BorgWarner has put in place key elements of the emobility ecosystem. Ashish Bhatia looks at the plug-and-play capability giving it an edge.

BorgWarner is in a position to accelerate the transition to emobility at large. In line with its electrification strategy ‘Charging Forward’, the company, at the Auto Expo 2023 – The Components Show showcased a range of emobility solutions. This included electrified powertrain components, high-energy battery systems and thermal management solutions. In a confident demonstration of how its innovative and sustainable products are helping Original Equipment Manufacturers (OEMs) transition to emobility, the company showcased battery systems, charging stations, electric motors, Integrated Drive Modules (IDM), power electronics and high-performance thermal management products like the high-voltage coolant heater. Averred Sudhir Chawla, Managing Director at BorgWarner Emissions Systems India Pvt. Ltd., “The Auto Expo is a great opportunity for BorgWarner to highlight our product and system solutions as well as provide insights into our ‘Charging Forward’ global company strategy, which aims to accelerate electrification efforts and commits to attaining carbon neutrality by 2035.”  

CV solutions

At its booth, the company attracted visible interest through a stack able, high-energy battery system known to feature a novel, flat module architecture. Offered in two form factors, it is said to adapt to the underbody of electric Light Commercial Vehicles (eLCVs) and buses. Designed especially for CV applications, its USPs include integrated battery system electronics and integrated liquid cooling. The pack weighs ~200 kg. At the far corner of the booth, a new, modular high-voltage eFan solution, and BorgWarner’s latest generation of inverters was proof that the company is go-to-market-ready and ahead of the curve with plug-and-play solutions successfully known to be deployed in global markets. The company is also geared to meet the Internal Combustion Engine (ICE) evolution through combustion technologies like hydrogen fuel injection systems for commercial vehicles. It also showcased the key conventional propulsion solutions.

The DC Fast Charging stations it displayed are compatible with all types of vehicles. They are said to offer great flexibility, ease of use, robustness and cost-effectiveness. These are made available in an integrated architecture and a distributed architecture. The high-power eFan system combines a cooling fan, electric motor and inverter. The high air flow rates cool large demanding thermal systems continuously. With a continuous rating of 40 kW, it is claimed to efficiently cool components such as the fuel cell, traction e-motor, battery and electronics in electric CVs. The fan is designed for CV voltage ranges of 550-850V. The high-voltage coolant heaters are for battery and cabin heating in battery-electric applications. The company also showcased the Gasoline EGR Modules, Valve for light vehicles, and Gasoline EGR with GDI Valve. It also brought along the EGR Module for CVs, eTurbo, High-Efficiency Turbocharger (HET), and rail with DI-CHG10 and DI-CHG15 Injector. In another section, the company showcased the Cam Torque Actuated Mid-Position Lock VCT CTA MPL and an electric cam phaser with Brushless DC Motor. The company displayed the EV charger model ZEVQC-7/600-P1 model. The USPs of the charger included a 6.6 kW power output, DC 200-600V charge voltage, and rated IP30. The EV charger model ZECD-32-J-BQ with a 7 kW power output, IP54 rated, was also on display. The IDM-425, eXD electric Cross Differential, electric Torque Vectoring Disconnect (eTVD), and a Battery Management System (BMS) were also showcased. An Ultra High Energy Battery Module, High Voltage Single Inverter and Viper Power Module, Gen 5 size 9 Inverter, HVLP-20 Inverter and the Electric-Mechanical On-Demand Transfer Case (EMOD) also generated interest.

Driven by tech and R&D

Citing how BorgWarner technical centres and research and development departments in India play a central role in achieving the ambitious goals defined under this initiative, Chawla drew attention to how the company extended support to local customers in meeting strict Indian emissions standards such as Bharat Stage VI (BSVI). The ‘Charging Forward’ strategy rests on pillars of organic EV growth, EV-focused Merger and Acquisition (M&A), and optimising the combustion portfolio. Taking us through the granular details, Jeans-Francois Savajols, VP – Of product strategy and Business Development – Emissions, Thermal and Turbo Systems at Borgwarner Inc. explained that the execution was to tap opportunities in line with the internal projections. From less than or equal to three per cent in 2021 to greater than 25 per cent in 2025, the company expects EVs to account for over 45 per cent of sales by 2030. The company is marching ahead with ease, a testimony to it is the estimated USD 3.1 bn current booked status against the target of organic EV sales for 2025 set at USD 2.5 bn. The company has been able to select like-minded and capable partners in Akasol for battery packs and modules in 2021; Santrol for LV emotors and Rhombus and SSE for DC Fast Charging. Here, the SSE closing is expected to go through in the first quarter of Financial Year 2023 (Q1-FY2023) subject to satisfaction of the customer closing conditions, he informed.