The magnet-free induction motor is intended to almost halve CO2 emissions

Two great minds in the development of permanent magnet-free motors are combining their know-how to develop an even more powerful inductive electric motor. Mahle and Valeo have teamed up to introduce the so-called Inner Brushless Electrical Excitation System (iBEE), a type of electric machine that eliminates the use of sensitive rare earths, promises strong performance and reduces carbon emissions over the entire life cycle directly from a high, steep point cliff.

We've been closely monitoring Mahle's work in permanent magnet-free motors since he introduced a cheaper, more efficient rare earth-free motor design in 2021. The German automotive supplier uses wireless induction with a rotor configuration it calls magnet-free contactless transmitter (MCT).

The MCT system replaces the physical magnets and mechanical brush-operated electromagnetic windings commonly used in motor rotor designs with wound coils that are magnetized by inductive electricity sent from a wireless transmitter. The facility not only eliminates reliance on rare earths and associated supply, mining and pricing issues, but also eliminates the physical wear and tear and necessary maintenance associated with physical brushes. According to Mahle, the MCT layout also allows for more compact packaging thanks to the use of fewer components.

For its part, French automotive supplier Valeo has focused on magnet-free stators and control systems for electric motors and is working with Renault on its next-generation E7A engine design, scheduled for launch in 2027. Its power-dense hairpin copper winding technology is integral to the E7A's stator design.

Mahle

The new joint development agreement between the two companies will combine Mahle's magnet-free rotor technology with Valeo's inverter and motor control technology to create an even more advanced evolution of magnet-free motor design for high-end vehicles. The new iBEE axle offers a power range between 220 and 350 kW (295 and 469 hp).

Mahle and Valeo also plan to work on an engine cooling system to achieve a better ratio of continuous to peak power. Mahle has used an oil cooling system as the backbone of its SCT engine, the “endurance champion” that blurs the line between peak and sustained power by running continuously at over 90% peak power. While the original SCT motor used permanent magnets, it was also designed to operate with the MCT inductive layout.

The two companies' goal is to reduce the overall carbon footprint by more than 40% compared to a permanent magnet electric motor of the same power. That's a further improvement on the 30 percent reduction target of Valeo and Renault's work on the E7A engine.

Valeo and Mahle plan to complete the first prototype tests by the end of 2024.

Source: Mahle/Valeo