SYNCHRO-SYM Technologies

 

Our Mission:

 

Innovate

For Our Clean, Efficient, & Sustainable

Energy Future!

 

SYNCHRO-SYM implements a patented integrated circuit and control architecture that goes far beyond the century old componentized circuit and control architecture of all other 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 integrated 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 comprises 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 (and all others) 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 continuous rated torque under the same voltage, an electric machine with a conventional two pole componentized circuit and control architecture would have a constant torque speed range of 3600 RPM with 60 Hz of excitation but a two pole integrated 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: When included, the electronic controller adds significant size, weight, loss, and cost to the electric machine system with the electric machine componentized circuit and control architecture (as shown).  Only with BRTEC, SYNCHRO-SYM places the BRTEC inside the otherwise wasted annulus space of the Axial Flux form factor, which equates to hidden controller occupation, controls half the power for full control, which equates to half the controller size, and comprises a patented bidirectional controller with direct AC-to-AC conversion without the large reactive components of a DC Link Stage, which equates to half the controller size for full control.  

 

NOTE: Since more copper equates to more power, the copper wire slot fill factor is a necessary goal. Specialty motor manufacturers are already achieving upwards of 80-90%, which is considered best case, with orthocyclic winding arrangement, square copper wires, etc.

 

NOTE: All electric machines, including so-called DC and permanent magnet (PM) electric machines, only function with alternating current and as a result, comprise AC windings with end turns that do not actively participate in the power conversion process but instead, contribute to parasitical electrical loss and flux leakage (i.e., reactive impedance) in accordance to the total length of the end-turns. Compared to distributed windings, some winding methods, such as concentrated windings, reduce the length of the end turns but sacrifice effective air-gap area and increase harmonic content. Segmented cores may improve winding placement but increase air-gaps (and reluctance) in the magnetic path. Motor design is juggling between pros and cons of windings and packaging styles.

 

NOTE: Distorted by years of extensive research and development, rare earth permanent magnet (RE-PM) electric machines are now considered the highest performing. But combinational RE-PM materials, such as Samarian cobalt, neodymium, dysprosium, etc., are difficult to mine, impose considerable environmental impact, and are supply limited to country cartels. Research, such as by ARPA-E, has been directed to reducing the needed quantity of RE-PM material in an RE-PM electric machine or to comparably improve the induction electric motor performance, which is PM free, by using 3D printing (for instance) or by bringing superconductor windings to practical reality, such as the idyllic AC superconductor winding. Already without RE-PMs, the patented SYNCHRO-SYM doubles the overall performance expected from a RE-PM electric machines and would be the natural evolution if induction electric motors or AC superconductors became the norm.

 

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.

 

 

Comments, Suggestions, or Collaborative Interest Welcomed!

 

[HOME]                   [Contact]

 

©2007, 2009, 2014, 2018  Best Electric Machine