Vehicle OEM BMW is recalling around 83 electric vehicles after concerns faults made during the lithium-ion cell manufacturing process could cause short circuits in the battery packs.
The Voluntary Safety Recall, effective from July 21, follows three incidents in the vehicle manufacturer’s iX SUV (model Year 2022 – 2023) and i4 Gran Coupe vehicles that were produced between November 22, 2021 and July 30, 2022.
The batteries in those recalled vehicles were manufactured by Samsung SDI, according to The National Highway Traffic Safety Administration (NHTSA), an agency of the US federal government.
Analysis of Samsung’s production process showed debris may have entered the cells during manufacturing with additional analyses identifying cathode pieces within the cell.
A notice by NHTSA noted the high-voltage battery manufacturer may not have produced the battery to specifications and as a result, a short-circuit could occur and lead to a thermal event.
The NHTSA website advised motorists not to drive or charge their vehicles, and to park outside and away from structures until the remedy was complete.
A BMW spokesman told BEST: “As part of quality controls and investigations on a few field cases carried out by the BMW Group, it was found that, in very rare cases, a manufacturing defect occurred in the production process of the cells within a limited period of time.
“This manufacturing defect may lead to malfunctions in the high-voltage battery. In rare cases, these can lead to discharge of the cell and, in a worst case scenario, to a fire.”
Battery incidents
According to an NHTSA report, BMW became aware on 16 April of a non-US field incident involving a 2022 BMW i4 eDrive40.
An engineering investigation was initiated, and Samsung was contacted.
Analysis of the battery manufacture Samsung’s production records suggested an irregularity during the production process which may have allowed debris to enter into a battery cell with additional analyses identifying cathode pieces within the battery cell.
On June 3, BMW became aware of a US incident involving a Model Year 2022 iX xDrive50, and on 19 June, 2022, BMW became aware of a non-US field incident involving a 2022 BMW iX M60.
Similar analyses were performed, and similar findings were identified involving an irregularity during Samsung’s production process.
Vehicle assembly information and supplier production and process records were reviewed to determine the number, and production dates, of potentially affected vehicles.