Valeo and MAHLE have partnered to develop an innovative magnet-free electric axle system designed for high-performance electric vehicles in the upper segment, with maximum power ranging from 220 kW to 350 kW. The new iBEE (Inner Brushless Electrical Excitation) system aims to transform the performance and efficiency of magnet-free electric motors. Through a joint development agreement, Valeo contributes its expertise in electric motors, highly efficient inverters and motor controls, while MAHLE brings its advanced magnet-free rotor technology and contactless transmitter (MCT) technology.
Valeo and MAHLE are working on an innovative cooling concept to achieve an excellent continuous-to-peak power ratio. Furthermore, the carbon footprint is expected to be reduced by more than 40% compared to a permanent magnet electric motor of equivalent power. Testing of the first prototype will be completed by the end of 2024.
Xavier Dupont, CEO of Valeo’s Power Division, commented: “This collaboration with MAHLE is a perfect fit. MAHLE develops the EESM rotor and its brushless excitation system, while Valeo contributes its expertise in power electronics to provide precise control of the electric motor and brushless system integrated in our inverter. This partnership enhances Valeo’s EESM portfolio for the upper segment and plays an important role in driving the automotive industry towards more innovative and sustainable solutions.
“The two front runners of electrification are uniting in this project. The new e-axle will benefit from MAHLE’s expertise in contactless transmitter technology. Together we will set a new benchmark in packaging and efficiency for EESM-based e-axles and take the next step towards future mobility for our customers”, said Martin Wellhofer, member of the MAHLE Group Management Board.
Valeo’s first EESM development is based on a collaboration with a European OEM, launched in 2022, to create a new magnet-free electric motor generation (EESM). The initial goals of the project were twofold; The first to get an all-in-one architecture with new stator and cooling technology to increase power density by 30% compared to existing motors equipping the current OEM’s vehicles on the road. Secondly, reducing its carbon footprint by 30% compared to an electric motor equipped with magnets (PMSM). Thanks exclusively to Valeo inverter expertise, a validation phase of more than 6 months was successfully finished with results far exceeding initial expectations in terms of power and efficiency. The performances are matching the levels of permanent magnet electric motors for B/C segment vehicles with all the benefits of magnet-free technology (no rare earths, low carbon footprint, …).
As part of its electrification strategy MAHLE is focusing on developing electric drive systems. Its contactless transmitter technology for magnet-free electric motors is a testament to the company’s strong expertise in this field. Due to its high maturity level it is an important enabler for the next evolution of EESM based e-axles. Avoiding the use of rare earth materials not only contributes positively to the sustainability of e-mobility but is also beneficial in terms of cost and resource security. The key feature is inductive and thus contactless and wear free power transmission allowing motor operation at benchmark efficiency levels.
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