The BMW Group has started series production of its sixth-generation high-voltage batteries in Shenyang, China. The site joins Debrecen in Hungary and Irlbach-Straßkirchen in Germany as the third plant in the Gen6 battery network. The packs will supply future Neue Klasse electric models built in China.

Shenyang in north-east China is now building BMW’s Gen6 high-voltage batteries. It is the third plant to do so, after Debrecen in Hungary and Irlbach-Straßkirchen in Germany. BMW calls the start of production another milestone in rolling out the technology worldwide. The batteries made in Shenyang are meant for future Neue Klasse models built in China.

The Neue Klasse is BMW’s new all-electric vehicle architecture, and the BMW iX3 was the first model to use it. Building the batteries in the same region as the cars is a central part of BMW’s plan to produce the new generation in several regions at once.

“The high-voltage battery is a key component of our all-electric vehicles and one of the BMW Group’s most important technologies for the future. The start of Gen6 battery production in China demonstrates how quickly and systematically we are industrializing our latest technology across our global production network. This creates a key prerequisite for the successful global ramp-up of the Neue Klasse,” said Dr. Raymond Wittmann, member of the Board of Management of BMW AG responsible for Production.

Wittmann added that Shenyang shows the company’s broader approach of building “locally, efficiently and close to our markets” to the same global standards.

Denser cells, quicker charging

The Gen6 battery uses newly developed cylindrical cells. BMW says they offer more than 20 per cent higher energy density than the previous cell generation. According to the company, charging speed and range both improve by up to 30 per cent.

Part of the gain comes from a cell-to-pack layout. The cells are fitted straight into the battery housing, so the separate module level is no longer needed. BMW says this makes better use of the available space and lets the same battery be adapted more easily to different vehicle models.

The pack is managed by the Energy Master, a central control unit developed in-house by BMW. It sits directly on the battery and combines key power-supply and battery-management functions.

How the packs are assembled

The cells are inspected first and then joined with cooling units to form cell clusters. After laser cleaning, the clusters are precision-welded to the cell contact system. A special foaming process then bonds the parts into a single mechanical unit, which BMW says improves safety, stability and durability. The housing is closed, sealed and riveted. The Energy Master is fitted last, and every battery then goes through a full end-of-line test.

Production data is recorded and analysed at every stage. BMW uses digital twins, data analytics and AI-supported inspection to spot faults early and keep each part traceable. Inline systems also check the laser-welded joints in real time.

Building batteries where the cars are built

BMW calls this a “local-for-local” strategy, meaning the batteries are made close to the vehicle plants they supply. The company says this shortens transport routes, keeps supply stable and makes the production network more resilient. The same production, quality and safety standards apply at every site.

Two more battery assembly plants are due to follow. Woodruff in the United States and San Luis Potosí in Mexico are set to start series production in the coming months. That will bring the Gen6 network to five sites across Europe, Asia and North America.

What it means

China is a large and highly competitive market for electric cars. Building batteries locally should help BMW supply its Chinese-built Neue Klasse models without relying on packs shipped from Europe. It also puts BMW’s new cell technology closer to the market where rivals compete hardest on charging speed and range.

Facts: BMW Gen6 high-voltage battery

  • Cell type: newly developed cylindrical cells
  • Energy density: more than 20 per cent higher than the previous cell generation
  • Charging speed and range: up by as much as 30 per cent
  • Construction: cell-to-pack, with no module level
  • Control unit: BMW Energy Master, mounted on the battery
  • Production sites in operation: Debrecen (Hungary), Irlbach-Straßkirchen (Germany), Shenyang (China)
  • Coming soon: Woodruff (USA) and San Luis Potosí (Mexico)

BMW says the batteries built in Shenyang will go into the Neue Klasse models it makes in China.

Source: www.press.bmwgroup.com