Valeo and Mahle are expanding their product offerings for magnet-free electric motors, specifically focusing on the development of an electric axle system with outputs of up to 350 kW. This collaboration follows a successful development partnership between Valeo and a European vehicle manufacturer in this technology area.
The partnership aims to create an innovative magnet-free e-axle designed for electric vehicles (EVs) with maximum outputs ranging from 220 to 350 kW. Both companies have set ambitious objectives, intending to enhance the performance and efficiency of magnet-free electric motors. While Mahle did not disclose specific efficiency targets, it indicated that the carbon footprint of the new system is expected to be reduced by over 40% compared to an equivalent permanent magnet electric motor. Additionally, it aims to achieve a 30% reduction in CO2 emissions and a 30% increase in power density compared to motors currently used in their vehicles.
Development work has already commenced, with the first prototype tests scheduled for completion by the end of 2024. A new cooling concept will also be implemented for this generation of electrically excited synchronous machines (EESM) to optimize the continuous to peak power ratio.
In this collaboration, Valeo will contribute its efficient inverters, while Mahle will provide its Mahle Contactless Transmitter (MCT) technology, which is integral to magnet-free rotors. “This cooperation with Mahle is a perfect match. Mahle develops the EESM rotor and their brushless excitation system. Based on our power electronics expertise, Valeo will provide dedicated control for this electric motor and brushless system embedded in our inverter,” stated Xavier Dupont, CEO of Valeo Power Division. “This partnership enhances Valeo’s EESM portfolio for the upper segment and is crucial for supporting the automotive industry’s shift towards more innovative and sustainable solutions.”
Martin Wellhoeffer, a member of the Mahle Group Management Board, emphasized the significance of the partnership, stating, “In this project, two leaders in electrification are joining forces. The new e-axle will benefit from Mahle’s expertise in contactless transmitter technology. Together, we will establish a new benchmark in packaging and efficiency for EESM-based e-axles, advancing our customers toward future mobility.”
