MAHLE Makes Highly Efficient Electric Motors for EVs

Mahle has announced that it is working on the development of highly efficient high-voltage traction motors that are meant to be used in fully electrified vehicles (EVs) and 48-volt drive motors for new-generation hybrids.

J.D. Kehoe, director of Product Development, Filtration and Engine Peripherals for MAHLE Filter Systems in North America, said that some of the new trends that are affecting development of powertrains include greater downsizing of internal combustion engines (ICE), 48-volt hybridization, and electric traction motors. MAHLE makes high-voltage and low-voltage traction motors for full-sized vehicles, and for 2-wheel- and 4-wheel-drive leisure vehicles which are used offroad.

Kehoe said that downsized internal combustion engines which have higher compression ratios, advanced combustion techniques, high boost and electrified turbocharger actuation will soon become a part of the automotive landscape. Kehoe added, “Smaller engines, for example, are expected to deliver 300 horsepower and 30 miles per gallon with a third less displacement.”

The MAHLE Group makes components which are used in 50 percent of the vehicles which are made across the globe every year.

According to Kehoe, 48-volt electrical systems are slowly gaining greater acceptance. Mahle had developed electrified HVAC systems and electric auxiliary components like electric oil coolers and hydraulic pumps to meet this surge in popularity of 48-volt electrical systems. Electrification has become more common even in the case of electrified riding mowers and material handling equipment.

MAHLE’s 48-volt drive systems come with integrated electronics and generally have an output of 14 kW (19 horsepower). They have been showcased on passenger vehicles like SMART. Kehoe said that EVs like the Chevrolet Bolt, Nissan Leaf and Tesla models have been in the news a regular basis though their sales actually account for only two to three percent of global deliveries. Many studies, including one by analyst Alix Partners project that by 2023 over 205 EV models will enter the market.

MAHLE’s high-voltage traction motors for automobiles use Imbedded Permanent Magnet (IPM) technology. They are liquid-cooled and can be controlled through liquid-cooled controllers which MAHLE has designed-and-patented.
Manufacturers can specify voltages ranging from 200 to 400 volts, which are based on a motor’s battery pack. The power delivered by each motor, up to 100 kW (134 horsepower), will depend on vehicle design.