supply an 800-volt Integrated Drive Module (iDM) for a new range-extended electric vehicle platform scheduled to enter mass production in 2029.
The system combines propulsion and power-generation functions into a single electric machine, consolidating two key components typically used in range-extended vehicles. BorgWarner said the design reduces packaging complexity while maintaining performance and efficiency.
The iDM integrates an inverter, dual clutches, a dual-mass flywheel and the customer’s internal combustion engine. In addition to generating electricity to extend driving range, the unit can also provide traction and support an all-wheel-drive mode when additional grip is required.
The inverter uses the company’s next-generation Viper power switches and dual-side cooled power module technology, designed to handle high voltages and currents while maintaining thermal stability. Such systems are increasingly used in high-performance electrified vehicles as automakers transition to 800-volt architectures for faster charging and improved efficiency.
Dr. Stefan Demmerle, vice president of BorgWarner Inc. and president and general manager of its PowerDrive Systems unit, said development was led by the company’s engineering team in China in collaboration with global specialists to optimize performance and packaging for next-generation range-extended vehicles.
BorgWarner said it provides end-to-end electrification technologies including electric motors, power electronics, software and system integration, supported by local manufacturing capabilities in major automotive markets.
Range-extended electric vehicles combine battery propulsion with an onboard combustion engine that generates electricity, offering longer driving range than battery-only models while maintaining electric driving characteristics.