Production of fifth-generation high-voltage batteries and battery modules for use in the BMW iX* and BMW i4 is now underway at the Competence Centre for E-Drive Production in Dingolfing. At the same time, the company is also increasing production capacity for its fifth-generation electric motor, which has been built in Dingolfing for the BMW iX3* since 2020 and will also power the BMW iX* and BMW i4. “We expect at least 50 percent of the vehicles we deliver to our customers worldwide to be electrified by 2030. To achieve this, we are relying on our extensive in-house drive train expertise: We are increasing capacity at existing drive train production locations – like here in Dingolfing – and developing capabilities at others – like recently in Regensburg and Leipzig,” explained Dr Michael Nikolaides, Senior Vice President, Production Engines and E-Drives, BMW Group.
The output and energy content of drive units and high-voltage batteries with fifth-generation BMW eDrive technology can be flexibly scaled. This means they can be optimally adjusted to suit different model variants.
Each vehicle uses up to two highly integrated e-drives, which combine the electric motor, power electronics and transmission in a single housing. Based on the design principle of a current-excited rotor, the fifth-generation e-drive does not require any materials classified as rare-earth metals.
BMW eDrive technology also comprises a high-voltage battery with state-of-the-art battery cell technology. The BMW Group agreed with its suppliers that they will only use renewable green power for producing fifth-generation battery cells. The entire high-voltage battery boasts outstanding qualities in the areas of performance, charging and discharging characteristics, durability and safety. The technically standardised production process for battery modules has been further developed in such a way that different module variants can be produced on the same production line – in line with the growing range of electrified vehicle models and performance levels. The production systems are highly flexible and scalable. Battery modules are produced from supplied prismatic battery cells at the respective BMW Group production location. A modular system developed in-house allows model-specific high-voltage batteries to be manufactured from these modules in a flexible arrangement.
The company has outstanding expertise and experience, both in the field of battery cell technology and in production of model-specific high-voltage batteries. The BMW Group conducts basic research in the fields of cell chemistry and cell design at its own Battery Cell Competence Centre. The BMW Group also produces battery cell prototypes itself. These battery cell prototypes are used in tests to validate the development maturity of battery cells and to demonstrate the effectiveness of the production processes. In addition, the prototype production of the battery cells serves the identification of process potentials as well as the optimization of the production processes. In this way, the BMW Group gains a thorough understanding of the entire battery cell value chain and the decisive competitive advantages its chemical and technical properties offer. This enables battery cells to be manufactured to precise specifications that are geared towards each vehicle’s individual requirements.
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