BMW is taking a proactive approach when it comes to the high-voltage batteries in its upcoming Neue Klasse EVs. The German automaker is determined to eliminate any potential battery issues by implementing a zero-defect strategy. This means that every cell that enters the factory undergoes rigorous quality checks to ensure it meets the required specifications.
While electric vehicle batteries are known for their reliability, the cost of replacing a failed battery can be exorbitant. BMW aims to alleviate this concern by ensuring that its Neue Klasse EVs are equipped with high-quality batteries right from the start. The company is leveraging AI technology to conduct advanced quality checks during the production process, guaranteeing that each cell is in optimal condition before being integrated into the battery pack.
The assembly process for the high-voltage batteries includes a meticulous cell clustering procedure, where the cells are connected to coolants, cleaned with lasers, and welded together. A monitoring system is in place to oversee the entire process and ensure that each step is executed flawlessly. Additionally, a foaming process is employed to safeguard all components and create a cohesive mechanical unit.
One notable feature of the Neue Klasse EVs is the integration of the high-voltage battery cells directly into the pack, eliminating the need for individual modules. This design not only streamlines the assembly process but also enhances the structural integrity of the battery pack, making it an integral part of the vehicle’s body.
After the assembly is complete, each battery pack, along with the central control unit, undergoes a comprehensive end-of-line inspection to verify that it meets BMW’s stringent quality standards. Markus Fallböhmer, Head of Battery Production at BMW AG, emphasized the company’s commitment to maintaining a zero-defect approach in battery production through intelligent quality checks.
BMW has forged partnerships with multiple battery suppliers to ensure a steady supply of cylindrical cells for its EVs. The automaker is set to establish five battery factories across three continents, including facilities in the United States and Mexico. By strategically locating these factories near vehicle production plants, BMW aims to streamline the battery assembly process and enhance operational efficiency.
With an 800-volt architecture and cutting-edge inverter technology, BMW’s Neue Klasse EVs promise to deliver superior performance, extended range, and faster charging capabilities. The company’s meticulous approach to battery production underscores its dedication to providing EV owners with reliable and high-quality vehicles.