Valeo and Mahle Develop Magnet-Free E-Axle
Valeo and Mahle are working together on a magnet-free electric axle for electric cars with peak powers of 220 to 350 kW. Tests of the first prototypes are expected to be completed by the end of 2024.
Exploded view of the iBEE system
Mahle GmbH
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Valeo and Mahle are jointly expanding their product portfolios for magnet-free externally excited synchronous machines (EESM), as announced by Mahle. Based on a development cooperation between Valeo and a European vehicle manufacturer in this area, Valeo now wants to enter the upper segments of electric vehicles together with Mahle.
To this end, the two companies want to join forces to develop a magnet-free e-axle that will be used in e-vehicles with peak outputs of 220 to 350 kW. With the technology of their new iBEE system (Inner Brushless Electrical Excitation), Valeo and Mahle want to optimize the performance and efficiency of magnet-free electric motors. In a recently signed joint development agreement, the two automotive suppliers have agreed to contribute their respective expertise to this project: Valeo for e-motors and inverters and Mahle for magnet-free rotors and its Mahle Contactless Transmitter (MCT) technology.
The partners also plan to develop a cooling concept to achieve the best possible ratio of continuous to peak power. Furthermore, the developers consider a reduction of the CO2 footprint of more than 40 % to be possible compared to a system with a permanent magnet electric motor of the same power. Tests on the first prototypes are expected to be completed by the end of 2024.
For Upper Vehicle Segments
Xavier Dupont, Valeo Power Division CEO, said: “This cooperation with MAHLE is a perfect match.
MAHLE develops the EESM rotor and their brushless excitation system. Based on our power electronics know-how, Valeo provides a dedicated control of this electric motor and brushless system embedded in our inverter. This partnership allows Valeo to complete its EESM portfolio towards upper segment and is key to support the evolution of the automotive industry towards more innovative sustainable solutions”.
Valeo’s first EESM project builds on a collaboration between Valeo and a European car manufacturer that has been ongoing since 2022 to develop a new generation of magnet-free electric motors (EESM). The project had two objectives: First, to develop an all-in-one architecture with a new stator and cooling system that can increase power density by 30 % compared to the current motors equipping the current OEM’s vehicles on the road. Second, to reduce the CO2 footprint by 30 % compared to an electric motor equipped with magnets (PMSM).
This is a partly automated translation of this[1] German article.