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 parts, now stands on the forefront of BMW’s largest technological shift in a long time. Right here, BMW is ramping up manufacturing of its sixth-generation (Gen6) high-voltage battery system, a breakthrough in effectivity, value 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. Although a number 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, out there in two heights: 95mm and 120mm. The shift from modules to a direct cell-to-pack (CTP) integration permits for better vitality density, decreased weight, and extra environment friendly use of area.
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 ingredient of the automotive. In contrast to typical 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, basically forming the car’s flooring.
As BMW defined, this has profound advantages:
- A decrease car 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 car.
In accordance 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 velocity is as important as vary, and BMW has addressed this by transitioning from a 400V system to an 800V structure. The 800V structure is just not new to the trade. Plenty of BMW’s direct and oblique opponents are already providing electrical automobiles with the extra advanced system. BMW was not able to share all the main points on what’s coming listed here are some particulars confirmed at this stage:
- 30% quicker 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, bettering 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 out there. This ensures that drivers can make the most of high-powered ultra-fast chargers whereas sustaining compatibility with present networks.
What they haven’t confirmed are the 10-80 p.c charging occasions (we tried getting a solution) and the charging fee. Our personal sources, however but not confirmed by BMW, level to 350 kW of quick charging and to a brand new NACS port put in on Neue Klasse automobiles which is able to give BMW entry to the Tesla charging community as properly.
The Vitality Grasp
One of many key enablers of this effectivity is the Vitality Grasp, a classy management unit developed in-house by BMW. In contrast to earlier programs the place numerous energy administration parts had been scattered all through the car, the Vitality Grasp acts as a central hub, distributing excessive and low-voltage vitality with better precision and intelligence. It additionally improves thermal administration, making certain optimum charging speeds with out extreme warmth buildup or vitality waste. Once more, we did attempt to get some concrete numbers with regards to thermal administration enhancements, however nothing was shared right now.
Moreover, BMW has designed the Vitality Grasp to be simply replaceable, addressing a serious concern in EV upkeep. Whereas Gen5 battery administration programs had been deeply embedded contained in the pack, the Vitality Grasp sits beneath the rear seats, making it much more accessible for servicing and repairs.
Extra Vary, Extra Effectivity, Much less Value
Vary nervousness has been a persistent problem in EV adoption, and BMW is tackling it head-on with a 30% enhance in vary in comparison with Gen5 fashions. In layman phrases? A variety of 600 to 900 km on the WLTP cycle. Naturally, the extra stringent EPA normal will carry these numbers a bit, however will nonetheless be aggressive in at this time’s market.
This isn’t only a results of greater vitality density (up 20%), but in addition BMW’s pursuit of effectivity beneficial properties throughout the board. Aerodynamics play a vital position on this enchancment. By eradicating the necessity for a separate underbody panel, BMW’s new battery-integrated flooring design creates a seamless, totally enclosed decrease floor. This reduces drag and contributes to the 20% general car effectivity enhance achieved with Gen6.
Weight financial savings are one other issue. By eliminating modules and integrating the battery into the construction, BMW removes redundant supplies, additional optimizing the car’s weight distribution and dynamics. How a lot lighter? They don’t seem to be prepared to speak that both.
However maybe probably the most spectacular achievement is value discount. BMW has minimize battery manufacturing prices by 40-50%, a staggering enchancment that can permit the corporate to worth its EVs extra competitively. This was achieved via not solely a simplified battery design, but in addition via extra environment friendly manufacturing methods, permitting fewer meeting steps and a excessive stage of standardization.
Bidirectional Charging
BMW’s Gen6 battery isn’t only for powering the automotive—it’s additionally an influence supply. 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-Residence, V2H).
- Cost different EVs when wanted (Automobile-to-Automobile, V2V).
The Function of Landshut: BMW’s Battery Innovation Hub
Whereas Munich’s Battery Cell Competence Middle (BCCC) focuses on analysis and cell chemistry improvement, Landshut is the place BMW brings these improvements to life. Right here, the corporate has made important investments in high-voltage battery manufacturing, making certain that its Gen6 know-how is manufactured to the best high quality requirements.
BMW can also be adopting a “local-for-local” technique, with 5 new Gen6 battery vegetation deliberate throughout Europe, North America, and China. This method minimizes CO₂ emissions from transportation, strengthens provide chain resilience, and creates native jobs.
Sustainability is on the core of BMW’s electrification push, with a concentrate on closing the battery supplies loop. The corporate is actively recovering lithium, nickel, and cobalt from end-of-life batteries and reintegrating them into manufacturing, decreasing reliance on newly mined supplies.
A Leap for BMW and Electrical Mobility
Strolling via Landshut, it grew to become clear that BMW’s Gen6 battery system is greater than an incremental improve—it’s an entire reinvention of how electrical automobiles are designed and constructed.
With greater vitality density, quicker charging, decrease prices, and new ranges of structural integration, the Neue Klasse will set a brand new benchmark for premium EVs. And shortly, these billion-dollar investments and numerous hours of engineering will materialize into the primary Neue Klasse EV: the iX3.
