Orbis Electric’s new axial flux motor fits inside a wheel, matches torque of a V8 engine

Motor-maker Orbis Electric has introduced a new axial flux motor-generator. HaloDrive is designed around a modular four-part architecture, and features innovations such as an injection-molded plastic stator and a tunable gearset.

The system is engineered to fit within a wheel, and is designed to deliver high torque and power density with great thermal stability.

HaloDrive has already been piloted by passenger vehicle OEMs for in-wheel propulsion systems and in heavy-duty truck fleets as diesel-replacement generators. According to Orbis, the electric motor improved one customer’s fleet fuel efficiency by 61%.

With a simple alteration in windings, the same motor housing and architecture can be repurposed as a high-efficiency generator. This enables an intriguing new application: using HaloDrive as a generator for electric transport refrigeration units (eTRU) in commercial trucks. Installed on the driveshaft or an axle, the HaloDrive motor converts the truck’s braking energy into electricity to power mobile refrigeration units. Orbis says when HaloDrive replaces a diesel-powered TRU, it can deliver up to a 100% reduction in diesel fuel consumption, and is 90% less expensive to operate.

Orbis boasts several benefits:

• Matching the torque of a V8 engine instantaneously, HaloDrive delivers torque density of 100 Nm/kg, outperforming conventional radial and axial flux designs.
• A compact, configurable architecture supports multiple drivetrain positions (P2, P3, P4, P5), facilitating seamless integration and rapid scaling across various applications and form factors without structural modifications.
• Up to 35% lower drivetrain costs compared to radial flux motors.
• Up to 97% operational efficiency.
• An injection-molded plastic stator (enabled by impingement oil cooling) and a tunable gear-reduction assembly amplify torque while reducing reliance on costly magnetic materials.

“With HaloDrive, we offer a high-performance axial flux motor that is not only highly efficient and powerful but also environmentally sustainable,” said Chance Claxton, CEO of Orbis Electric.

“HaloDrive not only meets the immediate electrification needs across a range of industries, but is also compact and efficient enough to position businesses for future energy and sustainability standards,” said Marcus Hays, founder and CTO of Orbis Electric. “We can achieve exceptional performance while also mitigating risks tied to rare earth materials, ensuring consistent availability and pricing stability.”

HaloDrive is now available, and Orbis Electric is seeking Tier 1 production partners as well as OEMs, fleet, and industrial clients.

Source: Orbis Electric