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May 19, 2020

BorgWarner opens Indiana laboratory

BorgWarner has opened a laboratory at its Noblesville Technical Centre in Indiana.

By Rhodri Morgan

BorgWarner has opened a laboratory at its Noblesville Technical Centre in Indiana.

The move will allow the company to develop, build, test, and validate prototypes of its electric product portfolio under one roof, creating cost synergies, increasing cross-functional collaboration and improving efficiency during the product development and testing process.

BorgWarner’s Noblesville Technical Centre lab will focus on the development of motors and power electronics for the light vehicle and commercial vehicle markets.

Engineers will have the ability to build, calibrate and test electric propulsion systems for feedback to design and analysis teams.

BorgWarner maintains housing the entire range of engineering and development disciplines together in the same location creates advantages, including the reduction of down time during the design process.

“Having engineering, testing and prototype together under one roof is a competitive advantage as we move toward a highly technical and electrified future,” said BorgWarner PowerDrive Systems president and GM, Stefan Demmerle.

“The ability to streamline processes and improve design collaboration and responsiveness amongst engineering and prototyping will be reflected in future technologies developed at Noblesville.”

The 40,000 square-foot lab will be home to many newly-built electric components, which will be used in both hybrid and electric vehicles. The laboratory expands BorgWarner’s hybrid and electric capabilities by providing a space where real-world conditions can be generated and updates can be made to progress technologies in the industry in a shorter time-frame.

The Noblesville lab is designed to maximise space; it moved all non-critical equipment such as high voltage cabinets, isolation transformers, and battery simulators, to an equipment platform, reserving space on the main floor for additional test cells. The interior insulated walls are modular allowing for layout changes.

BorgWarner equipped the facility with the entire scope of motor manufacturing equipment, which enables the prototype phase to emulate the production process and uncover lessons which can be transferred to the manufacturing plant responsible for mass production.

This equipment includes wire formers, slot liner insertion, wire insertion, laser welding, varnishing and end of line testing.

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