AUTOMOTIVE DESIGN
High-voltage inverters extend the range of plug-in hybrid and battery electric vehicles by approximately 5%
ELECTRIC DRIVES REIMAGINED
The evolution of traction inverter technology is poised to revolutionise the next generation of passenger cars
E
ach new generation of electric vehicles faces greater expectations from its prospective customers.
They must match or exceed the performance of their internal combustion-engine counterparts, travel further on a single charge, and become more aff ordable to encourage the transition to e-mobility. This presents challenges for vehicle designers; while battery technology is constantly evolving, which helps to improve performance and driving range. Attention to other design elements is also required. The electric drivetrain must become lighter and more compact; electrical and mechanical
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eff iciencies need to increase; and costs have to be constrained – all without compromising safety. With this in mind, BorgWarner
has updated its traction inverter technology in readiness for the next generation of passenger cars and medium-power commercial vehicles. The power module, cooling module and electrical control system have been redesigned, and production methods rationalised, leading to higher eff iciency, enhanced reliability, and easier integration with multiple vehicle architectures. This next generation traction
inverter operates at 800VDC with RMS phase currents of 650A
peak/400A continuous, off ering scalable power ratings of up to 400kVA. Scalability of the power output can be achieved by modifying component number or size; for example, a lower silicon carbide (SiC) die count or reduced capacitor footprint. Inverter performance and eff iciency are stable between -40 and +85°C and up to 5,000m altitude. Environmental protection against dust and water ingress is provided by the IP67-rated enclosure.
THE UPGRADE To achieve greater compactness and reduce weight, improved component integration, coupled with a revised
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