The YASA Story - Axial Flux Motors: The Future Of Electric Vehicle Propulsion

Summary

The Yasa Axial Flux Motor is a groundbreaking innovation in electric vehicle technology, offering exceptional efficiency, power density, and weight reduction compared to traditional motors. Originating from research in 2005, the motor's unique design allows for increased torque and smaller size, making it ideal for high-performance EVs. The collaboration with Mercedes-Benz AMG is key to scaling this technology for mass production, promising enhanced vehicle performance, reduced environmental impact, and significant advancements in electric vehicle design. The Yasa motor is set to revolutionize the automotive industry, with an eye toward the future of sustainable, high-efficiency electric vehicles.

Takeaways

• 😀 The YASA axial flux motor is a revolutionary, ultra-high-performance electric vehicle (EV) motor that offers superior power density, size, and weight compared to traditional electric vehicle motors.
• 😀 In 2005, electric vehicles were still not mainstream, and the question of why electric cars were not more prevalent sparked the development of advanced EV technologies.
• 😀 The research behind the YASA motor began with a PhD focused on investigating what an electric motor for the future EV industry should look like, leading to the development of the axial flux motor.
• 😀 Axial flux motors offer several advantages, including higher torque density and the ability to save significant space, which allows for lighter and more efficient electric vehicles.
• 😀 The YASA motor’s design allows for up to 480 horsepower from a motor that weighs only 24 kg, which is much lighter and more compact than a traditional radial flux motor with similar torque.
• 😀 One of the major breakthroughs in YASA's motor design is the YASA machine Yoplus, a new topology that reduces the diameter of the motor and makes it easier to package in vehicles.
• 😀 The unique segmented stator design of the YASA motor, combined with direct windings, allows for improvements in efficiency, weight reduction, and packaging flexibility.
• 😀 YASA motors contribute to EV range improvement by reducing vehicle weight and allowing for a reduction in battery size, leading to further compounding benefits such as lighter brakes and smaller components.
• 😀 The inherent torque density of YASA motors allows for compact motor designs that deliver high power, offering new opportunities for vehicle designers to explore innovative architectures and layouts.
• 😀 YASA's technology went through several iterations and challenges in scaling for mass production, including improving cooling systems, robustness, and manufacturing processes for higher volume production.
• 😀 Despite initial challenges like the lack of market demand for EVs in 2009 and an immature technology, YASA has since developed strong industry partnerships, including with Mercedes-Benz, to scale the production of its advanced motor technology.

Q & A

What is the Yasa axial flux motor and how does it differ from conventional electric vehicle motors?

The Yasa axial flux motor is an ultra-high-performance electric motor designed for electric vehicles, offering unmatched weight, size, and power density. It differs from conventional radial flux motors in its design, being shorter in length while providing greater torque density, enabling it to be more compact and lighter than traditional motors.

How does the Yasa motor contribute to improving the efficiency of electric vehicles?

The Yasa motor's high torque density allows for a smaller, lighter motor that reduces overall vehicle weight. This, in turn, improves energy efficiency, potentially reducing battery size, and increasing range due to the compound effect of lighter components, including smaller batteries, brakes, and other systems.

What key challenges did Yasa face when developing the axial flux motor technology?

Yasa faced several challenges, including the difficulty of manufacturing axial flux motors due to issues with cooling, controlling air gaps, and complex winding. Additionally, the lack of suppliers and machinery for mass production of this new technology posed a significant hurdle in scaling up.

What breakthrough in axial flux motor design did Tim achieve during his PhD?

Tim developed a new axial flux motor topology, the Yasa machine, which included a segmented stator and direct windings around each segment. This design allowed for a reduced motor diameter while maintaining high torque density, making it easier to package in vehicles.

How does the Yasa motor's design affect the overall weight and performance of an electric vehicle?

By reducing the weight of the motor, the Yasa motor contributes to an overall lighter vehicle. This leads to less energy consumption, improved range, and a more sustainable car design. The motor's high torque density also allows for new vehicle architectures that were previously impossible with radial flux motors.

How did Yasa scale their technology from a niche product to mass production?

Yasa began by targeting low-volume niche programs with luxury brands like Jaguar and Koenigsegg, gradually increasing production volumes. They also invested in building the necessary infrastructure, including machines to manufacture the motors and growing a supplier base to support mass production.

What role did Mercedes-Benz AMG play in Yasa's journey to scale their motor technology?

Mercedes-Benz AMG's partnership with Yasa helped accelerate the development and scaling of the motor technology. The collaboration allowed Yasa to innovate rapidly while leveraging Mercedes' expertise in mass production, ensuring the technology could be scaled to meet the needs of high-performance electric vehicles.

What is the significance of the direct oil cooling feature in Yasa's motors?

The direct oil cooling system in Yasa's motors ensures consistent cooling across the windings, preventing heat buildup and maintaining performance. This unique feature allows Yasa motors to sustain high power outputs without the thermal limitations typically faced by radial flux motors.

What impact does Yasa's motor design have on the future of electric vehicle architecture?

Yasa's motor design opens up new possibilities for electric vehicle architecture, allowing for more compact and efficient powertrains. The motor's small size and high torque density enable more flexible designs, such as concentric motor-gearbox setups, and offer opportunities for lighter, more efficient systems in future EV models.

What are some of the environmental benefits of using Yasa motors in electric vehicles?

Yasa motors contribute to reducing the environmental impact of electric vehicles by making them lighter, which reduces the energy required for manufacturing and driving. The compact motor design also allows for smaller battery sizes, further reducing material use and overall CO2 emissions in vehicle production.