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Magnet Less Electric Motor With Enhanced Vehicle Power
Two companies have partnered to broaden the selection of magnet-free electric motors for high-end use cases.
Valeo and MAHLE are partnering to create a cutting-edge magnet-free electric axle system for high-end electric vehicles with a power range of 295 to 469 horsepower (220 to 350 kilowatts).
According to the company, Valeo’s technology relies on the effective collaboration with a European OEM to develop magnet-free electric motor technology (EESM—Externally Excited Synchronous Motor).
Cutting-edge tech can boost magnet-less motor efficiency
The companies are unveiling a cutting-edge technology called the inner Brushless Electrical Excitation (iBEE) system, which they believe can transform the performance and efficiency of magnet-free electric motors.
“This cooperation with MAHLE is a perfect match. MAHLE develops the EESM rotor and their brushless excitation system,” said Xavier Dupont, Valeo Power Division CEO.
Dupont emphasized that Valeo offers specialized management of the electric motor and brushless system integrated within the inverter.
Dupont stated that this collaboration enables Valeo to expand its EESM portfolio for the upper segment and is crucial in aiding the automotive industry’s shift towards more innovative and sustainable solutions.
New cooling concept to be innovatively designed
Both companies agreed to a Joint Development Agreement which merges Valeo’s electric motor knowledge, efficient inverters, and motor control laws with MAHLE’s expertise in magnet-free rotor and MAHLE Contactless Transmitter (MCT) technology.
The companies are developing a new cooling idea to achieve an excellent ratio of continuous to peak power.
Furthermore, the companies stated in a press release that the carbon footprint is projected to decrease by over 40% compared to a similar power permanent magnet electric motor.
Anticipated completion of initial prototypes by the end of 2024
It is anticipated that the testing of the initial prototypes will be finished by the conclusion of 2024.
Valeo’s initial EESM project involves partnering with a European OEM to introduce a new magnet-free electric motor generation (EESM) in 2022.
The company stated that the project’s primary goals were twofold: to achieve a unified architecture with a new stator and cooling technology, and to boost power density by 30% compared to the current motors used in OEM vehicles on the road.
Secondly, to reduce its carbon footprint by 30% compared to an electric motor with magnets (PMSM).
The company stated that a validation phase lasting over 6 months was completed successfully with power and efficiency results exceeding initial expectations, largely due to Valeo’s inverter expertise.
“The performances are matching the level of permanent magnet electric motors for B/C segment vehicles with all benefits of a magnet-free technology (no rare earth, lower carbon footprint…),” said Valeo in a press release.
Systems for powering vehicles using Electricity
MAHLE stated that their main focus has been on the development of electric drive systems. Its contactless transmitter technology is said to be the essential factor for the future development of EESM-powered e-axles, eliminating the need for magnets in electric motors.
The company highlighted that refraining from using rare earth materials benefits e-mobility sustainability, costs, and resource security.
MAHLE states that the main characteristic is the inductive power transmission, which is contactless and wear-free, enabling motor operation at a high efficiency level.
Martin Wellhoeffer, a member of the MAHLE Group Management Board, mentioned that the new e-axle will take advantage of MAHLE’s knowledge in contactless transmitter technology.
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