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BorgWarner and Oak Ridge National Laboratory Celebrate Innovative Achievement in Electric Motors

In a significant milestone for the future of sustainable transportation, BorgWarner has been awarded the RD 100 Award in partnership with the Department of Energy's Oak Ridge National Laboratory (ORNL). This recognition is a testament to their groundbreaking co-development work that began back in 2021, focusing on a wireless excitation system for electrically excited synchronous motors (EESM).

The innovation in the spotlight is a rotary-transformer-based system that enhances the efficiency and reliability of electric motors used in both passenger and commercial vehicles. By utilizing this technology, BorgWarner eliminates the necessity for rare earth magnets, which not only mitigates supply chain risks but also contributes to the overall reliability of these motors. Notably, this technological advancement leads to a reduction in the size of the motor by an impressive 15%.

BorgWarner’s collaboration with ORNL has been key in developing a solution that meets various crucial benchmarks, including improved efficiency, lower costs, and ease of integration. Traditional electric motors are often limited by their specific designs and drivetrain compatibility, but this rotary transformer technology offers high compatibility across various drivetrain types and compact gearboxes.

Technological Breakthroughs and Patents

As highlighted by Harry L. Husted, Chief Technology Officer at BorgWarner, this partnership has fostered substantial advancements in technology, resulting in nine patent applications. The combination of BorgWarner’s extensive expertise in traction motors with ORNL's competence in wireless power transfer has given rise to a motor that not only matches but exceeds the performance and power density found in rare earth-based motors without relying on those materials. This achievement is a significant leap forward in electric motor technology.

The rotary transformer system efficiently transmits energy to the rotor with an impressive 92-95% efficiency rate. It supports incredibly high speeds, operating beyond 20,000 revolutions per minute. Additionally, BorgWarner’s brushless EESM motor exhibits a power density that is 25% greater than motors using rare earth magnets, marking a significant progression in the field.

Recognizing Excellence in Innovation

The RD 100 Awards have been recognizing extraordinary innovation in technology since their inception in 1963, judging entries based on their impact, novelty, and practical applications across various fields. BorgWarner and ORNL were honored in the IT/Electrical category, highlighting their leadership in advancing electric motor technology. The awards ceremony commemorating this achievement will take place on November 20th in Scottsdale, Arizona.

BorgWarner's commitment to delivering innovative and sustainable mobility solutions has remained steadfast for over 130 years. The company continues to play a transformative role in the automotive industry, helping pave the way for a cleaner and more efficient future.

Looking Ahead

Looking forward, the implications of this awarded technology extend well beyond the automotive industry. The innovations developed from this collaboration may serve various applications, from public transport systems to heavy-duty vehicles, potentially reshaping how electric motors are designed and utilized across multiple sectors.

In conclusion, BorgWarner’s collaboration with Oak Ridge National Laboratory exemplifies how strategic partnerships can lead to remarkable advancements in technology, promoting sustainable solutions that enhance both reliability and performance in electric mobility. As the automotive industry increasingly shifts towards electrification, such innovations will be crucial in reducing dependency on rare materials and bolstering efficiency, marking a new era in the evolution of electric vehicles.