BMW has moved its hydrogen-powered iX5 into a new development phase, with prototypes running a full testing programme while the third-generation fuel cell system enters a fresh assembly stage in Munich. In parallel, the company’s engine plant in Steyr, Austria, is being readied for future series production of the fuel cell system. The iX5 Hydrogen is set to become the BMW Group’s first hydrogen-powered production model, targeting a range of up to 750 km (466 miles) and refuelling in under five minutes.

The BMW Group says its first hydrogen production car has reached the next stage on the road to series manufacture. Current BMW iX5 Hydrogen prototypes are working through a comprehensive test programme, while the third-generation fuel cell system moves into a new assembly phase at the Hydrogen Competence Centre in Munich. At the same time, industrialisation work has started at the engine facility in Steyr, Austria.

According to the company, the priorities right now are validating the complete system, preparing for industrialisation, and making sure the fuel cell package delivers the driving character buyers expect from the brand.

“Our ambition for the BMW iX5 Hydrogen is clear: a true BMW – with Sheer Driving Pleasure. A perfectly coordinated overall system is crucial for this. Current testing demonstrates how the fuel cell system, high-voltage battery and electric drive train are already successfully integrated and how systematically we are developing the technology towards series production,” says Josef Hochreiter, head of Hydrogen Vehicles at the BMW Group.

What the prototypes are being tested for

The current programme concentrates on how the drivetrain behaves under demanding environmental and operating conditions. Engineers are checking that every component works inside the integrated vehicle system and fine-tuning the control strategy under high loads, with the aim of keeping the full performance of the drivetrain available at all times.

BMW says testing so far confirms the interaction between the fuel cell system, the electric motor, the high-voltage battery, the BMW Hydrogen Flat Storage and the Energy Master. The latter acts as the central control unit for the high-voltage system, and together with the new battery it is said to allow stronger recuperation and therefore better overall system efficiency.

The stated performance goal is driving performance on a par with the battery-electric BMW iX5, including a target of 0–100 km/h (0–62 mph) in less than five seconds.

Fuel cell assembly moves to the next stage

Alongside the road testing, the next prototype assembly phase for the third-generation fuel cell system is starting at the Hydrogen Competence Centre in Munich. Where the previous phase looked at whether components could be built and whether suppliers were qualified, this one is about finalising and validating the test methodology and laying the groundwork for robust, efficient manufacturing.

“Prototype assembly is about much more than manufacturing individual components. Each phase helps us optimise processes, gain experience and systematically share this knowledge with the teams in Steyr. In this way, we are laying the foundation for the next steps on the road to industrialisation,” says Claudia Stephan, head of Technology Development and Fuel Cell Prototype Assembly at the BMW Group.

Series production of the fuel cell systems is earmarked for BMW Group Plant Steyr. The first test benches and manufacturing equipment are already installed there and staff are being trained in stages. Additional system components are built at BMW’s Landshut site. The fuel cell system itself was co-developed with Toyota Motor Corporation.

Hydrogen as one option among several

BMW frames hydrogen as an addition to its battery-electric line-up rather than a replacement, aimed at drivers who need long range, quick refuelling and flexibility. The manufacturer quotes a target range of up to 750 km (466 miles) on the WLTP cycle and refuelling in less than five minutes, with fully electric, locally emission-free driving.

Once launched, the iX5 Hydrogen will make the new X5 unusually broad in powertrain terms: customers will be able to choose between battery-electric, plug-in hybrid, petrol, diesel and hydrogen fuel cell versions of the same model. That range of options is rare in the segment, where most rivals have narrowed their choices rather than widened them.

Development of the powertrain and tank system is being funded through the “HyPowerDrive” project under IPCEI Hy2Move. The German Federal Ministry of Transport is contributing 191 million euros and the state of Bavaria a further 82 million euros, with funding administered by Projektträger Jülich and coordinated by NOW GmbH.

Facts: BMW iX5 Hydrogen

  • Drivetrain: third-generation hydrogen fuel cell system, co-developed with Toyota, plus high-voltage battery and electric motor
  • 0–100 km/h (0–62 mph): under 5 seconds (target)
  • Range: up to 750 km (466 miles) WLTP (target)
  • Refuelling time: less than 5 minutes
  • Hydrogen storage: BMW Hydrogen Flat Storage
  • Fuel cell production: BMW Group Plant Steyr, Austria (planned); components from Landshut
  • Price and on-sale date: not stated

BMW has not named a market launch date or price. As the current cars are development prototypes, the company stresses that no binding WLTP consumption figures are available yet.

Source: www.press.bmwgroup.com