The BMW Group has announced advancements with its sixth-generation eDrive technology, referred to as Gen6. This new technology is characterized by a 30 percent increase in charging speed and range, with certain models expected to exceed these figures. The Gen6 high-voltage battery concept incorporates 800V technology and will first be implemented in the Neue Klasse, eventually extending to the entire electric vehicle lineup of the BMW Group. The design of the Gen6 high-voltage batteries is innovative, allowing for integration across various vehicle models, including high-performance variants from BMW M GmbH. The batteries will serve as structural components in the Neue Klasse vehicles, utilizing a “pack-to-open-body” architecture, while the new cylindrical cells will be integrated in a “cell-to-pack” manner, enhancing energy density by 20 percent compared to the previous generation.
Central to this technology is the BMW Energy Master, a control unit located on the high-voltage battery. This unit manages the power supply for both high and low-voltage systems and facilitates safe operation of the battery. The BMW Group has developed both the hardware and software for the Energy Master internally, allowing for real-time updates through Remote Software Upgrades.
In line with a “local for local” strategy, the high-voltage batteries for the Neue Klasse will be assembled in five new production facilities situated near existing vehicle plants. These facilities are located in Irlbach-Straßkirchen (Germany), Debrecen (Hungary), Shenyang (China), San Luis Potosí (Mexico), and Woodruff (USA). This strategy aims to mitigate risks associated with unforeseen political and economic events while securing and creating jobs.
The production of Gen6 batteries adheres to the “cell-to-pack” and “pack-to-open-body” principles, which streamline the manufacturing process by eliminating intermediate steps. The Gen6 powertrain continues to utilize an electrically excited synchronous motor (EESM), which offers efficiency and consistent power output at high speeds. Additionally, the new system includes an asynchronous motor (ASM) at the front axle, providing a compact design and cost efficiency.
The EESM technology has been significantly upgraded, with improvements to the rotor, stator, and inverter, all designed for the new 800V architecture. This includes advancements in cooling systems and overall weight reduction. The inverter, developed in-house, converts DC power from the high-voltage battery to AC for the electric motor.
The Gen6 technology promises a 40 percent reduction in energy losses, a 20 percent decrease in costs, and a 10 percent reduction in weight compared to the previous generation, enhancing overall vehicle efficiency by approximately 20 percent. The modular manufacturing concept allows for flexible production of various electric drive variants, leading to economies of scale.
Production of the Gen6 electric drive systems is set to begin at the BMW Group Plant Steyr in summer 2025, with pre-production already underway. The facility, which has a history of producing combustion engines, will play a crucial role in the manufacturing of electric drive components, aiming for an annual production capacity of 600,000 units. By 2030, the plant will see significant investment to bolster its electric mobility capabilities, ensuring the long-term viability of jobs and expertise in the region.
