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The design of a demonstration vehicle is presented where improvements to the electrical and air induction systems are made which provide increased performance with improved fuel economy. This is made possible by a 48 V architecture which enables the deployment of new components, specifically a belted motor generator unit (MGU) and electrically-driven compressor (eBooster®). The synergy between these components enables energy efficient means to collect regenerated energy and provide added torque, faster engine response, and extended engine off operation among a list of added features. Control features and strategy are highlighted along with simulation and vehicle test data. Resultant performance and fuel economy benefits are reviewed which support the contention of 48 V being a cost effective architecture to enable CO2 reduction relative to a higher voltage hybrid.

Considering the current trend towards the electrification of commercial vehicles, the development of Beam eAxle solutions has become necessary. The utilization of an electric drive unit in heavy-duty solid axle-based commercial vehicles presents unique and demanding challenges. These include the necessity for elevated peak and continuous torque while meeting packaging constraints, structural integrity requirements, and extended service life. One such solution was developed by BorgWarner to address these challenges. This paper offers a comprehensive overview of the design and development process undertaken for this Dual Motor Beam eAxle system. This includes the initial comparison of various eAxle solutions, the specifications of components selected for this design, and the initial results from dyno and vehicle development.

To better understand the technical challenges of commercial vehicle electrification, BorgWarner converted a production Internal Combustion Engine (ICE) medium duty truck into a fully electrified vehicle. The resulting vehicle includes a newly developed dual-motor rear Beam eAxle driven by a pair of high-performance silicon carbide (SiC) inverters, an 800V battery system, and a new thermal management system customized for the electric vehicle. This paper will detail the conversion process along with the key components involved in the build. The resulting performance of the fully electrified commercial vehicle will be presented in comparison to the original production vehicle. The primary aim is to outline what is entailed in an electric vehicle conversion and to share the learnings gained throughout this build and development process.

The transition towards electrification in commercial vehicles has received more attention in recent years. This paper details the conversion of a production Medium-Duty class-5 commercial truck, originally equipped with a gasoline engine and 10-speed automatic transmission, into a battery electric vehicle (BEV). The conversion process involved the removal of the internal combustion engine, transmission, and differential unit, followed by the integration of an ePropulsion system, including a newly developed dual-motor beam axle that propels the rear wheels. Other systems added include an 800V/99 kWh battery pack, advanced silicon carbide (SiC) inverters, an upgraded thermal management system, and a DC fast charging system. A key part of the work was the development of the propulsion system controls, which prioritized drivability, NVH suppression, and energy optimization.