BMW Group Unveils Groundbreaking 800V Electric Drive Technology for the Neue Klasse

Charge Faster, Drive Further: BMW Group Unveils Groundbreaking Electric Drive Concept with 800V Technology for the Neue Klasse

Munich/Landshut – The BMW Group is set to make significant strides in electric drive technology, heralding a new era of all-electric driving. During the Tech Days event in Landshut, the company showcased its advancements in high-voltage batteries and electric drive systems, utilizing the sixth generation of BMW eDrive technology. Every fully electric Neue Klasse vehicle will benefit from this innovation, with the first model slated for series production later this year at Plant Debrecen in Hungary.

Key Technology Highlights

• The BMW Energy Master: An intelligent central control unit for the high-voltage battery, developed and produced in-house at Plant Landshut.
• A revolutionary high-voltage battery concept, combined with the new BMW cylindrical cell, promises significant enhancements in energy density, charging speed, and range.
• A diverse range of electric motor types (SSM and ASM) demonstrates the BMW Group’s flexibility in electric drive systems.
• Expertise from the entire electric mobility value chain is consolidated in Bavaria and Austria, from development to recycling.

Commitment to Electric Mobility

Dr. Joachim Post, Member of the Board of Management of BMW AG, Purchasing and Supplier Network, emphasized the company’s dedication to electric mobility as a key growth area. “For the BMW Group, electric mobility is the future. We recognize that mobility needs vary across regions, and we aim to provide the best drive concept for every requirement,” he stated.

The Advantages of Gen6 High-Voltage Batteries

With the sixth-generation BMW eDrive technology (Gen6), the company is achieving a technological leap. Key improvements include:

• 30% faster charging speed
• 30% increase in range, with certain models surpassing these figures
• The introduction of 800V technology, enhancing performance across the fully electric product range.

The new high-voltage battery design allows for integration into various models, serving as a structural component in the Neue Klasse vehicles. The new BMW cylindrical cell boasts a 20% greater energy density than its predecessor, the Gen5 prismatic cell.

Intelligent Control with the BMW Energy Master

The BMW Energy Master plays a pivotal role in this technological advancement. Acting as the interface for power supply and data communication, it manages the electric motor and vehicle electrical system, ensuring safe operation of the high-voltage battery. The unit’s hardware and software are developed entirely in-house, enabling real-time updates via Remote Software Upgrades.

Local Production for Global Resilience

High-voltage batteries for the Neue Klasse will be assembled in five new production facilities strategically located near vehicle plants, adhering to a “local for local” approach. This model enhances production resilience against unforeseen political and economic events while creating and securing jobs. Additionally, the company has established agreements for five battery cell factories across Europe, China, and the USA.

Advanced Production Techniques

The Gen6 high-voltage batteries will utilize the “cell-to-pack” and “pack-to-open-body” principles, allowing for streamlined production and integration of cylindrical cells directly into the battery housing. The BMW Group has numerous patents associated with these innovations.

Before the global series production begins, thorough testing and development will occur at pilot plants in Parsdorf, Hallbergmoos, and Munich. The Energy Master will be produced at Plant Landshut, which will support all high-voltage battery assembly plants worldwide.

Sustainable Recycling Practices

As electric mobility expands, the focus on recycling high-voltage batteries is intensifying. In collaboration with SK tes, the BMW Group recovers valuable materials like cobalt, nickel, and lithium from end-of-life batteries, integrating them back into the supply chain. This closed-loop approach enhances efficiency and strengthens resilience.

Innovative Direct Recycling Solutions

The BMW Group is also advancing in direct recycling methods in partnership with its joint venture, Encory. A competence center for battery cell recycling is being established in Lower Bavaria, where innovative techniques will be implemented to recover and reuse valuable materials from battery cells.

Cutting-Edge E-Drive System

The Gen6 power unit maintains the principle of an electrically excited synchronous motor (EESM), allowing for optimal adjustment of the rotor’s magnetic field. This results in high efficiency and consistent power output. In addition, the new design features an asynchronous motor (ASM) variant for improved cost efficiency and compactness.

Performance Enhancements

The integration of new technologies and enhancements to existing systems results in substantial improvements:

• 40% reduction in energy losses
• 20% decrease in costs
• 10% weight reduction

This technology-open approach allows customers to select from various models equipped with different electric motor configurations.

Modular Manufacturing for Flexibility

The Gen6 electric drive system employs a modular manufacturing concept, leading to economies of scale, cost savings, and enhanced scalability. Series production will commence at BMW Group Plant Steyr in summer 2025, with pre-production already underway.

Advanced Thermal Management

Efficient thermal management is crucial for optimizing performance parameters, including range, real-world consumption, and acceleration. The Steyr facility develops thermal management systems for all BMW Group electric vehicles.

Conclusion

The BMW Group remains committed to leading the charge in electric mobility, leveraging innovative technologies and sustainable practices to enhance efficiency and performance across its vehicle lineup. With significant investments in production capabilities and recycling initiatives, the company is well-positioned for the future of electric driving.