The latest innovation from Orbis Electric, the HaloDrive modular axial flux motor-generator, a new generation of electric propulsion technology tailored for the increasingly complex needs of both commercial and passenger e-mobility.
The core of HaloDrive is a patented four-part modular architecture featuring an injection-molded plastic stator. This innovation results in a lighter, more compact design without sacrificing thermal stability or mechanical robustness. The inclusion of a tunable gearset enables the motor to adapt to a wide variety of drivetrain layouts, allowing for seamless integration across different platforms and making the system highly appealing for OEMs focused on flexible and scalable manufacturing.
From a performance perspective, HaloDrive sets a new industry benchmark with a torque density of 100Nm/kg, a metric that places it ahead of most radial and other axial flux competitors. This instantaneous torque output rivals that of a traditional V8 internal combustion engine, providing the kind of performance necessary for demanding traction and commercial vehicle requirements. Operational efficiency is a strong point as well, peaking at up to 97%. This high efficiency translates to minimal energy loss, lower operating temperatures, and greater reliability, whether the motor is propelling a vehicle or functioning as a stationary generator.
The versatility of HaloDrive is further underscored by its application range. While it can be deployed in traditional propulsion positions, its modular design also allows for in-wheel integration, bringing native torque vectoring and simplified automation to electric and hybrid vehicle assembly lines. The same hardware can be utilized with customized windings to operate as a generator. One particularly promising application is in electric
refrigeration units (eTRU), where the motor eliminates the need for diesel-powered onboard generators in commercial trucks. This shift not only eradicates refrigeration fuel consumption but also slashes operational costs by as much as 90%, representing a significant advance in both fleet efficiency and sustainability profiles.
System integration is further facilitated by the motor’s light, compact form factor, alternative magnet options that reduce reliance on rare earth materials, factory-ready cartridge bearings, and integrated ultra-light disc brakes. Orbis claims this design can yield up to 35% savings on total drivetrain costs compared to conventional radial motors. The speed of installation, often requiring less than three hours for generator deployments, and compatibility with standardized OEM assembly lines reinforce HaloDrive’s potential for widespread, rapid adoption.
