SYNCHRO-SYM Technologies
– BEM Portfolio of Patented Technologies For Transforming The Electricity Infrastructure –
– Our Mission –
Innovate For Our Clean, Efficient, and Sustainable Energy Future!
PRODUCT → OVERVIEW:
In accordance with Our Mission to “Innovate For Our Clean, Efficient, and Sustainable Energy Future,” Best Electric Machine (BEM) offers a disruptive portfolio of at least four patented, straight-forward-ready, symbiotic technologies, branded SYNCHRO-SYM Technologies, for re-inventing: a) smart electrically propelled transportation, 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 applied performance of enabling technologies, such as emerging wideband gap (WBG) power semiconductor switches, or reduce (if not eliminate) today’s stifling dependency on rare-earth materials that are insidiously controlled by a global adversary seeking world dominance with harmful consequences on free labor, free market, environmental, geopolitical, and technical innovation.
Only SYNCHRO-SYM Technologies are strategically (and ethically) essential for the “smart” electricity infrastructure!
PRODUCT → SYNCHRO-SYM Technologies:
SYNCHRO-SYM re-imagined the electric motor system by inventing 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 enabling invention of automatically exact, Brushless, Sensorless, and Multiphase Real Time Emulation Control (BRTEC) for continuously stable “synchronous” operation at any speed. In clear contrast, 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 a derivative of estimating field-oriented excitation control (FOC).
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 has previously 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.
Only SYNCHRO-SYM is the electric motor system with the rotor assembly stably and independently contributing additional “working power” to the electromechanical energy conversion process along with the active stator assembly!
Only SYNCHRO-SYM is the viable RE-PM free alternative to the RE-PM electric motor system by providing twice the continuous power density and octuple the peak torque density (e.g., gearless EV drive) at half the size, half the cost, and half the loss per unit of continuous power rating!
Only SYNCHRO-SYM comparably performs with today’s field-wound superconductor (or so-called super permanent magnet) electric motor system but without the loss, cost, size, and complexity of cryogenic provisioning!
Only SYNCHRO-SYM uniquely favors the employment of emerging wide bandgap (WBG) power semiconductors by at least doubling their expected performance and halving their cost when similarly applied to any other electric motor or generator system!
Only SYNCHRO-SYM “total system” power density reaches over 60 KW/L, specific power reaches over 15 KW/Kg, and efficiency reaches over 98% without rare-earth permanent magnets, high speed gearing, or exotic construction but with the same air-gap flux density design and with the size, loss, and cost of the electronic controller included!
Several electric vehicle propulsion motor manufacturers admirably prefer the traditional brush-slipring field-wound synchronous electric motor system for good reasons, such as RE-PM free Vitesco and BMW’s 5th generation e-drive (2022), why not go the next step with the brushless, RE-PM free, SYNCHRO-SYM that provides twice the continuous power density and octuple the peak torque density at half the cost and loss (per unit of continuous power rating)?
MOTORPRINTER re-imagined 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 cores that provides at least: 1) integral frame and winding assemblies, 2) cores with highest performing, ultrathin electrical steel, amorphous metal, or nanocrystalline metal ribbon, 3) additive manufacture with off-the-shelf, highly optimized feedstock materials that are electromagnetically, structurally, and thermally compatible with the product being manufactured instead of with the 3D Printer itself, 4) a small, remotely controlled, additive manufacturing footprint (e.g., shipping container) instead of the traditional century-old assembly line manufacturing with costly capital equipment inventory, large power consuming smokestack facilities, and oppressed offshored labor, and 5) accommodating production scaling by simply adding another small, low power consuming, self-contained footprint of MOTORPRINTER.
BEM-CAD re-imagined 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 the unique BRTEC electromagnetic computer conveniently 3D Printed within the otherwise wasted annulus space of the 3D Printed low frequency symmetric synchronous doubly-fed axial-flux electric machine entity for another level of system power density and inventory reduction with duplicate rotor and stator assemblies.
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 by providing distributed, field programmable, just-in-time, additive manufacture in a small, portable footprint.
BMSCC re-imagined bi-directional electronic power conditioning with the only Brushless Bidirectional Multiphase Self-Commutated Controller that provides a unique isolated, common mode rejecting, high power, 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.
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.
BM-HFMDB re-imagined 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, 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.
BM-HFDFB is essential for lowering the cost, reducing the size, and improving the efficiency of any electric transportation SoS, such as electric vehicles.
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 the 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., 5G), which is impractical with single mission, expendable satellites. Modular, lightweight, high power electric generator systems are being explored to reduce delivery, field installation, and sustainment costs of large offshore wind-turbines. Alone, the electric propulsion motor system market is expected to reach $1.4T by 2028 (BB) with a CAGR of 26.7%.
The direct-drive electric motor/generator (or electromagnetic) powertrain is the most efficient, reliable, and maintenance-free solution to any mechanically geared powertrain, including today’s geared electric motor powertrains, and as a result, would be the powertrain of choice for any vehicle type, including ICE vehicles, but only with a gearless, high torque capable electric motor system architecture as provided by SYNCHRO-SYM!
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 field oriented control derivative. 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. As a result, the performance marketing distinction between “me-too” asymmetric electric machine systems 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 an engineered selection of available materials, winding, packaging, manufacturing, thermal management, and electronic component performance enhancing techniques that would always result in the same stable maximum load speed (MLS) or constant-torque speed range 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 asymmetric electric propulsion motor system, such as NIDEC’s $billion investment in high volume electric vehicle motor manufacturing.
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 electric motor!
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?
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), cost, and loss while doubling the overall performance. Hypothesized by a century of electric machine study, the symmetric multiphase wound-rotor “synchronous” doubly-fed circuit and control architecture of SYNCHRO-SYM was 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 the other half of the loss, cost, and size of any electric machine system with the compounding effects of friction and electronic control, SYNCHRO-SYM provides at least double the continuous power density and octuple the peak torque density at half the cost, half the size (or double power density), and half the loss (including windage per unit of continuous power rating with 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 the “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, 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 an estimating field-oriented controller (FOC) derivative, 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 mitigate manufacturing and thermal management challenges of the asymmetric axial-flux synchronous electric motor system, including the 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 FOC derivative with the symmetry of a working power contributing “active rotor assembly” as only possible with the synchronous stabilization by an automatically exact, brushless, sensorless, and multiphase real time emulation controller (BRTECTM), the power density of the original MAGNAX electric machine system package would comparably double again per unit of continuous power rating of MAGNAX, the cost would comparably halve per unit of continuous power rating, the efficiency would comparably increase per unit of continuous power rating, and the peak torque would comparably octuple per unit of continuous power rating, all by effectively eliminating the compounding cost, loss, and size effects of the passive rotor assembly of RE-PMs with serious geopolitical, limited operational life expectancy, wasteful cogging drag, unfriendly environmental, and unsafe handling consequences and by replacing the full rated FOC with a half rated BRTEC.
The simple retrofit comparison between SYNCHRO-SYM and the original MAGNAX conveniently shows:
- Like MAGNAX, SYNCHRO-SYM follows the same material, winding, packaging, and electronic component enhancing techniques and as a result, is straight-forward ready,
- Like MAGNAX, SYNCHRO-SYM follows the same operation, design, construction, and manufacture and as a result, is straight-forward ready,
- Like MAGNAX, SYNCHRO-SYM uses off-the-shelf components (but without RE-PMs) and as a result, is straight-forward ready,
- 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,
- 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,
- 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) universal single AC, multiphase AC, or DC operation, ii) coveted field weakening for extended speed range, electronic control reliability, and highest efficiency at any speed, iii) efficient cog-less motoring and generating (i.e.,, no RE-PMs), iv) “comprehensive” leading, lagging, or unity power factor compensation over the entire speed range, v) “comprehensive” regeneration over the entire speed range, vi) 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, vii) the reliability and resiliency of BRTEC with inherent resonant switching, viii) the direct AC-to-AC power conversion of instantaneous, sensorless, 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, viv) best utilization of the axial-flux form factor by conveniently placing the compact HF electromagnetic computer of BRTEC within the otherwise wasted annulus of the electric motor axial flux core, when under the design of BEM-CAD and the manufacture by MOTORPRINTER, for another level of system power density and component inventory reduction with physically the same rotor and stator assemblies (less software programming), and vv) simple and highly effective demand based cooling method, which is inherent to SYNCHRO-SYM under the additive manufacturing of MOTORPRINTER and BEM-CAD.
While solving the challenges of 1) manufacturing production, 2) thermal management, and 3) soft magnetic material structural, permeability, and flux saturation limits of the axial flux electric motor system and with the unique ability of forming perfectly aligned slots and channels of any programmable shape in solid nanocrystalline or amorphous ribbon materials for placing windings, permanent magnets, reluctance saliencies, or cooling channels, the patented 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, portable, self-contained 3D Printing method that uniquely layers off-the-shelf performance enhancing materials without material property damage or tool wear, such as high performance amorphous or nanocrystalline metal ribbon, structural material, and magnet wire, which are optimally premanufactured to be electromagnetically, structurally, and thermally compatible with the resulting electric motor product, instead of traditional 3D Printers that universally layer specialized materials that are optimally premanufactured to be compatible with the 3D Printer, such as powders, filaments, etc., instead of the product being manufactured.
The patented circuit and control architecture of the automatically exact, Brushless, Sensorless, and Multiphase Real Time Emulation Controller (BRTEC) with electromagnetic processing and inherent resonant switching provides several patented hybrid configurations. For instance, the patented 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 (power switches) for higher efficiency, lower cost and lower size. The patented 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 → DEVELOPMENT:
The Koenigsegg Quark E-Motor is another asymmetric RE-PM electric motor system that publicly claims best overall performance of any other “me-too” (or asymmetric) motor system by applying Koenigsegg’s engineered selection of off-the-shelf packaging enhancing techniques. BEM-CAD results show that retrofitting the same Koenigsegg Quark E-Motor packaging with the new symmetric circuit and control architecture of SYNCHRO-SYM twice magnifies the overall performance, octuply magnifies peak torque, halves cost, and halves loss. Without exotic materials or manufacturing techniques, such as Halbach arranged permanent magnets, the RE-PM free SYNCHRO-SYM shows power density of 58 KW/L (versus Koenigsegg’s 31.3 KW/L), specific power of 14.4 KW/Kg (versus Koenigsegg’s 8.7 KW/Kg), and system efficiency of 98%, while always including the loss, cost, and size of the integral BRTEC. Likewise, H3X Technologies is struggling to reach the power density, specific power, and efficiency ratings of SYNCHRO-SYM.
Future BEM products that are best enabled by SYNCHRO-SYM Technologies, such as a ubiquitous but sightless green hydrogen capture method, a modular and programmable (SW) electric vehicle propulsion drivetrain method, an energy managed reciprocity method, etc.
PRODUCT → COMPANY:
The future of BEM depends on you!