High performance and excellent dynamics

By producing different types of electric motors as well as corresponding electronic control units (ECU) and other components, such as graphic displays and master CAN, we can offer our customers complete battery-operated drive systems.

Various configurations can be defined according to the application. They are mainly used as traction systems, in electrically assisted steering systems, hydraulic pump drive systems, and for other purposes.

AC induction motors and ECU

MAHLE’s AC induction motors are four-pole motors with an aluminum cage rotor and three-phase winding on the stator. The stator and rotor laminations are specially designed for low-voltage applications used in different electric vehicles. Induction motors offer excellent dynamics over a wide speed range and very low noise operation. The motors are powered and controlled by an AC ECU, which converts the DC voltage to three-phase voltage at the required amplitude and frequency. Thanks to additional settings of the ECU parameters, it can be well adjusted to the requirements of various installations and applications.

Advanced diagnostics and communications are provided through the CANOpen bus. AC induction motors with corresponding ECUs represent the best traction solution for battery-powered electric vehicles, such as golf carts, airport luggage carts, small electric cars, and other applications. Several motors are available in higher IP protections. AC induction motor drives are available in both low- (24–80V) and high-voltage ranges (200–450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.

BLPM motors and ECU

MAHLE brushless permanent magnet motors with ferrite or rare earth magnets on the rotor combine high performance and reliability with a simple design, resulting in  optimal price-performance ratios. The multipole motors offer high efficiency (> 90%) over a wide speed range and high torque at low speeds. Using a special motor design, the cogging torque level is extremely low. The motor has no commutator and brushes, nor slots and windings on the rotor. This ensures very low acoustic noise and torque ripple. This type of motor is powered and controlled by separate or built-in BLPM ECUs, whose basic function is to provide the electronic commutation to stator phases based on the rotor position (detected by an integrated absolute encoder).

Communication from/to external electronic devices is done by using analog signals, digital I/O, PWM signals, or CANOpen communication. Integrating the ECU in the motor housing creates a single, compact drive unit. Typical applications for such motor versions are steering applications and small traction motor drives. BLPM drive systems are available in both low- (12–80V) and high-voltage ranges (200–450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.

E-paperDrive systems for battery supplied vehicles