A major achievement for electric vehicle technology is that two leading automotive suppliers, Valeo and MAHLE, have partnered to build a novel EV motor that is free of magnets. The collaboration is based on the development of a new-generation electric axle system solution that is sustainable, innovative, and efficient in upper-segment electric cars.
This new engine is expected to transform the EV industry by removing the use of rare-earth magnets, which is a big ecological and materials issue, in addition to improving performance. In the following part, we will discuss the major factors of this innovative model of engagement.
The surprising way this motor removes the need for rare-earth magnets
Magnetic fields are needed in electric motors, and for many years, magnets have been used to provide this necessity. However, such magnets contain rare earth metals which are costly and pose a great threat to the environment.
Thus, with the help of the Externally Excited Synchronous Motor (EESM) technology, Valeo and MAHLE’s partnership wants to get rid of these materials. To this end, this motor design completely excludes the use of permanent magnets by incorporating a unique system referred to as the Inner Brushless Electrical Excitation (iBEE) technology.
Through the integration of Valeo power electronics and MAHLE’s advanced rotor design and contactless transmitter (MCT), the two companies are extending the performance of EV drive trains. The end product is a motor system that seeks to provide high efficiency, low emissions to the environment, and relatively low costs of production, making it convenient for the future of electric mobility.
These features make the new axle system revolutionary for EVs
The first goal of this cooperation is to develop a high-performance electric axle system for premium electric cars. The new system is designed to deliver peak power in the range of 220 kW to 350 kW (295 to 470 horsepower), which will be suitable for upper-segment EVs, powerful and efficient vehicles.
It also introduces a new cooling concept for the system that guarantees a continuous-to-peak power ratio for long-distance and high-performance driving. The new electric axle system also eliminates the use of magnets and incorporates a new technology that is expected to reduce carbon emissions greatly.
The carbon footprint of the new motor is anticipated to be above 40% less than that of other conventional motors that use permanent magnets, which will enhance the shift to environmentally friendly, efficient automobiles. The partnership of Valeo and MAHLE unites two automotive technology giants.
Valeo has a long experience in electric motors, inverters, and motor control systems, which, combined with MAHLE’s expertise in magnet-free rotors and contactless transmitter technology, will be beneficial for both parties. Together with these strengths, the companies plan to create a level of electrification of vehicles that has not been seen before.
A groundbreaking step towards sustainable electric mobility solutions
The latest technological advancement in electric axle systems is the magnet-free electric axle system, which has been developed by Valeo and MAHLE. Since prototype testing is expected to be done by the end of 2024, the companies are already on the journey to provide a solution that redefines the automotive industry.
The new motor system is free from the use of rare earth magnets and also holds the potential to offer better performance, costs, and environmental footprint. It is a perfect example of two automotive industry leaders coming together to work on the future of transportation.
With electric vehicles now established as the future of the car manufacturing industry, the growth of better and more sustainable technologies such as the Valeo-MAHLE magnet-free motor will help in driving the change of more efficient, eco-friendly vehicles for consumers across the world.
Therefore, the cooperation between Valeo and MAHLE can bring a new revolution to the electric vehicle market by providing an opportunity to replace motors made from expensive and toxic materials. The joining of forces of the two companies is paving the way for a new future of electric vehicles in terms of performance, efficiency, and sustainability, making the automotive industry’s transition to electric vehicles a reality.
