The automotive behemoths Mahle and Valeo have announced a collaboration to create a ground-breaking magnet-free electric motor system, marking a major advancement towards sustainable mobility. When compared to conventional permanent-magnet motors, this cutting-edge technology, called the Inner Brushless Electrical Excitation (iBEE) system, promises to significantly reduce carbon emissions by nearly 40%. Through this partnership, the production of electric motors will no longer require rare earth minerals, which has the potential to completely transform the automotive sector and improve vehicle efficiency.
The iBEE System: A Closer Look
The iBEE system represents a major advancement in electric motor design. Mahle’s Magnet-free Contactless Transmitter (MCT) technology replaces conventional permanent magnets with wound coils that are magnetized through inductive electricity. This shift not only reduces reliance on rare earth materials but also mitigates issues related to supply chain volatility and environmental concerns associated with mining. The MCT design allows for a more compact motor configuration, enhancing efficiency and integration into various vehicle models.
Valeo contributes its expertise in electric motor control technologies, having previously collaborated with Renault on the next-generation E7A motor, set for release in 2027. Their advancements in hairpin copper winding technology are crucial for achieving higher power density in electric motors. Together with Mahle, they aim to develop the new iBEE magnet-free electric axle, specifically targeting upper-segment electric vehicles.
Performance and Efficiency Goals
The iBEE axle is designed to deliver an impressive output range of 220 to 350 kW (approximately 295 to 469 hp), making it a competitive option for high-performance electric vehicles. The partnership also focuses on enhancing the motor’s cooling system to achieve an optimal continuous-to-peak power ratio. Mahle’s expertise in oil cooling, combined with the innovative design of the iBEE system, is expected to blur the lines between peak and continuous power, ensuring efficient operation under various conditions.
The ambitious goal of this collaboration is not only to enhance performance but also to significantly reduce the overall carbon footprint of the motor. By aiming for a reduction of more than 40% compared to traditional permanent-magnet motors, Mahle and Valeo are setting new benchmarks in sustainability within the automotive sector.
The ambitious goal of this collaboration is not only to enhance performance but also to significantly reduce the overall carbon footprint of the motor. By aiming for a reduction of more than 40% compared to traditional permanent-magnet motors, Mahle and Valeo are setting new benchmarks in sustainability within the automotive sector.
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Prototypes and Future Developments
Both companies are moving swiftly with their project timeline, expecting initial prototype testing to be completed by the end of 2024. This rapid development reflects their commitment to advancing electric vehicle technology while promoting sustainability. The collaboration is not just about creating a high-performance electric motor; it also aims to foster innovation in magnet-free technologies across the automotive industry.
Valeo’s previous experience in developing the Externally Excited Synchronous Motor (EESM) has laid a strong foundation for this new project. The initial targets focus on creating a new magnet-free electric motor architecture while significantly reducing carbon emissions.
The Impact of Magnet-Free Technology
Mahle’s innovations demonstrate how important sustainable practices are to e-mobility. In addition to improving sustainability, the lack of rare earth elements decreases expenses and lessens the danger to resource security. Mahle’s leadership in electric drive systems is further cemented by the MCT technology’s inductive and contactless power transmission capabilities, which guarantee high efficiency levels.Member of the Mahle Group Management Board Martin Wellhoeffer stressed that Mahle’s experience in contactless transmitter technology would be very helpful to their new e-axle, which would set a new benchmark for magnet-free motor performance.
The collaboration between Mahle and Valeo represents a turning point in the search for environmentally friendly transportation options. They are meeting the changing needs of the automobile industry and promoting a greener future by creating cutting-edge magnet-free motors that drastically cut carbon emissions. With continued development and prototype testing, this partnership has the potential to completely rethink sustainability and efficiency in the design of electric vehicles.
