SYNCHRO-SYM Technologies


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SYNCHRO-SYM implements a patented circuit and control architecture that goes far beyond the century old circuit and control architecture of electric propulsion solutions, such as the likes of MAGNAX (and all others), by eliminating the "passive" (but very expensive) rare earth permanent magnet (RE PM) arrangement on the rotor assembly to simultaneously make the rotor assembly an "active" contributor to the electromechanical energy conversion process (in addition with the "active" stator winding assembly). When retrofitted with the patented electric motor circuit and control architecture of SYNCHRO-SYM, the power density of the retrofitted MAGNAX highly optimized electric propulsion motor is doubled, its cost is halved, and its efficiency is increased by simply removing the arrangement of very expensive (and “passive”) rare earth permanent magnets (RE-PM) on the two rotor disk assemblies of MAGNAX and then replacing the arrangements with a similarly rated “active” multiphase winding set (as the original MAGNAX concentrated stator active winding set) and of course, brushlessly controlling the two active winding sets with SYNCHRO-SYM's brushless real time emulation controller (BRTEC) instead of the MAGNAX electronic controller.


IMPORTANT RESULTS: The SYNCHRO-SYM retrofit has a another directly and contactlessly excited active multiphase winding set on the rotor, which is equally rated to the single stator active multiphase winding set of the original MAGNAX, or two active winding sets providing twice the rated power within the same footprint as the original MAGNAX (i.e., twice the power density) but without the array of expensive rare earth permanent magnets). The SYNCHRO-SYM retrofit also conveniently provides "field weakening" for extended speed range.

NOTE: By retrofitting the same design, the same packaging, the same materials, and the same winding techniques as the original MAGNAX (while eliminating the extremely expensive and delicate RE-PM and the electronic control of MAGNAX), the performance comparison between the original MAGNAX and SYNCHRO-SYM is obvious and without possibility of manipulation by unsuspectingly comparing between different performance packaging, materials, design techniques, or specifications. Also, retrofitting conveniently shows SYNCHRO-SYM operation, design, construction, and manufacture are straight forward ready (as MAGNAX), conveniently shows SYNCHRO-SYM uses off-the-shelf components without exotic components or materials, such as rare earth permanent magnets, and conveniently shows SYNCHRO-SYM is adaptable to legacy, off-the-shelf, or fielded electric machine systems with customary engineering and manufacturing.


NOTE: Since power density, cost, efficiency are always calculated as per unit of power rating, the dual active winding sets of SYNCHRO-SYM provide twice the power output in the same package footprint as the original MAGNAX, which reasonably calculates to twice the power density per power rating, half the cost per power rating, and half the electrical loss per power rating of at least an induction electric machine with equal winding MMF on the rotor and stator assemblies.


NOTE:  In contrast to the asymmetric transformer circuit topologies, such as MAGNAX, the physics of a truly symmetric (or dual ported) transformer circuit topology (as only provided by SYNCHRO-SYM) shows air-gap flux density remains constant with increasing torque current (beyond magnetizing MMF) and as a result, SYNCHRO-SYM provides peak torque potential that is at least twice the peak torque potential of MAGNAX (which most definitely provides a transmission-less propulsion system that MAGNAX can only suggests).


NOTE: By doubling the power rating of the original MAGNAX package with two similarly rated "active" winding sets (as the original single MAGNAX stator active winding set) that are on the rotor and stator, respectively, the resulting electric machine, now called SYNCHRO-SYM, contiguously and variably operates with the same rated torque from sub-synchronous, such as from and including zero speed, to super-synchronous speed, such as at or above twice synchronous speed, for twice the "constant torque speed range" with a given frequency and voltage of operation as the original MAGNAX, which unquestionably equates to twice the power density, half the cost, and higher efficiency as the original MAGNAX. Therefore providing the same rated torque under the same voltage, an electric machine with a conventional two pole circuit and control architecture would have a constant torque speed range of 3600 RPM with 60 Hz of excitation but a two pole circuit and control architecture of SYNCHRO-SYM would have a constant torque speed range of 7200 RPM at 60 Hz of excitation i.e., universally recognized characteristics for twice the power.   


NOTE: Neglecting the safety issues, the voltage rating of any electronically controlled electric machine should be as high as possible to reduce the loss effects of the semiconductor junction voltage drops. For instance, a reasonable 0.6v semiconductor junction drop will dissipate 0.15% (0.6/400) of the 400v supply rating but in contrast, will dissipate 1.2% (0.6/48) of a 48 volt supply rating.


NOTE: There are other engineering requirements for a practical SYNCHRO-SYM retrofit of the axial-flux electric machine, such as MAGNAX...(READ MORE)


NOTE: Although MAGNAX was used for this example, the same retrofit process can be similarly applied to virtually any other electric machine system, such as Yasa Motors, EMRAX, Mclaren Racing, Rimac's Electric Motor Systems, BorgWarner.



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