BorgWarner 800-Volt Integrated Drive Module Secures REEV Truck Contract in North America

The BorgWarner 800-volt integrated drive module has secured a major supply agreement with a leading North American OEM for upcoming range-extended electric vehicle platforms. Under the contract, BorgWarner will deliver both its advanced 800-volt integrated drive module and a dual inverter generator module for use in REEV trucks and large-frame SUVs. Production is scheduled to begin in 2029, reinforcing the company’s position in high-voltage electrified propulsion systems across North America.

Contract Scope for REEV Trucks and SUVs

The agreement covers deployment of the BorgWarner 800-volt integrated drive module within next-generation range-extended electric vehicle architectures. These vehicles combine electric propulsion with an internal combustion engine to extend driving range, offering a balanced solution for large passenger and commercial platforms.

Application in Large-Frame Platforms

The systems will be integrated into trucks and full-size SUVs designed for demanding duty cycles. By combining electrified propulsion with range-extension capability, the BorgWarner 800-volt integrated drive module supports improved performance, higher efficiency and flexible vehicle packaging for both passenger cars and commercial vehicles.

Architecture of the 800-Volt Integrated Drive Module

The BorgWarner 800-volt integrated drive module is engineered as a scalable two-in-one solution. It integrates a fully integrated induction e-machine and gearbox into a compact assembly suitable for hybrid and battery electric vehicle platforms.

Induction E-Machine and Packaging Benefits

A key advantage of the induction e-machine is the elimination of permanent magnets, supporting supply chain resilience while maintaining competitive power density. The compact design allows the BorgWarner 800-volt integrated drive module to fit within constrained packaging environments shared with the internal combustion engine.

Dual Inverter Generator Module Integration

Alongside the primary drive unit, the dual inverter generator module pairs a permanent magnet electric machine with a dual inverter mounted directly to the internal combustion engine. This configuration enables efficient energy generation to recharge the battery and extend operational range in a range-extended electric vehicle.

Role of the Viper Power Module

The dual inverter system incorporates the next-generation Viper power module, described as a proprietary and power-dense switching solution. This semiconductor innovation enables a smaller and more cost-effective inverter configuration while meeting performance and efficiency targets. The commercial launch of this Viper power module marks a significant milestone within the broader BorgWarner 800-volt integrated drive module program.

Engineering and Manufacturing Capabilities

According to Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager of BorgWarner PowerDrive Systems, the award highlights the company’s broad propulsion portfolio in North America. The BorgWarner 800-volt integrated drive module complements a range of drive units, inverters, e-machines and control boards designed to deliver platform-based, high-performing and efficient electrified systems.

By combining compact packaging, scalable architecture and advanced semiconductor integration, the BorgWarner 800-volt integrated drive module strengthens electrification strategies for REEV trucks and SUVs entering production from 2029.