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, such as automobiles, airplanes, ships, and trains, b) the renewable energy industry, such as hydrogen, wind, tidal, and solar, c) the smart electricity industry, such as synchro-phasors, automatic power grid frequency synchronizers, and distributed power factor correctors, and d) the 3D Printing Industry of electric motors and generators with high power performance amorphous metal ribbon.

PRODUCT → SYNCHRO-SYM Technologies:

SYNCHRO-SYM is a patented Brushless “Symmetric” Electric Motor or Generator circuit and control architecture with the optimal symmetry of an “active rotor assembly” that stably and brushlessly contributes additional working power to the electromechanical energy conversion process along with the universally essential “active stator assembly,” all of which provides the “pinnacle” of electric motor technology with the working power of two similar directly excited bi-directional multiphase winding sets on the rotor and stator, respectively. All other electric motor or generator circuit and control architectures have the non-optimal asymmetry of a “passive rotor assembly” with either slip induction dependent windings, reluctance saliencies, rare-earth permanent magnets, or DC or single-phase field windings that cannot contribute additional working power to the electromechanical energy conversion process along with the active stator assembly. 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 electric machine package of air-gap flux density, winding, and electronic component techniques, then Conservation of Energy shows only 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 working power of only the single stator active winding set, such as the rare-earth permanent magnet electric motor, 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 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 new symmetric magnetic sharing circuit and control architecture that provides the most Versatile Smart Power Converter products but with the lowest cost, highest efficiency, highest power density possible, such as a Bi-Directional Multiphase Inductive (Wireless) Power Transfer System (M-IPTS).

BM-HFMDB is a patented hybrid Bi-directional, 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, 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 efficient electric motor or generator powertrain as the only practical alternative (e.g., E-mobility) with the emerging EV traction electric motor market, alone, conservatively estimated to reach nearly $40B by 2028 with a compounded annual growth rate (CAGR) of 35.32%. Efficient and high power density electric propulsion for higher and longer flying manned or unmanned airplanes is a needed reality for efficient and environmentally friendly short distance passenger flight or for broad coverage, high altitude 5G communication networks. Modular, lightweight, high power electric generator systems for large offshore wind-turbines are being explored to reduce field installation and sustainment costs. All together with electronic motor control, the entire commercial and passenger electric motor system market is estimated to reach as high as $1.4T by 2028. Ironically, the electric infrastructure industry is approaching this transformation without changing the century old, me-too, “asymmetric” electric motor or generator circuit and control architecture with the non-optimal asymmetry of a “passive” rotor assembly of slip-induction windings, reluctance saliencies, DC field windings (e.g., brush, brushless, conventional and superconductor), or rare-earth permanent magnets (RE-PM), such as the so-called transformational electric machine systems from MAGNAX, MAGNIX, MAGNA, and Turntide Technologies, with distinguishing performance differences narrowly limited to: a) strategically applying the same off-the-shelf materials, winding, and packaging 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 packaging techniques, c) attempting to patent empirical packaging results, which are easily evaded with empirical adjustment, or d) investing in “so-called creative” cost reducing manufacturing principles that reduce cost over performance, such as NIDEC’s $1.8 billion investment in high volume electric vehicle motor manufacturing because NIDEC recognized OEMs of electric vehicles are branding virtually the same performing asymmetric electric propulsion motor with minor performance distinction.

Only BEM is introducing a patented “brushless & symmetric” electric motor or generator system, called SYNCHRO-SYM, with a new circuit and control architecture, which comprises the “optimal working power production symmetry” of two similarly rated directly excited bi-directional multiphase (or “active”) winding sets stationed on the rotor and stator, respectively, that: a) shows at least double the performance at half the cost per unit of power rating of the “asymmetric” electric machine system with the working power production asymmetry of only a single similarly rated “active” winding set on the stator but with the additional loss, cost, and size of “passive” rotor slip-induction dependent windings, reluctance saliencies, DC field windings, or rare earth permanent magnets and b) provides twice the performance improvement expected from strategically applying the same available air-gap flux density, material, winding, packaging, and manufacturing techniques for performance distinction between asymmetric electric machine systems, all while also providing the best fault tolerance as expected from implementing directly excited multiple phase winding sets on the rotor and stator, respectively, that do not rely on slip-induction or multiphase slip-rings and brushes.  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, low and high frequency, electric motors, generators, and transformers, which are essential for implementing smart electricity with lower cost, size, and loss. Only BEM is investing in a patented Brushless Bi-directional Multiphase Self-Commutated Controller, which is essential for the smart electricity infrastructure. Only BEM is investing in 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 providing 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:

By simply retrofitting the century old asymmetric electric machine circuit and control architecture of MAGNAX, which was only enhanced with the commonly known RE-PM YASA packaging technique that comprises: 1) a so-called yokeless “active” stator assembly with a single directly excited multiphase winding set (i.e., singly-fed), 2) the asymmetry of a “passive” rotor assembly of rare-earth permanent magnets, and 3) an electronic controller derivative of field oriented control (FOC), 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 MAGNAX passive rotor assembly and FOC with the symmetry of an “active rotor assembly” that contributes an additional increment of working power production along with the active stator assembly as only possible with the stabilization of brushless multiphase real time emulation controller (BRTECTM), 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, which claims up to 5x the power density over the traditional radial flux asymmetric electric machine, would comparably double again (to up to 10x 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, the peak torque would at least comparably quadruple per unit of power rating, and any performance improvement from strategically applying specialized materials, winding, and packaging techniques would be twice magnified, all while eliminating the extravagant cost, persistent magnetism safety and handling, geopolitical consequences, limited operational life expectancy, environmentally unfriendly production, and unsustainable global supply chain issues of rare-earth permanent magnets and inherently providing a) universal single AC, multiphase AC, or DC operation, b) coveted field weakening for extended speed range and electronic control reliability, and c) providing leading, lagging, or unity power factor.

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 nearly two centuries of 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 but unlike MAGNAX, SYNCHRO-SYM is without exotic materials, such as rare earth permanent magnets,
  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 (and the next generation of optimized asymmetric motors from EMRAX, British YASA, DENSO, Turntide Technologies, Mahle, etc.), 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. Unlike MAGNAX, only the symmetric circuit and control architecture of SYNCHRO-SYM best utilizes the axial-flux form factor: a) by conveniently locating the integral BRTEC within the otherwise wasted annulus of the axial flux core for another level of power density, b) by uniquely providing the same assembly for rotor or stator 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 tuned 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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