Valeo And MAHLE Join Forces To Develop A Magnet-Free Electric Axle System
This innovative development could make Valeo and Mahle revolutionaries
Valeo is expanding its portfolio of magnet-free electric motors in collaboration with MAHLE, building on their successful joint development of the Externally Excited Synchronous Motor (EESM) technology.
This partnership aims to create an innovative magnet-free electric axle system designed specifically for upper segment electric vehicles, with peak power outputs between 220 kW and 350 kW. The new iBEE system (inner Brushless Electrical Excitation) promises to enhance performance and efficiency in magnet-free motor applications.
Moreover, under a Joint Development Agreement, Valeo will leverage its expertise in electric motors and high-efficiency inverters, while MAHLE will contribute its advanced magnet-free rotor technology, including the MAHLE Contactless Transmitter (MCT). Both companies are also developing a pioneering cooling concept to optimise the continuous to peak power ratio of the system.
Notably, this collaboration is expected to reduce carbon emissions by over 40 percent compared to conventional permanent magnet electric motors of similar power. The first prototype tests are set to conclude by the end of 2024.
Xavier Dupont, CEO of Valeo’s Power Division, also emphasised the synergy between Valeo and MAHLE, stating, “This partnership is a perfect match. MAHLE excels in developing the EESM rotor and the brushless excitation system, while Valeo offers dedicated control for this electric motor and brushless system through our advanced inverters.”
On top of that, he concluded by saying, “Together, we are expanding our EESM portfolio to meet the demands of the upper segment and advancing the automotive industry towards more sustainable solutions.”
Valeo’s initial EESM development, launched in 2022 with a European OEM, aimed to create a next-generation magnet-free electric motor. The project focused on two main goals, namely, achieving an all-in-one architecture that improves power density by 30 percent and reducing the carbon footprint by 30 percent compared to permanent magnet motors.
After a successful six-month validation phase, the results exceeded initial expectations, demonstrating power and efficiency levels comparable to traditional permanent magnet electric motors, while benefiting from a magnet-free design that eliminates reliance on rare earth materials.
MAHLE’s emphasis on developing electric drive systems and its expertise in contactless transmitter technology underscore its commitment to advancing e-mobility. The inductive, contactless power transmission ensures wear-free motor operation at benchmark efficiency levels, enhancing the sustainability and cost-effectiveness of future electric vehicles.
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