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Advancements in electronic stability controls systems such as brake based stability control; active steering and suspension have improved overall vehicle dynamics. However, further improvement in vehicle handling and dynamics can be achieved through adaptive AWD torque distribution. A new active AWD system has launched in 2006 on a high performance German sports car with BorgWarner's HIGH ENERGY ITM 3e™ electromagnetic on-demand coupling technology and controls. This technical paper will provide an application overview of the hardware and controls development that result in best in class energy dissipation, performance to weight ratio, and parasitic losses. These combined capabilities have enabled a significant enhancement to the vehicle's driving dynamics and overall vehicle performance.

The Controls and Software Engineering Team at BorgWarner Drivetrain Systems has successfully employed model-based software development for the past several years. Their drivetrain system control software, developed using MATLAB/Simulink/Stateflow, and autocoded using TargetLink, is on the road in many passenger vehicle applications. Using these tools, BorgWarner has realized the widely recognized benefits of model-based design; such as increased speed to market, improved quality, and reduced complexity. Validating algorithms early through simulation and rapid prototyping, then translating them to production software through automatic code generation has proven very successful for BorgWarner. When starting with model-based design, the BorgWarner team focused on developing the core application control algorithms in the modeling environment. Lower-level software such as I/O drivers, the task scheduler, and communication logic was still hand-coded.