Innovative winding solution for Axial Flux Motor

The axial flux electric motor is a type of brushless motor that has a flat, circular shape, resembling a pancake (hence the name “pancake” in English). They are available in a variety of sizes and powers and can be used in a wide range of applications, including robotics, automotive, consumer electronics, and the general industry. Axial flux electric motors are generally more compact, more efficient, and also perform better compared to traditional ones. However, the production of pancake motors is generally more complicated and expensive.

It is for this reason that Spin R&D office, in collaboration with Suzzi‘s Research and Development, has studied and developed a very innovative electrical winding solution that, while maintaining performance, simplifies the construction of the axial flux electric motor, making it very competitive.

What are the advantages of an axial flux motor compared to a traditional one? (intended as radial flux motor)

• High ‘torque/mass’ and high ‘torque/volume’ ratios: In the axial flux motor, the torque is proportional to the ‘Diameter^3’, while in the traditional radial flux motor the torque is proportional to ‘Diameter^2.Length’; the direct result is that the axial flux motor can develop the same torque as a traditional radial flux motor in a smaller clearance
• Low losses and, depending on the adopted cooling system, high heat dissipation and high overload capabilities
• Modularity and redundancy:
  • The shape factor of an axial flux motor, particularly the short axial length, promotes the possibility of stacking two or more machines to obtain a scalable structure
  •  Furthermore, each machine that constitutes the structure, can be electrically independent from the others, guaranteeing redundancy characteristics to the overall structure and its continuity of service in case of a failure of one of the constituent machines
• High robustness: At the beginning of this article we told you about the innovative winding solution for axial flow machines designed by our R&D Department in collaboration with Suzzi, an expert in winding production.

What are the advantages of Suzzi-Spin winding for axial flux machines?

• Technology that simplifies the assembly of different axial flux machine configurations characterized by concentrated winding around the teeth
  •  Single-Sided Configuration: Single Stator (SSAX) and Single Rotor
  •  Bi-lateral configurations:
    •  Double Stator (DSAX) with Single Rotor Interposed
    •  Double Rotor (DRAX) with Single Stator interposed and, in the configurations:
      •  With the stator yoke
      • Without stator yoke (Y.A.S.A.: Yoke-less And Segmented Armature)
• Possibility of using with
  • Round wires (traditional, to keep the production costs of the axial flux machine limited)
  • Rectangular wires (special, for maximizing the filling factor and, consequently, the performance and efficiency of the machine)
  • Litz wires (special, for reducing AC losses at high supply frequency/working speed of the machine)

If you want to view the technical parameters of axial flux motor for automotive click here.

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