Unofficial World Record 550 kW Output at Just 13.1 kg Weight

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The name YASA Motors is not widely known. A Mercedes subsidiary dedicated to building axial flux motors. On LinkedIn, CTO Tim Woolmer now presented a new record that was probably anything but expected even for the manufacturer.

The Mercedes-Benz subsidiary YASA has recently achieved a true technological milestone. Excerpts from an unexpected prototype success suggest that YASA has set a new benchmark in power-to-weight ratio. This is with a motor that leaves hardly any size comparisons on the test bench. The news caught the industry completely off guard but holds enormous potential for the future of electromobility.

Axial flux machine

Axial flux machines are a specific design of electric motors in which the magnetic flux runs along the axis of rotation. Instead of a cylindrical structure with the flux flowing from inside to outside (radially), the rotor and stator in axial flux motors are like two parallel discs, with the flux running through the disc axis. This design allows for particularly compact, flat motors with high power density and efficient cooling. Due to their low weight and high torque density, axial flux machines are especially attractive for applications with limited installation space and high power requirements. They are increasingly used in electric vehicles and aerospace applications.

But last week, YASA's prototype motor hit: 550kW from a 13.1kg motor = 42kW/kg.
Yes – 42kW/kg.

Tim Woolmer, CTO at YASA Motors via LinkedIn

The new drive

What makes this new drive system from YASA so special is not just the impressive performance, but particularly the way it has been achieved. It does not rely on exotic materials. According to the LinkedIn post, cobalt-iron laminates, litz wire, or 3D printing processes are not required. This makes the technology not only more robust but also significantly cheaper and easier to scale. In fact, the system is designed to be integrated into mass production with volumes between 10,000 and 50,000 units per year at reasonable costs. Even with conventional cooling fluids and standard temperatures, the continuous power output is nearly at the level of peak power. Initial tests show that outputs exceeding 500 kW have already been achieved, thanks to the support of Drive System Design, which expanded its test bench capacities specifically for this purpose. And this is just the beginning: further tests on a larger test bench are planned for the summer.

Even more exciting is the potential that arises from this technology. Details about it will follow later this year.

Further technical data

The LinkedIn post reveals the following technical data: Voltage: 670 V, Current: 850 A, Boost duration: 5 seconds – measured at a starting temperature of approximately 50°C. Meanwhile, the project lead signs off for a short creative break. He will return in September, hopefully with further details as well as an official measurement and more specifics. (mr)