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Borg Warner 31-03 eGearDrive 8.28

Borg Warner 31-03 eGearDrive 8.28
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Borg Warner 31-03 eGearDrive.

This single speed transfer case was developed by Borg Warner specifically for electric drive applications.   It has emerged as THE drive train for electric vehicle applications.

It was used by CODA with the UQM drive train and by Azure Dynamics with their eTransit Connect.  The Aptera and the Tesla Roadster also used this gearbox. 

The 8.28: 1 drive ratio is perfect for single ratio electric vehicle applciations.

Ideally suited for full performance electric vehicles on either front-wheel drive or rear-wheel drive transverse driveline applications, the BorgWarner 31-03 eGearDrive(TM) single-speed transmission delivers high torque capacity, high efficiency, and low noise, vibration and harshness (NVH) in a compact package. Named a finalist for the 2010 Automotive News PACE Awards, BorgWarner's eGearDrive™ transmission incorporates patented and proprietary technology as well as over 100 years of powertrain know-how. Through its high-efficiency gear train and compact, low-weight design, the BorgWarner eGearDrive™ transmission contributes to extended battery-powered driving range which in turn reduces the required amount of battery capacity needed. The transmission also achieves high torque capacity in a compact package with greater than 97% efficiency, while providing smooth, quiet operation. Approximately 99% of the materials used in the eGearDrive™ transmission are recyclable.

"BorgWarner's 31-03 eGearDrive is a purpose built, high performance transmission that can be broadly adapted to a variety of electric propulsion systems," said John Sanderson, President and General Manager, BorgWarner Drivetrain Systems. "Designed for fast-to-market implementation, we expect this eGearDrive transmission to accelerate growth in the all-electric and hybrid electric vehicle segments." In addition to providing primary drive for front-wheel drive and rear-wheel drive electric vehicles and hybrid electric vehicles, BorgWarner eGearDrive systems enable launch assist, energy recovery, and AWD performance for the secondary-driven axle on any type of vehicle. Also available is an optional electronically actuated park lock system as well as various electronic driveline disconnect systems.

We acquired 16 of these from the AZD auction and they are perfectly mated to the Seimens 5135 motors and includes a shaft adapter for this motor.   SOLD OUT!
We have been able to resupply direct from Borg Warner, but unfortunately not at the  liquidation price.

High Efficiency Helical Geartrain
Mass: 28kg
Speeds: Single
Efficiency: 97%
Rated continuous torque: 200 nm (145 ft-lbs)
Rated peak torque: 300 nm
Input speed: up to 14,000 rpm
Lubrication: splash

Borg Warner eDrive Data Sheet

Borg Warner eDrive to Siemens Coupler drawing

eGear Drive CAN bus Protocol Document

Borg Warner eDrive Shaft Options

Product Reviews

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1 Siemens 1PV5135-4WS14 AC Induction Motor1 Siemens 1PV5135-4WS14 AC Induction Motor

Siemens 1PV5135 4WS14 AC Induction Motor

This is perhaps the most unusual AC Induction Motor in the world.  Siemens makes extremely high quality heavy duty AC induction motors - mostly for yachts and busses, but some trains as well.  This motor was specially produced for the Azure Dynamics Ford eTransit Connect project and we obtained a large lot  of these motors, brand new in the box, from the Azure Dynamics liquidation auction.

What is so unusual about these motors is that Siemens typically designs very high voltage (600-750v) three phase AC induction motors.  This motor was specially produced for AZD and is wound for a relatively low 215vdc.  Azure Dynamics used them with a 335v pack using their DMOC645 inverter controller.

These are voltages much more amenable to conversion vehicles.  The motor was tested to 221 foot lbs - 297 Newton Meters at 300v and 400 amps.  This is the equivalent of 134 horsepower.

Liquid cooled: 50% glycol/water at 16 liters/min

This unit is tagged at a nominal voltage of 215 volts and 47 kW continous power at variance with the data sheet on this motor.  It was probably specially wound by Seimens for the Azure Dynamics eTransit Connect project.

Azure Dynamics Force Drive DMOC 645 InverterAzure Dynamics Force Drive DMOC 645 Inverter

Azure Dynamics Force Drive Digital Motor Controller (DMOC) Model 645

This is the Azure Dynamics 3-phase AC Motor Inverter.   This device is controlled by CANbus messages to drive the Seimens 1PV 5135-4WS14-Z AC Induction Motor.

Azure Dynamics was liquidated in November 2012 and we acquired a quantity of these in a liquidation sale. These are orphans as  there is no product support, warranty, or repair services from the manufacturer for this inverter.  

It was specially configured for the Ford eTransit Connect vehicle, and has no software to allow a stand alone operation.  It  requires a Vehicle Control Unit (VCU) to translate driver inputs into appropriate Controller Area Network (CAN) messages to control the inverter.

This is the configuration  used in our VW THING build and it works quite well, developing about 145 horsepower with the Siemens motor.. 

Support Forum for DMOC 645 Inverter and GEVCU

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Price: $3595.00

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