Axialvsradialplay

In addition to being a more compact motor, axial-flux motors offer many advantages over radial-flux machines. Some of those include:

In addition, many new innovations can benefit from axial-flux motors. Among them are wind turbines, due to the low profile and high torque-to-weight ratio, as well as medical bionics and advanced cinematography, due to the quality of motion and controllability. Industrial automation, such as robotics and conveyors, also benefit thanks to the motors’ durability and flexible form factor.

In his role as President and CEO of ECM PCB Stator Technology, Brian has driven ECM’s development as a global electric motor design and SaaS company. ECM pairs advanced Motor CAD and patented PCB Stator—printed circuit board—technology to create next generation electric motors that are lighter, quieter, and more energy and space efficient across a broad range of use cases.

Radialandaxialdirection

Within this conversation, there’s a broader question: “How to satisfy global demand for over a billion specialized electric motors annually—with more of them requiring axial-flux topology—across thousands of applications?”

In addition, the inherently thinner axial length of axial-flux motors creates new possibilities for integrating them within electric systems. These novel arrangements can positively alter the form-factor constraints on other elements within the system.

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Axialvsradialrotation

As the founder and CEO of sustainable energy firm, SourceOne,  Brian was responsible for the overall management and technical efforts of the company. He successfully raised equity investments, targeted, and acquired complementing business from a Fortune 500 company, and developed a uniquely qualified commercial, private utility offering.

Brian Casey is an expert in the energy and technology industry with over 30 years of experience. This includes leading two companies from growth-stage, to scale, to acquisition.

As a design tool, PrintStator enables users to create complex electric-motor designs from any set of motor parameters. The software uses proprietary design algorithms to quickly develop axial-flux, PCB Stator motor solutions and provides a range of customization options. These include motor dimensions, voltage/current restraints, performance specifications, target efficiency, and integration of the specific magnetic material.

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Axialvsradialmovement

Then there’s a frequently overlooked facet of the energy sustainability challenge—the world’s electric-motor sustainability problem. Research underscores that outdated electric-motor systems account for over 40% of global energy consumption.

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Axialandradialload bearing

In ECM’s view, the answer comes down to two factors: better technology and advanced Motor CAD offered via software as a service (SaaS). On the tech side, the company has specialized in design of axial-flux, air-core, printed-circuit-board—PCB Stator—electric motors. ECM’s PCB Stators replace the copper windings found in conventional electric machines with an ultra-thin stator.

That’s understandable since axial-flux motors and radial-flux motors are common classes of electric motors. Both convert electrical energy into mechanical energy, but they differ substantially in design and assembly. Detailed comparisons of axial versus radial flux have been done, usually landing on the conclusion that each has its pros and cons.

This has been especially true within the e-mobility and electric-vehicle (EV) space, as both American and European auto manufacturers have explored the potential upsides of using axial-flux motors in their drive systems.

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Radialvsaxialcontroller

In axial-flux motors, the magnetic field is parallel to the shaft and the windings are arranged in a planar fashion. This design allows for a more compact motor, with shorter axial length and a disc, rather than cylindrical, form factor. In a radial-flux motor, the magnetic field is perpendicular to the shaft and the windings are arranged in a cylindrical fashion. This design is typically larger and bulkier.

Under his direction, SourceOne created and implemented award winning, sustainable energy projects for its customers and secured multi-million-dollar energy efficiency and infrastructure contracts within the private and public sectors.

On the software side, ECM developed a Motor CAD platform, PrintStator, that enables enterprises, innovators, and engineers to design, market, and commercialize axial-flux machines that are smaller, quieter, and more energy and space efficient.

The EV space is innovating with and adopting axial-flux topology, too. Both Mercedes Benz and Ferrari are integrating axial-flux electric motors into their concept and high-performance EVs, touting the benefits of compact size, high-power density, and greater efficiency.

As the world rapidly electrifies, demand for specialized motors is exponentially ramping up. That’s because more of the devices we use in business and daily life are electrifying, too. And from e-mobility to consumer electronics, all of those devices need electric motors to operate.

In the broader scheme of things, a confluence of trends has shifted greater focus on this topic of differences, pros, and cons between axial flux and radial flux machines.

Veolia Environnement S.A. acquired SourceOne in April of 2007. Brian continued to grow SourceOne over the next several years, realizing double-digit growth in revenue and earnings and delivering significant shareholder value.

Macro currents—such as mass electrification and automation—are pushing global demand for specialized electric motors to over a billion units annually in a sector valued at over $200 billion. This booming electric motor demand is occurring in a long list of verticals: HVAC equipment, e-mobility, consumer electronics, household appliances, robotics, medical devices, aerospace, defense, and unmanned vehicles—you name it.

As a result, global electronics designers are delving deeper into electric-motor topology. Quite frequently, that research leads to this question: “What’s the difference between axial-flux and radial-flux electric motors?”

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Radialandaxialalignment

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In the long run, advanced Motor CAD via SaaS could be the most viable means to meet the world’s surging electric-motor needs at scale. That extends to the increasing demand for those of the axial-flux variety.

He holds a Bachelor of Science Degree in Electrical Engineering with a concentration in Power Systems & Delivery from Northeastern University.

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From there, he co-founded SourceGreen, an industrial scale solar energy development company that successfully created 8 MW of renewable solar energy within the state of Massachusetts. NextSun Energy acquired SourceGreen in 2013.

To scale this capability more broadly, PrintStator’s SaaS model makes it possible for any consumer electronics innovator—from startup entrepreneur to big-company engineer—to become an electric-motor designer and producer. The SaaS model extends options for vertical integration and production to large and small industry players.

However, over the past few decades, axial-flux motors have become more prevalent due to the advantages they offer over their radial counterparts. Some of these benefits weren’t feasible with legacy manufacturing methods and materials. However, new technology design platforms have expanded the advantages of axial-flux topology to a broader range of users and applications.

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PCB Stator motors designed via PrintStator are up to 70% lighter than traditional options while achieving efficiencies in the mid-90s, and requiring just 20% of the raw materials over conventional machines, according to ECM.

Brian currently serves on the board of Hubbell Power Systems owned Cantega Technologies—an industry-leading software platform for the manufacture of dielectric polymer products that serve the electric utility industry.

Difference betweenradialandaxialrunout

For example, several EV applications have successfully consolidated axial-flux motors entirely within wheel housings, creating additional space for batteries to extend range. Similarly, these motors in defense and aerospace applications offer options for additional sensors and room for larger payloads.

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The introspection occurring in this space reveals many electric-motor use cases that can benefit from axial-flux topology. Some common household applications of note include heating and cooling systems (e.g., pumps and fans), kitchen devices (e.g., blenders and coffee machines), power and yard tools (e.g., drills and lawnmowers), home appliances (e.g., washing machines and dishwashers), and other typical household items that aren’t as obvious (e.g., exercise bikes and baby rockers).

He has led the adoption of ECM’s technology by multiple partners across a broad range of verticals: HVAC, Consumer Electronics, E-Mobility, Fitness, Medical, Robotics, Renewable Energy, Aerospace, Defense, and more.

In exchange for a more tortuous magnetic circuit path, the end-turn penalty in the electric circuit is less. An axial-flux machine incorporating a more thermal and conductive printed-circuit-board (PCB) stator allows for more design optimization, both in terms of performance specs and customizable form factor. Wire-wound axial-flux machines don’t have this advantage.

In general, the major difference (and benefit) shared by all axial-flux machines is that flux has a more direct path compared to a radial-flux machine. This makes the magnetic circuit simpler and perhaps easier to implement, with low losses. However, since the poles in the axial-flux machine are shaped like sections of an orange, the electric circuit path on the outer end turn is more onerous. A radial-flux machine has the dual advantage.

Add it all up and there’s a need to design more electric motors than ever before with improved performance, efficiency, and optimization.

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Unsurprisingly, a number of these benefit categories share a symbiotic relationship. For example, the increased torque density in axial-flux motors is achieved by their pancake-like design, larger diameter, and shorter axial length. These characteristics support weight savings and higher torque-to-weight ratios of axial-flux machines. This, in turn, allows axial-flux electric motors to deliver more power in a compact package.