Discover how Beyond Motors achieves 1.2MW power via modular axial stacking. Learn about 10kW/kg density and torque density for heavy-duty propulsion.
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Discover how Beyond Motors achieves 1.2MW power via modular axial stacking. Learn about 10kW/kg density and torque density for heavy-duty propulsion.
In the engineering race to electrify heavy-duty transit, high-speed nautical vessels, and multi-ton cargo UAVs, the primary bottleneck has always been scalability. Traditionally, reaching megawatt-class power meant commissioning a custom, massive radial motor a process plagued by high R&D costs, manufacturing long-leads, and extreme integration weight.
At Beyond Motors, we have approached the problem through the lens of modularity. By leveraging the unique "pancake" geometry of our axial flux motor architecture, we have unlocked a path to 1.2MW of output through modular axial stacking. This approach doesn't just scale power; it scales the ROI of the entire powertrain.
In a traditional radial motor, increasing power typically requires increasing the length or the diameter of the rotor. This often results in "length-to-diameter" (L/D) ratios that create mechanical instability or require a complete chassis redesign.
Because axial flux motors are exceptionally thin, they are inherently "stackable." By aligning multiple rotors and stators on a single common shaft, we can multiply torque and power output without increasing the diameter of the motor housing.
Reaching the megawatt threshold requires more than just "adding more motors." It requires precise electromagnetic and mechanical synchronization. Our high-performance e-motors are designed with a hollow-center architecture and an internally splined hub, allowing for seamless mechanical coupling.
One might assume that stacking motors leads to weight penalties. On the contrary, our modular approach maintains a world-class power density of 10 kW/kg. By sharing structural end-plates and a unified cooling manifold across the stack, we minimize "dead weight," ensuring that a 1.2MW stack remains significantly lighter than any equivalent radial solution.
Two major hurdles exist in multi-stack electric propulsion: phase synchronization and thermal management.
In a triple-stack configuration (the AXM4 Triple), the central motor is often the most thermally challenged. We solve this via our patent-pending water cooling system. By utilizing a parallel-flow cooling manifold, each stator in the stack receives fresh coolant at the same temperature. This prevents the "thermal soak" effect, allowing for unmatchable continuous power even at megawatt levels.
Each motor in the stack can be driven by its own independent inverter. For CTOs in the aerospace and nautical sectors, this provides a built-in "fail-safe." If one inverter channel fails, the remaining motors in the stack continue to provide high-torque propulsion, ensuring mission safety and "limp-home" capability.
The ability to stack our motors up to 1.2MW opens up sectors that were previously unreachable for pure electric drives:
Scaling to 1.2MW shouldn't require a blank-sheet redesign. With the Beyond Motors AXM series, we provide a validated, high-density building block that grows with your project. Whether you are starting with a 200kW prototype or a 1.2MW production vessel, the architectural foundation remains the same.
Are you ready to design your megawatt powertrain?
If your project requires custom specs, sizing, or specific project requirements, our technical team is ready to provide the specific efficiency maps and CAD data needed to scale your project.
