There’s a new kid on the block. A new electric motor has made its way into China. BorgWarner secured new contracts, making its mark on the Chinese electric vehicle (EV) market. Since its founding years in 1928, they have delivered many innovative and sustainable mobility solutions. According to BorgWarner, they are guided by their commitment to inclusion, integrity, excellence, responsibility, and collaboration. The corporation also pledged to reach carbon neutrality by 2035.
BorgWarner’s new electric motor projects
BorgWarner’s presence expanded in the Chinese EV market. The corporation successfully secured new contracts to supply electric motors to three major automakers. The contracts comprise four projects. One of the projects includes supplying 400V high-voltage hairpin (HVH) motors to a prominent Chinese new energy vehicle manufacturer for its 200kW hybrid rear-drive platform, with manufacturing planned to start in August 2025.
BorgWarner will also produce motors for a 150kW pure electric platform, scheduled to start manufacturing in March 2026. The other two contracts cover electric motors for range-extended and plug-in hybrid vehicles, with manufacturing planned for August and October 2025.
“We are pleased to extend our success in China with several new electric motor business wins for a variety of hybrid and electric applications.” – Dr. Stefan Demmerle, President and General Manager of BorgWarner PowerDrive Systems.
Dr. Demmerle also emphasized their dedication to ensuring continuous innovation in their technology. They are dedicated to improving their manufacturing processes to deliver high-quality products and services, hoping to meet the evolving needs of new energy vehicle customers.
How the new electric motor works to deliver increased power density
BorgWarner has created a new electric motor technology called Ultra-Short HVH in support of these contracts. The corporation’s Ultra-Short HVH technology uses enhanced production processes to deliver extremely short-end turn lengths, decreasing the overall motor length. The Ultra-Short 400V HVH electronic motor decreased the end size by more than 5mm in comparison to traditional HVH winding. According to BorgWarner, this also lowers the axis volume, resulting in increased power density and reduced copper usage to ensure enhanced efficiency and lower costs.
Factory upgrades become straightforward due to the new electric motors’ high compatibility with existing production lines. The new electric motors are multifaceted and adaptable, supporting various ranges of new energy vehicle models. It also supports 400V and 800V platforms.
The new electric motors have high power and torque density
According to Electric Motor Engineering, the corporation’s new electric HVH motor is intended for XPeng vehicles, due to its high power, high torque density, and competitive cost. The motor has a maximum operation scope of 800 volts and a stator with an external diameter of 220mm. This was combined with the HVH winding technology of BorgWarner, creating the HVH220 motor.
New technology delivers 300 kW, 18,000 revolutions, and peak efficiency of 97%
The rotor contains a fixed magnet that utilizes exclusive technologies of stator insulation enhancement. The evolved power reaches 300 kW and a healthy maximum working speed of 18,000 revolutions per minute (rpm). This results in peak efficiencies exceeding 97%.
According to BorgWarner, they also studied indirect cooling.
“The gearbox oil cools the motor, improving the heat transfer and the total heat rejection by the system. Moreover, the direct cooling of the rotor oil draws heat from the electric motor’s core, permitting to obtain higher torque and power density.” – BorgWarner.
As the need for eco-friendly solutions in mobility increases, the pressure on corporations to keep up and provide also increases. The new electric motors will significantly and positively impact the EV market, lessening the pressure on many corporations. Like BorgWarner says on their website, they are “leading the automotive industry to a future that is cleaner, healthier, and safer for all.”
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