Automotive supplier Mahle has developed the most durable electric motor available. The traction motor, which is unique on the market, can run indefinitely with high performance. A new cooling concept makes this technological leap possible.
The new electric motor is surpassingly clean, light, and efficient and can be assembled without the use of rare earths by customer request. The new development is suitable for passenger cars and commercial vehicles as well as construction machines and tractors. With the superior continuous torque (SCT) E-motor, Mahle thus becomes a full-range provider in the field of electric drives and covers all needs from e-scooters to heavy-duty commercial vehicles as well as off-road and industrial applications. The new item will be presented for the first time at IAA Transportation in September 2022 in Hanover.
“Building large electric motors that deliver short-term high performance is easy. What was still lacking on the market until now were durable yet compact drives to make electric vehicles unrestricted for everyday use,” said Martin Berger, Director of Corporate Research and Advanced Engineering at Mahle.
On the drivetrain side, this clears the way for the replacement of the combustion engine in all vehicle classes. In 2021, Mahle presented a groundbreaking wear-free and scalable traction motor for passenger cars that runs very efficiently over a wide rpm range.
SCT E-motor, on the other hand, is designed in such a way that it is
particularly efficient within a certain rpm range. Despite its very compact and
light design, its continuous output is more than 90 percent of its peak output.
Unique on the market, this groundbreaking high ratio means a technological leap
and allows the use of electric vehicles of all kinds even under demanding
conditions. A classic example is driving an electric truck over mountain passes
or the multiple sprints of a battery electric passenger car. These scenarios
are only insufficiently covered by the electric motors available on the market
up to now.
resilience is achieved by the new Mahle electric motor through the use of an
innovative integrated oil cooling, which not only makes it more robust but also
allows the waste heat generated to be used in the vehicle’s complete system. At
the same time, the extremely compact design results in an advantage in the
costs of materials and weight—a lighter motor requires less material during
manufacture and increases the possible net load in commercial vehicles.
designing the product, Mahle opted for what is known as a permanently excited
motor, since this type enables a very compact design and no energy has to be
transferred to the rotor as “excitation current”. This makes the motor
efficient and wear-free. Neodymium magnets, currently the strongest permanent
magnets that can be produced, are used to generate the magnetic field in the
motor. However, to achieve greater independence from raw material prices and
geopolitical developments, the SCT E- motor can also be designed without
magnets for greater independence. Thanks to the unique contactless transformer
developed by Mahle, the magnet-free variant would also be wear-free and run
efficiently, while only requiring slightly more assembly space.
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