The way forward for BMW’s electrical mobility is being written in Landshut, Germany. This historic plant, lengthy recognized for its experience in light-weight development and powertrain elements, 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 pace that may 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 technology of EVs. Regardless that a few of the particulars have 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 power 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 technology 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 better power density, diminished weight, and extra environment friendly use of area.
The query of weight is essential, particularly provided that latest 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 mission lead for Gen6 batteries, to make clear this side. He famous that whereas the battery know-how has improved, the general weight just isn’t altering an excessive amount of.
However BMW didn’t cease there. The corporate can also be implementing pack-to-open-body integration, which means that the battery pack itself is a structural component of the automobile. Not like typical designs the place the battery is enclosed inside a separate housing after which put in within the automobile, the Neue Klasse fashions could have an open chassis till the battery is mounted, primarily forming the car’s ground.
As BMW defined, this has profound advantages:
- A decrease car weight, main to raised 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 car.
In line with BMW, this design philosophy eliminates pointless supplies, reduces manufacturing complexity, and enhances their capacity to scale battery sizes throughout completely different car sorts.
Quicker, Extra Environment friendly Charging with 800V Structure
For any EV, charging pace is as vital as vary, and BMW has addressed this by transitioning from a 400V system to an 800V structure. The 800V structure just isn’t new to the business. Lots of BMW’s rivals already provide electrical automobiles with the extra complicated system. BMW was not able to share all the small print, however listed here 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 power loss, enhancing general effectivity.
BMW has additionally built-in a versatile charging system, which means the Gen6 battery can swap between 800V and 400V charging, relying on the infrastructure accessible. This ensures that drivers can make the most of high-powered ultra-fast chargers whereas sustaining compatibility with current networks.
The Power Grasp
One of many key enablers of this effectivity is the Power Grasp, a complicated management unit developed in-house by BMW. Not like earlier methods the place varied energy administration elements have been scattered all through the car, the Power Grasp acts as a central hub, distributing excessive and low-voltage power with better precision and intelligence. It additionally improves thermal administration, making certain optimum charging speeds with out extreme warmth buildup or power waste.
Extra Vary, Extra Effectivity, Much less Value
BMW is tackling vary anxiousness head-on with a 30% improve in vary in comparison with Gen5 fashions, doubtlessly reaching 600 to 900 km on the WLTP cycle. Effectivity positive factors throughout the board, together with aerodynamics and weight financial savings, contribute to this enchancment.
Bidirectional Charging
The Neue Klasse will introduce bidirectional charging, permitting automobiles to:
- Feed electrical energy again into the grid (Automobile-to-Grid, V2G).
- Energy houses throughout outages (Automobile-to-House, V2H).
- Cost different EVs when wanted (Automobile-to-Automobile, V2V).
The Function of Landshut: BMW’s Battery Innovation Hub
BMW’s Gen6 battery system represents a whole reinvention of electrical car design and manufacturing, with improvements that may quickly materialize within the first Neue Klasse EV: the iX3.
