Two companies have collaborated to expand the product range of magnet-free electric motors to higher-end applications.

Valeo and MAHLE will develop an innovative magnet-free electric axle system aimed at high-end electric vehicles with peak power from 295 to 469 hp (220 kW to 350 kW).

Valeo’s technology is based on the successful joint development of magnet-free electric motor (EESM) technology with a European OEM, the company said.

Groundbreaking technology can increase the efficiency of magnet-free electric motors

The companies are introducing an in-house Brushless Electrical Excitation (iBEE) system, an advanced technology that they claim could revolutionize the performance and efficiency of magnet-free electric motors.

“This collaboration with MAHLE is a perfect match. MAHLE is developing the EESM rotor and their brushless excitation system,” says Xavier Dupont, CEO of Valeo Power Division.

Dupont emphasized that Valeo offers special control over this electric motor and the brushless system embedded in the inverter.

This partnership allows Valeo to complete its EESM portfolio towards the high end and is crucial to support the automotive industry’s evolution towards more innovative sustainable solutions, Dupont said.

Develop an innovative cooling concept

Both companies have signed a joint development agreement to combine Valeo’s expertise in electric motors, high-efficiency inverters and associated motor control laws and MAHLE’s expertise in magnet-free rotors with its MAHLE Contactless Transmitter (MCT) technology.

The companies are working on an innovative cooling concept to achieve an excellent continuous-peak power ratio.

In addition, the carbon footprint is expected to be reduced by more than 40% compared to a permanent magnet electric motor of equivalent power, the companies said in a press release.

The first prototypes are expected to be ready by the end of 2024

Testing of the first prototypes is expected to be completed by the end of 2024.

The first EESM development by Valeo is based on a collaboration with a European OEM launched in 2022 to create a new magnet-free electric motor generation (EESM).

The company claimed that the original objectives of the project were twofold; the first to feature an all-in-one architecture with a new stator and cooling technology to increase power density by 30% compared to the current engines that power current OEM vehicles on the road.

Secondly, to reduce the CO2 footprint by 30% compared to an electric motor equipped with magnets (PMSM).

The company also claimed that a validation phase of more than six months was successfully completed with results exceeding initial expectations in terms of power and efficiency, mainly thanks to Valeo’s expertise in inverters.

“The performance corresponds to the level of permanent magnet electric motors for B/C segment vehicles, with all the benefits of a magnet-free technology (no rare earth metals, lower CO2 footprint…),” Valeo said in a press release.

Electric drive systems

MAHLE claimed that it was focusing on the development of electric propulsion systems. Contactless transmitter technology for magnet-free electric motors is claimed to be the key enabler for the next evolution of EESM-based e-axles.

The company emphasized that avoiding the use of rare earth metals not only contributes positively to the sustainability of e-mobility, but is also beneficial in terms of costs and resource security.

The most important feature is the inductive and therefore contactless and wear-free power transmission, which allows the motor to operate at the highest level of efficiency, according to MAHLE.

Martin Wellhoeffer, member of the MAHLE Group Management Board, stated that 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 for our customers towards future mobility,” said Wellhoeffer.