BMW iX5 Hydrogen: Testing under real driving conditions, prototype assembly and industrialisation in parallel

Munich. The new BMW iX5 Hydrogen has reached the next development phase on the road to series production: Current prototypes are undergoing a comprehensive testing programme; in parallel, the third-generation fuel cell system is entering a new assembly phase at the Hydrogen Competence Centre in Munich. At the same time, preparations for industrialisation and future series production of the hydrogen fuel cell system are underway at the engine facility in Steyr, Austria.

With these steps, the BMW Group is systematically driving the development of its first hydrogen production vehicle. The primary focus is on further validation of the overall system, preparations for industrialisation and the integration of fuel cell technology into a vehicle concept with typical BMW driving dynamics.

“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.

Focus on systems integration, efficiency and driving dynamics 

Current testing is focused on validation of the overall system under demanding environmental and operating conditions. The development teams validate the functionality of all components within the integrated vehicle system and optimise the complex control of the systems, even under high loads. The aim is to ensure the full performance capabilities of the drive train at all times, while further optimising BMW's hallmark driving dynamics in the fuel cell electric vehicle.

Current testing confirms the coordinated interaction between the fuel cell system, electric motor, high-voltage battery, BMW Hydrogen Flat Storage and Energy Master. The innovative high-voltage battery and the Energy Master, as the high-voltage system’s central control unit, enable higher recuperation performance and therefore increase overall system efficiency. At the same time, development aims to achieve driving performance on a par with the BMW iX5, including a target acceleration from 0 to 100 km/h in less than five seconds.

Fuel cell system enters next phase of construction

Alongside vehicle testing, the next prototype assembly phase for the third-generation fuel cell system is getting underway at the Hydrogen Competence Centre in Munich. The focus is on finalising and validating the testing methodology, as well as further preparations for industrialisation.

The previous prototype phase centred on component buildability and basic qualification of suppliers.

The upcoming process steps establish the necessary conditions for robust and efficient manufacturing processes, making a significant contribution to future series production. Series production of fuel cell systems will take place at BMW Group Plant Steyr in the future.

“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.

Industrialisation: Close cooperation between development in Munich and series production in Steyr

With the start of this new assembly phase, the project has reached another important development step on the road to industrialisation. For this purpose, the first test benches and manufacturing equipment have already been set up at BMW Group Plant Steyr, with employees being trained in stages. The insights gained in this way form the basis for further industrialisation steps and the subsequent production ramp-up.

Hydrogen as additional electrical drive train option

With the BMW iX5 Hydrogen, the BMW Group continues to pursue its technology-open approach. Hydrogen can supplement battery-electric vehicles where high range, short refuelling times and high versatility are required.

With a targeted range of up to 750 kilometres* (WLTP), refuelling in less than five minutes and fully-electric driving, fuel cell technology opens up additional possibilities for locally emission-free individual mobility.z

Under the “HyPowerDrive” project, the German Federal Ministry of Transport (BMV) is funding the development of the powertrain and tank system for the BMW iX5 Hydrogen as part of IPCEI Hy2Move. The federal government is providing funding of 191 million euros. The project is also being (co-)financed by the state of Bavaria with a total of 82 million euros. The funding is administered by Projektträger Jülich (PtJ) and coordinated by NOW GmbH.

Questions and answers

How is BMW integrating hydrogen into its product line-up?

Following successful global testing of the pilot fleet, the BMW iX5 Hydrogen will be the first hydrogen-powered BMW Group production model released onto the market. Going forward, the new BMW X5 will offer customers the choice between a battery-electric drive train, plug-in hybrid, petrol, diesel or hydrogen fuel cell technology.

What is currently being tested in the BMW iX5 Hydrogen?

The focus of the current testing is on the interaction of all drive system components. This includes the fuel cell system, high-voltage battery, electric motor, hydrogen tanks and the overall system control unit. Efficiency, driving performance and driving dynamics will also be examined under different operating conditions.

How does the fuel cell system work?

Inside the fuel cell, hydrogen from the tanks reacts with oxygen from the ambient air in an electrochemical reaction. This generates the electric current that drives the electric motor and powers the vehicle. The BMW iX5 Hydrogen uses the third-generation fuel cell system co-developed by the BMW Group and Toyota Motor Corporation.

Where will the fuel cell system be produced going forward?

The BMW Group is preparing for future series production of the fuel cell system at BMW Group Plant Steyr. At the same time, the competence centres in Munich and Steyr are developing and assembling prototypes, while gaining experience for industrialisation. Additional system components are being manufactured at the BMW Group facility in Landshut.

What are the advantages of hydrogen fuel cell technology?

Hydrogen fuel cell vehicles offer locally emission-free driving, combining electric propulsion with short refuelling times. For the BMW Group, fuel cell technology supplements battery-electric vehicles primarily where high range and high versatility are required.