The way forward for BMW’s electrical mobility is being written in Landshut, Germany. This historic plant, lengthy identified for its experience in light-weight building and powertrain parts, now stands on the forefront of BMW’s greatest technological shift in many years. Right here, BMW is ramping up manufacturing of its sixth-generation (Gen6) high-voltage battery system, a breakthrough in effectivity, price discount, and charging velocity that can outline the upcoming Neue Klasse fashions.
We got an unique alternative to step inside BMW’s high-voltage battery workshop at Landshut, the place engineers and executives shared an in-depth take a look at the improvements shaping BMW’s subsequent era of EVs. Regardless that a few of the particulars had been held again for future occasions, the a number of technical workshops gave us a glimpse at how BMW intends to redefine electrical driving, from vitality storage to charging to sustainability.
New Battery Structure: From Modules to Structural Integration
BMW’s Gen6 battery is a dramatic departure from its predecessor, Gen5, which powers the present BMW iX1, iX2, iX3, iX, i4, i5 and i7 fashions. Whereas the earlier era relied on prismatic cells housed in particular person modules, the brand new system transitions to cylindrical cells with a 46mm diameter, accessible in two heights: 95mm and 120mm (4695 and 46120). The shift from modules to a direct cell-to-pack (CTP) integration permits for higher vitality density, diminished weight, and extra environment friendly use of area.
The query of weight is essential, particularly on condition that current BMW fashions haven’t precisely prioritized shedding kilos. Whereas the brand new powertrain boasts a ten p.c discount in weight, official figures for the general battery platform stay undisclosed. We requested Philip Guerrero, BMW’s challenge lead for Gen6 batteries, to make clear this facet. He famous that whereas the battery expertise has improved, the general weight shouldn’t be altering an excessive amount of.
However BMW didn’t cease there. The corporate can also be implementing pack-to-open-body integration, that means that the battery pack itself is a structural factor of the automotive. Not like standard designs the place the battery is enclosed inside a separate housing after which put in within the automotive, the Neue Klasse fashions may have an open chassis till the battery is mounted, primarily forming the automobile’s ground.
As BMW defined, this has profound advantages:
- A decrease automobile weight, main to higher effectivity and driving dynamics.
- A very flat underbody, enhancing aerodynamics and rising vary.
- Improved crash security, with the battery pack itself contributing to the structural integrity of the automobile.
Based on BMW, this design philosophy eliminates pointless supplies, reduces manufacturing complexity, and enhances their potential to scale battery sizes throughout completely different automobile sorts.
Sooner, Extra Environment friendly Charging with 800V Structure
For any EV, charging velocity is as crucial as vary, and BMW has addressed this by transitioning from a 400V system to an 800V structure. The 800V structure shouldn’t be new to the trade. Lots of BMW’s opponents already supply electrical autos with the extra complicated system. BMW was not able to share all the small print, however listed below are some confirmed particulars:
- 30% sooner DC charging in comparison with Gen5.
- As much as 300 km of vary added in simply 10 minutes.
- A dramatic 50% discount in vitality loss, enhancing general effectivity.
BMW has additionally built-in a versatile charging system, that means the Gen6 battery can swap between 800V and 400V charging, relying on the infrastructure accessible. This ensures that drivers can reap the benefits of high-powered ultra-fast chargers whereas sustaining compatibility with current networks.
The Vitality Grasp
One of many key enablers of this effectivity is the Vitality Grasp, a complicated management unit developed in-house by BMW. Not like earlier methods the place varied energy administration parts had been scattered all through the automobile, the Vitality Grasp acts as a central hub, distributing excessive and low-voltage vitality with higher precision and intelligence. It additionally improves thermal administration, making certain optimum charging speeds with out extreme warmth buildup or vitality waste.
Extra Vary, Extra Effectivity, Much less Price
BMW is tackling vary anxiousness head-on with a 30% enhance in vary in comparison with Gen5 fashions, doubtlessly reaching 600 to 900 km on the WLTP cycle. Effectivity good points throughout the board, together with aerodynamics and weight financial savings, contribute to this enchancment.
Bidirectional Charging
The Neue Klasse will introduce bidirectional charging, permitting autos to:
- Feed electrical energy again into the grid (Car-to-Grid, V2G).
- Energy properties throughout outages (Car-to-Residence, V2H).
- Cost different EVs when wanted (Car-to-Car, V2V).
The Function of Landshut: BMW’s Battery Innovation Hub
BMW’s Gen6 battery system represents an entire reinvention of electrical automobile design and manufacturing, with improvements that can quickly materialize within the first Neue Klasse EV: the iX3.
