Why Axial Flux Motors Are Opening up New Possibilities for Off-Highway Electrification

Why It Matters

The EDU tackles space, durability and serviceability hurdles that have slowed off‑highway electrification, letting OEMs add high‑performance electric drivetrains without major redesigns. Higher torque density and simplified gearboxes boost range and lower total cost of ownership for construction and commercial fleets.

Key Takeaways

• Turntide's EDU uses axial‑flux motor for 2‑4× power density.
• Semi‑integrated design lets inverter be mounted on or off the unit.
• Motor operates up to 85 °C ambient, with 50,000‑hour MTBF.
• Gearbox efficiency can rise from ~91% to 97‑98% using high torque.
• Scalable motor sizes (300‑430 mm) cover 60‑200 kW power range.

Pulse Analysis

Axial‑flux motors have long been praised for their pancake‑shaped architecture, which packs a large amount of copper and magnetic material into a short axial length. This geometry translates into markedly higher power‑to‑volume ratios compared with traditional radial‑flux machines, a trait that is especially valuable when vehicle packaging constraints dominate design decisions. In passenger cars the benefit is already evident, but off‑highway sectors such as construction, mining, and agricultural equipment face tighter space envelopes around the bell housing and stricter durability requirements. Leveraging axial flux therefore opens a pathway to electrify these heavy‑duty platforms without sacrificing performance.

Turntide’s new Electric Drive Unit builds on that premise with a ‘semi‑integrated’ layout that couples the axial‑flux motor and a compact gearbox while keeping the inverter location optional. The motor is engineered to tolerate ambient temperatures up to 85 °C and to survive 50,000 hours of operation, thanks to a fluidic cooling channel and vibration‑hardened stator design. By using conjugate heat‑transfer analysis and minimizing magnetic material, Turntide claims a two‑to‑four‑fold increase in torque density and gearbox efficiencies climbing from roughly 91 % to 98 %. Crucially, the architecture is designed for mass production, with off‑the‑shelf gear components that can be swapped in a few hours, reducing downtime on the field.

The implications for the off‑highway market are significant. Higher torque at low speeds lets OEMs eliminate multiple reduction stages, cutting weight and improving overall vehicle efficiency, which directly extends electric range and lowers operating costs for fleets. Turntide’s scalable family—spanning 60 kW to 200 kW and offering single or double‑stack configurations—covers a broad spectrum of equipment, from compact powersports to heavy excavators. As OEMs seek faster electrification pathways, the combination of compact form factor, robust thermal management, and service‑friendly design positions axial‑flux‑based drive units as a compelling alternative to conventional drivetrains.