A revolutionary motor has been developed by Mahle, one of the world’s largest tier-one auto parts suppliers. Boasting the title of the “perfect motor,” this compact creation utilizes cutting-edge technology to achieve superior performance. Notably, it does not rely on rare earth magnets, operates with contactless power transmission, and is capable of running at high power levels without overheating.
The Mahle motor is the result of combining two impressive concepts introduced by the company in 2021 and 2022. Firstly, the Magnet-free Contactless Transmitter (MCT) motor was unveiled, which replaced traditional permanent magnets with a set of wound-coil electromagnets in the rotor. These electromagnets are powered through contactless induction. By adopting this approach, Mahle not only reduced material costs but also eliminated the need for relying on China, which controls 97% of the world’s rare earth metal supply. Additionally, the MCT motor demonstrated remarkable energy efficiency, operating at over 95% efficiency across a wide range of speeds – a level previously achieved only by Formula E race cars.
The second concept introduced by Mahle was the Superior Continuous Torque (SCT) motor, which introduced an innovative cooling system. Unlike conventional electric motors that have a significant gap between their peak power and continuous power ratings due to the risk of overheating, the SCT motor implemented a pioneering cooling mechanism. This system incorporates a central intake that delivers cooling oil to the middle of the rotor. The centrifugal force generated by the rotor then propels the oil outward and around the stator before passing through a radiator or another heat harvesting system. Consequently, the SCT motor achieves exceptional cooling efficiency, allowing it to operate consistently at 93-100% of its peak power. This not only enhances performance but also enables vehicle manufacturers to save space and weight with its compact design, eliminating the need for oversized motors to ensure performance under high temperatures.
The MAHLE Superior Continuous Torque SCT E Motor
Building upon these innovative breakthroughs, Mahle has combined the strengths of both the MCT and SCT motors to create the new “perfect motor.” Although it is currently unnamed, this motor incorporates the SCT’s cooling concept into the MCT’s magnet-free, induction-powered design. As a result, it retains the advantages offered by both systems, including exceptional efficiency, sustained high performance without overheating, extended lifespan, and the ability to harvest heat. Additionally, since it does not require permanent magnets, the production cost is expected to be affordable.
Mahle will be showcasing this remarkable invention as a “technology toolbox” for original equipment manufacturers (OEMs) at the IAA Mobility expo in Munich. However, the timeline for a commercial release depends on auto manufacturers. It is worth noting that Mahle itself places the phrase “perfect motor” in quotation marks in its press release, perhaps indicating a note of irony. Nevertheless, the company’s confidence in its creation is evident.
Source: Mahle
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