Technology
Compact electric motors for e-Mobility
Axial Flux Motors: A strategic Breaktrough
Axial flux motors deliver superior power and torque density in a smaller, lighter package, directly addressing key challenges like space and efficiency.
Due to their higher torque density, lower RPM’s are needed to produce power compared to traditional radial flux motor, making them an ideal choice in multiple industries, where with traditional radial flux motor, you would need a multiple stage reduction which adds complexity and lowers efficiency.
When comparing axial flux motors to radial flux motors, one of the standout advantages of axial flux technology is its potential for higher efficiency. Axial flux motors eliminate the need for a gearbox, which significantly reduces mechanical losses and friction. This direct-drive design enhances energy transfer, leading to greater overall efficiency.
In contrast, radial flux motors typically incorporate gearboxes, which introduce additional friction and energy losses. This setup can impact the efficiency of power delivery and contribute to a heavier and bulkier system.
Moreover, axial flux motors often benefit from a more compact and lighter design, contributing further to their efficiency. Their improved thermal management also helps minimize energy losses due to heat.
Overall, axial flux motors can offer efficiency improvements of 5-15% compared to radial flux motors with gearboxes, making them a compelling choice for applications where maximizing energy efficiency is crucial.
How it works?
Electrical machines are typically categorized as either radial or axial flux machines.
Radial flux machines have been prevalent for quite some time, while axial flux machines have started to gain popularity in recent years, proving themselves as a solution for compact electric motors for e-Mobility.
In an axial flux motor, the magnetic flux flows along the axis of the motor, with the rotor and stator aligned so that the magnetic field lines pass directly between them along the motor’s length. In contrast, a radial flux motor features magnetic flux that flows radially from the center outward or vice versa. Here, the rotor is usually positioned inside the stator, with the magnetic field lines extending outward from the center.
Axial flux motor
Radial flux motor
Traditionally, axial flux motors were not widely adopted due to the complexity of their simulations. Unlike radial flux motors, which can often be modeled with simpler 2D simulations, axial flux motors require detailed 3D simulations to accurately capture their performance and behavior. This complexity made it challenging to design and optimize these motors efficiently, leading to limited use in practical applications.
Advances in computational tools and simulation technology have since addressed these challenges, making axial flux motors more feasible and increasingly popular in various industries.
Why Axial Flux motors are superior to radial?
In radial motors, the magnetic flux travels a longer route, moving from one rotor pole to the stator teeth, then through the stator material, and back to the next rotor pole. On the other hand, axial flux motors have a shorter, more direct path for the magnetic flux, moving straight from one pole to another through a small gap. This shorter path helps keep the magnetic field strong, which boosts efficiency and power density.
Axial flux machines use less copper and have reduced overhang, but they feature a higher active winding. This setup allows for more efficient winding with better heat management and cooling.
They also use less steel because they don’t require a stator yoke and have a more direct flux path. This streamlined design makes the motor lighter and more material-efficient.
All this allows axial flux motors to achieve up to 3 times higher torque density, 2 times better power density, a 45% lower CO2 footprint, and be typically 1/3 the length of their state-of-the-art radial flux counterparts.
As axial flux manufacturing technology advances, it is likely to capture a significant share of the market. At ASRUK, we are dedicated to making this transition a reality through our ongoing efforts.
Join the revolution now!
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