Valeo and Mahle expand their product range of magnet free E-motors

Mahle and Valeo are developing a magnet-free electric axle for high-performance EVs, boosting efficiency and cutting the carbon footprint by over 40%.

Stuttgart, Germany- Mahle GmbH., automotive parts manufacturer, and Valeo Inc., Mobility Technologies have partnered to develop a magnet-free electric axle system for high-performance electric vehicles, offering peak power between 220 kW and 350 kW. This innovative iBEE (inner Brushless Electrical Excitation) system combines Valeo’s expertise in electric motors and inverters with MAHLE’s magnet-free rotor technology. The system aims to boost efficiency and reduce the carbon footprint by over 40% compared to permanent magnet motors. The first prototypes will be tested by the end of 2024.

Mr. Xavier Dupont, Valeo Power Division CEO, said, “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. This partnership allows Valeo to complete its EESM portfolio towards upper segment and is key to support the evolution of the automotive industry towards more innovative sustainable solutions.'''

Mr. Martin Wellhoeffer, Member of the MAHLE Group Management Board, said, “In this project two front runners of electrification are joining forces. The new e-axle will benefit from MAHLE’s expertise in contactless transmitter technology. 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.”

In 2022, Valeo partnered with a European OEM to develop a new generation of magnet-free electric motors (EESM). The goals were to boost power density by 30% and reduce the carbon footprint by the same margin compared to magnet-based motors (PMSM). After a successful six-month validation phase, the motor exceeded expectations in power and efficiency, matching the performance of permanent magnet motors for B/C segment vehicles, while offering the advantages of magnet-free technology.

As part of its electrification strategy, MAHLE has developed contactless transmitter technology for magnet-free electric motors, a key enabler for next-gen EESM-based e-axles. This technology improves sustainability by eliminating rare earth materials, reducing costs, and ensuring resource security. Its inductive, contactless power transmission enables wear-free operation at top efficiency levels.