Decrypt BMW Motor Core Factory

- Nov 12, 2018-

There is a small town in Bavaria called Dingolfing (German: Dingolfing), which can be said to be the core manufacturing base of BMW electric cars. Recently, BMW Group has disclosed some Dingolfinger factories are little known. With the photos and information, we also have the opportunity to learn the details of the mysterious high-voltage battery system (modules, battery packs) and motors.

The Dingolfinger plant has been responsible for the production of two core components of the battery system and the motor. Several years ago, it began to provide battery systems for BMW ActiveE and ordinary hybrid vehicles, such as the 3 Series ActiveHybrid, the 5 Series ActiveHybrid and the 7 Series ActiveHybrid. After the launch of the i3 and i8 by the BMW Group, the core component line of the Dingolfinger plant was expanded to all models under iPerformance, including the i3, i8, 225xe, 330e and the latest 740e.

The BMW Group has invested more than 1 million Euros in the Dingolfinger plant to meet the demand for electrified components. The number of employees in the factory is also expected to increase from the current 100 to more than 200. This clearly shows the future of plug-in vehicles. Will grow rapidly.

Everyone has an impression about the general status of the entire plant, followed by the most important battery and motor production introduction.

Motor technology

Under the strategic development of internal development and eDrive electric drive technology, the BMW Group's goal is to provide customers with the same quality electric vehicle driving experience as BMW, and to be more competitive in the market to ensure the dynamic performance, efficiency and comfort of their products. The motor plays another important role in it. The motors used in the BMW i and iPerformance models have a high volume and weight-to-power ratio, providing linear power ratings and excellent efficiency over high speeds. These characteristics stem from special design principles, and the design team of i products knows how to innovate in a large number of design details.

Both the stator and the rotor are produced at the Dingolfinger plant and then connected to the motor housing. The assembly line is very flexible and the staff are trained to perform different operations. The U-shaped arrangement ensures a combination of flexibility and efficiency. At all workstations, components are delivered to the operator in an ergonomic manner. At the same time, the workstation can adjust the height and inclination to suit the needs of ergonomics. Most operations can be carried out in a sitting or stance position. This special way contributes to the high production quality of the eDrive electric drive components.

The high output ratio and motion characteristics of the motor are based on the continuous optimization of permanent magnet synchronous motor technology. For example, the stator consists of copper wires that are extremely compressed up to two kilometers. The stator is produced by encapsulating and insulating the metal sheet, and then stretching and cutting to form a coil.

The metal plates are joined by laser welding. The rotor assembly is also prepared using a special process. After the magnet is loaded into the rotor and riveted, the cooled rotor shaft is sintered without pressure to the heating member, so that the rotor is magnetized, and the entire assembly and assembly process is greatly simplified. In the final stage of the final assembly of the motor, the stator is first sintered into the motor housing without pressure at about 150 degrees and then inserted into the rotor. Once the other components have been installed and the relevant functional tests have been completed, the fully assembled motor can be mounted to the vehicle.

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