The future of the automotive industry is electric. The development of low-cost, highly compact and low environmental impact electrical machines (EM) is vital to the industry’s successful transition to electric vehicles. With this in mind, the EU-funded MAXIMA project will develop and validate a complete methodology to design an EM as well as the associated production system. Specifically, it will focus on a dedicated topology, axial flux synchronous machine (AFSM). While AFSM only covers a niche market due to high manufacturing costs, it provides strong unexplored options. MAXIMA’s objective is to enhance the performance and cost of ASFM by optimising the design and manufacturing/recycling processes while minimising the environmental impact.

MAXIMA aims to create a low-cost modular permanent magnet axial flux electrical machine with improved performance, and with a low environmental impact that caters specifically to the needs of the automotive market.

To achieve this, MAXIMA will develop an advanced multiphysics design procedure that includes new thermal management concepts. A digital twin will also be built to develop an optimal control strategy to operate the electrical machine up to the limit.

The end-of-life of the electrical machine will also be considered, with a focus on recycling the permanent magnet made from critical raw materials. MAXIMA will conduct a life cycle assessment for every solution, analyzing its impact throughout the lifecycle, with the goal of minimizing the environmental impact.

At the end of the project, prototypes will be manufactured for testing, assessment, and validation of the new concepts addressed in MAXIMA related to the modular design of the electrical machine, the optimal control based on the digital twin and the manufacturing/recycling process flow.