A research report indicates that axial flux motors offer flexible design capabilities, allowing customizable combinations of rotor and stator quantities based on application requirements, making them ideal power solutions for electric aircraft, electric vehicles, and robotic joints. Their flat structure and high-performance characteristics position them as the preferred solution for humanoid robot drive motors. Current mass production constraints include: minimal air gap deviations, significant heat dissipation pressure, high costs, and substantial mechanical stress. The report suggests that SMC integrated die-casting and stator structure optimization are expected to accelerate the commercial application of axial flux motors.
Key findings include:
Axial flux motors demonstrate structural advantages with high power density characteristics. Axial flux motors are disc-type motors where the magnetic flux path runs parallel to the rotating shaft. Compared to traditional radial flux motors at equivalent power levels, they can reduce weight and axial dimensions by half, offer broader high-efficiency operating ranges with efficiency areas exceeding 90%, and significantly enhance torque density and power density. Their flexible design allows customizable rotor and stator combinations based on application needs, providing ideal power for electric aircraft, electric vehicles, and robotic joints. The flat structure and high-performance characteristics make them promising candidates as the preferred solution for humanoid robot drive motors.
Precision disc structure and heat dissipation issues constrain axial flux motor mass production. The disc structure of axial flux motors creates manufacturing complexity: 1) Minimal air gap deviations affect magnetic flux distribution and axial magnetic attraction, easily causing vibration and noise while reducing lifespan. 2) Significant heat dissipation pressure: sandwich structure and high specific power result in low heat capacity, with rotor magnets prone to overheating and increased demagnetization risk. 3) High costs: special materials and complex manufacturing lead to elevated mass production costs. 4) Substantial mechanical stress: large-radius rotors experience centrifugal force during high-speed rotation, challenging structural stability.
SMC integrated die-casting and stator structure optimization expected to accelerate axial flux motor commercial applications. The industry currently employs: 1) SMC integrated die-casting: features isotropic magnetic properties, supporting complex three-dimensional magnetic flux design, compatible with 3D printing for large-scale stable manufacturing. 2) PCB stators: coreless design reduces weight and eddy current losses, improving efficiency and reliability. 3) Structural optimization: flat coils increase slot fill factor, strengthen magnetic fields, and boost power by 20-30%; coil shape optimization enhances heat dissipation efficiency. 4) Enhanced heat dissipation: liquid cooling channels, phase change materials, and carbon nanotube applications significantly improve thermal management capabilities.