SYNCHRO-SYM Technologies

Our Mission:

Innovate For Our Clean, Efficient, and Sustainable Energy Future!

PRODUCT →  EXECUTIVE SUMMARY:

In accordance with Our Mission, Best Electric Machine (BEM) provides a collaborative portfolio of patented technologies, branded SYNCHRO-SYM Technologies, for transforming the electric transportation, such as automobiles, airplanes, ships, and trains, the renewable energy, such as hydrogen, wind, tidal, and solar, and the smart electricity infrastructures, such as synchro-phasors, synchronous machines, automatic power grid frequency synchronizers, and distributed power factor correctors.

PRODUCT → SYNCHRO-SYM Technologies:

SYNCHRO-SYM is a patented “Symmetric” Electric Motor or Generator System circuit and control topology providing an “active” rotor assembly that effectively doubles the power density, shows octuple the peak torque density, halves the cost, and halves the loss within the same package of all other electric machine systems with a “passive” rotor assembly of slip induction dependent windings, reluctance saliencies, permanent magnets, or dc field windings, all while leaving the inadequate and geopolitically sensitive global supply of rare-earth (RE) permanent magnet materials (RE-PM) available for other more strategic applications.

MOTORPRINTER is a patented 3D Printer Method for the rapid additive manufacture of low and high frequency, high power, axial flux electric machine cores with 1) the highest performing electrical steel, amorphous metal, or nanocrystalline metal ribbon that have been impractical with conventional electric machine manufacturing, 2) with perfectly aligned slots of any programmable shape for windings, permanent magnets, reluctance saliencies, or cooling means, 3) with perfectly flat air-gap surfaces, and 4) with integral frame and winding assemblies; thereby, democratizing the manufacture of superior performing electric motor and generator systems.

BM-HFMDB is a patented Bi-directional, Balanced Multiphase, High Frequency, Electricity Micro-Distribution Bus with a new symmetric magnetic sharing circuit and control architecture that provides the most versatile micro-distribution bus with the highest efficiency but with half the cost, considerably higher power density, lower harmonic content, and fewer electronic stages in a system of systems (SoS) application.

BMSCC is a patented Brushless Multiphase Self-Commutated Controller with a new symmetric magnetic sharing circuit and control architecture that provides the most Versatile Smart Power Converter products with the lowest cost, highest efficiency, highest power density possible, such as a Bi-Directional Multiphase Inductive (Wireless) Power Transfer System (M-IPTS).

PRODUCT →  FOCUS:

A dramatic decline of the internal combustion engine (ICE) vehicle is predicted with the rapid adoption of the efficient electric motor or generator powertrain as the only practical alternative (e.g., E-mobility). Efficient electric propulsion for airplanes is quickly becoming a practical reality. Modular lightweight electric generator systems for large offshore wind-turbines are being explored. Industry is approaching this transformation without changing the century old, me-too, “asymmetric” electric motor or generator circuit and control architecture with the asymmetry of a “passive” rotor assembly of slip-induction windings, reluctance saliencies, rare-earth permanent magnets (RE-PM), or DC field windings; but instead, by improving its cost-performance with better materials, winding and packaging techniques, such as the emerging electric machine systems from MAGNAX and MAGNIX, by forming alliances with leading innovators, such as EM-motive, or by investing in “innovative,” cost reducing manufacturing methods, such as NIDEC’s $1.8 billion investment in high volume electric vehicle motor manufacturing.

Only BEM is introducing a patented axial flux “symmetric” electric motor or generator system, called SYNCHRO-SYM, with the symmetry of an “active” rotor assembly that at least doubles the performance of the “asymmetric” electric machine system while using the same material, winding, packaging and manufacturing techniques.  Also, only BEM is investing in a patented electric machine 3D Printing technology, called MOTORPRINTER, for revolutionizing and democratizing the rapid just-in-time additive manufacture of superior performing axial-flux electric motors, generators, and high frequency transformers.

PRODUCT →  SHOW ME:

By simply retrofitting the century old asymmetric electric machine circuit and control architecture package of MAGNAX, which was only enhanced with the commonly available RE-PM YASA packaging form that comprises: 1) a so-called yokeless “active” stator assembly with the directly excited multiphase winding set, 2) a “passive” rotor assembly of rare-earth permanent magnets (i.e., singly-fed), and 3) an electronic controller derivative of field oriented control (FOC), instead with the patented, integrated, brushless, multiphase, and symmetric electric machine circuit and control architecture of SYNCHRO-SYM, which keeps the MAGNAX active stator assembly but replaces the MAGNAX passive rotor assembly and FOC with an “active rotor assembly” as only possible with the brushless multiphase real time emulation controller (BRTEC) of SYNCHRO-SYM (i.e., synchronous symmetrical doubly-fed), then simple conceptual observation shows the power density of the original, highly package optimized MAGNAX electric machine system would again comparably double (with both the stator and rotor volumes equally contributing power to electromechanical conversion process), the cost would comparably halve per unit of power rating, the efficiency would comparably increase per unit of power rating, and the peak torque would at least comparably quadruple per unit of power rating, all while eliminating the extravagant cost, safety and handling issues of rare-earth permanent magnets with persistent magnetism, geopolitical consequences, limited operational life expectancy, and environmentally unfriendly production.

The simple retrofit comparison between the original MAGNAX and SYNCHRO-SYM also conveniently shows: 1) SYNCHRO-SYM operation, design, construction, and manufacture are straight-forward ready (like MAGNAX), 2) SYNCHRO-SYM uses off-the-shelf components (like MAGNAX) but without exotic components or materials, such as rare earth permanent magnets, 3) SYNCHRO-SYM is adaptable to legacy, off-the-shelf, fielded, or future electric machine systems with customary engineering and manufacturing (like MAGNAX), and 4) SYNCHRO-SYM easily leverages third party legacy or future electric machine design, packaging, material, winding, or construction techniques (as used by MAGNAX) but with double the effective performance results.

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The same SYNCHRO-SYM retrofit comparison can be applied to any asymmetric electric machine circuit and control architecture that always comprises a “passive asymmetric rotor assembly” of rare earth permanent magnets (RE-PM), slip-induction dependent windings, reluctance saliencies, or DC field windings:

  1. The “Synchronous Reluctance” electric machine system is sometimes described as a simple performance improving retrofit to the common slip-induction electric machine system by keeping the “active” power producing stator assembly but by replacing the “passive” slip-induction dependent squirrel cage rotor assembly with a reluctance (SyncR) rotor assembly that may include embedded rare-earth permanent magnets and a sophisticated waveform shaping field oriented controller (FOC) derivative for smoothing out the traditional issues of torque ripple and cogging of synchronous reluctance electric machine systems. Similarly to the slip-induction electric machine system retrofit, the complex passive rotor assembly and sophisticated FOC of any synchronous reluctance electric machine system can be replaced with an active rotor assembly and BRTEC to provide the circuit and control architecture of SYNCRO-SYM, which will double again the overall performance of the synchronous reluctance electric machine system while eliminating the extravagant cost, safety and handling issues of rare-earth permanent magnets.

    Note: Tesla’s IPM-SyncR electric machine system shows the complicated SyncR rotor assembly of rare earth permanent magnets and reluctance saliencies placement but without emphasizing the complexities and ramifications of the essential electronic shaping controller to provide a practical IMP-SyncR motor with up to 96% efficiency or without emphasizing similar performance trade space of an optimized slip-induction motor comprising a less complex copper wound rotor assembly and electronic controller. Also overlooked, the essential electronic controller has compounding effects on the overall loss, cost and size of any electric machine “system.” For instance, if the efficiency of the motor is 96% and if the efficiency of the essential electronic controller is also an impressive 96%, the actual compounded efficiency of the Tesla’s IMP-SyncR motor “system” for practical operation is only 92% (i.e., 96% x 96%).

  2. LinearLabs’ Hunstable Energy Turbine (HET) rare-earth permanent-magnet (RE-PM) electric machine system (RE-PM-EMS) recently advertised a four rotor concept providing twice the torque density and triple the power density as other RE-PM-EMS, but after reviewing the video, the four rotor concept is actually a single rotor assembly (of the century old asymmetric circuit and control architecture) with four rotor segments completely surrounding the directly excited stator multiphase (or active) winding set (i.e., so-called circumferential flux of HET) and as admirably claimed, the winding end-turns are seemingly eliminated with the effective air-gap area doubled. Without critiquing the practicality of a completely air-gap surrounded (or floating) active stator assembly without the necessary means to directly excite the multiphase (active) winding set, which would disrupt the crucial circumferential flux of HET, a SYNCHRO-SYM retrofit (as done with MAGNAX) would double the performance claims of LinearLabs’ HET motor while eliminating the cost, safety and handling issues of RE-PMs.

  3. By retrofitting the Nidec motor with the patented symmetric circuit and control architecture of SYNCHRO-SYM while using the same materials, winding, packaging, manufacturing, and thermal management techniques, Nidec’s electric motor performance would again be doubled and its production cost halved, all without including the additional savings of eliminating expensive rare earth permanent magnets or without transforming Nidec’s manufacturing with MOTORPRINTER, which is the only high speed 3D Printer of amorphous or nanocrystalline axial-flux electric motors and generators.

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