Revving Up EVs: Axial Flux Motors

Summary

Sources

electrichybridvehicletechnology.com

In the evolving landscape of the automotive industry, electric vehicles stand at the forefront of innovation, and YASA's axial flux motors are igniting a revolution, particularly in the realm of battery electric vehicles. This transformative technology, while tracing its lineage back to the ingenuity of Michael Faraday over two centuries ago, has faced challenges that have confined it to niche applications. However, YASA has been rewriting the narrative, aiming to propel axial flux motors into the mainstream of electric vehicles. With the Vision One-Eleven concept, Mercedes-Benz has showcased a glimpse into the future of electrified performance cars. Paying homage to the revolutionary C111 of the 1970s, the Vision One-Eleven's heart beats with the rhythm of YASA's axial flux motors. This concept car is more than a tribute; it is a testament to the potential of axial flux technology in exploring futuristic propulsion methods. The inception of YASA is a story of academic curiosity meeting real-world application. Tim Woolmer, the Chief Technology Officer of YASA and the mind behind the company's innovation, embarked on a journey during his PhD to reimagine electric propulsion technology. With the ratification of the Kyoto protocols in 2005, the imperative to cut greenhouse emissions became clear, and transportation was squarely in the crosshairs. The electric vehicle market, then in its infancy, became the focal point of Woolmer's research. Woolmer's foray into the academic literature revealed that axial flux motors offered superior torque density, power density, and required less weight and volume compared to their radial counterparts. Despite these advantages, the challenges of manufacturing and cooling these motors loomed large. Enter soft magnetic composite, a material that emerged as a game-changer in the late 1990s. This material, with its coating that allows for pressing into three-dimensional shapes, became the key to unlocking the potential of axial flux motors. YASA's innovation did not stop at the material level. The design of the motor itself underwent a radical transformation. By segmenting the stator and eliminating the stator yoke, YASA created a motor with significantly reduced weight, higher torque density, and improved cooling efficiency. This design enabled a 50-kilogram radial motor's performance to be achieved by an axial motor weighing less than 20 kilograms. The motorsport arena became the proving ground for YASA's technology, showcasing its prowess at the Pikes Peak race in Colorado. An electric car equipped with YASA's motor shattered records and expectations, demonstrating the viability of electric power in high-performance applications. As the technology matured, the interest of automotive original equipment manufacturers (OEMs) piqued, with prestigious names like Ferrari and Lamborghini incorporating YASA's motors into their vehicles. However, the most significant endorsement came from Mercedes-Benz, which chose not merely to become a customer but to invest heavily in YASA, acquiring a controlling stake. This strategic partnership is set to accelerate the production of axial flux motors, leveraging Mercedes-Benz's manufacturing acumen to potentially transform the production of full battery electric vehicles. The implications of this partnership extend beyond numbers and into the very design of future vehicles. The compact size of axial flux motors opens the door to in-wheel motor applications, promising a radical reimagining of vehicle architecture. Woolmer's vision looks even further ahead, with advancements in technology anticipated to double the power and torque density in the coming years. This progress points to a future where electric vehicles are not just incrementally improved but are fundamentally redefined. The partnership between YASA and Mercedes-Benz represents a pivotal moment in the automotive industry. It signifies a commitment to a more sustainable future, one where electric vehicles are synonymous with high performance and innovation. As this technology continues to evolve, the promise of axial flux motors in revolutionizing the electric vehicle landscape becomes increasingly tangible, heralding a new era of automotive design and engineering. The history of axial flux motors is a captivating tale of scientific prowess that stretches back over two centuries. Invented by the illustrious Michael Faraday, these motors were initially conceptualized as part of the pioneering experiments that laid the groundwork for the understanding of electromagnetism. Yet, despite their early promise, axial flux motors faced significant obstacles that hindered their widespread adoption. The complexity of manufacturing axial flux motors stood as a towering challenge. Traditional radial flux motors, with their simpler construction, were more feasible for mass production. The axial design, in contrast, required a non-traditional approach to stacking laminations, and the intricate winding patterns presented considerable difficulties. Furthermore, the cooling of these motors was another critical issue. Effective heat dissipation is crucial for maintaining performance and ensuring the longevity of the motor, but the design of axial flux motors made this a particularly vexing problem. YASA's approach to these challenges was both innovative and transformative. The company's embrace of soft magnetic composite materials was a significant leap forward. This material allowed for the pressing of intricate three-dimensional shapes, simplifying the manufacturing process and addressing the limitations of traditional lamination stacking. The unique properties of soft magnetic composites also played a pivotal role in enhancing the motors' cooling capabilities. Through these advancements, YASA was able to overcome the historical hurdles associated with axial flux motors. The result was a new breed of electric motors that were not only lighter and more compact but also more efficient and capable of delivering higher torque density. This evolution from an academic curiosity to a viable, high-performance application marks a milestone in the journey of axial flux motors. As the narrative of axial flux motors continues to unfold, the achievements of YASA stand as a beacon of innovation in the electric vehicle industry. The company's pioneering work has paved the way for these motors to transition from specialty applications to potentially becoming the cornerstone of the next generation of battery electric vehicles. The future of transportation, electrified by axial flux motors, promises to be one where efficiency, performance, and sustainability converge to redefine the automotive experience. The strategic alliance between YASA and Mercedes-Benz marks a significant chapter in the evolution of electric vehicles. This partnership is more than a mere collaboration; it represents a fusion of YASA's cutting-edge axial flux motor technology with the manufacturing prowess and global reach of one of the most storied names in the automotive industry. Mercedes-Benz's decision to acquire a controlling stake in YASA is a clear indicator of the importance it places on the future of electric mobility. This investment is poised to catalyze the growth of axial flux motor technology, bringing it into the limelight of the automotive sector. For YASA, the integration into the Mercedes-Benz ecosystem provides an unparalleled opportunity to scale up production and refine its technology to meet the rigorous demands of mass-market applications. The implications of this partnership extend well beyond the immediate benefits of increased production capacity and shared expertise. By incorporating YASA's motors into its vehicles, Mercedes-Benz signals a commitment to not only embracing electric vehicles but also pushing the boundaries of their performance. The lightweight and high-efficiency characteristics of axial flux motors are set to enhance the overall design and capability of battery electric vehicles, offering consumers a driving experience that rivals, if not surpasses, traditional combustion engines. Moreover, the collaboration is anticipated to yield dividends in terms of sustainability. High-performance electric vehicles that are more efficient and lighter can lead to reduced energy consumption and longer driving ranges, thereby addressing two critical concerns often associated with electric vehicle adoption. As this technology becomes more accessible and enters the mainstream market, the potential for a significant reduction in transportation-related emissions grows ever more achievable. Another transformative aspect of the YASA and Mercedes-Benz partnership is the potential impact on vehicle architecture. The compact size of axial flux motors offers the tantalizing prospect of novel design configurations, including the possibility of in-wheel motor applications. Such a development could revolutionize car design, allowing for more spacious interiors, improved handling, and even the elimination of conventional drivetrains. In summary, the union of YASA and Mercedes-Benz stands as a testament to the transformative power of collaboration in the automotive industry. It is a partnership that promises to bring high-performance, sustainable electric vehicles to a broader audience. As this technology continues to advance, it is poised to reshape the landscape of personal transportation, heralding a new era of electric vehicle dominance that is sustainable, efficient, and thrilling to drive.