German parts supplier Mahle recently said it has developed a new technology for electric vehicle motors that can operate at high power and maximum efficiency without the need for magnets and rare earth elements.
The motor technology portfolio developed by Mahle brings together the advantages of its benchmark products SCT (ultra-high continuous torque) motors and MCT (magnetic non-contact power transmission) motors. The result is a "perfect motor" that combines long-lasting high peak power, contactless and therefore wear-free power transmission, no need for rare earths and maximum efficiency.
In the "MAHLE 2030+" corporate strategic framework, electrification is one of the future strategic areas. The other two areas are thermal management and efficient and clean internal combustion engines.
Both the MCT magnetless motor and the SCT ultra-high continuous torque motor can operate without contact and do not require rare earths. They are Mahle's recent innovations in the field of electric drive. MCT technology that does not require rare earths not only makes production more environmentally friendly, but also has advantages in terms of cost and raw material security. The motor is particularly efficient in almost any operating condition, and its efficiency advantages are fully demonstrated in the most common real-world traffic situations.
Durability is a major feature of MCT motors, because the current transmission between the rotating and fixed parts inside the motor is non-contact, so no wear occurs. Because of this, the motor is maintenance-free and has a particularly wide range of applications. MAHLE's SCT electric motors are the most durable in their class, capable of high power output indefinitely. To achieve this technological leap, new cooling technology is indispensable. Innovative integrated oil cooling technology not only makes the motor reliable and durable, but also enables the utilization of waste heat in the entire vehicle system. The small size, light weight and high efficiency of this new motor make it second to none in its class. The extremely compact design also brings material cost and weight advantages - the lighter motor requires less material in production, while increasing the payload of commercial vehicles.
MCT motors exhibit extremely high efficiency in a wide range of speed and torque; while SCT motors are designed to achieve the highest efficiency at optimized main operating points. Another advantage of this lightweight and compact motor is its continuous output of 93% to 100% of peak torque, which has been proven by testing. This unprecedented and unprecedented high output ratio enables it to be applied to various electric vehicles, even under very harsh working conditions, such as electric trucks traveling over mountains and pure electric cars repeatedly accelerating rapidly, etc. .
So far, there are very few motors on the market that can cope with such application scenarios.
Extended reading - the following reports on this matter in 2021:
Breakthrough magnetless motor does not use any rare earth materials and has an efficiency of over 95%
German automotive powertrain supplier Mahle is developing a magnetless electric motor it says will operate at over 95% efficiency in almost all operating conditions. The motor uses induction technology (and therefore contact-free, wear-free and maintenance-free) to transmit power between the fixed and rotating parts of the motor.
Asynchronous motors use field coils in the rotor to generate a magnetic field, Mahle said, combining the different technical advantages of one electric motor. It does not use any rare earth materials, is environmentally attractive, and offers advantages in terms of cost and resource security.
This magnetless motor is certainly a breakthrough as it offers several advantages that have not yet been combined in a product of this type, offering customers a product with outstanding efficiency at a relatively low cost.
Energy is transferred to the rotor via an alternating field. The energy is converted into direct current to power the electromagnetic coil, eliminating the need for permanent magnets. The coil induces a magnetic field in the motor's air gap, which creates torque. The magnetic field can be easily controlled depending on the operating point. For more cutting-edge technology research visit: https://byteclicks.com
The rugged motor technology is primarily targeted at automotive drivetrains and is said to be scalable and can be used in anything from small passenger cars to large commercial vehicles. It is expected to be several years before the technology can be commercialized.
