Scalable, end-to-end solutions for an evolving trend

Although its evolution in the different markets shows a notable disparity, the fact is that the electric vehicle continues to materialise in new projects that have an impact on the transformation of the value chain. 

BorgWarner has a long history of supplying solutions for vehicle propulsion and we drive the electrification of vehicles with a wide range of products including power electronics, batteries, electric motors and thermal management systems. “Our expertise in propulsion systems enables us to offer scalable and highly efficient solutions for OEMs making the transition to electric mobility. On the process side, we focus on sustainable and efficient manufacturing to meet growing demand. We are committed to delivering advanced and reliable technologies that support the global shift to electric vehicles", they say. 

In this regard, they claim to be incorporating power electronics and software into their products on a large scale, which for them means adding new engineering capabilities and new manufacturing processes. "This makes our products more complex, because they have a mix of mechanical, electronic and thermal systems, which poses challenges in both design and manufacturing”.

On the other hand, and in terms of how they are applying digitalisation to increase efficiency in terms of quality and costs and the possibilities offered by AI-based solutions, they detail that their product development is digitalised, starting with the design of the product in a virtual environment, and continuing with extensive virtual simulation work to confirm and optimise the product. “In terms of AI-based solutions, we are leveraging that capability in software development, where we are using AI technology to improve the speed and quality of development. We are also using AI and machine vision to streamline quality inspection in some of our manufacturing operations”.

Finally, regarding their outlook until 2035 for the coexistence of electric vehicle projects with high-efficiency combustion vehicles, they comment that there is a lot of uncertainty in the market and that it is difficult to predict the future. “We expect the shift towards greater electrification to continue. BorgWarner remains committed to both electrification and the improvement of combustion technologies, ensuring that we can meet the diverse needs of global markets during this transition phase towards electrification. We have a resilient product  portfolio that positions us well, regardless of how the market evolves”.

Scalability and compatibility

Clara Otero, Senior Director of Automotive Electrification Systems at NXP Semiconductors, says NXP's electrification solutions manage power flow in EVs with flexibility and precision to extend driving range and keep vehicles on the road longer. ‘With complete system solutions for EVs, NXP's electrification solutions deliver the optimised performance and integrated safety OEMs need and are designed for scalability and cross-fleet compatibility,’ she says.

Thus, NXP's digital and analogue mixed-signal semiconductors enable vehicle electrification for all the different subsystems, from battery management units and traction motor inverters to DCDC converters, on-board chargers and thermal management units. "We also provide software drivers and middleware to facilitate customer integration efforts for the software-defined vehicle in cooperation with different partners. With our system-level solutions we help to reduce costs and efficiency by optimising the overall energy management of the vehicle", she says. 

In terms of challenges, Otero points out that electric motors have no legacy compared to combustion engines, which allows them to start from scratch in terms of EE architectures. "In addition, EVs need a heavy and expensive battery that needs to be optimised. The EV industry is developing and innovating rapidly to find the cost/performance sweet spot", she says.

She points to challenges such as overall system optimisation (balancing the weight, cost and safety of the battery with the efficiency and cost of the motor to extend the EV's range and maximise its lifespan), increasing the efficiency of the motors and battery, or meeting consumers' needs for fast and safe charging, among others.

As for AI, he says it plays an important role in various aspects, from R&D and design to manufacturing and testing of our products. "AI algorithms accelerate product development and further improve product quality and performance. In addition to using AI in our internal processes, AI has become an integral part of our product offerings, such as machine learning accelerators embedded in our integrated circuits and enabling AI to optimise application functions. We work with leading partners to ensure that our customers can also use the latest AI tools".  

For example, they combine their high-precision analogue cell measurement components with efficient ML processing to calculate the battery's state of health and state of charge to extend battery life and increase safety. Another example is using the engine efficiency measurement sensor to ensure optimal operating conditions to extend engine life and enable predictive maintenance.

Finally, looking to the future, they see a clear market shift towards electrified vehicles, including BEVs, PHEVs and HEVs, which will reach 72% penetration in new vehicles by 2030, up from 35% today. “Compared to last year, we see a shift from pure electric vehicles (BEVs) to hybrid vehicles, both still growing (BEV introduction is less ambitious in favour of hybrids). NXP supplies semiconductors for both xEV and ICE and can effectively manage the transition”, Clara Otero comments.

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Report published in AutoRevista 2.395