Unity is strength. And in this case, it seems so. Two greats in the design of electric motors without permanent magnets have combined their knowledge to create an even more capable inductive electric motor. Mahle and Valeo have teamed up to introduce the Internal Brushless Electrical Excitation (iBEE) system. This electric machine eliminates the need for sensitive rare earths, promises good performance and greatly reduces life cycle carbon emissions.
Mahle has long been interested in motors without permanent magnets and in May 2021 it already showed an economical and efficient motor design without rare earths, the MCT, which replaces physical magnets and electromagnetic windings mechanically driven by brushes. This configuration eliminates the dependence on rare earths (and the supply, extraction and pricing issues that come with it), and also eliminates the physical wear and maintenance associated with physical brushes. Mahle says the MCT design also allows for more compact packaging by using fewer components.
For its part, French automotive supplier Valeo focused on stators and control systems for magnetless electric motors, working with Renault on its next-generation E7A motor design, scheduled to launch in 2027. Its copper winding technology with High power density yoke is integral to the E7A’s stator design.
The new joint development agreement between the two companies will combine Mahle’s magnetless rotor technology with Valeo’s motor control and inverter technology to create an even more advanced evolution of magnetless motor design for higher segment vehicles. The new iBEE will offer power between 220 and 350 kW (295 and 469 HP).
Mahle and Valeo also plan to work on an engine cooling system aimed at achieving a superior ratio between continuous and peak power. Mahle has used an oil cooling system as the backbone of its SCT engine, the ‘endurance champion’ that blurs the line between maximum and continuous power by running continuously at over 90% of maximum power. While the original SCT motor used permanent magnets, it was also designed to operate with the MCT inductive design.
The two companies aim to reduce the carbon footprint by more than 40% compared to a permanent magnet electric motor with equivalent power. Improves Valeo and Renault’s 30% reduction target for work on the E7A engine. And when will we have it? Valeo and Mahle are expected to complete initial testing of the prototype by the end of 2024.
