Axial - Raxial Flux







AXIAL - RAXIAL FLUX EV MOTORS


C/M already despite having R&D production test models opted for a selection of EESM & Magnet standard motors due to cost challenges with Flux options 

Axial flux motors, known for high power density and a compact "pancake" shape, typically cost more than traditional radial motors. Small, industrial-grade motors (1-5 kW) generally cost $300–$1,200, while high-power EV/aerospace units (30-200+ kW) range from $4,500 to over $20,000. Prices are highly variable based on customization and performance, with high-performance units from vendors often listed in the thousands. 


Key Cost Factors & Market Data

• Small Motors (1–5 kW): ~$300 – $1,200, often used for robotics or small automation.

• Medium Motors (5–30 kW): ~$1,200 – $4,500, common in AGV (Automated Guided Vehicle) systems.

• High-Power/EV Motors (30–200+ kW): ~$4,500 – $20,000+.

• Specialized Units: Specialized EV axial flux motors (e.g., YASA 750) are targeted at high-performance applications.

• Retail/Specialty: A 7KW Axial Flux Motor is listed around $1,150, while smaller industrial units can be found in the $200-$500 range on wholesale sites. 


Why They Cost More

• Manufacturing Complexity: The design, which often features dual rotors and high magnetic flux, can be more complex to produce, requiring higher precision than standard motors.

• Materials: High-performance units often use expensive materials like carbon fiber for magnet retention to handle high-speed rotation.

• High Performance: These motors offer 2-4 times the energy density of traditional motors, making them ideal for high-performance, weight-critical applications (e.g., supercars, drones) rather than cost-sensitive mass production. 

Note: While raw material costs can be higher, these motors often save money in overall system integration (e.g., in HVAC, by reducing installation complexity). 

Low-cost axial flux motors leverage compact, "pancake" designs with high power density, reduced material usage (less copper and iron), and simpler assembly to lower costs, often featuring PCB windings or ferrite cores for improved affordability. These motors are ideal for electric vehicles, marine propulsion, and industrial applications requiring high torque at low speeds. 


Key Low-Cost Technologies & Designs:

• PCB Windings: Printed circuit board windings reduce manufacturing complexity and component count.

• Ferrite Cores/Magnets: Utilizing cost-effective ferrite materials instead of expensive rare-earth magnets for specific applications like fans.

• Slotless/Modular Design: Simplified, modular construction allows for lower manufacturing costs.

• Somaloy Components: 3D soft magnetic composite (Somaloy) materials enable efficient, lower-cost production. 


Key Providers and Types:

• YASA Ltd: Known for high-power-density axial flux motors that use less material for cost savings.

• Infinitum: Produces axial air-core motors that eliminate core losses and reduce weight.

• Allient, Inc. (SA Series): Offers slotless, easily manufacturable axial flux motors for direct-drive applications.

• Turntide Technologies: Manufactures compact axial flux motors with high torque and high efficiency.

• Golden Motor: Offers the GMX Hyper Torque 7KW motor designed for high torque in smaller spaces.

• Beyond Motors: Provides high-performance axm series motors for diverse applications.

• Phi-Power: Specializes in axial flux motors for, for example, electric excavators and heavy vehicles.

• Evolito Ltd: Focuses on axial flux motors for the aerospace industry. 


Benefits:

• High Power Density: High power per unit weight.

• High Efficiency: Often exceeding 95%.

• Compact Design: Ideal for space-constrained applications.

• Reduced Material Use: Less material required, leading to lower costs. 


Applications:

• Electric Vehicles (EVs): Used for increased efficiency and reduced weight, as shown by manufacturers like McLaren.

• Marine Propulsion: High torque at low speeds eliminates the need for a gearbox.

• Industrial Automation: Used in fans, pumps, and other industrial equipment.

• Aerospace: Used for electric vertical takeoff and landing (eVTOL) vehicles. 

Axial flux motors, with their high efficiency and power density, are becoming a key technology for a wide range of industries, offering a sustainable and efficient alternative to traditional radial flux motors.

Thermal impregnation
Windings & hairpin windings

Motor reliability and longevity is vital for the success of modern electricvehicles. The long-term electric performance of electric motors can be increased by flawless insulation. A high-quality impregnation is essential to suppress partial discharges and absorb vibrations inside stators and rotors. 


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H.I.3 with training & Education available publicly & privately through CIG - C/M 

sydneysspacelive.blogspot.com

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