Axial flux

In an axial flux motor (disk rotor), the magnetic fields are formed in an axial direction, i.e. parallel to the motor shaft. Compared to conventional radial flux motors, axial flux motors offer numerous advantages in terms of compactness, including high torque and high power density as well as the possibility of reducing the overall weight, particularly in the drive train. Axial flux machines have a shorter and more direct flux path that runs directly from one pole to the other through the air gap. This shorter path helps to maintain a strong magnetic field, which contributes to higher efficiency and power density.

 

Different designs

An axial flux motor differs from radial motors in that the magnetic field is aligned along the axis of rotation. The stator and rotor are disk-shaped and lie parallel to each other.

Axial flux motors can basically be divided into two types:

  • H-design: The stator is located between two rotors that are axially offset from each other, which enables a high torque density and efficiency.
  • EIƎ design: Here, two stators are positioned on the outside and the rotor is located between them. This improves the cooling options and enables a higher power output with the same volume.

Both designs are characterized by their compact design and high power density. Here is an overview of the designs described:

Toroidal production

Axial flux motor technology is used in various applications. This requires spiral-wound packages made from electrical sheet materials, the precise manufacture of which is very demanding. Coiled, backlack-packaged and mechanically processed toroidal cores enable the realization of customer components with the highest demands on geometry, mechanics and magnetics.

The packages are precisely wound and high-strength baked in an innovative process. This is followed by mechanical finishing. Prototypes are manufactured on specially developed production systems in close cooperation with the customer.

Stator variants

Axial flux motors use different stator variants that are specifically adapted to the requirements of the design and application. The selection depends on the desired design, flux density, choice of material, coil configuration, power density and numerous other properties.

Rotor variants

Rotors made of wound electrical steel in axial flux machines offer compact designs and high efficiency. The winding of the sheet metal reduces eddy current losses and improves the magnetic properties. The wound structure results in a low moment of inertia, ideal for dynamic applications. Their adaptability enables optimized designs for specific power and torque requirements.

Advantages of wound toroidal cores for axial flux motors

  • GEOMETRIC FREEDOM thanks to geometrically flexible toroidal core machining.
  • MAXIMUM PRECISION thanks to a specially developed manufacturing process combined with precise machinability.
  • MAXIMUM STRENGTH thanks to the full-surface bonding of the spirally wound layers of the electrical steel stack.
  • BEST MAGNETIC BEHAVIOUR thanks to the full-surface insulation of the superimposed layers.
  • MINIMUM MATERIAL USE due to the endless wound electrical steel strip material.

Material store

Electrical steel slit strip is required for the production of wound toroidal cores. To enable us to manufacture your parts as quickly as possible, we keep an extensive stock of a wide range of sheet metal grades. Our stock includes sheet metal grades in accordance with the IEC 6040-8-8 and DIN EN10106 standards or are readily available.

Click here for more information to the material stock list