SYNCHRO-SYM Technologies

Our Mission:

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

PRODUCT →  EXECUTIVE SUMMARY:

In accordance with Our Mission of innovating for our clean, efficient, and sustainable energy future, Best Electric Machine (BEM) provides a complementary portfolio of patented circuit, control, and additive manufacturing technologies, branded SYNCHRO-SYM Technologies, for transforming the electric infrastructure industries, which include: a) the electric propulsion and transportation industry, c) the smart electricity industry, and d) the 3D Printing Industry of electric motors and generators.

PRODUCT → SYNCHRO-SYM Technologies:

SYNCHRO-SYM is a patented “Symmetric” Electric Motor or Generator circuit and control architecture that provides the pinnacle of electric motor-generator technology with the optimal symmetry of an “active rotor assembly” that stably and brushlessly contributes additional working power (or active power) to the electromechanical energy conversion process along with the universally essential “active stator assembly.” All other electric motor or generator circuit and control architectures have the non-optimal asymmetry of the traditional “passive rotor assembly” with either slip induction dependent windings, reluctance saliencies, rare-earth permanent magnets, or DC or single-phase field windings that cannot stably contribute additional working power to the electromechanical energy conversion process along with the universally essential active stator assembly. As a result, the active stator assembly solely determines similar power rating and size between all optimally designed asymmetric electric motors. With the reasonable assumption that the rotor or stator assembly consumes half of the electric motor or generator real estate, loss, or cost within the same package of air-gap flux density, winding, material, and electronic component techniques and with the symmetric working power of two active winding sets on the rotor and stator, respectively, Conservation of Energy shows SYNCHRO-SYM is half the size (or twice the power density), half the cost, half the loss, and octuple the peak torque density per unit of power rating of all other electric motor or generators with the asymmetric working power of only a single stator active winding set, such as all rare-earth permanent magnet electric motors, while also providing adjustable leading, lagging or unity power factor and coveted field weakening capability at any speed, including zero speed.

MOTORPRINTER is a patented 3D Printer Method for the rapid additive manufacture of low and high frequency, high power, axial-flux electric motor, generator, and transformer cores: 1) with 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 without secondary tooling processes, and 4) with integral frame and winding assemblies, all of which will democratize the manufacture of superior performing electric motor and generator systems and provide power magnetics, such as electromagnetic transformers that are capable of extracting the theoretical performance of emerging wide bandgap semiconductor technology.

BMSCC is a patented hybrid Brushless Bi-directional Multiphase Self-Commutated Controller with a unique low energy but high power, 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, and lowest distortion possible, which is essential for implementing synchronous or asynchronous, grid forming (GFM), inverter based resources (IBR), such as a Bi-Directional Multiphase Inductive (Wireless) Power and frequency Transfer System (M-IPTS), fast electric vehicle chargers, etc.

BM-HFMDB is a patented hybrid Bi-directional, Multiphase, High Frequency, Electricity Micro-Distribution Bus with a unique low energy but high power, symmetric magnetic sharing circuit and control architecture that provides the most versatile micro-distribution bus with the highest efficiency and power density but with half the cost, lower harmonic content, and fewer active electronic stages in a system of systems (SoS) application, such as electric vehicles, electric airplanes, etc. with multiple SYNCHRO-SYMs or BMSCCs.

PRODUCT →  FOCUS:

A dramatic decline of the internal combustion engine (ICE) vehicle is anticipated with the rapid adoption of the much more efficient electric traction motor powertrain as the only practical alternative (e.g., E-mobility) and as a result, the evolving EV electric traction motor market, alone, will reach nearly $40B by 2028 with a compounded annual growth rate (CAGR) of 35.32%. Efficient and high power density electric propulsion for manned or long duration, solar powered, unmanned airplanes is needed for efficient and environmentally friendly short distance passenger flight or for high altitude 5G communication networks with broadest coverage possible. Modular, lightweight, high power electric generator systems for large offshore wind-turbines are being explored to reduce field installation and sustainment costs. With electronic motor control included, the electric motor-generator system propulsion market is estimated to reach $1.4T by 2028. Ironically, the entire electric infrastructure industry is approaching this transformation with the same century old, me-too, “asymmetric” electric motor or generator circuit and control architecture with a “passive” rotor assembly of rare-earth permanent magnets (RE-PM), such as the so-called transformational RE-PM electric motor systems from MAGNAX, MAGNIX, MAGNA, H3x, and Turntide Technologies, slip-induction windings, reluctance saliencies, or DC field windings (e.g., brush, brushless, conventional and superconductor), which leaves their performance distinction limited to: a) empirically applying the same off-the-shelf materials, winding, packaging, and electronic component performance enhancing techniques, which results in the same stable Maximum Load RPM (or constant torque speed range) when equally applied, b) forming alliances with leading innovators, such as EM-motive, to mutually leverage verified empirical packaging techniques, c) attempting to patent empirical packaging results, which are easily evaded with empirical adjustment by the competition, or d) investing in creative cost reducing manufacturing principles, such as NIDEC’s $1.8 billion investment in high volume electric vehicle motor manufacturing, after recognizing OEMs of electric vehicles are branding virtually the same performing asymmetric electric propulsion motor.

Only BEM is introducing a patented electric motor or generator system, called SYNCHRO-SYM, with a new “symmetric” circuit and control architecture, which comprises the “optimal symmetry” of two similarly rated directly excited bi-directional multiphase (or “active”) winding sets stationed on the rotor and stator, respectively, for a combined working power production that: a) brushlessly and stably operates from sub-synchronous to super-synchronous speeds, b) shows at least double the performance at half the cost per unit of power rating of the traditional electric machine system with the asymmetric circuit and control architecture, which comprises the “non-optimal asymmetry” of only a single similarly rated “active” winding set stationed on the stator for working power production but with the additional loss, cost, and size of “passive” slip-induction dependent windings, reluctance saliencies, DC field windings, or rare earth permanent magnets stationed on the rotor, c) provides twice the Maximum Load RPM for a given torque, voltage, and frequency of excitation, d) provides twice the performance improvement expected from empirically applying the same available air-gap flux density, material, winding, packaging, and manufacturing techniques for minor performance distinction between asymmetric electric machine systems, and e) provides the best fault tolerance as expected from implementing directly excited (i.e., independent) multiple phase winding sets on the rotor and stator, respectively, that do not rely on slip-induction or multiphase slip-rings and brushes. For example, if an asymmetric electric motor circuit and control architecture, such as H3X, claims 3x the power density of other asymmetric electric motor circuit and control architectures, which can only be the result of empirically tuning available performance enhancing air-gap flux density, materials, winding, packaging, and electronic component techniques, then retrofitting the same package with the symmetric circuit and control technology of SYCHRO-SYM will double again the power density, halve again the cost, halve again the loss, and quadruple again the peak torque, while also eliminating the delicate and costly RE-PMs and inherently providing field weakening and leading, lagging, or unity power factor control.  Only BEM is introducing 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, low and high frequency, electric motors, generators, and transformers, which are essential for implementing smart electricity with lowest cost, size, and loss. Only BEM is introducing a patented Brushless Bi-directional Multiphase Self-Commutated Controller, which is essential for the smart electricity infrastructure. Only BEM is introducing a patented Bi-directional, Balanced Multiphase, High Frequency, Electricity Micro-Distribution Bus, which is essential for lowering the cost and improving the efficiency of the overall electric vehicle System of Systems. Only BEM is introducing a complementary portfolio of patented technologies, branded SYNCHRO-SYM Technologies, for a complete System of Systems approach that reduces overall size, improves overall efficiency, and lowers total cost of ownership, which is unlike the individual element approach of others.

PRODUCT →  SHOW ME:

MAGNAX is an electric motor system with some of the highest performance metrics on the market as only the result of applying the commonly known RE-PM YASA winding and packaging technique that comprises: a) a so-called yokeless “active” stator assembly with a single directly excited multiphase winding set (i.e., singly-fed), b) the asymmetry of a “passive” rotor assembly of rare-earth permanent magnets, and c) an electronic controller derivative of field oriented control (FOC). By simply retrofitting the century old asymmetric electric machine circuit and control architecture of MAGNAX, instead, with the patented, integrated, brushless, multiphase, and symmetric doubly-fed electric machine circuit and control architecture of SYNCHRO-SYM, which keeps the MAGNAX active stator assembly but replaces the size, loss, and cost of the MAGNAX passive rotor assembly and FOC with the symmetry of an “active rotor assembly,” as only possible with the stabilization of a brushless multiphase real time emulation controller (BRTECTM), that contributes additional working power production to the electromechanical conversion process along with the active stator assembly, simple qualitative observation in compliance with the governing Law of Conservation of Energy shows that at any speed, including zero speed, the power density of the original MAGNAX electric machine system package would comparably double again (for up to 10x the power density instead of the MAGNAX 5x power density), the cost would comparably halve, the efficiency would comparably increase, and the peak torque would at least comparably quadruple, all by: a) effectively eliminating the size, loss, and cost of the passive rotor and FOC, b) eliminating the extravagant cost, safety and handling, geopolitical consequence, limited operational life expectancy, and environmentally unfriendly production issues of rare-earth permanent magnets, and c) inherently providing: i) universal single AC, multiphase AC, or DC operation, ii) coveted field weakening for extended speed range and electronic control reliability, and iii) comprehensive leading, lagging, or unity power factor compensation.

The simple retrofit comparison between the brushless and “symmetric” circuit and control architecture of SYNCHRO-SYM and the original “asymmetric” circuit and control architecture from MAGNAX conveniently shows:

  1. Like MAGNAX, SYNCHRO-SYM material, winding, and packaging techniques are well understood with over a century of practical evolution,
  2. Like MAGNAX, SYNCHRO-SYM operation, design, construction, and manufacture are straight-forward ready,
  3. Like MAGNAX, SYNCHRO-SYM uses off-the-shelf components,
  4. Like MAGNAX, SYNCHRO-SYM is adaptable to legacy, off-the-shelf, fielded, or future electric machine systems with customary engineering and manufacturing,
  5. Like MAGNAX, SYNCHRO-SYM easily leverages third party legacy or future electric machine design, packaging, material, winding, or construction techniques but with double the effective performance results,
  6. But unlike MAGNAX, only the symmetric circuit and control architecture of SYNCHRO-SYM best utilizes the axial-flux form factor and emerging wide bandgap electronic semiconductor switches: a) by conveniently placing the integral BRTEC, which is without bulky capacitors and with transformer magnetics uniquely integrated into the motor core assembly, within the otherwise wasted annulus of the axial flux core for another level of system power density, b) by uniquely providing the same assembly for rotor or stator, which include BRTEC, for inventory reduction, c) by inherently providing the coveted field weakening capability for extended speed range, d) by providing BRTEC with inherent resonant switching for electronic controller reliability, e) by eliminating the cogging drag of the persistent magnetism of permanent magnets, f) by eliminating the extravagant cost, environmental harm, and geopolitical consequences of RE-PMs, and g) by providing optimum performance at any speed, including zero speed, with stable, independent, and brushless excitation control of both the rotor and stator active winding sets.

The patented MOTORPRINTER uniquely democratizes the manufacture of axial-flux electric machines with a compact, scalable, low waste, non-smokestack 3D Printing method (or additive manufacturing method) that just-in-time manufactures high frequency (HF) and low frequency (LF) electric motors, generators, and transformers with compatible high performance amorphous or nanocrystalline metal ribbon, such as found in SYNCHRO-SYM, which provides a competitive advantage over all other electric machine manufacturers, such as BEM in particular with SYNCHRO-SYM.

The patented circuit and control architecture of the Brushless Real Time Emulation Controller (BRTEC) provides several patented hybrid configurations with electromagnetic processing. For instance, the patented BM-HFMDB provides the power distribution and connection between multiple SYNCHRO-SYMs in a system of system (such as 4 independent wheel motors in an electric vehicle or EV) with half the number of active devices (power switches) for higher efficiency, lower cost and lower size. The patented BMSCC allows compact and efficient solid-state translation from any power, such as DC, single, and multiphase AC, to any voltage, frequency, or phase, such as an EV battery controller and an EV charger.   

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