Market Overview

MAHLE Develops Highly Efficient Electric Motors for Auto Industry


MAHLE is developing high-voltage traction motors for fully electrified
vehicles (EVs) as well as 48-volt drive motors for new-generation

J.D. Kehoe, director of Product Development, Filtration and Engine
Peripherals for MAHLE Filter Systems in North America, said greater
internal combustion engine (ICE) downsizing, 48-volt hybridization, and
electric traction motors are all affecting powertrain development.

MAHLE produces high-voltage and low-voltage traction motors for
full-sized vehicles, as well as for off-road 2-wheel- and 4-wheel-drive
leisure vehicles.

"Downsized internal combustion engines, with higher compression,
advanced combustion, high boost and electrified turbocharger actuation
will be part of the automotive landscape for decades to come," Kehoe
said. "Smaller engines, for example, are expected to deliver 300
horsepower and 30 miles per gallon with a third less displacement."

The MAHLE Group has components on 50 percent of the vehicles annually
produced worldwide.

Kehoe noted that 48-volt electrical systems also are gaining acceptance.
To meet the challenge, MAHLE has developed electrified HVAC systems and
electric auxiliary components such as electric oil coolers and hydraulic
pumps. Even electrified riding mowers and material handling equipment
have become more common.

MAHLE's 48-volt drive systems are supplied with integrated electronics
to govern a typical output of 14 kW (19 horsepower) and have been
demonstrated on passenger vehicles such as the SMART.

EVs, whether Chevrolet Bolt, Nissan Leaf or Tesla, have achieved high
market profiles, though actual sales hover at two to three percent of
global deliveries, Kehoe said. On the other hand, analyst Alix Partners
estimates that by 2023 more than 205 EV models will have entered the

MAHLE's high-voltage traction motors for automobiles employ Imbedded
Permanent Magnet (IPM) technology. The motors are liquid-cooled and are
governed by MAHLE-designed-and-patented liquid-cooled controllers.

Manufacturers may specify voltages from 200 to 400 volts, based on a
motor's battery pack. Power delivered by each motor, up to 100 kW (134
horsepower), will depend on vehicle design.

MAHLE also offers automakers higher-voltage motors. These IPM motors
operate in the 400-800-volt range, with up to 96-percent efficiency and
peak power output up to 180 kW, or 240 horsepower. The design is
flexible and adaptable to customer requirements.


MAHLE is a leading international development partner and supplier to the
automotive industry. With its products for combustion engines and their
peripherals as well as solutions for electric vehicles, the group
addresses all the crucial issues related to the powertrain and air
conditioning technology—from engine systems and components to filtration
to thermal management. MAHLE products are fitted in at least every
second vehicle worldwide. MAHLE components and systems are also used off
the road—in stationary applications, for mobile machinery, rail
transport, as well as aerospace and marine applications.

More information is available at

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