Axial FLUX motor assembly and manufacture

Abstract

The present disclosure is directed to an axial flux motor, including: a housing; a stator assembly including a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing including at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field without the at least one hole exceeding a threshold.

Description

Attorney Docket Number: 10654-2504882AXIAL FLUX MOTOR ASSEMBLY AND MANUFACTURECROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 63 / 692,905, filed on September 10, 2024, the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUNDField

[0002] The present disclosure relates to axial flux motors, methods of manufacturing the same, and methods of adjusting the same.Technical Considerations

[0003] Axial flux motors are electric motors in which the gap between the rotor and stator is aligned parallel with the axis of rotation, such that the direction of magnetic flux therebetween is aligned parallel with the axis of rotation, rather than radially aligned with the axis of rotation.

[0004] While axial flux motors can be highly efficient and have a variety of important applications, certain challenges arise based on the geometry of their design. For example, the strong metallic housing, which is electrically conductive, provides high mechanical integrity, but such housing can also result in locations of high concentration of fluctuating magnetic fields causing electrical eddy currents induced by these fields, which can be detrimental to motor performance. Moreover, such motors often use concentrated windings that have a high number of winding connections, thus increasing the complexity in manufacturing the motor. Still further, once assembled, such motors can be difficult to adjust without first disassembling the motor.SUMMARY

[0005] The present disclosure relates to axial flux motors, methods of manufacturing the same, and methods of adjusting the same that overcome some or all of the deficiencies identified above.Page 1 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0006] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing including at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field without the at least one hole exceeding a threshold.

[0007] In some non-limiting embodiments or aspects, the at least one hole may not be defined entirely through the housing.

[0008] In some non-limiting embodiments or aspects, the at least one hole may be defined entirely through the housing.

[0009] In some non-limiting embodiments or aspects, the axial flux motor may further include a coolant flowed through the at least one hole.

[0010] In some non-limiting embodiments or aspects, the axial flux motor may further include a non-conductive material arranged in the at least one hole.

[0011] In some non-limiting embodiments or aspects, the threshold may include a local leakage flux density exceeding an average leakage flux density within 10-30 mm of a stator assembly surface by at least 25%, such as at least 50% or at least 75% and / or the threshold comprises a local leakage flux density of from 5-200 mT within 10-30 mm of the stator surface.

[0012] In some non-limiting embodiments or aspects, the stator may include a plurality of permanent magnets, where the at least one hole may be arranged in the housing adjacent to a magnet of the plurality of magnets.

[0013] In some non-limiting embodiments or aspects, the at least one hole may be arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.

[0014] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing including at least one hole defined at least partially therethrough, the at least one hole is arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.Page 2 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0015] The present disclosure relates to a method of manufacturing an axial flux motor, the method including: arranging a housing; fixing a stator assembly to the housing; and arranging a rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing; and defining at least one hole in the housing, the at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold.

[0016] In some non-limiting embodiments or aspects, the method may further include: before defining the at least one hole, testing the axial flux motor to determine concentration of fluctuating magnetic field in at least one location of the housing; and based on the determined concentration of fluctuating magnetic field in the at least one location of the housing, identifying the location of the housing having a concentration of fluctuating magnetic field exceeding a threshold.

[0017] In some non-limiting embodiments or aspects, the testing may include modeling, with a modeling system, the concentration of fluctuating magnetic field in the at least one location of the housing.

[0018] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator including a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further including a concentrated winding arrangement in which a first winding including a first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

[0019] In some non-limiting embodiments or aspects, the winding arrangement may further include: a second winding including a second, single length of wire wound around a second subset of the plurality of poles corresponding to a second phase; and a third winding including a third, single length of wire wound around a third subset of the plurality of poles corresponding to a third phase.

[0020] In some non-limiting embodiments or aspects, the first single length of wire may include a multistrand wire including a plurality of parallel strands.

[0021] In some non-limiting embodiments or aspects, the plurality of parallel strands may be individually isolated from one another, such as Litz wire.

[0022] The present disclosure relates to a method of manufacturing an axial flux motor, the method including: winding a concentrated winding arrangement around aPage 3 of 316761723. DOCXAttorney Docket Number: 10654-2504882 stator including a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the winding arrangement including winding a first winding including a first, single length of wire around a first subset of the plurality of poles corresponding to a first phase.

[0023] In some non-limiting embodiments or aspects, the method may include: fixing the wound stator to the housing; and arranging a rotor spaced apart from the wound stator along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

[0024] In some non-limiting embodiments or aspects, winding the concentrated winding arrangement may include: winding a second winding including a second, single length of wire around a second subset of the plurality of poles corresponding to a second phase; and winding a third winding including a third, single length of wire around a third subset of the plurality of poles corresponding to a third phase.

[0025] In some non-limiting embodiments or aspects, the concentrated winding arrangement may be pre-prepared separate from the stator, the winding the concentrated winding arrangement around the stator may further include: securing the pre-prepared concentrated winding arrangement to corresponding poles of the stator.

[0026] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator assembly including a carriage and the stator including a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, where the stator is mounted to the carriage, and the carriage is mounted to the housing, where the carriage is configured to adjust a distance that the stator is spaced apart from the rotor.

[0027] In some non-limiting embodiments or aspects, the carriage may mechanically isolate the stator from the housing, where the carriage may optionally thermally, electrically, and / or magnetically isolate the stator from the housing.

[0028] In some non-limiting embodiments or aspects, the carriage may be mounted to a surface of the housing, where the carriage may be configured to be adjustably moved in a direction perpendicular to the surface.

[0029] In some non-limiting embodiments or aspects, the carriage may be configured to adjust a distance that the stator is spaced apart from the rotor withoutPage 4 of 316761723. DOCXAttorney Docket Number: 10654-2504882 disassembling a first stator assembly and a rotor assembly from a second stator assembly.

[0030] The present disclosure relates to a method of adjusting an axial flux motor, the method including: providing the axial flux motor described herein; adjusting a position of the carriage to adjust the distance that the stator is spaced apart from the rotor.

[0031] In some non-limiting embodiments or aspects, the position of the carriage may be adjusted before, between, and / or after operation of the axial flux motor.

[0032] In some non-limiting embodiments or aspects, the position of the carriage may be adjusted during operation of the axial flux motor, thereby adjusting a magnetic flux of the axial flux motor.

[0033] In some non-limiting embodiments or aspects, the position of the carriage may be adjusted without disassembling the first stator assembly and the rotor assembly from the second stator assembly.

[0034] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; further including a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly including the rotor.

[0035] In some non-limiting embodiments or aspects, the bearing may not be attached directly to the housing.

[0036] In some non-limiting embodiments or aspects, the rotor may be arranged between and spaced apart from a plurality of stator assemblies, where a position of the rotor between the plurality of stator assemblies may be adjustable after assembly of the axial flux motor.

[0037] In some non-limiting embodiments or aspects, the position of the rotor between the plurality of stator assemblies may be adjustable by the bearing mount being configured to adjust a distance that the rotor is spaced apart from the housing.

[0038] The present disclosure relates to a method of manufacturing an axial flux motor including: preparing a bearing mount holding a bearing, the bearing mount configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly including a rotor; attaching the bearing mount to the housing; fixing a stator assembly comprising a stator to a housing; and arranging thePage 5 of 316761723. DOCXAttorney Docket Number: 10654-2504882 rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

[0039] The present disclosure relates to an axial flux motor including: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing including at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold, the stator including a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further including a concentrated winding arrangement in which a first winding including a first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

[0040] In some non-limiting embodiments or aspects, the stator assembly may include a carriage and a stator including the plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator may be mounted to the carriage, and the carriage may be mounted to the housing, the carriage may be configured to adjust a distance that the rotor is spaced apart from the stator assembly.

[0041] In some non-limiting embodiments or aspects, the axial flux motor may include a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly including the rotor.

[0042] The present disclosure also includes the following clauses.

[0043] Clause 1 : An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing comprising at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field without the at least one hole exceeding a threshold.

[0044] Clause 2: The axial flux motor of clause 1 , wherein the at least one hole is not defined entirely through the housing.

[0045] Clause 3: The axial flux motor of clause 1 or 2, wherein the at least one hole is defined entirely through the housing.

[0046] Clause 4: The axial flux motor of clause 3, further comprising a coolant flowed through the at least one hole.Page 6 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0047] Clause 5: The axial flux motor of any of clauses 1 -4, further comprising a non-conductive material arranged in the at least one hole.

[0048] Clause 6: The axial flux motor of any of clauses 1 -5, wherein the threshold comprises a local leakage flux density exceeding an average leakage flux density within 10-30 mm of a stator surface by at least 25%, such as at least 50% or at least 75% and / or the threshold comprises a local leakage flux density of from 5-200 mT within 10-30 mm of the stator surface.

[0049] Clause 7: The axial flux motor of any of clauses 1 -6, wherein the stator comprises a plurality of permanent magnets, wherein the at least one hole is arranged in the housing adjacent to a magnet of the plurality of magnets.

[0050] Clause 8: The axial flux motor of any of clauses 1 -7, wherein the at least one hole is arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.

[0051] Clause 9: An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing comprising at least one hole defined at least partially therethrough, the at least one hole is arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.

[0052] Clause 10: A method of manufacturing an axial flux motor, such as the axial flux motor of any of clauses 1 -9, comprising: arranging a housing; fixing a stator assembly comprising a stator to the housing; and arranging a rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing; and defining at least one hole in the housing, the at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold.

[0053] Clause 1 1 : The method of manufacturing the axial flux motor of clause 10, comprising: before defining the at least one hole, testing the axial flux motor to determine concentration of fluctuating magnetic field in at least one location of the housing; and based on the determined concentration of fluctuating magnetic field in the at least one location of the housing, identifying the location of the housing having a concentration of fluctuating magnetic field exceeding a threshold.Page 7 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0054] Clause 12: The method of manufacturing the axial flux motor of clause 1 1 , wherein the testing comprises modeling, with a modeling system, the concentration of fluctuating magnetic field in the at least one location of the housing.

[0055] Clause 13: An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further comprising a concentrated winding arrangement in which a first winding comprising a first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

[0056] Clause 14: The axial flux motor of clause 13, the winding arrangement further comprising: a second winding comprising a second, single length of wire wound around a second subset of the plurality of poles corresponding to a second phase; and a third winding comprising a third, single length of wire wound around a third subset of the plurality of poles corresponding to a third phase.

[0057] Clause 15: The axial flux motor of clause 13 or 14, wherein the first single length of wire comprises a multistrand wire comprising a plurality of parallel strands.

[0058] Clause 16: The axial flux motor of clause 15, wherein the plurality of parallel strands are individually isolated from one another, such as Litz wire.

[0059] Clause 17: A method of manufacturing an axial flux motor, such as the axial flux motor of any of clauses 13-16, comprising: winding a concentrated winding arrangement around a stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the winding arrangement comprising winding a first winding comprising a first, single length of wire around a first subset of the plurality of poles corresponding to a first phase.

[0060] Clause 18: The method of manufacturing the axial flux motor of clauses 17, comprising: fixing the wound stator to the housing; and arranging a rotor spaced apart from the wound stator along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

[0061] Clause 19: The method of manufacturing the axial flux motor of clause 17 or 18, winding the concentrated winding arrangement comprising: winding a second winding comprising a second, single length of wire around a second subset of the plurality of poles corresponding to a second phase; and winding a third windingPage 8 of 316761723. DOCXAttorney Docket Number: 10654-2504882 comprising a third, single length of wire around a third subset of the plurality of poles corresponding to a third phase.

[0062] Clause 20: The method of manufacturing the axial flux motor of any of clauses 17-19, wherein the concentrated winding arrangement is pre-prepared separate from the stator, the winding the concentrated winding arrangement around the stator further comprising: securing the pre-prepared concentrated winding arrangement to corresponding poles of the stator.

[0063] Clause 21 : An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator assembly comprising a carriage and the stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, wherein the stator is mounted to the carriage, and the carriage is mounted to the housing, wherein the carriage is configured to adjust a distance that the stator is spaced apart from the rotor.

[0064] Clause 22: The axial flux motor of clause 21 , wherein the carriage mechanically isolates the stator from the housing, wherein the carriage optionally thermally, electrically, and / or magnetically isolates the stator from the housing.

[0065] Clause 23: The axial flux motor of clause 21 or 22, wherein the carriage is mounted to a surface of the housing, wherein the carriage is configured to be adjustably moved in a direction perpendicular to the surface.

[0066] Clause 24: The axial flux motor of any of clauses 21 -23, wherein the carriage is configured to adjust a distance that the stator is spaced apart from the rotor without disassembling a first stator assembly and a rotor assembly from a second stator assembly.

[0067] Clause 25: A method of adjusting an axial flux motor, comprising: providing the axial flux motor of any of clauses 21 -24; adjusting a position of the carriage to adjust the distance that the stator is spaced apart from the rotor.

[0068] Clause 26: The method of adjusting the axial flux motor of clause 25, wherein the position of the carriage is adjusted before, between, and / or after operation of the axial flux motor.

[0069] Clause 27: The method of adjusting the axial flux motor of clause 25 or 26, wherein the position of the carriage is adjusted during operation of the axial flux motor, thereby adjusting a magnetic flux of the axial flux motor.Page 9 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0070] Clause 28: The method of adjusting the axial flux motor of any of clauses 25- 27, wherein the position of the carriage is adjusted without disassembling the first stator assembly and the rotor assembly from the second stator assembly.

[0071] Clause 29: An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; further comprising a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising the rotor.

[0072] Clause 30: The axial flux motor of clause 29, wherein the bearing is not attached directly to the housing.

[0073] Clause 31 : The axial flux motor of clause 29 or 30, comprising the rotor arranged between and spaced apart from a plurality of stator assemblies, wherein a position of the rotor between the plurality of stator assemblies is adjustable after assembly of the axial flux motor.

[0074] Clause 32: The axial flux motor of claim 31 , wherein the position of the rotor between the plurality of stator assemblies is adjustable by the bearing mount being configured to adjust a distance that the rotor is spaced apart from the housing.

[0075] Clause 33: A method of manufacturing an axial flux motor, such as the axial flux motor of any of clauses 29-32, comprising: preparing a bearing mount holding a bearing, the bearing mount configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising a rotor; attaching the bearing mount to the housing; fixing a stator assembly comprising a stator to a housing; and arranging the rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

[0076] Clause 34: An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing comprising at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold, the stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further comprising a concentrated winding arrangement in which a first winding comprising aPage 10 of 316761723. DOCXAttorney Docket Number: 10654-2504882 first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

[0077] Clause 35: The axial flux motor of clause 34, wherein: the stator assembly comprises a carriage and a stator comprising the plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator is mounted to the carriage, and the carriage is mounted to the housing, the carriage is configured to adjust a distance that the rotor is spaced apart from the stator assembly.

[0078] Clause 36: The axial flux motor of clause 34 or 35, further comprising: a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising the rotor.

[0079] These and other features and characteristics of the present disclosure, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Additional advantages and details are explained in greater detail below with reference to the non-limiting, exemplary embodiments that are illustrated in the accompanying schematic figures, in which:

[0081] FIGS. 1 A-1 B show schematic diagrams of an axial flux motor, according to non-limiting embodiments or aspects of the present disclosure;

[0082] FIG. 2 shows a view of an axial flux motor housing including magnetic holes, according to non-limiting embodiments or aspects of the present disclosure;

[0083] FIG. 3 shows several views of a stator and housing assembly, according to non-limiting embodiments or aspects of the present disclosure;

[0084] FIG. 4 shows a view of a single phase of windings assembled to a stator, according to non-limiting embodiments or aspects of the present disclosure;Page 1 1 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0085] FIG. 5 shows a view of a three phase set of windings for assembly onto a stator, according to non-limiting embodiments or aspects of the present disclosure; and

[0086] FIG. 6 shows a process flow diagram of a method of manufacturing an axial flux motor, according to non-limiting embodiments or aspects of the present disclosure.DETAILED DESCRIPTION

[0087] For purposes of the following detailed description, it is understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0088] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in its respective testing measurement.

[0089] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0090] In this application, the use of the singular includes the plural and plural encompasses the singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and / or” unless specifically stated otherwise, evenPage 12 of 316761723. DOCXAttorney Docket Number: 10654-2504882 though “and / or” may be explicitly used in certain instances. Further, in this application, the use of “a” or “an” means “at least one” unless specifically stated otherwise.

[0091] As used herein, the transitional term “comprising” (and other comparable terms, e.g., “containing” and “including”) is “open-ended” and open to the inclusion of unspecified matter. Although described in terms of “comprising”, the terms “consisting essentially of” and “consisting of” are also within the scope of the disclosure.

[0092] Referring to FIGS. 1 A and 1 B, the present disclosure is directed to an axial flux motor 10. An axial flux motor is motor in which the magnetic flux flow axially (or parallel to) the motor shaft. This is in contrast to radial flux motors where the magnetic flux flows radially between the rotor and stator. The distinct configuration of axial flux motors provides several notable benefits, particularly in improving power density and efficiency. Axial flux motors may include rare earth permanent magnets.

[0093] FIGS. 1 A and 1 B show non-limiting examples of an axial flux motor 10. Axial flux motor 10 may be an electric motor. In FIG. 1 A, a dual rotor axial flux motor 10 is shown, whereas in FIG. 1 B, a dual stator axial flux motor is shown. While dual rotor and dual stator design varieties are shown, it will be appreciated that other numbers and arrangements of rotors and stators are within the scope of the present disclosure, such as a single stator, single rotor design.

[0094] FIG. 1 A shows axial flux motor 10 having a stator 12 arranged between a first and second rotor 14a, 14b. Stator 12 may be spaced apart from rotors 14a, 14b, such that there is a gap therebetween. Rotors 14a, 14b may be configured to rotate relative to stator 12 and housing 18 (see FIG. 2). Rotors 14a, 14b may have a plurality of permanent magnets 16 arranged around the perimeter thereof. Permanent magnets 16 may be arranged on a surface of rotors 14a, 14b adjacent to stator 12.

[0095] FIG. 1 B shows axial flux motor 10 having a rotor 14 arranged between a first and second stator 12a, 12b. Rotor 14 may be spaced apart from stators 12a, 12b, such that there is a gap therebetween. Rotor 14 may be configured to rotate relative to stator 12 and housing 18 (see FIG. 2). Stators 12a, 12b may have a plurality of permanent magnets 16 arranged around the perimeter thereof. Permanent magnets 16 may be arranged on a surface of stators 12a, 12b adjacent to rotor 14.

[0096] Axial flux motor 10 of the present disclosure may be particularly suited for use in a number of applications. These applications include, but are not limited to, automotive and / or transportation applications, aerospace and / or aviation applications, heating, ventilation, and air conditioning (HVAC) applications, data center coolingPage 13 of 316761723. DOCXAttorney Docket Number: 10654-2504882 applications, industrial machinery applications, renewable energy systems applications, defense applications, and the like.1. Selectively Arranged Holes

[0097] Referring to FIG. 2, axial flux motor 10 may comprise: a housing 18 having at least one stator assembly comprising a stator 12 and at least one rotor 14 (not shown) arranged therein. Stator assembly may be fixed to housing 18. Rotor 14 may be rotatable relative to housing 18. Rotor 14 may be spaced apart from stator assembly (and thus stator 12) along a rotation axis of the rotor (see FIG. 1 A-1 B). Housing 18 may comprise at least one (e.g., a plurality of) hole 20 defined at least partially therethrough, the at least one hole 20 arranged at a location of the housing 18 having a concentration of fluctuating magnetic field without the at least one hole 20 exceeding a threshold.

[0098] Housing 18 may be made of metal and / or other electrically conductive material. Housing 18 being made of metal may provide for suitable structural integrity of axial flux motor 10. Removing metal material from housing 18 as described in the present disclosure may mitigate excess energy losses that would have been caused by the non-removed section of the metal housing 18.

[0099] The at least one hole 20 may be defined entirely through housing 18. For example, housing 18 may be manufactured and then holes 20 subsequently drilled completely through one or more sections of the housing, or the housing may be manufactured to contain the holes 20 entirely therethrough. A wall of a section of housing 18 may be completely removed such that the hole 20 goes entirely therethrough.

[0100] The at least one hole 20 may not be defined entirely through housing 18. For example, the holes 20 may be only partially defined through housing 18. For example, housing 18 may be manufactured and then holes 20 subsequently drilled only partially (less than fully) through one or more sections of housing 18, or the housing may be manufactured to contain holes 20 partially therethrough. A wall of a section of housing 18 may be partially removed such that the hole 20 goes partially but not entirely therethrough. Partially therethrough may be at least 10% (by distance) therethrough, such as at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, or at least 70% therethrough. Partially therethrough may be less than 100% (by distance) therethrough, such as less than 95%, less than 90%, or less than 80% therethrough.Page 14 of 316761723. DOCXAttorney Docket Number: 10654-2504882Partially therethrough may be from 10% to less 100% (by distance) therethrough, such as from 20%-80%, from 40%-70%, or from 50%-60% therethrough.

[0101] In some non-limiting embodiments or aspects, axial flux motor 10 may further comprise a coolant (not shown) flowed through at least one hole 20. For example, one or more tubular channel (e.g., tube, hose, pipe, etc.) may flow coolant through hole 20. The coolant may be used to cool one or more component of axial flux motor 10 before, during, and / or after operation thereof. Coolant may cool stator 12, which may be a heat-generating component of axial flux motor 10 during operation. Coolant may comprise any suitable liquid material configured to cool components of axial flux motor 10. Non-limiting examples of coolants include at least one of the following: water, oil, ethylene glycol-based coolant, and / or any combination thereof. Use of a coolant can increase efficiency of axial flux motor 10, improve thermal management thereof, and even reduce size and / or weight of axial flux motor 10.

[0102] In some non-limiting embodiments or aspects, holes 20 (whether partial or full) may not be filled with material. In some non-limiting embodiments or aspects, holes 20 (whether partial or full) may comprise a non-conductive material arranged in at least a portion of the hole 20. For example, hole 20 may be filled with the liquid coolant as previously described. For example, hole 20 may be filled with a non- conductive polymeric material. Non-limiting examples of non-conductive materials that may be used to at least partially fill hole 20 include at least one of the following: polyamide (PI), polysulfone (PSU), polyetherimide (PEI), polyphenylene sulfide (PPS), and / or any combination thereof.

[0103] Holes 20 may be defined in one or more sections of housing 18. Location of holes 20 in housing 18 may be selected based on a concentration of fluctuating magnetic field in various regions of the housing 18 that initially does not have holes 20. Before defining at least one hole 20 in housing 18, housing 18 may be tested to determine concentration of fluctuating magnetic field in at least one location of housing 18. Based on the determined concentration of fluctuating magnetic field in the at least one location of housing 18, locations of housing 18 having a concentration of fluctuating magnetic field exceeding a threshold may be identified. One or more of these identified regions of housing 18 may then be modified to include at least one hole 20 in the region. Modifying housing 18 to include holes in identified regions thereof may reduce eddy currents induced by axial flux motor 10 compared to the same axial flux motor 10 except without at least one hole 20. In other words, thePage 15 of 316761723. DOCXAttorney Docket Number: 10654-2504882 arrangement of holes 20 in housing 18 may reduce eddy currents induced by axial flux motor 10 compared to the same axial flux motor 10 except without at least one hole 20.

[0104] The threshold for determining hole 20 location may comprise a local leakage flux density exceeding an average leakage flux density within 10-30 mm of stator 12 surface by at least 25%, such as at least 50% or at least 75%. Additionally and / or alternatively, the threshold for determining hole 20 location may comprise a local leakage flux density of from 5-200 mT (0.005-0.2 T) within 10-30 mm of the stator surface. Determining the threshold and / or where to arrange the at least one hole may involve an iterative process in which high intensity of alternating field inducing eddy currents are observed (e.g., via modeling and / or experimentation), material in the location is removed, and the revised geometry is tested (e.g., via modeling and / or experimentation), and the process is iterated as needed to reduce eddy currents and the concomitant ohmic losses.

[0105] Stator 12 may comprise a plurality of permanent magnets 16 (see FIG. 1 B), wherein at least one hole 20 is arranged in housing 18 adjacent to a magnet 16 of the plurality of magnets. Adjacent to in this case may mean that hole 20 is directly aligned with the magnet 16 and extends some distance away (all the way through or not). Adjacent may refer to a hole 20 whose center aligns with some part (e.g., is within the projected area) of the nearest magnet face. In some non-limiting embodiments, material may be removed from 0 to 6 mm from the magnet 16.

[0106] In some non-limiting embodiments or aspects, the axial flux motor may comprise: housing 18; stator assembly comprising a stator 12 fixed to housing 18; and rotor 14 rotatable relative to housing 18, rotor 14 spaced apart from stator assembly along a rotation axis of rotor 14; housing 18 comprising at least one hole 20 defined at least partially therethrough, the at least one hole 20 arranged to reduce eddy currents induced by axial flux motor 10 compared to the same axial flux motor 10 except without at least one hole 20.

[0107] A method of manufacturing an axial flux motor (e.g., axial flux motor 10 of FIG. 2) may comprise: arranging housing 18; fixing stator assembly comprising a stator 12 to housing 18; and arranging rotor 14 spaced apart from stator assembly along a rotation axis of rotor 14. Rotor 14 may be arranged rotatable relative to housing 18. The method may include defining at least one hole 20 in housing 18, the at least one hole 20 defined at least partially therethrough. The at least one hole 20Page 16 of 316761723. DOCXAttorney Docket Number: 10654-2504882 may be arranged at a location of housing 18 having a concentration of fluctuating magnetic field exceeding a threshold. As shown in method 100 of FIG. 6, Step 1 , housing 18 may be manufactured having holes 20 as described herein by machining housing 18 to the determined shape.

[0108] The method may further comprise: before defining at least one hole 20, testing axial flux motor 10 to determine concentration of fluctuating magnetic field in at least one location of housing 18; and based on the determined concentration of fluctuating magnetic field in the at least one location of housing 18, identifying the location of housing 18 having a concentration of fluctuating magnetic field exceeding a threshold.

[0109] Testing may encompass modeling and / or experimental testing, and / or otherwise performing an analysis on a real and / or simulated motor (or components thereof).

[0110] The testing may comprise experimental testing in which an actual and / or model axial flux motor is built and subsequently tested for local leakage flux density.

[0111] The testing may comprise modeling, with a modeling system, the concentration of fluctuating magnetic field in the at least one location of the housing. For example, the modeling system may comprise a modeling software configured to simulate conditions of an axial flux motor design.

[0112] A result of the testing may comprise measurements and / or determinations of a local leakage flux density relative to locations of housing 18. Regions of housing 18 determined to have local leakage flux density exceeding a threshold may be modified to include one or more holes 20.2. Single Length Wire Per Phase

[0113] Referring to FIGS. 4-5, a winding arrangement 28 is shown for axial flux motor 10 that may comprise: housing 18; stator assembly comprising a stator 12 fixed to housing 18; and rotor 14 rotatable relative to housing 18, rotor 14 spaced apart from stator assembly along a rotation axis of rotor 14 (see FIGS. 1 B-2 for foregoing components). Stator 12 may comprise a plurality of poles 30 spaced apart from one another and arranged around a perimeter of stator 12. Stator 12 may further include a concentrated winding arrangement 28 in which a first winding comprising a first, single length of wire 32 is wound around a first subset of the plurality of poles 30 corresponding to a first phase.Page 17 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0114] Distributed windings (sometimes called lap or wave windings, hairpin is one type) may include one length of wire 32 running through multiple slots around the machine. Concentrated windings may include the wire 32 wound at least one time around one pole 30 and two leads come out one side. The leads are then connected as needed. The present disclosure may use concentrated windings, but the concentrated windings in a phase may all be in one length of wire 32. A distributed winding may be a technical term used to describe a spatially varying effective flux linkage with the winding. A concentrated winding may have a flux linkage that is “concentrated” at discrete locations within the motor.

[0115] As shown in FIG. 5, winding arrangement 28 may further comprise a plurality of separate windings (e.g., a first, second, and third winding). Second winding may comprise a second, single length of wire 32b wound around a second subset of the plurality of poles 30 corresponding to a second phase; and third winding may comprise a third, single length of wire 32c wound around a third subset of the plurality of poles 30 corresponding to a third phase. First, second, and third wires 32a-32c may each be separate wires.

[0116] The single lengths of wire may each comprise a multistrand wire comprising a plurality of parallel strands 34.

[0117] The plurality of parallel strands 34 may be individually isolated from one another. For example, wire 32a-32c may comprise Litz wire. The utility of creating a full phase of windings from one length of multi-strand and / or Litz wire may be the reduction in number of required connections, which can be a particularly timeconsuming process when using Litz wire.

[0118] A method of manufacturing axial flux motor 10 may comprise: winding concentrated winding arrangement 28 around stator 12 comprising a plurality of poles 30 spaced apart from one another and arranged around a perimeter of stator 12. Winding arrangement 28 may comprise winding a first winding comprising a first, single length of wire 32a around a first subset of the plurality of poles 30 corresponding to a first phase.

[0119] The method may comprise: fixing the wound stator 12 to housing 18; and arranging rotor 14 spaced apart from the wound stator 12 along a rotation axis of rotor 14, rotor 14 arranged rotatable relative to housing 18.

[0120] Winding concentrated winding arrangement 28 may comprise: winding a second winding comprising a second, single length of wire 32b around a secondPage 18 of 316761723. DOCXAttorney Docket Number: 10654-2504882 subset of the plurality of poles 30 corresponding to a second phase; and winding a third winding comprising a third, single length of wire 32c around a third subset of the plurality of poles 30 corresponding to a third phase.

[0121] In some non-limiting embodiments or aspects, as shown in FIG. 4 and Step 2b of FIG. 6, the single length wires 32a-32c may be directly wound around their respective poles 30 to form the phases.

[0122] As a non-limiting example of a three-phase winding, a wire of first phase may be wound around one stator pole, and the wires for second phase and third phase may be wound around the next poles in order. Next, the wires may be routed to the next pole in the same phase and wound around the corresponding pole again. The process may be repeated until all phases are wound.

[0123] In the non-limiting example of FIG. 4, a 6-pole phase may have 12 ends that need connected if a single coil is not used, but using a single coil (e.g., wire) for the entire 6-pole phase as described in the current disclosure may have only 2 ends, such that the present disclosure may simplify the design of axial flux motor 10.

[0124] In some non-limiting embodiments or aspects, as shown in FIG. 5 and Step 2a of FIG. 6, concentrated winding arrangement 28 may be pre-prepared separate from stator 12, and the winding the concentrated winding arrangement 28 around stator 12 may further comprise: securing the pre-prepared concentrated winding arrangement 28 to corresponding poles 30 of stator 12. For example, the preprepared concentrated winding 28 may be formed prior to adhering to stator 12, such as by winding the wires to a mandrel, finishing the coils (e.g., adhere / twist to bobbin, wire heat bonding, impregnate and anneal, etc.), and weaving and terminating the winding harness. Pre-prepared concentrated winding 28 may then be adhered to stator 12 as shown in FIG. 4.

[0125] As a non-limiting example of a three-phase winding pre-prepared and added to the stator, a winding machine may be used. First, the wire may be secured to a rotating mandrel, and the wire may be fed onto a mandrel matching the geometry of one pole. After completing the correct number of turns, the wire may be fed onto another identical mandrel located on the same rotating spindle. The process may be repeated until the number of poles per phase are wound onto the mandrels on the winding machine. Next, the coils may be secured with either tape, vacuum pressure impregnation, a heat-setting wire coating, or some other method and removed from mandrels. Coils may potentially be wound with or without bobbins. Finally, threePage 19 of 316761723. DOCXAttorney Docket Number: 10654-2504882 continuous lengths of connected coils may be arranged together in a braided fashion (see Fig. 5) and inserted onto the proper stator poles corresponding to phases 1 -3.3. Movable Stator Assembly Relative to Housing

[0126] Referring to FIG. 3, an axial flux motor 10 is shown. Axial flux motor 10 is shown according to (a) a perspective view, (b) a top view, (c) a side view, and (d) a bottom view. As previously described (and shown in FIGS. 1 B, 2, and 4) axial flux motor 10 may comprise: housing 18; stator assembly comprising stator 12 fixed to housing 18; and rotor 14 rotatable relative to housing 18, rotor 14 spaced apart from stator assembly along a rotation axis of rotor 14.

[0127] Stator assembly may comprise a carriage 22 and stator 12 may comprise a plurality of poles 30 spaced apart from one another and arranged around a perimeter of the stator 12. Stator 12 may be mounted to carriage 22, and carriage 22 may be mounted to housing 18. Carriage 22 may be configured to adjust a distance (see gaps between stators 12a-12b and rotor 14 in FIG. 1 B) that stator 12 is spaced apart from rotor 14. For example, carriage 22 may be adjusted such that a surface thereof moves farther away from or closer to the surface of housing 18 to which it is attached. Carriage 22 may be mounted to a surface of housing 18 such that carriage 22 is configured to be adjustably moved in a direction perpendicular to the surface of housing 18. This movement of carriage 22 farther away from or closer to the surface of housing 18 (e.g., up and down relative to housing 18) may adjust the distance of stator 12 from housing 18 (and also the distance between stator 12 and rotor 14). Thus, carriage 22 may be adjustable in order to adjust (e.g., select) a distance between stator 12 and rotor 14.

[0128] With continued reference to FIG. 3, carriage 22 may mechanically isolate stator 12 from housing 18. In some non-limiting embodiments or aspects, carriage 22 may thermally, electrically, and / or magnetically isolate stator 12 from housing 18. Carriage 22 may be made of at least one of the following: a polymeric material, a metal, a composite material, and / or any combination thereof. Stator 12 may be fixed to carriage 22 using an adhesive. Carriage 22 may be attached to housing 18 in a manner which facilitates its movements along one or more axes. Carriage 22 may be attached to housing 18 by one or more fastening features, sliding features, or other alignment features.Page 20 of 316761723. DOCXAttorney Docket Number: 10654-2504882

[0129] Carriage 22 may be configured to adjust a distance that stator 12 is spaced apart from rotor 14 without disassembling a first stator assembly and a rotor assembly (e.g., comprising rotor 14) from a second stator assembly. Thus, the design of carriage 22 may enable easier adjustment of stator 12 relative to rotor 14 without significantly disassembling axial flux motor 10.

[0130] As shown in FIGS. 1 B-3, housing 18 may contain a stator assembly on each side of a rotor assembly, and additional part(s) may be arranged in between which hold the distance between the two and obstruct ingress. The design described in the present disclosure avoids disassembling the two stator-housing subassemblies from the rotor subassembly to change the rotor-stator gap. The position of carriage 22 may be adjusted without disassembling the first stator assembly and the rotor assembly from the second stator assembly.

[0131] A method of adjusting an axial flux motor 10 as shown in FIG. 3 may comprise: providing axial flux motor 10 as shown and described herein; and adjusting a position of carriage 22 to adjust the distance that stator 12 is spaced apart from rotor 14.

[0132] The position of carriage 22 may be adjusted before, between, and / or after operation of axial flux motor 10.

[0133] The position of carriage 22 may be adjusted during operation of axial flux motor 10, thereby adjusting a magnetic flux of axial flux motor 10.

[0134] As shown in method 100 of FIG. 6, Step 3 includes assembling stator 12 to housing 18. Stator 12 may be manufactured by alloy casting and / or core processing, and housing 18 may be manufactured as describe in connection with Step 1 . At Step 3, the manufactured stator 12 may be assembled relative to manufactured housing 18, which may include fixing stator 12 relative to housing 18. Stator’s position 12 may be adjusted relative to housing 18 (and rotor 14) by adjusting carriage 22 as described herein.

[0135] A strategy known as mechanical flux weakening may alter the magnetic flux path in a motor in a way that decreases the magnetic flux flowing through the gap. Flux weakening may be achieved by a motor controller by employing armature reaction along the d-axis to limit the flux linkage from the permanent magnets. This reduces torque generally and reduces back EMF for a given speed, enabling higher speed operation. This is desirable at high speeds, where voltage may become a constraint. Electrical flux weakening exhibits significant tradeoffs including reducedPage 21 of 316761723. DOCXAttorney Docket Number: 10654-2504882 efficiency due to the increased current and in some topologies an enhanced risk of demagnetization of permanent magnets. These tradeoffs can be eliminated by altering the flux path to achieve flux weakening without injecting d-axis current. In this nonlimiting embodiment, stator’s 12 distance from the rotor 14 may be altered to achieve this effect by lead screw-based actuation, pneumatic- or hydraulic-based actuation, or some other method.4. Separate Component Engaging Bearing

[0136] Referring to FIG. 3, axial flux motor 10 may comprise housing 18; a stator assembly comprising stator 12 fixed to housing 18; and rotor 14 rotatable relative to housing 18, rotor 14 spaced apart from the stator assembly along a rotation axis of rotor 14. Axial flux motor 10 may further comprise a bearing mount 24 detachable from housing 18. Bearing mount 24 may hold a bearing 26 and be configured to adjust a position of bearing 26. Bearing 26 may be configured to attach to a rotor shaft of a rotor assembly comprising rotor 14.

[0137] Bearing mount 24 holding bearing 26 may be configured to adjust a position of bearing 26 using a mechanism similar to the mechanism for adjusting a position of carriage 22 as previously described. For example, the rotor 14 may be arranged between and spaced apart from a plurality of stator assemblies, where a position of rotor 14 between the plurality of stator assemblies (and thus stators 12) may be adjustable after assembly of the axial flux motor 10 (see FIG. 1 B). The position of rotor 14 between the plurality of stator assemblies may be adjustable by bearing mount 24 being configured to adjust a position of bearing 26. Bearing mount 24 may be configured to adjust a distance that rotor 14 is spaced apart from housing 18 (e.g., since the rotor shaft of the rotor assembly is attached to bearing 26 in bearing mount 24). In some non-limiting embodiments or aspects, if the position of rotor 14 is to be adjusted relative to both stators 12, rotor 14 position may be adjusted using bearing mount 24. In some non-limiting embodiments or aspects, if the position of rotor 14 is to be adjusted relative to only one of stators 12, stator 12 position may be adjusted using carriage 22. Some combination of bearing mount 24 and carriage 22 may be used to select the position of stator(s) 12 relative to rotor(s) 14.

[0138] In some non-limiting embodiments, bearing 26 may not be attached directly to housing 18 but may be indirectly attached to housing 18 via bearing mount 24 as described herein. Having an additional component (e.g., bearing mount 24) whichPage 22 of 316761723. DOCXAttorney Docket Number: 10654-2504882 holds bearing 26 rather than having bearing 26 inserted directly into housing 18 allows for a thinner, more cost-effective housing part and improves ease of assembly.

[0139] A method of manufacturing an axial flux motor 10 as shown in FIG. 3 may comprise: preparing bearing mount 24 holding bearing 26, bearing mount 24 configured to adjust a position of bearing 26. Bearing 26 may be configured to attach to a rotor shaft of a rotor assembly comprising rotor 14. FIG. 3(a) shows bearing mount 24 and bearing 26, and rotor shaft (not shown) of rotor 14 may be arranged to sit in bearing 26. The method may include attaching bearing mount 24 to housing 18 and fixing a stator assembly comprising stator 12 to housing 18. The method may include arranging rotor 14 spaced apart from the stator assembly along a rotation axis of rotor 14, rotor 14 arranged rotatable relative to housing 18.

[0140] Referring to Step 4 of FIG. 6, axial flux motor 10 may be prepared by assembling stator 12, housing 18, and rotor 14 as previously described. Winding arrangement 28 may be assembled relative to stator 12 to prepare axial flux motor 10 The completed axial flux motor may comprise stator 12 (e.g., including permanent magnets 16), rotor 14, housing 18 (e.g., including holes 20), and winding arrangement 28 assembled together as described herein.

[0141] It will be appreciated that any of the foregoing design features may be incorporated into the design of the axial flux motor described in this disclosure in combination with any other of the foregoing design features. For example, an axial flux motor according to the present disclosure may combine any two or more of the following design features: (1 ) the selectively arranged holes (2) the single length of wire per phase; (3) the movable stator assembly relative to the housing; and (4) the separate, detachable component (e.g., bearing mount) for engaging the bearing, and / or any combination thereof.

[0142] Although embodiments have been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the disclosure is not limited to the disclosed embodiments or aspects, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present disclosure contemplates that, to the extent possible, one or more features of any embodiment or aspect can be combined with one or more features of any other embodiment or aspect.Page 23 of 316761723. DOCX

Claims

Attorney Docket Number: 10654-2504882WHAT IS CLAIMED IS1 . An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing comprising at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field without the at least one hole exceeding a threshold.

2. The axial flux motor of claim 1 , wherein the at least one hole is not defined entirely through the housing.

3. The axial flux motor of claim 1 , wherein the at least one hole is defined entirely through the housing.

4. The axial flux motor of claim 3, further comprising a coolant flowed through the at least one hole.

5. The axial flux motor of claim 1 , further comprising a non- conductive material arranged in the at least one hole.

6. The axial flux motor of claim 1 , wherein the threshold comprises a local leakage flux density exceeding an average leakage flux density within 10-30 mm of a stator surface by at least 25% and / or the threshold comprises a local leakage flux density of from 5-200 mT within 10-30 mm of the stator surface.

7. The axial flux motor of claim 1 , wherein the stator comprises a plurality of permanent magnets, wherein the at least one hole is arranged in the housing adjacent to a magnet of the plurality of magnets.Page 24 of 316761723. DOCXAttorney Docket Number: 10654-25048828. The axial flux motor of claim 1 , wherein the at least one hole is arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.

9. An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the housing comprising at least one hole defined at least partially therethrough, the at least one hole is arranged to reduce eddy currents induced by the axial flux motor compared to the same axial flux motor except without the at least one hole.

10. A method of manufacturing an axial flux motor, the method comprising: arranging a housing; fixing a stator assembly comprising a stator to the housing; and arranging a rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing; and defining at least one hole in the housing, the at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold.1 1. The method of manufacturing the axial flux motor of claim 10, comprising: before defining the at least one hole, testing the axial flux motor to determine concentration of fluctuating magnetic field in at least one location of the housing; and based on the determined concentration of fluctuating magnetic field in the at least one location of the housing, identifying the location of the housing having a concentration of fluctuating magnetic field exceeding the threshold.Page 25 of 316761723. DOCXAttorney Docket Number: 10654-250488212. The method of manufacturing the axial flux motor of claim 1 1 , wherein the testing comprises modeling, with a modeling system, the concentration of fluctuating magnetic field in the at least one location of the housing.

13. An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further comprising a concentrated winding arrangement in which a first winding comprising a first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

14. The axial flux motor of claim 13, the winding arrangement further comprising: a second winding comprising a second, single length of wire wound around a second subset of the plurality of poles corresponding to a second phase; and a third winding comprising a third, single length of wire wound around a third subset of the plurality of poles corresponding to a third phase.

15. The axial flux motor of claim 13, wherein the first single length of wire comprises a multistrand wire comprising a plurality of parallel strands.

16. The axial flux motor of claim 15, wherein the plurality of parallel strands are individually isolated from one another.

17. A method of manufacturing an axial flux motor, the method comprising: winding a concentrated winding arrangement around a stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the winding arrangement comprising winding a first winding comprisingPage 26 of 316761723. DOCXAttorney Docket Number: 10654-2504882 a first, single length of wire around a first subset of the plurality of poles corresponding to a first phase.

18. The method of manufacturing the axial flux motor of claim 17, comprising: fixing the wound stator to the housing; and arranging a rotor spaced apart from the wound stator along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

19. The method of manufacturing the axial flux motor of claim 17, winding the concentrated winding arrangement comprising: winding a second winding comprising a second, single length of wire around a second subset of the plurality of poles corresponding to a second phase; and winding a third winding comprising a third, single length of wire around a third subset of the plurality of poles corresponding to a third phase.

20. The method of manufacturing the axial flux motor of claim 17, wherein the concentrated winding arrangement is pre-prepared separate from the stator, the winding the concentrated winding arrangement around the stator further comprising: securing the pre-prepared concentrated winding arrangement to corresponding poles of the stator.21 . An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; the stator assembly comprising a carriage and a stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, wherein the stator is mounted to the carriage, and the carriage is mounted to the housing,Page 27 of 316761723. DOCXAttorney Docket Number: 10654-2504882 wherein the carriage is configured to adjust a distance that the stator is spaced apart from the rotor.

22. The axial flux motor of claim 21 , wherein the carriage mechanically isolates the stator from the housing.

23. The axial flux motor of claim 21 , wherein the carriage is mounted to a surface of the housing, wherein the carriage is configured to be adjustably moved in a direction perpendicular to the surface.

24. The axial flux motor of any of claim 21 , wherein the carriage is configured to adjust a distance that the stator is spaced apart from the rotor without disassembling a first stator assembly and a rotor assembly from a second stator assembly.

25. A method of adjusting an axial flux motor, the method comprising: providing the axial flux motor of claim 21 ; adjusting a position of the carriage to adjust the distance that the stator is spaced apart from the rotor.

26. The method of adjusting the axial flux motor of claim 25, wherein the position of the carriage is adjusted before, between, and / or after operation of the axial flux motor.

27. The method of adjusting the axial flux motor of claim 25, wherein the position of the carriage is adjusted during operation of the axial flux motor, thereby adjusting a magnetic flux of the axial flux motor.

28. The method of adjusting the axial flux motor of claim 25, wherein the position of the carriage is adjusted without disassembling the first stator assembly and the rotor assembly from the second stator assembly.

29. An axial flux motor, comprising: a housing;Page 28 of 316761723. DOCXAttorney Docket Number: 10654-2504882 a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor; further comprising a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising the rotor.

30. The axial flux motor of claim 29, wherein the bearing is not attached directly to the housing.

31. The axial flux motor of claim 29, comprising the rotor arranged between and spaced apart from a plurality of stator assemblies, wherein a position of the rotor between the plurality of stator assemblies is adjustable after assembly of the axial flux motor.

32. The axial flux motor of claim 31 , wherein the position of the rotor between the plurality of stator assemblies is adjustable by the bearing mount being configured to adjust a distance that the rotor is spaced apart from the housing.

33. A method of manufacturing an axial flux motor, the method comprising: preparing a bearing mount holding a bearing, the bearing mount configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising a rotor; attaching the bearing mount to the housing; fixing a stator assembly comprising a stator to a housing; and arranging the rotor spaced apart from the stator assembly along a rotation axis of the rotor, the rotor arranged rotatable relative to the housing.

34. An axial flux motor, comprising: a housing; a stator assembly comprising a stator fixed to the housing; and a rotor rotatable relative to the housing, the rotor spaced apart from the stator assembly along a rotation axis of the rotor;Page 29 of 316761723. DOCXAttorney Docket Number: 10654-2504882 the housing comprising at least one hole defined at least partially therethrough, the at least one hole arranged at a location of the housing having a concentration of fluctuating magnetic field exceeding a threshold, the stator comprising a plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator further comprising a concentrated winding arrangement in which a first winding comprising a first, single length of wire is wound around a first subset of the plurality of poles corresponding to a first phase.

35. The axial flux motor of claim 34, wherein: the stator assembly comprises a carriage and a stator comprising the plurality of poles spaced apart from one another and arranged around a perimeter of the stator, the stator is mounted to the carriage, and the carriage is mounted to the housing, the carriage is configured to adjust a distance that the rotor is spaced apart from the stator assembly.

36. The axial flux motor of claim 34, further comprising: a bearing mount detachable from the housing, the bearing mount holding a bearing and configured to adjust a position of the bearing, the bearing configured to attach to a rotor shaft of a rotor assembly comprising the rotor.Page 30 of 316761723. DOCX

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