Valeo, in collaboration with Mahle, is expanding its portfolio of magnet-free electric motors to cater to “upper-segment” vehicles. The partnership aims to develop a magnet-free electric axle system with peak power ranging from 220kW to 350kW, the companies said. The new technology, known as the iBEE system (inner Brushless Electrical Excitation), seeks to enhance the performance and efficiency of magnet-free electric motors.

Valeo and Mahle have signed a joint development agreement in which Valeo said it will contribute its knowledge in electric motors, inverters, and motor control, while Mahle will provide its experience with magnet-free rotors and Mahle Contactless Transmitter (MCT) technology. Together, they are also working on a new cooling concept to improve the continuous to peak power ratio, they said. The carbon footprint of this system is expected to be reduced by over 40% compared to a permanent magnet electric motor of equivalent power. Prototype testing is scheduled for completion by the end of 2024.

“This cooperation with Mahle is a perfect match. Mahle develops the EESM rotor and their brushless excitation system. Based on our power electronics know-how, Valeo provides a dedicated control of this electric motor and brushless system embedded in our inverter,” Xavier Dupont, Valeo Power Division CEO said. “This partnership allows Valeo to complete its EESM portfolio towards the upper segment and is key to supporting the evolution of the automotive industry towards more innovative sustainable solutions.”

“The new e-axle will benefit from Mahle’s expertise in contactless transmitter technology,” Martin Wellhoeffer, member of the Mahle Group management board. “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.”

Valeo said its initial EESM development began with a European OEM in 2022, focusing on creating a new generation of magnet-free electric motors. The project aimed to develop an all-in-one architecture with a new stator and cooling technology to increase power density by 30% compared to current motors. Additionally, it sought to reduce the carbon footprint by 30% compared to motors with magnets (PMSM). After a six-month validation phase, Valeo said the results exceeded expectations in terms of power and efficiency, matching the performance of permanent magnet electric motors for B/C segment vehicles.

Mahle said its focus on developing electric drive systems is part of its electrification strategy. By avoiding rare earth materials, the company said the technology contributes to the sustainability of e-mobility and offers cost and resource security advantages. The key feature is the inductive, contactless, and wear-free power transmission, allowing for motor operation at benchmark efficiency levels, Mahle said.