BMW Begins Production of Powertrain for Neue Klasse
The Bavarian automaker BMW Group has begun series production of powertrains for its upcoming family of electric vehicles, called Neue Klasse, at its plant in Steyr, Austria, where it has invested more than €1 billion.
This sixth-generation eDrive (Gen6) is the first fully electric powertrain to be produced at this facility, which has more than 40 years of experience in the development and manufacture of internal combustion and hybrid units for the BMW and MINI brands.
The site will continue to manufacture diesel and gasoline engines in parallel. In fact, it is at this same industrial complex that the engines for the 3 Series sedans assembled in San Luis Potosí are produced.
“Today we are laying the foundation for the future of the BMW Group,” explained Milan Nedeljković, member of the Board of Management of BMW AG responsible for Production, during the start of operations.
“As the first production site for the Gen6 electric motor, the Steyr plant is central to the Neue Klasse and the continued development of our global production network,” said the executive, explaining that the eDrive will be shipped from this factory to the entire production network, including Mexico.
In his speech, Klaus von Moltke, Vice President of Engine Production at BMW AG and Director of the Steyr plant, said he was proud to deliver the first electric motor, a commitment he made three years ago.
“What we are launching here today is more than just an increase in production. It is a firm commitment to Europe, to technology, and to the future,” he added.
Moltke explained that the plant's technological openness and flexibility will be key to securing long-term jobs.
Around 1,000 employees will work on the assembly of electric motors. Depending on global demand, half of the total workforce at the Steyr location could be employed in electric mobility by 2030.
“Steyr will remain the heart of our powertrain expertise—both for combustion engines and electromobility,” the executive insisted.
With the exception of the aluminum housing, which is produced in Landshut, Germany, all key components of the innovative and highly integrated eDrive will be manufactured in Steyr, including the electronic assemblies.
The inverter will be produced in a new in-house clean room environment, marking the Austrian engine complex's entry into the field of electrical engineering.
The components of the Steyr eDrive will be assembled on two new lines. The overall production concept for Gen6 follows the principle of a modular system, enabling the production of different highly flexible electric powertrain derivatives for the entire Neue Klasse model range.
The modular concept generates positive economies of scale and cost savings in both development and production. It also improves the scalability of production volumes and keeps production and the supply chain highly flexible.
Comprehensive Improvements
The electric motor has undergone significant development for Gen6: The rotor, stator, and inverter have been holistically designed for the new 800-volt architecture of Gen6 technology, maximizing the performance capabilities and efficiency of the powertrain.
The inverter uses 800-volt technology and silicon carbide (SiC) semiconductor technology to increase efficiency. Fully integrated into the electric motor housing, the inverter converts the direct current from the high-voltage battery into alternating current for the electric motor.
The intelligent use of new technologies in the eDrive resulted in a 40% reduction in energy loss, a 20% reduction in costs, and a 10% reduction in weight when comparing the future BMW iX3 50 xDrive with a Gen5 xDrive model.
“All of this contributes significantly to the approximately 20% increase in overall vehicle efficiency,” explains Martin Kaufmann, SVP of Global Powertrain Development at BMW AG.
The efficient powertrain design, together with the high energy content of the high-voltage battery, enables a range of up to 800 kilometers in the BMW iX3 50 xDrive, the first model in the Neue Klasse.
