E-motors of the fifth generation: final assembly line, associates inserting and assembling power electronics, several e-motors on the assembly line, leak test, final assembly, Production line basic e-motor: Assembly, inserting of stator

Automatic station, set module, screw together terminal strips, transfer unit (11 tons transverse load), set cover, screw together cover High-voltage battery housing, screwing of connectors and cables, inserting the battery modules, screwing terminal strips, transfer between different mounting transport systems, installation of the cover

Module production: provision of prismatic battery cells, application and testing of the cell, film application, plasma cleaning and plasma activation, stacking of battery modules, welding of double modules, application of adhesives for the cooler, quality check of the battery modules (resistance measurement), finished battery modules with cover in a transport box.

Drone footage of the BMW Group E-Drive Production Competence Center Dingolfing (Plant 02.20)

The BMW Group has an extensive inhouse expertise in producing drivetrains. Our global production network supplies our vehicle plants with the drivetrain our customer wants — for electrified models as well as for models with a combustion engine. Electromobility is becoming more and more important. Sectional images Michael Nikolaides In 2020 the BMW Group started series production of its 5th generation e-drivetrain, which will be used in new BMW models like the BMW i4 and the BMW iX. By 2030 we expect at least 50% of our global vehicles to be delivered to our customers with an electrified drivetrain. In response to that, we are systematically expanding our production network for e-drivetrains. We are increasing capacities in existing locations and we are developing capabilities in others. We are growing our staff for the e-drive production almost exclusively through a transformation of personnel currently working in otherareas of the company. By doing that, we can get most of the expertise of our associates and offer attractive and future-proof jobs.

The heart of any electric vehicle is the e-drivetrain. Battery electric vehicles are fully electric. Partially electric vehicles, so-called plug-in hybrids, are also equipped with a combustion engine. Put in very simple terms, every electric vehicle has an e-motor and a high-voltage battery. For our high-voltage batteries, we start by assembling the battery cells into battery modules. We then mount these modules and connect them to the high-voltage batteries. For our fifth-generation e-drivetrains, the stator, rotor, housing, and transmission are all produced in-house by BMW. We then assemble these components along with the power electronics to make an electric drivetrain. We do all of this without using rare earths. The high-voltage battery stores the electric energy in the vehicle. The energy is then converted into motion by the e-motor. To do this, the mobile rotor rotates through dynamic magnetic fields in the stator. The finished components of the fifth-generation e-drivetrain, i.e., the high-voltage battery and e-motor, are then delivered to our vehicle production plants for installation, for example to Dingolfing for the iX or to Munich for the i4. Sectional images Sven Jochmann

Rotor winding with copper wire, joining rotor shaft

Cutting the copper wire, bending process, inserting the copperpins into the stator, soldering the tips

Engraving of the engine number, assembly base motor, assembly transmission, assembly, end of line test