MAXIMA: Modular Axial Flux Motor for Automotive

The MAXIMA project, funded by the Horizon Europe programme, aims to design and develop a low-cost
modular permanent magnet (PM) axial flux electrical machine (EM) for the automotive market with improved performances
while limiting the use of critical raw materials (CRM) and the environmental impact. The project started in February 2023 and
will last 4 years. To achieve this objective, the project will develop an advanced multiphysics design procedure that combines
new concepts for thermal management and a Digital Twin (DT) to optimise control strategies and operate the EM to its full
potential. To reduce costs, the project will optimise the EM's manufacturing process flow using a modular concept design for
mass production. The project will also address the EM's end-of-life by considering recycling options for the PM, which is
made from critical raw materials. To reduce the project's environmental impact, the life cycle of each solution will be analysed
using Life Cycle Assessment (LCA). The project will conclude with the manufacturing of prototypes for testing, assessment,
and validation of the new concepts addressed in MAXIMA, including the modular EM design, optimal control based on DT,
and the manufacturing/recycling process flow. Limitations of the MAXIMA project may include that the methodology being
developed must address multiple conflicting constraints, including efficiency, cost reduction, high performance in
power/torque density, and recyclability, particularly for critical raw materials. Finding a design that satisfies all of these
requirements may be challenging. Additionally, the project may face obstacles in achieving the desired balance between cost
reduction, performance improvement, and environmental impact reduction. The MAXIMA project offers a new approach to
designing and developing low-cost, high-performance EMs for the automotive market that takes into consideration the entire
value chain from raw material suppliers to car manufacturers. The project also focuses on the development of a methodology
for designing and manufacturing EMs, which will accelerate the time to market and reduce costs. Furthermore, the use of DT
for optimal control of the EM represents an innovative approach to improving performance. In conclusion, the MAXIMA
project represents a significant step forward in the development of low-cost, high-performance EMs for the automotive market.
The project brings together a diverse group of stakeholders to address the main technological and scientific challenges in
designing and manufacturing these machines while reducing their environmental impact. The project will lead to tools and
know-how which will reduce the time to market for future EMs while providing a validated methodology and new technologies
like Digital Twin for operating EMs to their full potential