SYNCHRO-SYM VIDEO

 

 

- Real Innovation For Our Energy Future -

 

 

Electric Machine Cost & Density Analysis:

 

The U.S. Department of Energy (DOE) predicts that by 2020 the electric machine system (EMS) cost will be $4.7/KW as a result of "developing efficient and low cost non-rare earth permanent magnet electric motors that take advantage of lower loss materials enabled by new processing methods."[1]

 

[At $4.7/kW, it is reasonably assumed that the cost prediction does not include the electronic controller for practical application.]

 

Just before the exponential increase in rare earth permanent magnet (RE-PM) material, the DOE previously predicted virtually the same electric machine (EM) cost (i.e., $4.7/KW) as a result of the introduction of rare-earth permanent magnets (RE-PM) into the EM but recently, the DOE has come to realize that the price of RE-PM materials will continue to escalate by at least the principles of simple economics, such as as supply and demand, and by other inflationary issues, such as environmental concerns mining RE-PM materials, regulations, inflation, cartel control, minable rarity, etc. Therefore, it is suspiciously difficult to believe that the same economic forces won't act upon the newest low cost prediction of $4.7/KW but for sure, the DOE cost predictions seemingly by fiat cannot inspire invention of new innovative processing methods or apparatus that actually reduce costs throughout the entire life cycle of the electric machine.

 

Already ahead of the competition while "innovating for our clean and sustainable energy future," BEM is reducing cost not by fiat but by innovating new EM system technology that actually improves performance cost-effectively, such as the Synchro-Sym electric machine system or SS-EMS, and by innovating manufacturing enabling technology that rapidly manufactures axial-flux (or disk shape) electric machines just-in-time with low loss materials, such as amorphous metal, that have been known to significantly improve performance but have been impractical to manufacture since their early introduction.[2] For instance, Best Electric Machine (BEM) leveraged the 3D Printer patent, called MotorPrinter, for the rapid just-in-time volume production of custom amorphous metal axial-flux core EM(s) with an integral frame and bearing assembly from raw structural steel instead of from the usual extensive inventory of high cost pre-manufactured precision component castings.[3]   So if $4.7/kW, 1.6 kW/Kg, and 5.7 kW/L for the EM "system" are achievable by 2020 as the DOE predicts, BEM flagship technology, the Motorprinter enabled SS-EMS, should achieve nearly half the predicted cost (e.g., $2.35/KW) and size (e.g., 3.2 kW/Kg and 11.4 kW/L) not by fiat but by its simple doubly-fed physics of operation.

 


[1] John M. Miller, Oak Ridge National Laboratory, "Electric Motor R&D," "2013 U.S. DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation Meeting, May 15, 2013.

[2] Theoretical considerations by Polard [Zahra Nasiri-Gheidari, Hamid Lesani,A Survey on Axial Flux Induction Motors, PRZEGLAD ELEKTROTECHNICZNY (Electrical Review), ISSN 0033-2097, R.88 NR 2/2012] show the axial-flux electric machine can reduce copper utilization by 13-14% and iron utilization by 21.5-32.5% compared to the traditional radial-flux electric machine. Furthermore, amorphous metal can reduce core loss, which is 15% of the total loss of any electric machine, by up to 80%, but show properties that make manufacturing difficult (e.g., no practical amorphous metal EMS is available to date).  

[3] Amorphous metal electric machine cores can reduce core loss by up to 80%.


ELECTRIC MACHINE PERFORMANCE CRITERIA
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Note: The Radial Flux prototyping of the Advanced Brushless Wound-Rotor Synchronous Doubly-Fed Electric Motor Or Generator System is shown as our Icon, which predates the axial-flux SS-EMS Technology.

 

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