Mahle’s Threefold Approach for the Future: E-Mobility, Efficiency, and H2 Combustion Engines

In addition to the “perfect electric motor,” the Swabians are also presenting a new integrated thermal management module that reduces system complexity and is expected to enable 20 percent more range. And in the outdoor area of the event, we can test for the first time the inductive charging station developed in cooperation with Mahle and Siemens.

System competence is a crucial success factor in electrification, notes Franz at the event in the company's own hydrogen test center in Stuttgart. This is because the interaction of the individual components is significantly more complex in electric drives than in combustion engines. Mahle is presenting a new technology kit for electric motors that combines the advantages of the benchmark SCT and MCT electric motors. The “perfect motor” is intended to combine sustained high peak performance, contactless and thus wear-free power transmission, the elimination of rare earth elements, and maximum efficiency.

“Mahle will position itself as a system champion in electromobility,” says CEO Arnd Franz.

In addition, the supplier has developed a new thermal management module that brings together essential components of thermal management. This reduces installation space, development effort, and costs, and makes the overall system significantly more efficient: Up to 20 percent more range is possible – the battery needs to be charged less frequently.

New Products Before the IAA

Mahle will present both products to a broad audience for the first time at IAA Mobility. Other topics at the trade fair will include components for green internal combustion engines. The Stuttgart-based technology group positions itself as a globally operating partner of automobile manufacturers, open to various technologies based on the needs of global markets. Electrification and thermal management, as well as highly efficient, sustainable combustion engines, are the strategic focus.

“Electrification is the future topic for Mahle,” emphasizes Franz.

Battery-electric vehicles offer Mahle nearly triple the revenue potential of vehicles with internal combustion engines. The group is focusing in this area on electric drives and intelligent charging. The goal is to increase range and performance, as well as to advance fast charging capability and charging comfort.

At the same time, however, CEO Franz must admit that the company has not yet made any money in the e-mobility sector. Currently necessary investments far exceed profits, says Franz. He expects profits in this area only in four to five years.

Modular Motor Without Rare Earths

Over the past two years, Mahle has introduced two highly innovative electric motors: the MCT (Magnet-free Contactless Transmitter) which operates contactlessly and without rare earths, and the long-lasting SCT (Superior Continuous Torque) electric motor. Now, for the first time, the group is combining the features of both concepts in a technology modular system.

“With this unique modular system for electric motors, we can offer our customers customized solutions,” explains Franz.

In response to inquiries, Franz specified that Mahle is already in talks with several major automobile manufacturers and the engine will go into production in 2027.

Inductive Charging – in collaboration with Siemens

For charging infrastructure, Mahle relies on both wired solutions for long-term parkers (Mahle chargeBIG) and wireless charging – a convenient and promising alternative for electric vehicles. Together with Siemens, Mahle is developing a complete system comprising infrastructure and vehicle technology to set standards for inductive charging systems. During Tech Day, the automotive supplier presented a new automated positioning system for this charging technology.

We were able to test the system prototype and were immediately convinced by the simplicity of the charging solution. Shortly before the parking spot with the induction loop, the electric vehicle detects the charging opportunity and guides the driver into the correct position with simple arrows on the display. The vehicle and induction charger automatically couple and then start the charging process.

"Charging up to 11 kW is possible; fast charging is not practical with this solution," explains Volker Schall, Head of Inductive Charging System Design at Mahle. "It is still unclear when we will go into production with it. If a major electric vehicle manufacturer decides to opt for wireless charging, things could move very quickly."

Editor's note – inductive charging

The major electric vehicle manufacturer could soon make an appearance – Tesla recently acquired the Freiburg startup Wiferion. Wiferion had specialized in inductive charging solutions. It will be interesting to see when Tesla advances with wireless charging.