SYNCHRO-SYM TECHNOLOGIES

PRODUCT → SHAPING OUR ENERGY FUTURE:

In accordance with Our Mission to “Innovate For Our Clean, Efficient, and Sustainable Energy Future,” Best Electric Machine (BEM) offers a portfolio of at least four patented, straight-forward-ready technologies, branded SYNCHRO-SYM Technologies, for reimagining: a) smart electric propulsion, b) smart 3D printing method of high performance axial-flux electric motors, generators, and transformers, c) smart electric power conditioning, and d) smart electric polyphase micro-distribution, which will significantly magnify the expected gain from applying performance enhancing technologies, such as emerging wideband gap (WBG) power semiconductor switches, and will ethically mitigate today’s stifling dependency on rare-earth materials that are insidiously controlled by a global adversary seeking world dominance.

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Only SYNCHRO-SYM Technologies are “ethically” essential for the apolitically “smart” future of green technology!

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PRODUCT → SYNCHRO-SYM Technologies:

SYNCHRO-SYM reimagined the electric motor (and generator) system with the only “Symmetric” Electric Motor or Generator Circuit and Control Architecture with the optimal symmetry of an “active rotor assembly” that independently contributes an additional increment of working power (or active power) to the electromechanical energy conversion process along with the universally essential “active stator assembly” of all electric motor systems, which is only possible with the breakthrough invention of automatically precise, Brushless, Sensorless, and Multiphase Real Time Emulation Control (BRTEC) for enabling continuously stable “synchronous” operation at any speed.

All other electric machine systems implement the “Asymmetric” Electric Motor or Generator Circuit and Control Architecture with the non-optimal asymmetry of a “passive rotor assembly” of either slip-induction dependent windings, reluctance saliencies, rare-earth permanent magnets (RE-PM), or DC field windings that effectively wastes half of the precious electric motor real-estate, power potential, and cost by not stably and independently contributing additional working (or active) power to the electromechanical energy conversion process along with the universally essential active stator assembly, which is always controlled by an estimating derivative of field-oriented control (FOC), such as direct-torque control (DTC).

By simply retrofitting the “passive rotor assembly” of the “me-too” asymmetric circuit and control architecture of all other electric motor or generator systems with the “active rotor assembly” of the symmetric circuit and control architecture of SYNCHRO-SYM, a century of classic electric motor and generator study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention has proven the power density of the original asymmetric electric machine “system” package would double, the loss would halve, the cost would halve, and the peak torque would octuple (per unit of continuous power rating).

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Only SYNCHRO-SYM “total system” power density reaches over 60 KW/L, specific power reaches over 16 KW/Kg, and efficiency reaches over 96% at only 4000 RPM and 1.25T with traditional electric motor packaging and construction techniques and with the size, loss, and cost of the electronic controller “extraordinarily” included in the overall performance calculations!

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MOTORPRINTER reimagined electric motor manufacture with the only 3D Printer Method for the low cost, rapid, just-in-time, additive manufacture of low or high frequency, high power, axial-flux electric motor, generator, and transformer wound cores: 1) with integral frame and winding assemblies, 2) with a unique thermal management system, 3) with off-the-shelf, highly optimized feedstock layering materials that are electromagnetically, structurally, and thermally compatible with the electric machine product being additively manufactured, such as highest performing, ultrathin electrical steel, amorphous metal, or nanocrystalline metal ribbon, structural material, and magnet wire, instead of being compatible with the 3D Printer itself, such as the typical 3D Printer feedstock powders, filaments, etc., 4) within a small, remotely controlled footprint (e.g., shipping container) instead of the traditional century-old assembly line manufacturing with costly capital equipment inventory, large industrial power consuming smokestack facilities, and oppressed offshored labor, and 5) with production scaling by simply adding or stacking another small, household powered, self-contained footprint.

BEM-CAD reimagined electric motor design with the only computer-aided-design (CAD) tool that simultaneously designs axial-flux SYNCHRO-SYMs, RE-PM electric machine systems, and Induction electric machine systems to the same continuous torque, air-gap flux density, maximum load speed (MLS), frequency of excitation, and port voltage design and with the same material, winding, thermal management, electronic component, and packaging performance enhancing techniques for truly equitable cross-comparative analysis. Interfaced to BEM-CAD, MOTORPRINTER is programmed to additively manufacture (or 3D Print) axial-flux SYNCHRO-SYMs with its unique BRTEC electromagnetic computer conveniently and proportionally 3D Printed within the otherwise wasted annulus space of the low frequency symmetric synchronous doubly-fed axial-flux electric machine entity, which provides another level of system power density and another level of system inventory reduction with duplicate rotor and stator assemblies.

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Only MOTORPRINTER under the programmable control of BEM-CAD will revolutionize and democratize the manufacture of superior performing low and high frequency, axial-flux electric motors, generators, and transformers and neutralize the advantage of offshoring manufacturing with exploited labor by providing distributed, field programmable, just-in-time, additive manufacture in a small, deployable footprint.

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BMSCC reimagined bi-directional electronic power conditioning with the only Brushless Bidirectional Multiphase Self-Commutated Controller that provides a unique isolated, common mode rejecting, high power, fault tolerant, high frequency zero-crossing fault detection and fusing, inherent resonant switching, automatically exact symmetric magnetic sharing circuit and control architecture (i.e., high power gyrator) that provides the most versatile Smart Power Converter products with automatic frequency translation and the lowest cost, highest efficiency, highest power density, and lowest distortion possible.

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BMSCC is essential for implementing synchronous or asynchronous grid forming (GFM), inverter based resources (IBR), such as Bidirectional Multiphase Inductive (Wireless) Power and frequency Transfer Systems (M-IPTS), fast electric vehicle chargers, static synchronous compensators (STATCOM) for enabling the flexible AC transmission system (FACTS), compact high power phase shifting transformer, etc.

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BM-HFMDB reimagined electric power micro-distribution with the only Bidirectional, Multiphase, High Frequency, Electricity Micro-Distribution Bus that provides a unique isolated, common mode rejecting, high power, fault tolerant, high frequency zero-crossing fault detection and fusing, inherent resonant switching, automatically exact symmetric magnetic sharing circuit and control architecture (i.e., high power gyrator) that halves the cost, halves the number of active electronic stages, halves the loss, halves the harmonic content, and halves the complexity of the entire system of systems (SoS) application, such as electric vehicles, electric airplanes, etc.

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BM-HFDFB is essential for lowering the cost, reducing the size, and improving the efficiency of any electric transportation SoS, such as electric vehicles.

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PRODUCT → FOCUS:

A dramatic decline of the traditional internal combustion engine (ICE) vehicle with a mechanically geared powertrain is anticipated with the rapid adoption of the more universally efficient, energy recovery, electric propulsion motor powertrain (e.g., E-mobility), which leaves the electric motor/generator and micro-distribution system as a major consumer of electric vehicle (EV) loss, cost, and size. Efficient, high power density electric propulsion is needed for environmentally friendly short distance passenger airplanes or for autonomous unmanned, long duration, high altitude, solar powered (e.g., no fuel for launch, landing, or sustainment), field maintenance returnable, self-adaptable flying platforms for the broadest, most reliable communication network coverage possible (e.g., commercially installed 5G), which is impractical with single mission, expendable satellites and associated land-based communication. Modular, lightweight, high power electric generator systems are being explored to reduce delivery, field installation, and sustainment costs of large offshore wind-turbines. Without considering commercial applications, the electric propulsion motor system market is expected to reach $1.4T by 2028 (BB) with a CAGR of 26.7%.

Ironically, the entire electric motor/generator system industry is approaching this electricity infrastructure transformation with the same century old, “asymmetric” electric motor or generator circuit and control architecture with the non-optimal asymmetry of the universally essential “active” stator assembly comprising a directly excited (e.g., bidirectional) multiphase winding set (or active winding set) but a “passive” rotor assembly comprising either rare-earth permanent magnets (RE-PM), slip-induction dependent windings, reluctance saliencies, or DC field windings (e.g., conventional or superconductor electromagnets) with associated provisioning, such as brushes, sliprings, RE-PM structural and thermal reinforcements, cryogenics, etc., and an estimating FOC or DTC. Unlike the “active stator assembly,” which always determines the overall torque rating of the asymmetric electric motor system by independently contributing working power to the electromechanical energy conversion process, the “passive rotor assembly” effectively wastes the other half of precious electric motor and generator system power potential, cost, and real-estate by not independently contributing additional working power to the electromechanical energy conversion process along with the active stator assembly. As a result, the performance marketing distinction between “me-too” asymmetric electric machine systems from different manufacturers with a single active winding set is always: a) hiding the pertinent technical details of the electric motor system from the EV specifications to avoid exposing “me-too” similarity, b) enhancing performance by empirically applying a different selection of available materials, winding, packaging, manufacturing, thermal management, and electronic component performance enhancing techniques, such as the axial-flux formfactor, that would always result in the same stable constant-torque speed range (or maximum load speed (MLS)) and associated performance if equally applied between asymmetric electric motor systems with the same continuous torque, excitation frequency and voltage, and air-gap flux density specifications, c) forming alliances with leading innovators to mutually leverage verified empirical packaging techniques, or d) investing in creative cost-reducing manufacturing after recognizing electric vehicle OEMs are cunningly marketing virtually the same performing, century-old, asymmetric electric propulsion motor system, such as NIDEC’s $billion investment in high volume electric vehicle motor manufacturing with a global adversary seeking world dominance.

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Today’s best solution for mitigating the environmental consequences of “consuming fossil fuels” is to rapidly adopt the “me-too” RE-PM electric motor system, which ironically, is cartel-controlled by a global adversary seeking world dominance with blatant disregard to the geopolitical, forced labor, environmental, and pricing consequences of producing its RE-PMs, including significant price increases as expected from past experience when future shortages occur?

Demonstrating the global adversary’s insidious control on electric motor innovation and manufacture, today’s best solution to the geopolitical, forced labor, environmental, and pricing consequences of producing RE-PM electric machine systems is restricted to only reducing the amount of deliberately pricier RE-PM materials by mating a high speed (and therefore smaller) RE-PM electric motor system with an unusual high frequency electronic excitation controller and an extraneous, high-speed gearbox that ironically “compounds” the overall complexity, cost, reliability, maintenance, noise, size, and loss of the entire propulsion drivetrain! Similarly, moving to prevalent but very low energy product ferrite permanent magnets only exasperates this problem by requiring even higher operating speeds and larger gearboxes for the same power density but lower efficiency and reliability permanent magnet electric motor systems!

Although the common understanding amongst electric motor manufacturers is directed towards reducing the dependency on precious, costly, environmentally destructive, and geopolitically sensitive rare-earth permanent magnet (RE-PM) materials, manufacturers of so-called yokeless, coreless, or PCB electric motor systems with deeper airgaps, such as Infinitum Electrics, are ironically increasing the amount of RE-PM materials per unit of power rating?

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Only BEM is introducing a patented synchronous electric motor or generator system, called SYNCHRO-SYM, with the optimal “symmetric” circuit and control architecture that wirelessly, synchronously, and stably combines the working power production of two similarly rated “active” winding sets that are symmetrically placed on the rotor and stator, respectively, to inherently maintain the same electric motor package footprint of material (less RE-PMs), construction, cost, and loss while doubling the overall performance. Proven by at least a half century of basic electric machine study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention, the symmetric multiphase wound-rotor “synchronous” doubly-fed circuit and control architecture of SYNCHRO-SYM is known to be only possible with the breakthrough invention of automatically exact, brushless, sensorless, and multiphase real time emulation control (BRTEC) for guaranteeing continuously stable “synchronous” operation from sub-synchronous to super-synchronous speeds, including zero and synchronous speeds, regardless of random rotor or line destabilizing perturbations. Effectively, the patented BRTEC is the only control technology with the “digital twin” embedded in the runtime control hardware and software instead of applied as a onetime design tool during engineering, development, and manufacture. Therefore, under the same MLS design for a given continuous torque, frequency and voltage of excitation, and air-gap flux density, all while reasonably assuming the rotor or stator consumes half of the loss, cost, and size of any electric machine system with the compounding effects of friction and electronic control included, particularly in an axial-flux format with similar rotor and stator disks assemblies, SYNCHRO-SYM is a drop-in replacement that provides at least double the continuous power density (or half the size) and octuple the peak torque density at half the cost, and half the loss (per unit of continuous power rating) by the combined performance of dual active winding sets (i.e., doubly-fed) in the same package of material (less RE-PMs), winding, electronic component, thermal management, and manufacturing techniques as any “asymmetric” electric motor circuit and control architecture with a single active winding set (i.e., singly-fed).

Only BEM is introducing a portfolio of patented enabling technologies, branded SYNCHRO-SYM Technologies, that reduces overall size, improves overall efficiency, and lowers overall cost of an electrical System of Systems (SoS) application, such as wind turbine farms and electrically propelled ships, airplanes, and land vehicles. SYNCHRO-SYM Technologies include: a) a patented (and only) electric machine 3D Printing technology, called MOTORPRINTER, for revolutionizing and democratizing the rapid just-in-time additive manufacture of superior performing axial-flux low frequency electric motor and generator systems, such as SYNCHRO-SYM, and high frequency, high power electric transformers, such as BRTEC, which are essential for lowering the cost, size and loss of the smart electricity infrastructure, b) a patented (and only) Brushless Bidirectional Multiphase Self-Commutated Controller, which is essential for successfully implementing the smart electricity infrastructure, and c) a patented (and only) Bidirectional, Balanced Multiphase, High Frequency, Electricity Micro-Distribution Bus, which is essential for lowering the cost and improving the efficiency of the electric vehicle SoS.

PRODUCT → SHOW ME:

Comprising the asymmetry of a “passive rotor assembly” of rare-earth permanent magnets (RE-PM) and a state-of-art but estimating control derivative of FOC, MAGNAX shows some of the highest performance metrics for the century old, me-too asymmetric electric motor system by empirically applying an engineered selection of commonly understood RE-PM YASA packaging enhancing techniques to leverage its advantages while mitigating the manufacturing and thermal management challenges of the axial-flux asymmetric synchronous electric motor system with the compounding structural, permeability, and flux saturation limits of soft magnetic material.

By simply retrofitting the same asymmetric circuit and control technology of MAGNAX with the patented brushless and symmetric multiphase wound-rotor synchronous doubly-fed electric machine circuit and control technology of SYNCHRO-SYM, which keeps the MAGNAX active stator assembly with the same continuous torque, excitation frequency and voltage, and air-gap flux density ratings but instead, replaces the size, loss, and cost of the MAGNAX “passive rotor assembly” and estimating control derivative of FOC with the symmetry of a working power contributing “active rotor assembly,” as only possible with synchronous stabilization by an automatically exact, brushless, sensorless, and multiphase real time emulation controller (BRTEC^TM), the power density of the original MAGNAX electric machine system package would comparably double again per unit of continuous power rating, the cost would comparably halve, the efficiency would comparably double, and the peak torque would comparably octuple, as was proven by at least a half-century of electric motor study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention, all by replacing the full rated estimating control derivative with a half rated BRTEC and by effectively eliminating the compounding cost, loss, and size effects of the passive rotor assembly of RE-PMs with known safety, handling, limited operational life expectancy, wasteful cogging drag, unfriendly environmental, and geopolitical consequences with the symmetry of another active winding set.

This simple retrofit comparison between SYNCHRO-SYM and the original MAGNAX (or any other electric motor system) conveniently shows:

1. Like MAGNAX, SYNCHRO-SYM follows the same material, winding, packaging, and electronic component enhancing techniques and as a result, is straight-forward ready,
2. Like MAGNAX, SYNCHRO-SYM follows the same operation, design, construction, and manufacture and as a result, is straight-forward ready,
3. Like MAGNAX, SYNCHRO-SYM uses off-the-shelf components (but without RE-PMs) and as a result, is straight-forward ready,
4. Like MAGNAX, SYNCHRO-SYM is adaptable to legacy or future electric machine systems with customary engineering and manufacturing and as a result, is straight-forward ready,
5. Like MAGNAX, SYNCHRO-SYM easily leverages third party legacy or future electric machine design, packaging, material, winding, or construction enhancing techniques but with double the expected performance gain and as a result, is straight-forward ready,
6. But unlike MAGNAX, only the symmetric circuit and control architecture of SYNCHRO-SYM with two similarly rated active winding sets advantageously placed on the rotor and stator, respectively, inherently provides: i) the same packaging footprint, ii) universal single AC, multiphase AC, or DC operation, iii) coveted field weakening for extended speed range, electronic control reliability, and highest efficiency at any speed, iv) efficient clogless motoring and generating (i.e., no RE-PMs), v) inherently indestructible without the fragility and limited life expectancy of RE-PM but with the precision control of BRTEC and the proprietary thermal management as only provided by MOTORPRINTER, vi “comprehensive” leading, lagging, or unity power factor compensation over the entire speed range, vii) “comprehensive” regeneration over the entire speed range, viii) best utilization of emerging wide bandgap electronic semiconductor switches with a circuit and control technology that doubles their expected performance with half their expected cost per unit of power rating, ix) the reliability and resiliency of BRTEC with inherent resonant switching, x) the direct AC-to-AC power conversion of instantaneous, sensorless, multiphase, and automatic electromagnetic computing (i.e., BRTEC) with inherent active filtering, which eliminates the DC Link Stage of FOC with banks of large, expensive, inefficient, and delicate low frequency, high power capacitors, xi) the unique power conditioning method of BRTEC inherently provides pure sinusoidal excitation, which minimizes electrical stress on electronic components, xii) best utilization of the axial-flux form factor by conveniently and proportionally placing the compact electromagnetic computer of BRTEC within the otherwise wasted annulus of the electric motor axial flux core, which physically provides the same rotor and stator assemblies (less software programming), and xiii) a simple and highly effective demand based cooling method for another level of system power density and component inventory reduction, all of which are inherent to SYNCHRO-SYM under the additive manufacturing of MOTORPRINTER and the design control of BEM-CAD.

While solving the challenges of manufacturing production and thermal management of the axial-flux electric motor system with the structural, permeability, and flux saturation limits of soft magnetic composites, MOTORPRINTER revolutionizes and democratizes the manufacture of low and high frequency axial-flux electric motors, generators, and transformers, such as found in SYNCHRO-SYM, with a rapid, just-in-time, compact, incrementally scalable, low waste, non-smokestack, remotely controlled, deployable, self-contained 3D Printing method. Also, the circuit and control architecture of the automatically precise, Brushless, Sensorless, and Multiphase Real Time Emulation Controller (BRTEC) with electromagnetic processing and inherent resonant switching provides several patented hybrid configurations. For instance, BM-HFMDB provides the power distribution to multiple SYNCHRO-SYMs in a system of system, such as electric vehicles, with half the number of active devices (i.e., power switches), fault tolerance, and high frequency zero-crossing fault detection and conduction fusing for higher efficiency, lower cost and lower size and BMSCC allows compact and efficient solid-state power conditioning, gyration, and 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.

PRODUCT → THE SYNCHRO-SYM E-MOTOR:

BEM’s E-mobility market study verified the Koenigsegg Quark E-Motor credibly claims best overall performance of any other “me-too” (or asymmetric) motor system by applying Koenigsegg’s engineered selection of readily available packaging enhancing techniques but with a componentized remote electronic controller and as a result, the Quark E-Motor will be the initial market focus of the SYNCHRO-SYM E-Motor. Without exotic materials, such as RE-PMs, or construction techniques, such as Halbach arranged permanent magnets, the SYNCHRO-SYM E-Motor shows “total system” power density of 66 KW/L (versus Koenigsegg’s 31.3 KW/L), specific power of 16 KW/Kg (versus Koenigsegg’s 8.7 KW/Kg), and total system efficiency of 97% at 4000 RPM and 1.25T while extraordinarily including the loss, cost, and size of the integral BRTEC, which also demonstrates SYNCHRO-SYM’s double expected performance gain as proven by at least a half-century of electric motor study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention. With a very complex arrangement of RE-PMs and integrated electronics, other asymmetric RE-PM electric motor systems (for electric airplane propulsion), such as H3X Technologies Motor and MIT’s Megawatt Motor, are struggling to reach the power density, specific power, and efficiency ratings of the SYNCHRO-SYM E-Motor.

With its superior performance and straight-forward additive manufacture with MOTORPRINTER (under the design control of BEM-CAD) and with the designed-in convenience of incrementally stacking SYNCHRO-SYM E-Motors lengthwise (i.e., power stacking) to provide incrementally higher power rating, redundant fail-tolerance by at least multiplicity, smaller effective diameter, and simpler electronic conditioning, the same SYNCHRO-SYM E-Motor product shows double the performance and reliability of Koenigsegg newest E-Motor introduction, called Dark Matter.

PRODUCT → OUR STORY:

PRODUCT → COMPANY:

BEM hopes the reader is not flabbergasted by the vast leap in cost-performance provided by SYNCHO-SYM Technologies, which was already proven by over a half century of independent electric motor study, research, and publication that were reimagined to practical reality by BEM’s patented method of state-of-art high frequency magnetics, electronic switching of multiphase power conditioning, and brushless real-time emulation control that were verified by a regiment of circuit and control architecture prototyping, and instead, BEM hopes the reader takes the necessary time to understand the SYNCHRO-SYM concept of operation. It will become evident that any electricity infrastructure product can benefit from applying SYNCHRO-SYM Technologies, including the electric motor systems of our perceived electric motor competitors by simply eliminating the asymmetry of a wasted “passive rotor assembly” of either slip-induction dependent windings, reluctance saliencies, rare-earth permanent magnets, or DC field windings from the original packaging.   

The future of BEM SYNCHRO-SYM Technologies, such as 3D Printing of electric motors and SYNCHRO-SYM, depends on you!   

PRODUCT → FUTURES:

An ad hoc collage of future BEM products, which are uniquely enabled by the compact, low cost, high efficiency, and rare-earth material free SYNCHRO-SYM Technologies, describes a ubiquitous, autonomous, and sightless far offshore, green hydrogen capture sail ship method, a modular and programmable (SW) electric vehicle propulsion drivetrain method, an energy reciprocity management method, an ultra-high altitude, repairable, autonomous swarming, meshed communication solar powered drone method, and etc.