Innovate For Our Clean, Efficient, and Sustainable Energy Future!
In accordance with Our Mission, Best Electric Machine (BEM) provides a collaborative portfolio of patented technologies for transforming the electric transportation (automobiles, airplanes, ships, trains, etc.), renewable energy (hydrogen, wind, tidal, etc.), and smart electricity infrastructures (synchrophasors, synchronous machines, automatic power grid frequency synchronizers, distributed power factor correctors, etc.), branded SYNCHRO-SYM Technologies.
PRODUCT → EXECUTIVE SUMMARY:
By “innovating for our clean, efficient, and sustainable energy future” with the complementary suite of patented SYNCHRO-SYM Technologies, BEM brings the electric vehicle, renewable energy, and the smart electricity infrastructure beyond today’s reality.
HOW: Provide the only superior performing, lower cost electric motor and generator system that is free of permanent magnet (PM) materials, thereby leaving the precious, inadequate, and geopolitically sensitive global supply of rare-earth (RE) permanent magnet materials available for other strategic applications.
HOW: Provide the only 3D Printing means for democratizing the additive manufacture of superior performing electric motor and generator systems.
PRODUCT → SYNCHRO-SYM Technologies:
SYNCHRO-SYM is a patented “symmetric” Electric Motor or Generator System with a new brushless, integrated, symmetric magnetic sharing circuit and control architecture that unlike all other electric machine systems with a passive rotor assembly of slip induction dependent windings, reluctance saliencies, permanent magnets, or dc field windings, makes the rotor assembly an active power contributor to the electrical to mechanical conversion process, which effectively doubles the power density, quadruples the torque density, halves the cost, and halves the loss of the electric machine system within the same package of materials, windings, and manufacturing techniques per unit of power rating.
MOTORPRINTER is a patented 3D Printer Method for the rapid additive manufacture of low and high frequency, high power, axial flux electric machine cores, such as for additively manufacturing the new symmetric magnetic sharing circuit and control architecture of SYNCHRO-SYM, with high performance electrical steel, amorphous metal, or nanocrystalline metal ribbon, with perfectly aligned slots of any programmed shape for windings, permanent magnets, reluctance saliencies, or cooling, with perfectly flat air-gap surfaces, and with integral frame and winding assemblies.
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:
Automakers are predicting a dramatic decline of the internal combustion engine (ICE) vehicle by transitioning to the electric powertrain as the only practical alternative (e.g., E-mobility) and as a result, the electric propulsion motor “system” market for electric vehicles (alone) is expected to surpass $100B by 2029. Similarly, the AC Industrial electric motor market is expected to reach $152B by 2025 (without including the electronic controller of the “system”).
In response, industry is forming alliances with leading electric machine innovators, such as EM-motive, or developing a new generation of “axial flux” electric propulsion motors for electric vehicles, such as the emerging electric machine system from MAGNAX. In contrast to investing in new innovative motor technology, NIDEC is investing $1.8 billion in high volume electric vehicle motor manufacturing to reduce the cost of Nidec’s electric motors.
PRODUCT → SHOW ME:
Like MAGNAX, BEM is introducing a new transformational axial flux electric motor or generator system, called SYNCHRO-SYM, for revolutionizing at least the electric vehicle and the wind turbine markets. Like NIDEC, BEM is investing in its transformational electric machine 3D Printing technology, called MOTORPRINTER, for revolutionizing the just-in-time additive manufacture of axial-flux electric motors, generators, and high frequency transformers, such as for SYNCHRO-SYM Technologies. But unlike all other so-called electric machine system manufacturers and suppliers that always exploit the century old asymmetric electric machine circuit and control architecture with a power consuming “passive” rotor assembly of permanent magnets, DC field winding, reluctance saliencies, or slip-induction dependent windings, BEM invented a symmetric electric machine circuit and control architecture, called SYNCHRO-SYM, with a power contributing “active” rotor assembly and is also providing other complementary SYNCHRO-SYM Technologies, such BM-HFMDB and BMSCC, to enable or enhance its application.
By simply retrofitting the century old asymmetric electric machine circuit and control architecture package of MAGNAX, which comprises a so-called yokeless “active” stator assembly, a “passive” rotor assembly of rare-earth permanent magnets (i.e., singly-fed) mounted on steel back-iron plates, and an electronic controller derivative of field oriented control (FOC) that was only enhanced with packaging art available to all, such as the RE-PM YASA packaging form, with the patented, integrated, brushless, and symmetric electric machine circuit and control architecture of SYNCHRO-SYM, which comprises the MAGNAX active stator assembly under the same air-gap flux density, voltage, and speed but instead of the MAGNAX passive rotor assembly and FOC, an “active rotor assembly” with another directly excited multiphase winding set found on the active stator assembly (i.e., doubly-fed) as only possible with the SYNCHRO-SYM brushless real time emulation controller (BRTEC), the power density of the already highly optimized MAGNAX electric machine system would comparably double (with both the stator and rotor volumes equally contributing to electromechanical power conversion), its cost would halve, its efficiency would increase, its peak torque would at least quadruple, and 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 would be eliminated.
NOTE: To conceptually simplify the conversion of MAGNAX, which has a very complexity Yokeless and Segmented Armature (YASA) axial flux form with two air-gaps and two rotor disk assemblies, each of which comprise bearings and an arrangement of RE-PMs mated to a solid back-iron plate for structural support and for closing the magnetic path, the retrofit did not account for replacing the two rotor disk assemblies with two active disk assemblies, each of which would comprise bearings and an arrangement of windings, which are similar to the MAGNAX active stator winding set but with half the number of the winding turns, mated to a laminated back-iron plate.
By retrofitting the original MAGNAX with SYNCHRO-SYM, which includes replacing the field oriented controller (FOC) derivative of the original MAGNAX with the brushless real time emulation controller (BRTEC) of SYNCHRO-SYM, the performance comparison between the original MAGNAX and SYNCHRO-SYM is an obviously equitable qualitative comparison that shows SYNCHRO-SYM provides at least twice the power density, half the loss per KW, and half the cost per KW as the original MAGNAX with the same design, packaging, materials (less RE-PMs), and winding techniques under the same rated air-gap flux density, speed, and voltage and frequency of excitation because both the stator and rotor, together, of only SYNCHRO-SYM actively contribute power to the electromechanical conversion process. Also, the retrofit of MAGNAX conveniently shows: 1) SYNCHRO-SYM operation, design, construction, and manufacture are straight-forward ready (like MAGNAX), 2) SYNCHRO-SYM uses off-the-shelf components without exotic components or materials, such as rare earth permanent magnets (like MAGNAX), 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 doubles the effective performance of third party legacy or future electric machine design, packaging, material, winding, or construction techniques.
The same SYNCHRO-SYM retrofit comparison can be applied the century old asymmetric electric machine circuit and control technology 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:
- 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 replacing (or retrofitting) the “passive” slip-induction rotor assembly with a “passive” synchronous reluctance (SyncR) rotor assembly (including any embedded rare-earth permanent magnets to smooth out its traditional issues of torque ripple and cogging) and by replacing the field oriented controller (FOC) with a more sophisticated derivative with reluctance waveform shaping. While keeping virtually the same continuous torque rating and the same system active power rating with nearly the same loss, size, and cost per KW of active power rating for a given air-gap flux density, voltage and frequency of excitation, and pole count, the resulting retrofit only eliminates the associated cost, size, and loss of the extraneous slip-induction rotor squirrel cage winding set. In contrast, the simple SYNCHRO-SYM retrofit also keeps the “active” power producing stator assembly, replaces the FOC with the BRTEC, and eliminates the associated cost, size, and loss of the extraneous rotor squirrel cage winding set but instead of incorporating a “passive reluctance rotor assembly,” incorporates an “active rotor assembly” that together with the active stator assembly, doubles the system active power rating, quadruples the peak torque, halves the loss, size, and cost per KW of active power rating, and eliminates the RE-PMs.
- Recently introduced, LinearLabs’ HET rare-earth permanent-magnet (RE-PM) electric machine system (RE-PM-EMS) claims 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 (as other electric machines) but with four segmented RE-PM components completely surrounding the stator active winding set (i.e., so-called circumferential flux of HET) and as a result, end-turns are seemingly eliminated with the effective air-gap area doubled, which are admirable claims. Without critiquing the practicality of a completely air-gap surrounded (or floating) stator assembly, the performance claims, the stator winding complexity, or the structural complexity of the segmented rotor assembly, the performance claims of the century old asymmetric circuit and control architecture of LinearLabs’ HET motor would be doubled and the RE-PMs eliminated, if the HET was retrofitted with the new symmetric electric machine circuit and control architecture of SYNCHRO-SYM (as done with MAGNAX).
- 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 manufacturing with MOTORPRINTER, which is the only high speed 3D Printer of amorphous or nanocrystalline axial-flux electric motors and generators.