BorgWarner targets more-sustainable E-MOTORS

System optimization and lifecycle analysis are key to taking heavy rare earths out of next-gen motors for commercial EVs.

All components of an electric propulsion system - the motor, battery pack and inverter, in particular - are interrelated and optimized for a system function. Still, there are significant trade-offs in cost and what's best for sustainability when developing today's e-drive systems, according to David Fulton, director of rotating electric machines, PowerDrive Systems at BorgWarner Inc.

“The dominant design for motors today is probably the worst for sustainability in terms of KPIs [key performance indicators] as well as highest in cost. But it serves the greater good of the system [by enabling] the lowest cost for the battery pack and inverter,” Fulton said at the 2023 SAE COMVEC conference, during his presentation on next-gen motor technology for commercial vehicles.