BorgWarner, a global product leader providing innovative and sustainable mobility solutions for the automotive market, has received a $4.09 million award from the U.S. Department of Energy (DOE) to design and develop a fast current charger advanced and economical DCFC. BorgWarner has been awarded one of 25 research, development and demonstration projects aimed at advancing electrification, reducing vehicle emissions and improving electric vehicle charging infrastructure.

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BorgWarner received a US Department of Energy (DOE) award of $4.09 million to design and develop an advanced and cost-effective direct current fast charger (DCFC).

BorgWarner will lead the 36-month DCFC project in coordination with U.S.-based vendors and research partners including Michigan State University, eTransEnergy, Cityfi, State of Michigan, and Barton Marlow, in addition to vendor support from components from Wolfspeed, Inc. The project is scheduled to kick off in the first quarter of 2022.

“As a leader in electrification, we are proud to receive this funding to take our current state-of-the-art technology to the next level to meet industry needs and create a cleaner, more efficient world. in energy,” said Davide Girelli, President and CEO of BorgWarner Morse Systems. “We are excited to once again partner with the DOE and work with our project partners to develop the next generation of DCFC technology.”

The project goal is to develop the next generation DCFC system with 20-30% cost reduction with increased power density, reduced energy losses, reduced package size and improved reliability. Ultimately, the new technology will enable widespread adoption of similar chargers. BorgWarner and its project partners will work to deliver a charger with 10 charging stations collectively capable of a total of 350 kW. With the flexibility and adaptability of BorgWarner’s single-stage power conversion and power module architecture, the charger will be able to power up to five vehicles at once (with five more plugged in and ready to go). be charged). Based on the project design, the charger will demonstrate product scalability from 150kW to 350kW or more and produce output power from single 25kW power modules.

DCFCs allow charging at a much faster rate than conventional Level 2 alternating current (AC) chargers with the same ease of accessibility. DC power can be supplied directly to the vehicle battery, resulting in greater efficiency. Additionally, as DCFCs enable higher power levels, charging stations can deploy multiple charging points so that multiple vehicles can be charged simultaneously. The unit will be designed to support current electric vehicles, with the ability to be easily upgraded to support potential future battery electric vehicles that operate at higher voltages.

“Combined with our long-standing reputation for excellence, BorgWarner has a seasoned team ready to tackle targeted areas of innovation to achieve our DCFC goals,” continued Girelli. “Our unique conversion architecture, power module design and packaging, power electronics capabilities and module building block approach will be the factors that will ensure a successful project launch for the vehicle market. electrical.”

For a complete list of projects selected for this DOE funding opportunity, click here.

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