Huaxin Securities: Axial flux motors are expected to become the next generation of actuators with SMC integrated die-casting and optimized stator structure accelerating commercialization

According to the Zhitong Finance APP, Huaxin Securities released a research report stating that axial flux motors have flexible designs that can combine the number of rotors and stators according to application needs, providing ideal power for electric aircraft, electric vehicles, and robotic joints. Their flat structure and high-performance characteristics are expected to make them the preferred solution for humanoid robot drive motors. Currently, the factors limiting mass production include: slight air gap deviations, high thermal pressure, high costs, and significant mechanical stress. The firm believes that SMC integrated die-casting and stator structure optimization are expected to accelerate the commercial application of axial flux motors.

The main points of Huaxin Securities are as follows:

Axial flux motors have obvious structural advantages, featuring high power density and other characteristics

Axial flux motors are disc-type motors with a magnetic flux path parallel to the rotor shaft. Compared to traditional radial flux motors, they can reduce weight and axial dimensions by half at the same power level, have a wider efficient range, and achieve an efficiency area of over 90%, significantly enhancing torque density and power density. Their flexible design allows for the combination of rotor and stator numbers according to application needs, providing ideal power for electric aircraft, electric vehicles, and robotic joints. Their flat structure and high-performance characteristics are expected to make them the preferred solution for humanoid robot drive motors.

Precision disc structure and thermal issues restrict the mass production of axial flux motors

The disc structure of axial flux motors brings manufacturing complexity: 1. Slight air gap deviations can affect magnetic flux distribution and axial magnetic attraction, easily causing vibrations and noise, reducing lifespan. 2. High thermal pressure: The sandwich structure and high power-to-weight ratio lead to low thermal capacity, making rotor magnets prone to overheating and increasing the risk of demagnetization. 3. High costs: Special materials and complex manufacturing result in high mass production costs. 4. Significant mechanical stress: Large-radius rotors experience centrifugal forces at high speeds, posing challenges to structural stability.

SMC integrated die-casting and stator structure optimization are expected to accelerate the commercial application of axial flux motors

Currently, the industry mainly adopts: 1. SMC integrated die-casting: It has isotropic magnetism, supports complex three-dimensional magnetic flux designs, and is compatible with 3D printing for large-scale stable manufacturing. 2. PCB stators: The coreless design reduces weight and lowers eddy current losses, enhancing efficiency and reliability. 3. Structural optimization: Flat coils improve slot filling rates, resulting in stronger magnetic fields and a 20-30% increase in power; optimizing coil shapes enhances thermal efficiency. 4. Enhanced cooling: New applications such as liquid cooling channels, phase change materials, and carbon nanotubes significantly improve thermal management capabilities