BMW Brilliance Automotive Opens High Voltage Battery Center in Shenyang,
Enters New Phase of New Energy Vehicle Development

• BBA becomes the first premium automotive joint venture to establish a high voltage battery center in China
• The highly automated production line applies Industry 4.0 technologies to produce state-of-the-art high voltage battery packs
• Strengthened by local R&D capabilities, the High Voltage Battery Center is dedicated to developing cutting-edge battery technologies
• The High Voltage Battery Center produces batteries for The All New BMW 530 Le iPerformance
• BMW Brilliance enters a new stage of localization underpinned by strong NEV development capabilities

(Beijing/Shenyang) BMW Brilliance Automotive (BBA) today opened its “High Voltage Battery Center” located at its Tiexi Powertrain Plant in Shenyang, China. In doing so, BBA becomes the first premium automotive joint venture to establish a high voltage battery (HVB) center in China. BBA’s HVB Center is dedicated to developing HVB technologies for use in premium new energy vehicles (NEVs) that are tailored for the Chinese market. The first HVB developed and produced by BBA will be used in The All New BMW 530 Le iPerformance.

The automotive industry is undergoing profound changes. Sustainability policies regarding fuel consumption, emissions and safety are being updated at an increasing pace, while consumer demands are also evolving. Having anticipated these changing industry dynamics well in advance, BMW Brilliance has developed a clear strategy to lead the industry with concrete achievements. BMW Brilliance is building a complete NEV ecosystem that covers the entire industry value chain from R&D capabilities, battery solutions and technology leadership, to brand and product, charging and infrastructure and e-mobility services.

BBA’s HVB Center in Shenyang is BMW Group’s third comprehensive battery center worldwide, and the BMW Group’s first outside of Germany incorporating battery R&D, production and testing in one location. The HVB Center’s innovative and bespoke in-house production process enables BBA to differentiate itself from competitor brands and ensures customers driving its electrified models receive the full BMW driving experience.

Dr. Johann Wieland, President & CEO, BMW Brilliance, said: “The HVB Center opening is a critical milestone for BBA that further strengthens our position as an e-mobility leader. It reconfirms our commitment to China and provides another example of successful Sino-German cooperation and innovation. BBA is entering a new stage of localization featuring intelligent manufacturing, innovation and sustainable development.”

Cutting-edge technology for highest quality manufacturing

The HVB Center is a competence center which brings together battery production, R&D, quality, laboratory, procurement and supply chain management functions. A robust and flexible production process means BBA can achieve faster product launches while delivering a battery product that combines optimal safety, durability and performance.

At BMW Brilliance, HVB packs are produced in two stages. In the first, highly-automated process, standard lithium-ion cells are processed and combined into a larger unit, known as the battery module. In the second stage, battery modules are mounted together with connections, control units and cooling units in an aluminum housing to form a complete HVB pack. This production process has two decisive advantages: first, standardized battery modules mean that properties and quality standards are uniform, forming the basis for a wide variety of electric drive variants. Second, the aluminum housing size and shape, as well as the number of battery modules used, can be perfectly adapted and tailor-made for each vehicle.

At BBA’s HVB Center, innovative production processes have been applied in order to carry out double-module battery production. State-of-the-art robotics ensure maximum accuracy in the highly automated process of forming double modules from lithium-ion cells. The application of advanced and Industry 4.0 technologies means the Center sets new standards for HVB production in China. An integrated process management (IPM) system for quality management leverages big data to trace battery cells and processes through production, including information as detailed as tightening torque. Automatic laser welding gives high accuracy and stable weld quality, adding strength and reliability to the battery frame and electrode connections, thereby enhancing battery function and safety. Optical checking is enabled by 3D cameras that detect abnormal trends in welding and foil application, verify and optimize welding quality, and flag potential quality defects.

The entire production process takes place in an environment with strictly controlled cleanliness, humidity and temperature. Plasma cleaning technologies are used for surface cleaning to achieve increased surface tension force for better application of foil and glue. In the final stage of module assembly, the double-module is completed in an isolated workshop with a controlled constant humidity of under 31% to ensure gluing quality. Another feature of the automated production line is the robotic arms equipped with suction cups that capture and deliver cells, preventing any potential risks involved in manual handling.

Local technology innovation for enhanced performance

The development of the double-module concept led by BBA is used exclusively on The All New BMW 530 Le iPerformance. The localization of HVB technology innovation has brought various advantages. Incorporating BMW Group’s latest eDrive technology, The All New BMW 530 Le iPerformance will be one of the most intelligent and advanced premium NEVs ever produced in China.

The energy density of the HVB in The All New BMW 530 Le iPerformance reaches 111wh/kg, the highest among BMW PHEV models globally and a 70% increase on the last generation BMW 5 Series plug-in hybrid. Powered by unique eDrive technology, The All New BMW 530 Le iPerformance can achieve an e-range of 61 km and 140 km/h at top electrical speed. Fuel consumption is as low as 1.9 l/100km. Charging time is only 4 hours.

The battery has achieved 1,502 technical criteria, attaining a perfect balance between e-range, performance and safety. The battery pack has passed repeated firing, watering, collision and leakage tests. In China’s most extreme testing environments at -40C, the battery pack can still provide stable power output – a testimony to its supreme reliability.

A progressive BBA is driving forward NEV development

BBA is dedicated to leading NEV development in China. With 4 products in 4 years, BBA is shaping the future of premium e-mobility in China; the forthcoming introduction of The All New BMW 530 Le iPerformance will represent further progress. The two BBA plants in Shenyang are highly flexible and capable of producing traditional combustion engine vehicles and NEVs on the same production line. Opened this year in July, BBA’s new R&D Center is set up for the development of NEVs and bespoke solutions for models tailored to the Chinese market.

BBA is not only expanding its e-mobility offerings but building a complete NEV ecosystem. This includes more than 200 BMW 4S/5S stores with NEV service capabilities in China. By the end of 2017, BMW customers will have access to a public charging network of 65,000 pillars across China.