Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules

In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting to environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight of complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric-magnetic-mechanical behaviours are usually difficult to optimize separately since their objectives are often contradictory. Thus, BorgWarner PDS Engineering is using tools involving close coupling to optimize iDM products. The lecture will focus on the innovation and optimization which are supported by several key pillars in the scope of a Next Generation iDM development. These are based on the following strategic levers such as process and design development, material development and control strategy among others. This ensures to tailor all components at the best of their capabilities to reduce their weight and maximize their use. Finally, the results achieved by the high-fidelity model-based optimization on the selected example will be presented (e.g., impact of the cooling improvement on overall iDM performances), demonstrating the benefit of capturing the system from eagle-eye detail up to a helicopter view in the design phase of next generation eDrives.