BMW Battery Technology

- Nov 12, 2018-

BMW battery technology

Battery technology

The popularity of electric vehicles in the future depends to a large extent on the advancement of battery technology. The performance of the battery must meet a series of customer requirements such as endurance, charging time, power output, reliability, durability, safety and cost.

Battery systems, motors and intelligent energy management systems are the cornerstones of the eDrive electric drive technology for the BMW iSeries and iPerformance models. The BMW Group decided to develop these electric drive core components in the early stage as if it were a traditional engine. It can adjust the needs of different specific models in different situations, make full use of the electrification advantages of the powertrain, and reduce fuel consumption and carbon emissions in an all-round way. Maintain a dynamic driving experience and performance.

BMW's battery pack meets the high standards required to match luxury cars. Whether it is short-distance or long-distance, performance needs to be stable, even if the available energy is reduced, it will not affect the driving experience. This is the main difference between BMW's own battery and other manufacturers' battery packs. At the same time, the battery packs manufactured by the Dingolfinger plant have better temperature adaptability, and only the extremely low outdoor temperature will affect the battery performance, but in this case, the BMW Group requires that the remaining battery capacity remains at A wider state of charge (SOC). In addition, battery system design requires a long life warranty of at least 8 years.

In order to achieve the best quality of collision safety, durability (reliability) and battery performance, scientific and rigorous production processes are indispensable, and the Dingolfinger factory is the center of the electric drive system manufacturing center. BMW i-series and plug-in hybrid models always purchase batteries from those leading lithium-ion battery manufacturers. When a new generation of batteries enters the market, they will start a new round of purchases, which ensures that BMW can always use the best. Commercial battery technology.

BMW believes that it will only succeed if it has a deep understanding and research on battery chemistry and battery manufacturing processes, as in the field of internal combustion engines. To this end, the BMW Group has established its own battery research department for technical evaluation. BMW's international research network covers the entire industry value chain of battery technology, covering a wide range of fields, including even material development. Only advances in battery materials are the most effective levers to improve battery system performance, such as energy density, charging, power and cost, while achieving high standards of reliability, long life and safety.

Some studies are a collaboration between BMW's joint material manufacturers and battery manufacturers. Innovative technologies and methods ensure that today's and tomorrow's BMW plug-in cars are always equipped with the best battery technology and are more compatible with luxury quality, which also makes Ding The Goldinger plant has a more flexible and quality-oriented production process. Going bigger, this definitely helps BMW to become a leader in the electric car segment.

The modular design system enables BMW's automotive products to combine both standardization and flexibility. The parallel relationship between the product mix and the production process of the Dingolfinger plant can be reflected in the configuration of the new production equipment. The new production workshop has about 6,000 square meters allocated to the eDrive electric drive components, and the 1500 square meters specializes in the production of motors and battery modules, 1000 square meters. For battery assembly, the capacity of all equipment can be rapidly doubled in a short period of time without affecting production efficiency. The idle space can further increase the overall production capacity of the electric drive system.

Similar flexibility is also reflected in the eDrive portfolio itself. BMW developed a modular design system on which motors and batteries of different sizes, performances and models can be developed following shared, standardized design principles and common basic features. The combination of standardization and flexibility gives BMW the ability to cover all current and future pure electric and plug-in hybrid models. More importantly, the expandable architecture is more comparable in price than conventional power vehicles of the same class of power and performance. The modular strategy allows the electric drive components of the BMW i and iPerformance models to be produced simultaneously on standardized production lines. In this way, BMW is able to react flexibly to changing market demands and quickly integrate existing production processes to create new models. .

The Dingolfinger plant produces two battery stages for the battery components produced by BMW i and iPerformance. The first is a highly automated phase that assembles externally sourced lithium-ion batteries into modules, each containing 16 battery cells, integrated with connectors, controllers, and cooling systems, and packaged in an aluminum casing. The battery pack needs to meet the different models loaded, usually with 5 or 6 modules. It is automatically fastened by bolts and connected by electrical connectors. Even if a fault occurs, only a separate module needs to be replaced. It is not necessary to replace the entire battery pack. The maintenance workload and danger are greatly reduced. The replacement module only needs to disassemble the cooling system. It does not involve other components.

The modular design principle allows battery packs with common basic features and quality standards to be customized to match different models, and each module can be mounted in the best fit and predetermined position in the car.

The design and manufacture of battery packs is also an example of BMW's R&D knowledge transfer. Numerous production technologies have brought high quality and reliability to BMW's original i3 and i8-loaded battery packs, and have been continuously improved and improved since then. The Dingolfinger factory will conduct a preliminary inspection of the externally-acquired batteries to ensure accurate specifications, then enter the highly automated module assembly process, robotic operation coating bonding, packaging into groups, module frame pressure welding, thermal management system, laser Welding cell connection.

The finished modules are finally formed into a complete battery pack, and the Dingolfinger plant currently produces three different types of battery packs, using a cellularmanufacturing process, which provides extreme flexibility. Level while ensuring efficiency and quality. This means that the battery's manufacturing capabilities can also be adjusted to meet changing needs, and new technology versions can be easily integrated into the production process.

In addition, the coolant circuit of the vehicle air conditioning system is also used to cool the battery, and the gaseous coolant directly cools the battery unit. This method ensures efficient temperature control, since the heat transfer from the evaporation process is straightforward, it is more efficient than the addition of additional media, making the cooling system particularly compact. At the same time, the risk of liquid being released in the event of a collision is also guarded against.

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