A significant development in electric vehicle (EV) technology has emerged from a partnership between leading automotive suppliers Valeo and MAHLE, who are collaborating to create an innovative EV motor devoid of magnets. This partnership is focused on delivering a new-generation electric axle system that promises to be sustainable, efficient, and suitable for high-end electric vehicles.
The new motor arises from a growing need within the EV industry to address the environmental and economic challenges posed by rare-earth magnets, which have long been integral to electric motors. These magnets are not only costly but also environmentally hazardous. Speaking about the technological innovation, Valeo and MAHLE aim to eliminate the requirement for these magnets by employing Externally Excited Synchronous Motor (EESM) technology. This cutting-edge design incorporates a distinctive system dubbed Inner Brushless Electrical Excitation (iBEE), which altogether removes the reliance on permanent magnets for generating necessary magnetic fields.
Through the collaboration, Valeo's expertise in power electronics combines with MAHLE's advancements in rotor design and contactless transmitter (MCT) technology, leading to a motor system that enhances the efficiency of EV drive trains. The projected output ranges from 220 kW to 350 kW (approximately 295 to 470 horsepower), positioning the system to cater to the needs of premium electric vehicles characterised by pinnacle performance and efficiency.
Additionally, the novel cooling method integrated into this electric axle system enables maintaining optimal performance across various driving conditions, including prolonged distances and high-performance scenarios. This technological blend is anticipated to reduce carbon emissions by more than 40% compared to traditional motors reliant on permanent magnets, thus contributing to the ongoing transition towards more environmentally friendly transportation solutions.
Valeo, recognised for its extensive background in electric motors, inverters, and motor control systems, and MAHLE, known for its innovation in magnet-free rotors and contactless transmitting technologies, are pooling their resources and expertise to catalyse the evolution of vehicle electrification. The partnership has set a timeframe for prototype testing to be conducted by the end of 2024, signalling a serious commitment to redefining automotive capabilities.
The development of this magnet-free electric axle system not only highlights a major shift in electric vehicle manufacturing but also illustrates the increasing importance of collaboration within the automotive industry. This joint effort by Valeo and MAHLE signals a potential breakthrough in creating more efficient, cost-effective, and sustainable electric vehicles, which are quickly becoming the mainstream expectation for consumers around the globe. As the automotive industry continues its transition towards electric vehicles, this partnership may pave the way for broader adoption of innovative technologies that emphasise performance and environmental responsibility.
Source: Noah Wire Services