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  • Writer's pictureNATALIA SOUSA

The highly efficient magnet-free electric motor developed by Mahle

MAHLE says it is currently developing a new kind of magnet-free electric motor that does not require rare earth elements. This makes production more environmentally sustainable and brings advantages in terms of costs and resource security. The central feature of the new motor is the inductive and thus contactless power transmission—this allows the motor to operate wear-free and particularly efficiently at high speeds. The efficiency is above 95% at almost all operating points—a level previously has only been achieved by Formula E racing cars. MAHLE has thus succeeded in combining the strengths of various electric motor concepts in one product. This new development is easily scalable, so it can be used in anything from subcompacts to commercial vehicles.

“With our new electric motor, we’re living up to our responsibility as a sustainably operating company,” says Michael Frick, Chairman of the MAHLE Management Board (ad interim) and CFO. “Dispensing with magnets and therefore the use of rare earth elements offers great potential not only from a geopolitical perspective but also concerning the responsible use of nature and resources.”

“Our magnet-free motor can certainly be described as a breakthrough because it provides several advantages that have not yet been combined in a product of this type,” says Dr Martin Berger, Vice President Corporate Research and Advanced Engineering at MAHLE. “As a result, we can offer our customers a product with outstanding efficiency at a comparatively low cost.”

The new traction motor from MAHLE is highly efficient—at almost all operating points—and demonstrates these advantages in segments where vehicles are primarily operated in real road traffic.

The new electric motor is also characterized by a high degree of durability because the necessary transmission of electrical currents between the rotating and stationary parts inside the motor takes place without contact and is therefore wear-free. This makes the engine maintenance-free and suitable for a wide range of applications.

MAHLE uses an innovative simulation process in which various motor designs are adjusted along different parameters until an optimum is found during its development. This approach is significantly faster and cheaper than conventional processes. In this way, MAHLE is helping to quickly create the necessary technical conditions to advance e-mobility sustainably worldwide.

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