Driving electrification in the commercial EV market

This manufacturer reveals how its latest product launches are set to drive innovation in the commercial electric vehicle market.

For more than a century, Borgwarner has been supplying the automotive industry with innovative products for conventional Internal Combustion Engine (ICE) vehicles. Now a global manufacturer of electrification and mobility solutions, the company is continuing to develop advanced products and technologies that are helping to improve the sustainability of commercial transportation. The latest spate of product launches from the manufacturer holds true to this mission, from innovations in Lithium Iron Phosphate (LFP) battery packs and DC fast charging to advanced components for electric powertrains.

A BOOST FOR LFP BATTERIES

In February, Borgwarner announced a strategic eight-year partnership with FinDreams Battery, a subsidiary of BYD Company Limited, to become the only non-OEM localised manufacturer with rights to localise LFP battery packs for commercial vehicles in Europe, the Americas and select regions of Asia Pacific.

“Since the announcement, we’ve been working hard on our new LFP battery designs and also talking to customers,” says Harry Husted, CTO of Borgwarner. “FinDreams will supply BorgWarner with its LFP blade cells and some production equipment for battery pack assembly. The design of the battery packs is being done by BorgWarner, using some design elements from FinDreams to ensure compatibility with their manufacturing process steps.”

The term ‘blade cell’ refers to its structural design as a long, thin battery cell with side terminals. Husted explains: “The cross-beam-like design of the cell and the terminals on the side of the cell bring benefits in volumetric energy density and electrical interconnection while reducing battery pack assembly complexity. This gives BorgWarner LFP battery packs a competitive combination of cost and performance that we can offer to our customers.”

According to Husted, one of the standout advantages of LFP battery packs is their cost efficiency. “They are less expensive to produce than other lithium-ion batteries, primarily because they do not rely on scarce and expensive materials like cobalt and nickel,” he continues. “This cost advantage can significantly reduce the total cost of ownership for commercial fleet operators.”

LFP batteries also typically have a longer cycle life, meaning they can endure more charge and discharge cycles before their capacity degrades. “This longevity is particularly valuable for commercial vehicles to deliver improved TCO, long-term reliability and minimal downtime,”

FAST CHARGING

BorgWarner is also making an impact with its new DC charging system, which Husted describes as an, “excellent solution for rapid charging, with a scalable power range of 120kW up to 360kW, making it suitable for fast charging CV depots and also in public and high traffic areas.” The conversion from AC to DC voltage happens within the charging station power electronics to deliver DC directly to the battery, greatly reducing charging times.

“The primary benefit of DC fast charging is significantly reduced charging times because higher power is delivered directly to the battery,” Husted says. “AC chargers run at a slower rate because the AC to DC conversion step is done in the vehicle’s onboard charger, which is sized at a lower power level. The scalable power options of our DC fast charging station offer flexibility to meet a wide range of depot and charge point operator needs. Our charger is equipped with two output cables to allow two vehicles to charge simultaneously.”

BorgWarner’s DC fast charging stations are specifically designed to handle the high energy demands of commercial and passenger vehicles that often have a need for fast charging ‘on the go’. This makes them ideal for use in depots, and along highways. The charging station also offers a more convenient and streamlined experience for the user due to quick turnaround time and higher power output. The company has already deployed 50,000 of its DC fast charging stations in Asia.

DRIVING INNOVATION

“BorgWarner has long been committed to driving innovation in the automotive sector, and our latest advancements are a testament to that commitment,” Husted says. “Our new technologies are centred on enhancing the efficiency, sustainability and overall performance of commercial vehicles.”

In addition to its LFP battery packs and DC fast charging stations, BorgWarner is also making gains in electric powertrains.

“We are advancing in powertrain electrification with our range of CV inverters and eMotors, which are at the heart of the propulsion system in electrical commercial vehicles,” Husted explains. “We’ve also focused on thermal management solutions, such as our advanced battery coolers and high-power eFans, which are essential for managing operating temperatures in electric drivetrains, thereby extending the performance, lifespan and efficiency of these systems. These innovations are collectively helping to reduce emissions, improve energy efficiency and lower the total cost of ownership for commercial fleet operators, contributing to revolutionising the commercial transportation landscape and creating a cleaner, more efficient world.”

Looking ahead, Husted believes the pace of technological advancement in battery energy density will be a pivotal influence on the future of the commercial transportation industry. “The development of batteries that offer higher energy density, faster charging times and lower costs will be key to accelerating the adoption of electric commercial vehicles,” he says. “Secondly, the expansion of reliable and widespread fast-charging networks will be essential for supporting long-haul and high-utilisation fleet operations. This will include upgrades to electrical distribution infrastructure in some areas in order to supply power to DC fast charger depots.”

For more information visit: www.borgwarner.com