Latest trends in on- and off-highway

The commercial vehicle market is an important segment for BorgWarner, which offers a wide range of technologies for on-road vehicles.

The latest product introductions were the (lithium ferrophosphate) LFP battery packs and a scalable DC fast charging station, but BorgWarner’s product portfolio for commercial vehicles includes eMotors, inverters, and thermal management solutions, such as battery coolers and 800V eFans, all designed to optimize electrified powertrains.

The drive module with integrated electric motor is part of BorgWarner’s offering for commercial vehicles.

The company also provides high-efficiency turbochargers, exhaust gas recirculation (EGR) systems, and other advanced combustion technologies that continue to be relevant in hybrid and alternative fuel engines.

According to Harry Husted, BorgWarner’s chief technology officer, this segment is dominated by some major trends which are bringing forward a significant transformation driven by electrification, increased demand for fuel efficiency, and stricter emission regulations. “The trend towards zero-emission powertrains, including battery electric and hydrogen fuel cells, is accelerating,” Husted said.

“BorgWarner’s offerings directly address these trends with products like our LFP battery packs for electrification, high-efficiency turbochargers and EGR systems for combustion engines, and integrated power electronics for electrified vehicles. Our goal is to provide comprehensive solutions that enhance efficiency and reduce emissions across various propulsion architectures.”

The new LFP battery packs by BorgWarner are specifically engineered for commercial vehicles and aim at reducing cost and insuring a longer cycle life and faster charging. “Our LFP battery packs are designed to deliver optimal performance in demanding operating conditions, making them well-suited for commercial fleets. Key features include high energy density and robust thermal management, all of which contribute to extended range and reduced downtime for electric commercial vehicles.”

The battery packs are modular and scalable, allowing for flexible integration into a wide variety of vehicle platforms.

Husted explained that the LFP battery packs are a new addition to BorgWarner’s product portfolio and represent a significant step forward. “What sets these LFP battery packs apart is their cost-effectiveness and modularity, as we’re offering several form factors.”

Husted said that LFP batteries have a longer cycle life and maintain performance even under very demanding operating conditions, making them ideal for the rigorous usage patterns of commercial vehicles. “This new development addresses the specific challenges of commercial vehicle electrification, providing a reliable and efficient energy solution that supports sustainability goals while minimizing total cost of ownership.”

The new BorgWarner DC fast charging stations are also designed for the commercial vehicle market and target applications such as public charging networks and commercial EV fleet operations. “However, the scalable power range from 120 kW up to 360 kW makes them versatile enough to support passenger car charging as well, particularly in high-demand locations like highway service areas,” added Husted.

Some of BorgWarner’s new technologies, including the LFP battery packs and DC fast chargers, are also suitable for off-highway applications, such as construction and agricultural equipment.

BorgWarner’s new DC fast charging stations are scalable and cover a power range from 120 kW to 360 kW.

According to Husted, the robust design, scalability, and high performance of these solutions make them adaptable to the unique requirements of off-highway vehicles, which often demand high power output and durability in challenging environments.

But the company is not solely focused on electrification technologies and keeps developing its more conventional technologies, particularly around high-efficiency turbocharging, exhaust gas recirculation, variable cam timing (VCT) and other advanced combustion solutions.

The company believes these innovations are critical as they support the ongoing improvement of internal combustion engines and hybrid systems, enhancing fuel efficiency and reducing emissions.

Husted remarked how in the internal combustion engine market there is a trend towards alternative fuels. “There is a strong focus on enhancing the efficiency and emissions performance of existing engine platforms to meet upcoming regulations, even as the industry moves towards electrification.”

BorgWarner’s offerings in this field are designed to help engine manufacturers meet these evolving demands. “We continue to innovate in this space to ensure that our customers have the tools they need to deliver cleaner, more efficient engine technologies,” concluded Husted.