AUBURN HILLS, Mich.,
April 10, 2018 /PRNewswire/ --
Automotive News awarded BorgWarner with a prestigious 2018 PACE
Award for its groundbreaking S-wind wire forming process for
electric motors and alternators. The game-changing manufacturing
process enables high-volume production of high-voltage electric
motors up to 350 volts. Already in production on a 12-volt
alternator for Hyundai Motor Company, BorgWarner expects to launch
the technology in a first-of-its-kind 300-volt S-wind motor for an
on-axis P2 hybrid vehicle from a major global automaker in late
2019. The compact, high power density technology is particularly
well-suited for P2 hybrids, which BorgWarner expects will become a
dominant hybrid architecture.
"On behalf of everyone at BorgWarner, we are incredibly honored
to receive our tenth PACE Award. Thank you to Automotive News and
the judging panel for recognizing the hard work, creativity and
innovation of our engineers," said Dr. Stefan Demmerle, President and General Manager,
BorgWarner PowerDrive Systems. Sponsored by Automotive News, the
annual PACE Awards honor superior innovation, technological
advancement and business performance among automotive suppliers.
Known around the world as the industry symbol of innovation, PACE
stands for Premier Automotive Suppliers' Contribution to
Excellence.
First developed in 2010, BorgWarner has produced its patented
and proven S-wind stator for alternator applications. The new
proprietary, low-impact manufacturing process enables the high
power density and space-saving advantages of S-wind technology for
high voltage hybrid and electric vehicles because there is less
stress to the wire insulation. This manufacturing process
innovation enables BorgWarner to produce smaller, more powerful
high-voltage electric motors on a mass scale and will help drive
growth in the hybrid and electric vehicle market, resulting in more
environmentally-friendly vehicles on the road.
Enables Cost-effective Production of High-voltage
Motors
S-wind stators feature continuous copper wire segments formed
into a zig-zag S-shape which are then inserted into the stator
assembly. Traditionally, wire conductors for S-wind stators are
formed using a pneumatic anvil punching process. However, the
striking action may stress the wire insulation, and the
inconsistent final shape causes additional stress on the wire
during assembly into the stator. While acceptable for 12-volt
applications, a process resulting in less stress to the insulation
system is desired for high-voltage applications in order to
maximize motor durability and reliability. To create an S-wind
stator for high-voltage motors, BorgWarner's engineers developed a
proprietary low-impact forming process to create a nearly perfect
zig-zag S-shape that minimizes stress on the wire insulation and
eliminates additional stress during assembly.
The proprietary manufacturing process achieves significantly
faster cycle times, reduces scrap and requires less floor space.
This competitive advantage allows BorgWarner to produce a
high-volume, cost-effective solution for automakers.
Smaller, More Powerful Electric Motors for Variety of
Applications
BorgWarner's compact and power-dense solution is well-suited for
P2 hybrid electric vehicles, where installation space is very
limited. BorgWarner's S-wind stator is nearly 30 percent shorter
and delivers more than 50 percent higher torque density than a
concentrated-wound stator, establishing a new standard in P2 hybrid
electric vehicle applications. Lower mass and a more efficient
manufacturing process reduce complexity and cost, while rectangular
wire improves slot fill density and heat transfer. Distributed
winding offers better cooling and reduces torque ripple—the
periodic increase and decrease in torque output as the motor shaft
rotates—for smoother rotation and less noise, vibration and
harshness (NVH), a key property during pure electric
propulsion.
Since the wire-forming process can accommodate wires of various
sizes, the S-wind stator configuration is applicable across many
48-volt to 350-volt motor applications. In BorgWarner's portfolio,
the technology will have a positive impact on a variety of products
including alternators, integrated belt alternator starters (iBAS),
electric all-wheel drive (eAWD) technology, P2 modules, electric
drive motors and ePropulsion systems, depending on the application
requirements.
About BorgWarner
BorgWarner Inc. (NYSE: BWA) is a global product leader in clean
and efficient technology solutions for combustion, hybrid and
electric vehicles. With manufacturing and technical facilities in
66 locations in 17 countries, the company employs approximately
29,000 worldwide. For more information, please visit
borgwarner.com.
BorgWarner received a 2018 Automotive News PACE Award for its
S-wind wire forming technology for alternators and electric motors,
an innovation that enables high-volume production of high-voltage
electric motors for hybrid and electric vehicles.
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SOURCE BorgWarner