Valeo and MAHLE have teamed up to create an innovative magnet-free electric axle system, targeting high-end electric vehicles with peak power output between 220 kW and 350 kW. The system, called the iBEE (inner Brushless Electrical Excitation), aims to improve the performance and efficiency of magnet-free electric motors.
Under a joint development agreement, Valeo brings its expertise in electric motors, inverters, and motor control systems, while MAHLE contributes its knowledge of magnet-free rotor technology and the MAHLE Contactless Transmitter (MCT). The collaboration also includes developing an advanced cooling system to optimize the continuous-to-peak power ratio. The motor is expected to reduce its carbon footprint by over 40% compared to conventional magnet-based electric motors. Prototype testing is set to finish by the end of 2024.
Valeo Power Division CEO Xavier Dupont highlighted that the collaboration combines MAHLE’s rotor and brushless excitation technology with Valeo’s power electronics expertise. This partnership allows Valeo to enhance its EESM portfolio for upper-segment electric vehicles.
MAHLE Group Board Member Martin Wellhoeffer emphasized the project’s significance in leveraging MAHLE’s contactless transmitter technology to set new benchmarks for efficiency and packaging in e-axle systems, contributing to future mobility advancements.
Valeo’s development of EESM technology began in 2022 with a European OEM, focusing on creating a magnet-free electric motor. The project achieved a 30% increase in power density and a 30% reduction in carbon footprint compared to magnet-equipped motors, all while maintaining performance levels similar to those of permanent magnet motors.
MAHLE has been focusing on electric drive systems and its contactless transmitter technology for magnet-free motors. This technology not only enhances sustainability by avoiding rare earth materials but also improves cost efficiency and resource security. Its inductive, contactless power transmission ensures the motor operates at high efficiency levels.
