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Axial Flux Motors with high power density & SMCs with simplified & cost-effective manufacturing of complex shapes results into a motor, that is more durable, compact, and efficient with optimized performance & reduced costs.
Axial flux motors (AFMs), also known as pancake motors, are a type of electric motor in which the direction of magnetic flux between the rotor and stator is aligned parallel to the axis of rotation. They are particularly important for electric vehicle (EV) and electric airplane applications, where high power density, lightweight, and efficiency are crucial. In this blog, we will explore how AFMs work, their benefits, and how soft magnetic composites (SMCs) can unlock their hidden potential.
What Are Axial Flux Motors?
Axial flux motors (AFMs) are a type of electric motor with a unique design that arranges the rotor and stator in a disc-like shape, rather than the cylindrical shape of conventional motors. This compact design allows for a higher power density, as the rotor and stator are placed on either side of the air gap. Additionally, AFMs are more efficient than conventional motors due to their shorter magnetic path length and reduced core loss.
Benefits of Axial Flux Motors
One of the main benefits of axial flux motors is their high-power density. Because of their compact design, they can pack more power into a smaller space, making them ideal for EV and electric airplane applications. They also offer high torque and efficiency, making them more suitable for airplane applications. Few companies also deploy carbon-fibred housing to reduce the weight further for such an application.
SMCs and AFMs
SMCs a.k.a. soft magnetic composites material is made of a mixture of iron powder and an insulating binder, that allows the material to be easily formed into complex shapes using conventional molding process. Such material when molded and sintered with right composition and processes can offer a completely new domain of possibilities for optimization in the performance of motor. A motor made by soft magnetic composites can withstand comparatively harsher conditions, is more dense or compact. Such a motor would also offer high permeability, lower core/ eddy current loss and lesser energy consumption.
These composites play an important role in simplifying the manufacturability and this helps in significantly reducing the stator cost of an AFM, which is one of the most complex and difficult components to manufacture.
Reducing Bill of Material with SMCs
In addition to making AFM manufacturing easier, SMCs can also reduce the bill of material for an AFM. This is because SMCs can be made with a high magnetic flux density, which allows for a thinner stator core. This reduces the amount of material required and can result in a lower overall cost for the motor.
Comparing SMCs with Traditional Axial Flux Motors Using Laminations
Traditional axial flux motors typically use laminations in their design, which can come with a variety of inherent weaknesses. One of the main issues is that the stator is difficult to manufacture and automate due to the complex shape of the laminations. This can result in a higher manufacturing cost and longer lead times. Additionally, laminations are prone to eddy current losses, which can reduce the efficiency of the motor.
Alleviating These Issues with SMCs
SMCs can alleviate all these issues and unlock the hidden assets of AFMs by providing a more manufacturable and cost-effective solution. With the help of these composites, the stator can be easily formed into intricate shapes and smooth corners without wasting the material in the stage of molding and sintering process, thus, reducing the manufacturing cost and lead time.
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