Paris Motor Show 2024: Valeo and Mahle Also Develop Electric Motors for Luxury Cars
Based on the successful joint development of magnet-free electric motor technology (EESM - Externally Excited Synchronous Motor) with a European OEM, Valeo is now expanding its portfolio of magnet-free electric motors for upper segment vehicles in collaboration with Mahle. The two companies are combining their strengths to jointly develop an innovative magnet-free electric axle, intended for use in electric vehicles with peak power outputs ranging from 220 to 350 kW. With the technology of their new iBEE System (Inner Brushless Electrical Excitation – inner brushless electrical energy transmission), the companies aim to revolutionize the performance and efficiency of magnet-free electric motors. In a recently signed joint development agreement, both automotive suppliers have agreed to contribute their respective expertise to this project: Valeo for e-motors and high-efficiency inverters, and Mahle for magnet-free rotors with its Contactless Transmitter (MCT) technology. Additionally, the partners will develop an innovative cooling concept to achieve an outstanding ratio of continuous to peak power. Furthermore, the developers consider a reduction in CO2 footprint by more than 40 percent compared to a system with a permanently excited e-motor of the same output to be possible. Testing of the first prototypes is expected to be completed by the end of 2024.
"This collaboration is the perfect match. Mahle develops the EESM rotor and its brushless excitation system. Based on its expertise in power electronics, Valeo provides the control of the electric motor and the brush-free system, which is integrated into Valeo's inverter. This partnership allows Valeo to expand its EESM portfolio towards upper vehicle segments and is key to developing more sustainable solutions for the automotive industry," believes Xavier Dupont, Valeo Power Division CEO.
"Two pioneers of e-mobility join forces," says Martin Wellhöffer, a member of the Mahle Group Management Board. The new electric axle will benefit from the Swabians' technological expertise in magnet-free contactless transmitters. He promises new benchmarks for space and efficiency of EESM-based electric axles.
First Project Running Since 2022
Valeo's first EESM project builds on a collaboration with a European car manufacturer that has been ongoing since 2022, aimed at developing a new generation of magnet-free electric motors (EESM). The first objective is to develop an all-in-one architecture with a new stator and new cooling system, which can increase the power density compared to the current vehicle engines of the manufacturer by 30 percent. Secondly, they aim to reduce the CO2 footprint by 30 percent compared to permanently excited electric motors.
Thanks primarily to Valeo's inverter expertise, they have exceeded expectations in terms of performance and efficiency following a successful six-month validation phase, according to the statement. The results correspond to the characteristics of permanently magnet-excited electric motors for small car and compact segments, while offering all the advantages of magnet-free technology, such as the elimination of rare earth elements and a lower CO2 footprint, as the French supplier boasts. Mahle sees a crucial key for the next evolutionary stage of EESM-based electric axles due to the high maturity of the technology.
```Translated automatically from German."The elimination of rare earth elements is not only a positive contribution to the sustainability of e-mobility but also brings advantages in terms of costs and resource security. A key feature is the inductive and thus contactless power transmission – it allows the motor to operate wear-free and enables an efficiency that sets new standards," the Swabians promote.
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