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 peak 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 control, while MAHLE brings its advanced magnet-free rotor technology and Contactless Transmitter (MCT) technology.
Valeo and MAHLE are working on an innovative cooling concept in order to achieve an outstanding continuous to peak power ratio. Moreover, the carbon footprint is expected to be reduced by more than 40% versus a permanent magnet electric motor of equivalent power. The testing of the first prototypes will be completed by the end of 2024.
Xavier Dupont, CEO of Valeo’s Power Division, commented: “This collaboration with MAHLE is an ideal 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 into our inverter. This partnership enhances Valeo’s EESM portfolio for the upper segment and plays a crucial role in driving the automotive industry’s shift toward more innovative and sustainable solutions.”
“In this project two front runners of electrification are joining forces. The new e-axle will benefit from MAHLE’s expertise in contactless transmitter technology. Together we will be setting a new benchmark in packaging and efficiency for EESM based e-axles and taking the next step for our customers towards future mobility”, said Martin Wellhoeffer, Member of the MAHLE Group Management Board.
Valeo’s first EESM development is based on a cooperation with a European OEM launched in 2022 in order to create a new magnet-free electric motor generation (EESM). The initial targets of the project were double; first to get an all-in-one architecture with a new stator and cooling technology in order to increase by 30% the power density compared to the current motors equipping the current OEM’s vehicles on the road. Secondly, to shrink its carbon footprint by 30% vs. an electric motor equipped with magnets (PMSM). A validation phase for more than 6 months was successfully ended with results level over the initial expectations in terms of power and efficiency especially thanks to Valeo inverter expertise. The performances are matching the level of permanent magnet electric motors for B/C segment vehicles with all benefits of a magnet-free technology (no rare earth, lower carbon footprint, …).
As part of its electrification strategy MAHLE has been focusing on developing electric drive systems. Its contactless transmitter technology for magnet-free electric motors is testament to the company’s strong expertise in this field. Thanks to its high maturity level it is a key enabler for the next evolution of EESM based e-axles. Avoiding the use of rare earth materials does not only positively contribute to the sustainability of e-mobility but is also advantageous in terms of costs and resource security. The key feature is the inductive and thus contactless and wear-free power transmission allowing motor operation at benchmark efficiency level.
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