A few days ago, Mercedes finally announced the start of serial production of your axial flux motor at the historic Berlin-Marienfelde plant. This has serious implications for the future of electric cars, as the technology that powers this engine promises to redefine what a high-performance electric vehicle can do. That is why under these lines we are going to tell you all the details.
What exactly happened. On June 9, Mercedes confirmed the start of serial production of this new engine in Berlin-Marienfelde, the historic factory founded in 1902 that has now been converted into the center par excellence for the brand’s high-performance electric motors.
The first production model to debut is the new Mercedes-AMG GT 4 Door Coupea car that has also been left in the background in the conversations of recent weeks due to Ferrari and its first electric, Luce. However, this new vehicle will be the very first host of Mercedes’ new axial flow engine, which enters large-scale industrial manufacturing in a 30,000 square meter plant, three pavilions and seven production lines.
Why is this engine different?. The vast majority of current electric cars use radial flux motors. In these, the magnetic field goes from the center outward, like the spokes of a bicycle wheel. In an axial flux motor, this field runs parallel to the axis of rotation, which allows the internal components (rotor, stator, etc.) to be coupled in flat layers facing each other, something like a sandwich. This arrangement makes the engine much more compact and lighter for the power it is capable of generating.
Where does this technology come from?. The story begins in 2009, when engineers from the University of Oxford They founded the British company YASA with the aim of developing axial flux electric motors. Before arriving at Mercedes, YASA already supplied its engines to manufacturers such as Ferrari, Koenigsegg and Lamborghini. In 2021, Mercedes acquired the company seeing the potential these engines could have in their future AMG models.
From there, the challenge was to transfer this technology from the laboratory to the mass production chain, something that, according to the company itself“for a long time it was considered barely feasible due to its complexity.”
Figures. In its development phase, YASA presented an engine weighing just 13.1 kilos capable of generating 550 kW, which is equivalent to 738 HP, with a power density of about 42 kW per kilogram. It is no small feat, since if we compare these figures to those of the best radial engines, it practically doubles them. In more recent iterations, that same concept, weighing only 12.7 kilos, reached 750 kW of peak power, close to 1,000 HP.
What comes out of those production lines. The AMG GT 4 Door Coupé mounts three axial flux motors grouped in modules called High Performance Electric Drive Units, which integrate motor and reducer in the same housing. One is on the front axle, less than 9 centimeters wide, and two on the rear axle, just 8 centimeters wide.
Despite these dimensions, in its most powerful version (the AMG GT 63) the set adds 1,169 HP and 2,000 Nm of torque, with acceleration from 0 to 100 km/h in 2.1 seconds and a maximum speed of 300 km/h with the specific high-performance package.
The challenge of manufacturing it. Making this engine in series has required processes that did not exist before. And just as account Mercedes in its official publication, of the 98 stages that make up manufacturing, 65 are used for the first time within the Mercedes group and 35 are completely unprecedented worldwide, generating more than 30 patent applications.
According to the brand, one of the most technically demanding steps is what the factory calls “the wedding”, the moment in which the stator is placed between the two magnetic rotors. The magnetic forces are equivalent to about 900 kilos, and the margin of error allowed is less than a tenth of a millimeter. To do this, a control algorithm sends adjustments in the last 0.5 seconds of the process to ensure alignment.
Mbeyond the AMG GT. The axial flux engine has not arrived in Berlin just to power an electric supercar. From Autoblog they point out that, given its compact and modular design, the technology is easy to adapt to different platforms. The usual industry logic also applies here, as when production volumes increase, costs fall. So there is hope that these types of engines will end up reaching more accessible models in the future. We will have to wait to find out if it really ends up being like this. For now, ArenaEV point to the CLA as a possible future candidate.
It should be noted that Mercedes is not the only one working on axial flux engines, but it is the first to bring them to mass production in a series vehicle. Manufacturers such as Ferrari, BMW, Koenigsegg or Alpine are already investigating this technology. After all, electric cars are heavy by nature, so a lighter and more compact engine helps offset that burden without sacrificing performance. Tim Woolmer, CEO and founder of YASA, affirms that this technology “will change the game in the high-performance automotive sector.” We’ll see if it ends up being that way.
Cover image | Mercedes-Benz
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