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 → ELEVATOR SPEECH:
In accordance with Our Mission to “Innovate for our clean, efficient, and sustainable energy future,” Best Electric Machine (BEM) offers a portfolio of patented, straight-forward-ready technologies, branded SYNCHRO-SYM Technologies, for transforming electrically propelled transportation, smart electric power conditioning and distribution, and 3D Printing of high-performance electric motors, generators, and transformers with: a) a new electric motor-generator circuit and control technology that without rare-earth permanent magnets (RE-PM) provides twice the power density and octuple the peak torque at half the cost and half the loss per unit of power rating of any other electric motor system, b) an electric vehicle micro-distribution bus that lowers the cost, complexity, size, and loss of the entire electrical system of systems of an electric vehicle, such as the battery charger, motor controller, etc., and c) the only programmable, high speed, 3D Printer of virtually any size, high performance, axial-flux electric-motor system within a small, portable, scalable footprint that democratizes electric motor manufacture with distributed, automated, additive manufacturing, instead of today’s insidious controlled by a global adversary seeking world dominance on the back of oppressed labor and global innovation.
ABOUT OUR WEBSITE
Instead of the expensively fancy rendering but technically irrelevant website of our competitors, which is essential to cunningly market their “me-too” electric motor system with the non-optimal asymmetry of the universally essential “active stator assembly” and a “passive rotor assembly” with rare-earth permanent magnets (but also, slip-induction dependent windings, DC field windings, or reluctance saliencies) provides better performance than another “me-too” electric motor system with the same package design parameters, BEM’s technically detailed but frugally plain website is essential to indisputably verify that our patented “synchronous” electric motor system (and SYNCHRO-SYM Technologies) with the optimal synchronous symmetry of a stable doubly-fed “active rotor assembly” provides twice the performance within the same packaging as universally proven by postulating a stabilizing brushless real time emulation control (BRTEC) means during the last century of electric motor study!
– SYNCHRO-SYM Technologies are straight-forward-ready! –
PRODUCT → SYNCHRO-SYM Technologies:
SYNCHRO-SYM is the only “Symmetric” Synchronous Electric Motor or Generator Circuit and Control Architecture with the optimal symmetry of an “active rotor assembly” that stably, wirelessly, independently, and synchronously contributes an additional increment of working power (or active power) to the electromechanical energy conversion process along with the universally essential “active stator assembly” that provides the rate torque (and power) of all electric motor systems. SYNCHRO-SYM is only possible under the patented breakthrough invention of automatically exact, Brushless, Sensorless, and Multiphase Real Time Emulation Control (BRTEC) for stable synchronous operation, regardless of speed. All other electric machine systems use the me-too “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 wastes precious electric motor real-estate, power potential, and cost by not independently contributing additional working power to the electromechanical energy conversion process along with the universally essential active stator assembly. High performance asymmetric electric motor systems always use today’s state-of-art but inexact control derivative of an estimating field-oriented excitation controller (FOC). By simply retrofitting any other high performance electric motor or generator system with the brushless, stable, synchronous, and symmetric circuit and control architecture of SYNCHRO-SYM, which uniquely makes the otherwise wasted rotor assembly an additional active power contributor to the electromechanical energy conversion process in accordance with the electric machine laws of physics, a century of classic electric motor and generator study universally confirmed that the power density of the original “me-too” 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 within the same package footprint of materials (less RE-PMs), windings, electronic components, manufacturing, excitation frequency and voltage, speed, continuous torque, and air-gap flux density, all without the problematic issues of permanent magnets.
Simply said, if a manufacturer of a practical motor system flaunts a 50% improvement in power density, efficiency, or cost per unit of power rating as only possible by empirically applying a selection of available materials, winding arrangements, electronic components, packaging, thermal management, or manufacturing techniques, then retrofitting the same package (less RE-PMs) with the new circuit and control technology of SYNCHRO-SYM will show a 100% improvement in power density, efficiency, and cost per unit of power rating and also, an octuple improvement in peak torque, all by uniquely making the rotor assembly an additional “active” contributor to the power conversion process along with the active stator assembly.
It follows that only SYNCHRO-SYM comparably performs with the futuristic field wound superconductor (or so-called super permanent magnet) electric motor system but without the loss, cost, size, and complexity of cryogenic provisioning and also, only SYNCHRO-SYM uniquely favors the employment of wide bandgap (WBG) power semiconductors by at least doubling their expected performance when applied to any asymmetric electric motor or generator system.
MOTORPRINTER is the only 3D Printer Method for the rapid additive manufacture of low or high frequency, high power, axial-flux electric motor, generator, and transformer cores: 1) with the integral frame and winding assemblies, 2) with the highest performing, ultrathin electrical steel, amorphous metal, or nanocrystalline metal ribbon that has been impractical with conventional electric machine manufacturing due to high tool wear, material damage, or ultrathin material machine dexterity, 3) with perfectly aligned slots and channels of any programmable shape for windings, permanent magnets, reluctance saliencies, or cooling means, 4) with perfectly flat air-gap surfaces without the tool wear and material damage by secondary tooling processes, such as blanchard grinding, and 5) within a small, remotely controlled, additive manufacturing footprint (e.g., shipping container) instead of the traditional century-old vertical assembly line manufacturing with costly capital equipment inventory, large smokestack facilities, and oppressed offshored labor.
BEM-CAD is 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 enhancing techniques for truly equitable cross-comparative analysis. Interfaced to BEM-CAD, MOTORPRINTER additively manufacturers (or 3D Prints) axial-flux SYNCHRO-SYMs with the BRTEC electromagnetic computer conveniently and compactly placed within the otherwise wasted annulus space of the low frequency symmetric doubly-fed electric machine entity for another level of system power density and inventory reduction.
MOTORPRINTER with BEM-CAD will revolutionize and democratize the manufacture of superior performing electric motors, generators, and high power, high frequency electromagnetic transformers by providing distributed, field programmable manufacture in a small portable footprint.
BMSCC is the only Brushless Bidirectional Multiphase Self-Commutated Controller with 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 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 is the only Bidirectional, Multiphase, High Frequency, Electricity Micro-Distribution Bus with 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 micro-distribution bus with the highest efficiency and power density at half the cost, half the active electronic stages, and lowest harmonic content in a 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 system, 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, comprehensive energy recovery, electric propulsion motor powertrain (e.g., E-mobility), which leaves the electric motor/generator (or electromagnetic) 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, field maintenance returnable, flying platforms instead of single mission, expendable satellites for the broadest, most reliable communication network coverage possible (e.g., 5G). 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 gearless or direct-drive electric motor/generator (or electromagnetic) powertrain is the most efficient, reliable, and maintenance-free solution to the traditional mechanically geared powertrain and as a result, will be the powertrain of choice, regardless of ICE or Electric Vehicle type!
Ironically, the entire electric motor/generator system industry is approaching this electric transformation with the same century old, “me-too,” asymmetric electric motor or generator circuit and control architecture with the non-optimal asymmetry of the universally essential “active” stator assembly and 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. Unlike the “active stator assembly,” which determines the torque and power rating of the asymmetric electric motor system, the “passive rotor assembly” effectively wastes the other half of precious electric motor and generator system power potential, cost, and real-estate without independently contributing an additional increment of working power to the electromechanical energy conversion process. As a result, the performance marketing distinction between “me-too” asymmetric electric machine systems is limited to: a) hiding the technical details of the electric motor system from the EV specifications to avoid exposing “me-too” similarity, b) enhancing performance by empirically applying 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 design parameters, c) forming alliances with leading innovators to mutually leverage verified empirical packaging techniques, 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 electric vehicle OEMs are cunningly marketing virtually the same performing asymmetric electric propulsion motor system.
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 environmental and human suffering consequences of producing its RE-PMs?
Demonstrating the global adversary’s insidious control on electric motor innovation and manufacture, today’s best solution to the geopolitical, forced labor, environmental, and expensive consequences of producing RE-PM electric machine systems is restricted to only reducing the amount of deliberately pricier RE-PM materials by ironically mating a very high speed (and therefore smaller) RE-PM electric motor system with an unusually high frequency electronic excitation controller to an extraneous, high-speed gearbox that actually “compounds” the overall complexity, cost, reliability, maintenance, noise, size, and loss of the entire propulsion drivetrain?
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, directly excited (e.g., bidirectional) multiphase winding sets (or “active” winding sets) that are symmetrically placed on the rotor and stator, respectively, to inherently maintain the same electric motor footprint of material (less RE-PMs), cost, and loss while doubling the overall performance. Hypothesized by a century of electric machine study, the symmetric synchronous circuit and control architecture of SYNCHRO-SYM is only possible with the patented breakthrough invention of automatically exact, brushless, sensorless, and multiphase real time emulation control (BRTEC) of the rotor and stator torque and magnetizing fluxes for continuously stable “synchronous” operation from sub-synchronous to super-synchronous speeds, including zero and synchronous speeds, regardless of random rotor or line perturbations. Effectively, BRTEC is the only power conditioning and process control technology with the “digital twin” embedded in the system control hardware instead of applied as a design tool during engineering development. Therefore, under the same MLS design for a given continuous torque, frequency and voltage of excitation, and air-gap flux density, while including the compounding effects of electronic control and reasonably assuming the rotor and stator, each, consume half of the loss, cost, and size of any electric machine, SYNCHRO-SYM provides at least double the continuous power density at half the cost, half the size (or double power density), half the loss (including windage), and octuple the peak torque per unit of continuous power rating as the “asymmetric” electric motor circuit and control architecture with the same package of material (less RE-PMs), winding, electronic component, thermal management, and manufacturing techniques.
The patented electric motor circuit and control technology of SYNCHRO-SYM eliminates RE-PMs while providing twice the performance and octuple the peak torque (e.g., gearless EV drive) within the same packaging of size, cost, and loss as the RE-PM electric machine system and also, the patented electric motor 3D Printer Method of MOTORPRINTER democratizes the manufacture of high-performance electric motors, such as SYNCHRO-SYM, with distributed additive manufacturing in a small footprint!
The double performance gain of SYNCHRO-SYM over all other electric machine systems, including the RE-PM electric machine system, has been verified by a simple qualitative proof and by extrapolation from the qualitative analysis by an electric machine expert.
Also, 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 vehicles, by at least halving the number of active components. 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 Brushless Bidirectional Multiphase Self-Commutated Controller, which is essential for successfully implementing the smart electricity infrastructure, and c) a patented 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 inexact electronic excitation control derivative of estimating field-oriented controller (FOC), MAGNAX shows some of the highest performance metrics for the century old, me-too asymmetric electric motor system by empirically applying commonly understood RE-PM YASA packaging enhancing techniques to mitigate manufacturing and thermal management challenges, including the structural, permeability, and flux saturation limits of soft magnetic material.
By simply retrofitting the same asymmetric circuit and control architecture of MAGNAX with the patented brushless and symmetric multiphase 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 but instead, replaces the size, loss, and cost of the MAGNAX “passive rotor assembly” and estimating FOC with the symmetry of a working power contributing “active rotor assembly” as only possible with the synchronous stabilization of 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 (for twice the publicized 5x power density of MAGNAX), the cost would comparably halve, the efficiency would comparably increase, and the peak torque would comparably octuple, all by effectively eliminating the compounding cost, loss, and size effects of FOC and the passive rotor assembly of RE-PMs with serious geopolitical, limited operational life expectancy, wasteful cogging drag, unfriendly environmental, and unsafe handling consequences.
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, 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, and 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 the same rotor and stator assemblies.
While solving the manufacturing production and thermal management challenges and eliminating the structural, permeability, and flux saturation limits of soft magnetic material with the unique ability of forming perfectly aligned slots and channels of any programmable shape for windings, permanent magnets, reluctance saliencies, or thermal management in solid nanocrystalline or amorphous ribbon materials, the patented MOTORPRINTER revolutionizes and democratizes the manufacture of axial-flux high frequency and low frequency electric motors, generators, and transformers, such as found in SYNCHRO-SYM, with a rapid, just-in-time, compact, scalable, low waste, non-smokestack, remotely controlled, 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 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, which provides another competitive advantage over all other electric machine manufacturing.
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 the most recent electric motor system that publically claims best overall performance from all other “me-too” (or asymmetric) RE-PM motor systems by the application of Koenigsegg’s empirical selection of available packaging enhancing techniques. With the same packaging techniques, BEM-CAD results show that retrofitting the Koenigsegg Quark E-Motor with the new symmetric circuit and control architecture of SYNCHRO-SYM twice magnifies the performance.
Future BEM products that are best enabled by SYNCHRO-SYM Technologies, such as a ubiquitous but sightless green hydrogen capture method, modular and programmable (SW) electric vehicle propulsion drivetrain method, energy managed reciprocity method, etc.
PRODUCT → COMPANY:
The future of BEM depends on you!