Revolutionising efficiency: The breakthrough axial flux motor

For more than a century, industrial motors have remained largely unchanged in their core design, relying on radial flux technology to power everything from manufacturing lines to heavy-duty machinery. While this approach has been refined over time, the industry has faced a fundamental challenge: how to make motors more compact, efficient and adaptable – without sacrificing power.

Axial flux technology is not new; it has existed for over a century, but has only recently become viable for large scale industrial use. Now WEG has taken axial flux technology to meet industry requirements and industrial applications.

Radial and axial flux motors represent two distinct approaches to electric motor design. In a radial flux motor, the magnetic field flows outward from the centre of the rotor, much like the spokes of a wheel. This design has been the standard for industrial motors for years, offering reliability and proven performance.

Axial flux motors turn conventional design on its head by arranging the rotor and stator in a flat, disc-like structure, allowing the magnetic flux to flow along the axis of the motor. This layout results in a much higher power density, meaning these motors can pack more power into a smaller, lighter package. With their ability to provide higher power-toweight ratios combined with improved cooling methods, axial flux motors are increasingly seen as the next frontier in motor technology.

RESEARCH AND DEVELOPMENT
WEG has consolidated years of research related to axial flux technology with the first industrial platform for this technology, which began in 2023 and became known as the W80 AXgen platform. With its experience and capabilities in industrial motor production WEG has industrialised axial flux technology.

However, the development of the W80 AXgen presented unique challenges. Unlike traditional motors, axial flux motors are difficult to scale up for mass production due to limitations in materials and manufacturing processes. Overcoming these hurdles required extensive research and development, with WEG’s team investing significant effort in this area.

Simulation played a key role in the creation of the W80 AXgen. WEG partnered with Ansys to leverage advanced simulation tools, such as Ansys Mechanical, Fluent, Granta, Maxwell and Electronics, to refine every aspect of the motor’s design. With the help of this technology, WEG was able to optimise the motor’s electromagnetic performance, thermal management and material selection. Ansys solutions provided the ideal balance of simulation speed and predictive accuracy, enabling WEG to test and develop a motor with remarkable power density and a lightweight design.

EFFICIENCY AND PERFORMANCE
The impact of this extensive research, development and planning has been significant. The new motor achieves an impressive efficiency class of IE5 and beyond, setting a new benchmark in the sector. Moreover, this milestone represents more than just an energy-efficient design, it also promises substantial financial benefits for end-users.

Available in frame sizes ranging from 160 to 250, achieving up to 400kW, the motor's compact size and weight not only make production more efficient but also cut down on logistical costs by minimising transportation needs. This contributes to sustainability goals by reducing CO2 emissions, not just through more efficient operation, but by improving the efficiency of the entire lifecycle of the motor, from manufacture to delivery.

Beyond its efficiency, the W80 AXgen offers exceptional power and versatility. With a constant torque range of 1000:1 and a constant power range of 1.3 times the nominal speed, it delivers reliable performance across a wide spectrum of operational conditions. Coupled with its state-of-the-art liquid cooling system that can handle both fresh or deionised water and oil (ISO VG up to 46), the motor is designed to maintain optimal performance even in the most demanding environments.

THE FUTURE OF AXIAL FLUX TECHNOLOGY
Looking ahead, the introduction of axial flux motors for industrial applications represents more than just an incremental improvement – it’s a transformation in how motors are designed and manufactured. As industries continue to evolve, the need for more efficient, adaptable and sustainable solutions will only grow.

The W80 AXgen reflects the future of motor technology, taking axial flux from concept to reality. By overcoming the challenges of scaling up this design, WEG has created a motor that not only sets new efficiency benchmarks but redefines what's possible in terms of size, weight and power.

As industries demand more adaptable and sustainable solutions, the W80 AXgen is poised to lead the charge, proving that the future of motors is not just about keeping up with the times – it’s about reshaping them entirely.

The design of the W80 AXgen enables the machine builder to develop new ideas, gaining competitive advantages by reducing weight and footprint while increasing efficiency without compromising machine performance.

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This article appeared in Renew magazine. To read more or request your personal digital or print edition of Renew, click here.