Following a successful collaboration with a European OEM on the development of magnet-free electric motor technology (EESM – Externally Excited Synchronous Motor), Valeo is expanding its range of magnet-free electric motors to include upper segment vehicles, in partnership with MAHLE.
Valeo and MAHLE have entered into a collaborative agreement to create a magnet-free electric axle system tailored for high-end electric vehicles, with potential outputs ranging from 220 kW to 350 kW. This system, known as the iBEE (inner Brushless Electrical Excitation), aims to transform both performance and efficiency in magnet-free electric motors.
The partnership merges Valeo’s proficiency in electric motors, high-efficiency inverters, and motor control laws with MAHLE’s expertise in magnet-free rotor technology, particularly through its MAHLE Contactless Transmitter (MCT) technology.
Together, they are developing an advanced cooling concept to achieve a superior continuous-to-peak power ratio. Additionally, the system is projected to reduce carbon emissions by over 40% compared to traditional permanent magnet electric motors of similar power. The first prototypes are expected to be tested by the end of 2024.
Valeo Power Division CEO Xavier Dupont discussed the collaboration with MAHLE, describing it as a perfect match. MAHLE is working on the EESM rotor and their brushless excitation system. Valeo contributes its expertise in power electronics to precisely control the motor and brushless system within their inverter. Dupont emphasized that this partnership is essential for Valeo to enhance its EESM offerings for premium segments and aids the automotive industry’s move towards more innovative and sustainable solutions.
Martin Wellhoeffer, from the MAHLE Group Management Board, also spoke about the project, highlighting that it brings together two leaders in electrification. The new e-axle will incorporate MAHLE’s advanced contactless transmitter technology. He noted that together, they plan to set new standards in packaging and efficiency for EESM-based e-axles, pushing their customers towards the future of mobility.
The initiative with a European OEM that started in 2022 marks Valeo’s first venture into developing a new generation of magnet-free electric motors, aiming to boost power density by 30% compared to existing motors and to decrease its carbon footprint by 30% compared to magnet-based electric motors (PMSM). After over six months of validation, the results have exceeded initial expectations, achieving performance comparable to permanent magnet motors in B/C segment vehicles while offering the advantages of magnet-free technology, such as the absence of rare earth elements and a reduced carbon footprint.
MAHLE’s focus on electric drive systems as part of its electrification strategy showcases its deep expertise in contactless transmitter technology for magnet-free motors. This technology, which is highly mature, plays a critical role in the evolution of EESM-based eAxles, offering cost-effective and resource-secure solutions without the need for rare earth materials. Its inductive, contactless, and wear-free power transmission ensures motor operation at optimal efficiency levels.
