Eliminating reliance on rare earths and other critical raw materials, enhancing performance, and nearly halving CO2 emissions across the entire lifecycle—these are the promised benefits of the new prototype electric motor without permanent magnets, which Mahle and Valeo plan to unveil by the end of 2024.
The Franco-German partnership announced the project on October 14, focusing on the development of an innovative magnet-free electric axle system for premium electric vehicles. The new motor, known as iBEE (inner Brushless Electrical Excitation), will deliver peak power outputs ranging from 220 kW to 350 kW.
Valeo and Mahle’s Permanent Magnet-Free Electric Motor
Since 2022, Valeo has been advancing Externally Excited Synchronous Motors (EESM), focusing on wound rotor technology and advanced control systems. This expertise will be combined with Mahle’s Contactless Transmitter (MCT) technology, which relies on wireless induction. By eliminating the need for magnets and brushes, this approach addresses wear-and-tear and maintenance challenges while removing dependence on rare earths and associated supply risks.
Building on Previous Innovations
The collaboration builds on the legacy of Valeo’s work with Renault on the E7A motor, which featured an all-in-one architecture, innovative cooling systems, and improved stator design. That motor achieved a 30% increase in power density and a 30% reduction in carbon footprint compared to magnet-based motors.
With the new partnership, the goal is even more ambitious: a 40% reduction in lifecycle emissions. Additionally, Mahle and Valeo are working on a new cooling system to optimize the ratio between continuous and peak power. This system adapts Mahle’s SCT motor technology, which operates at over 90% of peak power, for use in the magnet-free motor.
A Step Forward for Future Mobility
“In this project, two pioneers in electrification are joining forces. The new e-axle will benefit from Mahle’s expertise in contactless transmitter technology,” said Martin Wellhoeffer, Mahle Board Member. “Together, we will set a new benchmark in packaging and efficiency for EESM-based e-axles, taking the next step toward future mobility for our customers.”