Aisin starts production of BMW Neue Klasse electric drive units in China

Aisin has begun production of electric drive units for BMW's Neue Klasse models at its plant in Tangshan, China, bringing a long-standing partnership between the two companies into the electric vehicle era.

The collaboration dates back to 2005, when Aisin and BMW began working together on six-speed automatic transmissions for petrol-powered cars. More than two decades later, the partnership has expanded into electric powertrain manufacturing.

Production network based on BMW standards

The Tangshan facility is part of a three-site manufacturing network established by BMW and Aisin to produce electric drive units for the Neue Klasse.

BMW's plant in Steyr, Austria, began production first in summer 2025, setting the benchmark for manufacturing processes and quality control. Aisin's Tangshan plant has now entered mass production, while its facility in the Czech Republic is expected to follow in 2027.

BMW's production and quality requirements have been adopted throughout the Tangshan operation. A dedicated project room has also been set up to coordinate the programme, with several BMW Supplier Quality Management (SQM) specialists based at the site.

BMW technical experts and senior executives from Germany have made repeated visits to oversee the project. Development and preparation took three years.

Nearly RMB 1 billion invested

Aisin has committed nearly RMB 1 billion (approximately RM 650 million) to the project, including a dedicated BMW production facility covering more than 30,000 square metres. The operation has a workforce of over 460 production staff, supported by more than 300 technical specialists involved in development and validation.

Under the arrangement, BMW is responsible for product development, while Aisin adapts its manufacturing capabilities to meet BMW's specifications. The Tangshan plant will produce electrically excited synchronous motors (EESMs), with production processes customised specifically for the BMW programme.

Tested for durability and extreme temperatures

Before reaching production, the electric drive units underwent an extensive validation programme combining BMW's own requirements with additional testing developed by Aisin.

The durability programme included more than 7,000 hours of testing under different operating conditions, simulating prolonged use and long-distance driving.

A further two million vibration and cyclic tests were conducted at varying frequencies to reproduce the stresses of real-world driving, from uneven roads and potholes to high-speed vibration and stone impacts.

The units were also tested across temperatures ranging from -40°C to 80°C to verify their ability to operate in both freezing and extremely hot conditions.

Quality checks at every stage of production

Quality control at the Tangshan plant covers both incoming components and finished products. Every incoming part is inspected, while each completed drive unit undergoes noise and functional testing, with particular attention paid to abnormal gear noise. More than 500 quality checkpoints are incorporated into the production process.

The facility also maintains tightly controlled manufacturing conditions. Its workshops follow Germany's VDA cleanliness standards and use air showers and vacuum cleaning equipment to limit airborne particles. Anti-static protection is installed throughout assembly areas handling sensitive electronic components, such as inverters.

Precision engineering in the motor and inverter

Several specialised processes are used in the production of the electric drive units.

For the stator, Aisin combines hairpin winding technology with drip impregnation to insulate the windings. Both the resin application and welding processes are automated. The rotor uses a high-speed winding process and vacuum potting with specialised encapsulation gel, helping to ensure precise control of the excitation current and a faster response.

The inverter is assembled in an ISO 8.0 cleanroom. Laser welding and OCT process monitoring are used, while AI-assisted inspection checks for surface defects and inconsistencies in adhesive application.

Reducing noise and vibration

Low noise and vibration are also key priorities in the development of the new electric drive units. Aisin has applied a range of measures to improve NVH (noise, vibration and harshness) performance.

These include low-noise gear design, optimisation of the motor housing's structure, vibration isolation and acoustic insulation. During machining, upgraded German precision gear-honing equipment is used to keep variations in the gear-tooth surface at the micrometre level, helping to reduce gear whine and ghost noise.

Each completed unit is then tested on a high-precision dynamometer rig. The tests cover the full operating speed range, as well as sudden acceleration and throttle lift-off, allowing engineers to assess noise and vibration under changing torque loads.

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