MAHLE develops new electric motor SCT E-motor to promote electric mobility

Automotive parts supplier Mahle Group has developed the most durable electric motor on the market, the SCT (superior continuous torque) E-motor, which is small, light, and highly efficient. It can be customized according to customer needs without the use of rare earths, can work for a long time, and has high performance. It is reported that the new motor will debut at the Hannover International Commercial Vehicle Show IAA in September 2022.

With the market launch of the new motors, MAHLE has become a full-line supplier in the field of electric drives, covering all requirements from e-scooters and passenger cars to heavy commercial vehicles, off-road vehicles, and applications in the industrial sector.

“It is easy to manufacture large electric motors with short-term high performance. But until now, the market has lacked a drive that is durable and compact enough to enable unrestricted everyday use of electric vehicles,” says Martin Berger, Vice President Research and Advanced Engineering at MAHLE. “Our new SCT E-motor is the solution to these requirements.”

Image source: MAHLE Group

In terms of powertrain, the SCT E-motor paves the way for all vehicles to replace internal combustion engines. In 2021, MAHLE launched a groundbreaking wear-free, scalable traction motor for passenger cars that operates efficiently over a wide speed range.

On the other hand, the SCT E-motor is designed in such a way that it is particularly efficient within a certain speed range. Despite its very compact and lightweight design, its continuous power can reach more than 90% of the peak power, compared to 50%-60% previously, which is unique on the market. Thanks to this, a wide range of electric vehicles can be used even under demanding conditions. So far, existing motors on the market have not been able to meet the requirements of some specific scenarios.

The gradual improvement of cooling technology has also made it possible for motor technology to develop by leaps and bounds. By using innovative integrated cooling oil, MAHLE's new motor is not only more durable, but also can use the waste heat generated for the entire system of the vehicle. At the same time, the extremely compact design of the new motor has advantages in terms of material and weight costs - lighter motors require less material during the manufacturing process and increase the possible net load of commercial vehicles.

Image source: MAHLE Group

When designing this product, MAHLE chose permanent magnet motors because they allow for a very compact design and do not require energy to be transferred to the rotor as an “excitation current”, making the motors more efficient and wear-free. Neodymium magnets are the strongest permanent magnets that can be produced and are used to generate the magnetic field in the motor. However, in order to reduce raw material prices and geopolitical influences on the supply chain, the SCT E-motor can also be designed to be rare earth-free. Thanks to the unique contactless transformer developed by the MAHLE Group, this rare earth-free version will also have the advantages of wear-free and efficient operation and only require slightly more assembly space.

In response to the question of "where the new motor will be produced", Dr. Harald Straky, Vice President of Automotive Electronics and Mechatronics at MAHLE Group, responded, "This will be determined by the needs and regions of our customers. We do business all over the world, so let's wait and see." According to Straky, some customers have shown great interest in this new motor.

Electric mobility is one of the important strategic areas of the MAHLE Group in the future. So far, more than 60% of the group's sales come from non-passenger car internal combustion engines. By 2030, this proportion will increase to 75%. The new motor will be an important part of the group's electrification strategy.