Revolutionary magnet-free electric motor enhances EV power and reduces CO2 emissions by 40%.

The two companies are collaborating to create an innovative cooling solution designed to enhance the continuous-to-peak power ratio of their electric motor systems.

New Magnet-Free Electric Motor Set to Enhance EV Power, Slash CO2 Emissions by 40%
Updated: Oct 16, 2024 07:47 AM EST
By Prabhat Ranjan Mishra

Valeo and MAHLE are joining forces to broaden the application range of magnet-free electric motors, focusing on high-performance segments. They aim to develop an advanced magnet-free electric axle system specifically for upper-segment electric vehicles, offering peak power between 295 and 469 horsepower (220 kW to 350 kW).

This initiative builds upon successful collaborative work on magnet-free electric motor technology (Externally Excited Synchronous Motor, or EESM) with a European OEM.

Cutting-Edge Technology to Improve Motor Efficiency
The companies will introduce an inner Brushless Electrical Excitation (iBEE) system, a groundbreaking technology poised to enhance the performance and efficiency of magnet-free electric motors.

“This collaboration with MAHLE is a perfect fit, as MAHLE specializes in developing the EESM rotor and its brushless excitation system,” stated Xavier Dupont, CEO of Valeo’s Power Division. He emphasized Valeo’s expertise in controlling the electric motor and brushless system integrated within the inverter.

This partnership is crucial for Valeo to expand its EESM offerings into the upper segment, supporting the automotive industry’s shift towards more innovative and sustainable solutions, according to Dupont.

Joint Development Agreement for Innovative Cooling Concept
The companies have signed a Joint Development Agreement, combining Valeo’s strengths in electric motors, efficient inverters, and motor control with MAHLE’s expertise in magnet-free rotors and its Contactless Transmitter (MCT) technology. They are working on a novel cooling concept aimed at achieving an exceptional continuous-to-peak power ratio.

Additionally, they anticipate reducing the carbon footprint by over 40% compared to equivalent permanent magnet electric motors, as stated in a recent press release.

First Prototypes Set for Completion by End of 2024
Testing of the initial prototypes is expected to wrap up by the end of 2024. Valeo's first EESM development, initiated in 2022 in collaboration with a European OEM, aims to establish a new generation of magnet-free electric motors.

The project’s primary objectives are twofold: to create an all-in-one architecture featuring a new stator and cooling technology that boosts power density by 30% compared to current motors, and to reduce carbon emissions by 30% relative to permanent magnet motors (PMSMs).

Valeo claims that a validation phase lasting over six months yielded results exceeding initial expectations in terms of power and efficiency, thanks in large part to their inverter expertise.

“The performance levels are comparable to those of permanent magnet electric motors used in B/C segment vehicles while enjoying the benefits of magnet-free technology, including the absence of rare earth materials and a reduced carbon footprint,” Valeo announced.

Advancements in Electric Drive Systems
MAHLE has emphasized its focus on developing electric drive systems, asserting that its contactless transmitter technology for magnet-free electric motors is pivotal for the next generation of EESM-based e-axles. By eliminating rare earth materials, MAHLE contributes to e-mobility sustainability while also enhancing cost-effectiveness and resource security.

The standout feature of this technology is its inductive, contactless, and wear-free power transmission, which enables motor operation at optimal efficiency levels.

Martin Wellhoeffer, a member of the MAHLE Group Management Board, expressed confidence that the new e-axle will leverage MAHLE’s expertise in contactless transmission technology.

“Together, we will establish a new benchmark for packaging and efficiency in EESM-based e-axles, advancing our customers’ journey toward future mobility,” Wellhoeffer concluded.