With the patented electric motor circuit and control architecture of SYNCHRO-SYM, the MAGNAX highly optimized electric propulsion motor power density can be doubled again, the cost halved again, and the efficiency increased again by simply removing the two very expensive (and “passive”) rare earth permanent magnet (RE-PM) disk assemblies of MAGNAX and then replacing the arrangement of RE-PMs with a similar concentrated “active” multiphase winding set arrangement (as the YASA stator active winding set) and brushlessly controlling the active winding set(s) with SYNCHRO-SYM's brushless real time emulation controller (BRTEC) instead of the MAGNAX electronic controller.

 

By doubling the power rating of the original MAGNAX package with two similarly rated active winding sets (as the original MAGNAX stator active winding set) that are placed on the rotor and stator, respectively, the resulting electric machine, now called SYNCHRO-SYM, contiguously and variably operates from sub-synchronous, such as zero speed to synchronous speed, to super-synchronous speed, such as twice synchronous speed, with "twice" the constant torque speed range for 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. Since power density, cost, efficiency are always calculated with per unit of power rating, SYNCHRO-SYM shows twice the power density, half the cost, and higher efficiency with twice the power in the same package as the original MAGNAX (via two active winding sets). 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 MAGNAX electronic control with another active winding set under BRTEC), the performance comparison between the original MAGNAX and SYNCHRO-SYM is straight forward, exact, and without any possible manipulation with different packaging, materials, or design techniques. Although MAGNAX was used for this example, the same retrofit process can be similarly applied to virtually any other electric machine.

 

The SYNCHRO-SYM conversion also provides field weakening for extended speed range and at least a factor higher peak torque potential (which most definitely provides the transmission-less propulsion system that MAGNAX only suggests).

 

In conclusion, SYNCHRO-SYM can actually make the MAGNAX electric machine better, less expensive, and at the same time, can make MAGNAX compatible with MOTORPRINTER for the rapid additive manufacturing with high performance materials, such as amorphous metal ribbon.

o   Any investment in BEM is an investment in the newest and most advanced manufacturing and electric machine circuit (i.e., synchronous multiphase wound-rotor doubly-fed) and control (i.e., BRTEC) technology available, which can conveniently leverage the newest available materials, form, or manufacturing for another level of performance magnification.

o   Any investment in other electric machine companies, such as MAGNAX, Yasa Motors, EMRAX, etc., is an investment in traditional electric machine technology with only the introduction of newest available materials, form, or manufacturing for the same performance enhancement.

 

QUALIFYING CONSIDERATIONS:

 

NOTE: Generally located on the rotor, permanent magnets (PM) do not "actively" contribute to electromechanical power conversion and as a result, PMs are "passive" devices (e.g., PMs have no electrical power port to contribute active power to the electromechanical power conversion). In reality, the "active" multiphase winding set required by all electric machines (that is generally located on the stator for electrical connection convenience) determines the torque and power rating of any optimally designed electric machine, including PM electric machines, with the high energy product of the very expensive rare earth (RE) PM only determining the ease of setting up the air-gap flux density without considering field weakening.  When optimally designed, the effective air-gap area and the following size of the active multiphase winding set (per unit power rating) are determined by the air-gap flux density, which is design constrained by the flux saturation limit of the magnetic core and core material, such as laminated electrical steel (superconductor electric machines excluded from this discussion).  The air gap flux density is not determined by the high energy product of RE-PMs or the even higher peak magneto-motive-force (MMF) potential of a winding compensated for heat dissipation (after all it takes winding MMF to magnetize a PM), although PMs show smaller size and support a deeper air gap (for instance, 1 mm vs 2 mm) and windings provide field weakening for extended speed range. Likewise, the size of the stator assembly determines the size of the rotor body and together, the rotor and stator bodies with robust frames overwhelmingly determine the size of the electric machine.  In consideration, all optimally designed electric machines show virtually the same torque, the same effective air-gap area, and the same size active winding set for the same air-gap flux density for the same air-gap flux density. As supporting evidence, today’s specialty induction electric machines with copper rotor and optimized materials and designs are achieving similar size and efficiency for a given torque as optimally designed RE-PM electric machines (but without the extravagant cost and manufacturing issues of RE-PMs).

 

NOTE: Unlike winding MMF, passive, delicate, expensive, environmentally unfriendly, and global supply limited permanent magnets, such as rare earth permanent magnets (RE-PMs), show degrading performance, such as demagnetization, over normal operational life, which accelerates during stress, such as expected in an electric vehicle application.

 

NOTE: Packaging, winding, and thermo management techniques consume significant size and cost of any electric machine because of the large dynamic and magnetic forces exerted on the frame and bearings and the thermo dissipation of the active winding set(s) found in all electric machines, including PM electric machines.

 

NOTE: Doubly fed electric machines uniquely show the performance of two multiphase active winding sets in the same package, which equates to twice the power density.

 

NOTE: Without considering the formidable issues of cryogenics, superconductor electric machines achieve tens of times more MMF (and resulting air gap flux density) than conventional copper windings or PM coercivity. Without providing details, SYNCHRO-SYM Technologies can bring superconductor electric machines closer to reality.

 

NOTE: Without actively contributing (or adding) to electromechanical conversion power, core material, which is found in all conventional electric machines, and permanent magnet material are “passive” materials, regardless of their performance improving qualities, such as directing the magnetic path to the air-gap by the high permeability core material that is unlike air. Note: Even the “coreless” or yokeless terms seem to suggest there is no core material but in fact, the magnetic path is routed through the PM core material, which exhibits the density and permeability of electrical steel.

 

NOTE: Like SYNCHRO-SYM, only synchronous electric machines, such as permanent magnet electric machines, precisely know the magnetic flux phase angle by the mechanical angle of the rotor position. In contrast, the magnetic flux phase angle of the induction electric machine is variably relative to the mechanical position of the rotor. As a result, synchronous electric machines have precise control and asynchronous (induction) electric machines use estimation for control. Unlike BRTEC of SYNCHRO-SYM, delays in measurement and excitation synthesis by conventional state of art offline processing, particularly at speeds or frequency with large time constants, such as low speeds, always contribute to stability issues. 

 

NOTE: Electric machines with a primary and secondary winding transformer circuit topology (asymmetric or symmetric) show higher peak torque potential (e.g., 2-3 times rated torque) than electric machines that are truly asymmetric (e.g., no rotor winding), such as PMs or saliencies (reluctance) replacing the secondary winding set (e.g., 1.5 times rated torque). Universal electric machines, such as the electromechanically commutated DC electric machine, show peak torque up to 5 times rated torque. Only, SYNCHRO-SYM has a truly symmetric (or dual ported) transformer circuit topology (that keeps airgap flux constant with increasing torque current) and as a result, shows factors of higher peak torque potential (e.g., 8 times rated torque). See electric machine torque 101 whitepaper for details.  

 

 

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

 

NOTE: There are other simple but transformational advantages of SYNCHRO-SYM...(READ MORE)

 

 

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