– Only Practical Brushless, Symmetric, Synchronous Doubly-Fed Electric Motor or Generator System –
Innovate For Our Clean, Efficient, and Sustainable Energy Future!
SYNCHRO-SYM → BOTTOM LINE UP FRONT:
– Whatever a manufacturer may claim as the best performing electric motor system for a given frequency and voltage of operation, the circuit and control technology of SYNCHRO-SYM will double the performance claim at half the cost with the same packaging but simpler construction without rare-earth permanent magnets. –
To provide a more obvious comparison, this example considers the axial-flux formfactor of electric motors with similar adjacent stator and rotor disks separated by a bearing assembly, where the rotor and stator disks can be interchanged without affecting the “mechanical aspects” of the electric motor, such as physical size, friction, etc.:
Step 1: Simply remove the non-optimal asymmetry of the “passive rotor assembly” disk, which comprises slip-induction dependent windings, reluctance saliencies, DC field windings, or rare-earth permanent magnets (RE-PMs) and associated provisioning, such as brushes, sliprings, RE-PM structural and thermal reinforcements, conventional or superconductor electromagnets, etc., from the ubiquitously applied asymmetric electric motor circuit and control architecture, and also, remove its inexact, full power rated control derivative of an estimating flux-oriented excitation controller (FOC) or direct torque control (DTC).
Note: The “passive rotor assembly” reasonably consumes half of the asymmetric electric motor real estate, cost, or operating loss, which includes core, electrical, electronic control, and friction loss, but without independently contributing additional working power to the electromechanical energy conversion process along with the universally essential “active stator assembly,” which comprises the directly excited (e.g., bidirectional) multiphase winding set (or active winding set) that determines the overall torque and power rating of the asymmetric electric motor while reasonably consuming the other half of the electric motor real estate, operating loss, or cost.
Note: The inexact, estimating field-oriented excitation controller (FOC) of the asymmetric electric motor system compounds the size, loss, and cost of the “total motor system” but cannot contribute working power to the electromechanical energy conversion process.
Step 2: Replace the “passive rotor assembly” disk with the optimal symmetry of an “active rotor assembly” disk, which comprises another similarly rated active winding set as found on the universally essential active stator assembly disk, which is only possible by replacing the full-rated estimating FOC with the synchronous stabilization of a half power rated, automatically exact, brushless, sensorless, and multiphase real time emulation controller (BRTECTM).
Note: Unlike the passive rotor assembly, the “active rotor assembly” of only the symmetric synchronous doubly-fed electric motor circuit and control architecture, called SYNCHRO-SYM, stably, wirelessly, independently and synchronously contributes an additional increment of working power (or twice the working power) to the electromechanical energy conversion process along with the “active stator assembly.”
Result: With twice the constant torque speed range (i.e., maximum load speed or MLS) for a given continuous torque, excitation frequency, excitation voltage, and air-gap flux density design, 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 has already proven the unique brushless, symmetric, and synchronous circuit and control architecture of SYNCHRO-SYM with dual “active” winding sets on the rotor and stator, respectively, to preserve the same electric motor footprint of material, cost, and loss, provides twice the power (and octuple the peak torque) at half the cost, half the size, and half the loss as the original asymmetric circuit and control architecture of all other electric motor systems with a single “active” winding set and a “passive” rotor of rare-earth permanent magnets (RE-PM) (i.e., synchronous), DC field windings (i.e., synchronous), slip-induction dependent windings (i.e., asynchronous), or reluctance saliencies (i.e., asynchronous or synchronous) within the same packaging as was proven by at least a half century of electric machine study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention.
For instance to achieve the same performance as an axial-flux SYNCHRO-SYM with the same custom selection of available optimizing material, winding, cooling, electronic control, and packaging techniques, which all electric machine system manufacturers leverage to improve their advertised performance that would always result in similar performance if equally applied, all asymmetric axial-flux RE-PM electric machine system contestants would have to: 1) include the additional “compounding” loss, cost, and size of an electric motor controller with double the power rating and excitation frequency and a step-up transformer to double the supply voltage in order to double the MLS speed at the same continuous torque as SYNCHRO-SYM or 2) mechanically couple the additional loss, cost, and size of another similar RE-PM electric machine “system” with its own controller in order to double the continuous torque at the same port voltage and MLS speed as SYNCHRO-SYM.
SYNCHRO-SYM → THE ONLY GAME CHANGER FOR THE ELECTRIC PROPULSION WORLD:
In keeping with our mission statement, “Innovate for Our Clean, Efficient, and Sustainable Energy Future,” BEM patented a practical Symmetric Dual Active Winding Axial-Flux electric propulsion motor circuit and control architecture with “active” stator and rotor assemblies, called SYNCHRO-SYM, which is unlike all other electric propulsion motor systems with the same me-too asymmetric circuit and control architecture comprising a single active stator assembly and a “passive rotor assembly” of predominantly RE-PMs or instead, slip-induction dependent windings, DC field windings, or reluctance saliencies. By extraordinarily including the compounding loss, cost, and size of the electronic controller (e.g., system) in the overall performance calculations, SYNCHRO-SYM uniquely provides:
- Both rotor and stator assemblies actively contributing power to the electromechanical energy conversion process with the performance of two “active” winding sets within the same form and fit packaging
- No permanent magnets, such as expensive, environmentally unfriendly, geopolitically sensitive rare-earth permanent magnets (RE-PM), with associated cogging and torque ripple issues, which were shown to increase electric vehicle power requirements by up to 5% without a shaft-axle decoupling means, safety and manufacturing issues, and life expectancy issues
- Twice the continuous power density (per unit of continuous power rating)
- Half the cost (per unit of continuous power rating)
- Half the loss (twice the efficiency) (per unit of continuous power rating)
- Half the cost (per unit of continuous power rating)
- Octuple the peak torque potential (per unit of continuous power rating) for highly reliable less complex, and low maintenance gearless (direct drive) electric vehicles
- Half the iron use and as a result, small iron losses and double material utilization with two “active” winding sets within the same form and fit packaging
- “Effective” double slot fill factor with two “active” winding sets within the same form and fit packaging
- Simple construction with the only additive manufacturing tooling
- Coveted field weakening capability with half the magnetizing MMF for highest efficiency at any speed
- Inherent soft switching (or resonant switching) for no switching loss
- Leverages the same present or future performance enhancing techniques
- Comprehensive leading, lagging or unity power factor adjustment at any speed, including zero speed
- Comprehensive regeneration over the entire speed range
- Simple but highly effective cooling concept with an inherent, highly efficient, demand-based cooling method as only provided by the additive manufacturing of MOTORPRINTER under BEM-CAD
- Virtually 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
SYNCHRO-SYM → BRTEC → ULTRA EFFICIENT INTEGRATED SiC CONTROLLER:
- The Symmetric Dual Active Winding Axial-Flux Motor of SYNCHRO-SYM effectively enhances the applied performance of SiC MOSFET by 2-3x at ½ the cost (per unit of continuous power rating)
SYNCHRO-SYM → MOTORPRINTER → HIGH QUALITY MANUFACTURING & PRODUCTION FACTS:
- On the road to perfection with a clear plan and a strong team
- Today: Fabricating our additive manufacturing tooling for high quality sample production and testing
- Tomorrow: Starting serial production in 2026
- Low cost, small footprint, and efficient additive, just-in-time manufacturing (i.e., only electric motor 3D Printer, called MOTORPRINTER, with non-crystalline metal ribbon)
- No permanent magnets to complicate the manufacturing process, tooling, and safety
SYNCHRO-SYM → THE ONLY ELECTRIC MOTOR SYSTEM:
Only SYNCHRO-SYM reimagined the electric motor system with an “active rotor” assembly that brushlessly, stably, contiguously, and independently contributes additional “working power” to the electromechanical energy conversion process along with the universally essential “active stator” assembly in the same “system” packaging but without permanent magnets and their associated issues!
Only SYNCHRO-SYM reimagined the brushless, multiphase-wound-rotor, doubly-fed, “synchronous” electric motor with the essential brushless real-time emulation control means, which provides twice the constant-torque speed for a given excitation frequency, voltage, and torque for twice the continuous power density and octuple the peak torque density at half the size, half the cost, and half the loss per unit of continuous power rating of any other electric motor system!
Only SYNCHRO-SYM doubles the expected performance gain and halves the expected cost of applying performance enabling material, winding, electronic component, cooling, and packaging techniques to any other electric motor or generator system, such as emerging wide bandgap power semiconductors (WBG)!
Only SYNCHRO-SYM is the viable RE-PM free alternative to the RE-PM electric motor system!
Only SYNCHRO-SYM comparably performs with today’s DC 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 will be the electric motor of choice when the AC superconductor becomes available!
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!
– Several electric vehicle propulsion motor manufacturers admirably prefer the traditional “passive DC field-wound rotor” synchronous electric motor system for enhancing performance and the ethical reason of eliminating RE-PMs, such as the E-Motors from ZF, Mahle, Vitesco and BMW’s 5th generation e-drive (2022)! –
– Why not leap to the next simple step with the “brushless,” RE-PM free, “active multiphase-wound rotor,” “synchronous” SYNCHRO-SYM is a drop-in replacement that provides twice the continuous power density and octuple the peak torque density at half the cost and loss with the same packaging (per unit of continuous power rating)? –
SYNCHRO-SYM → THE REIMAGINED ELECTRIC MOTOR SYSTEM:
All electric motor and generator systems (i.e., electric machine systems) follow the classic textbook introductory study that begins with the symmetrical electromagnetic relationships of the symmetric multiphase wound-rotor [synchronous] doubly-fed electric machine system circuit and control architecture (see 4.1.19 – 4.1.23 of Figure 1) and as a result, comprises the symmetry of two “directly excited” (i.e., bidirectional and without slip-induction dependency) “multiphase winding sets” (i.e., active winding sets) or doubly-fed, which is the most possible without duplicating electric machine circuit topology, that are advantageously placed on the rotor and stator, respectively, to inherently maintain the same electric motor system rotor and stator footprint of materials, cost, and loss (less RE-PMs).
But the symmetric multiphase wound-rotor [synchronous] doubly-fed electric machine system circuit and control architecture is only possible by postulating the breakthrough invention of a multiphase excitation control means during its study that is brushless, instantaneous (i.e., real time), sensorlessly and automatically exact (i.e., emulation), and uniformly bidirectional (i.e., brushless, sensorless, multiphase real time emulation excitation control, called BRTEC TM) in order to:
a) Guarantee stable synchronous operation, regardless of rotor or line perturbations from sub-synchronous to super-synchronous speeds, including synchronous speed, and as a result, eliminate the asymmetric instability of relying on slip-induction excitation, particularly about or at synchronous speed where slip-induction ceases to exist,
b) Provide double constant-torque speed range (i.e., Maximum Load Speed or MLS) for a given continuous torque, excitation frequency, port voltage, and air-gap flux density (e.g., 7200 RPM with 1 pole-pair @ 60 Hz of excitation versus 3600 RPM for all others), which is tantamount to twice the power density at half the cost and half the loss per unit of power rating by reasonably assuming the rotor and stator consume similar real-estate, loss, and cost with the compounding effects of friction and electronic control in accordance with the electric machine laws of physics, such as Faraday’s Law, Ampere Circuital Law, Lorentz Force Law, and Maxwell Equations,
c) Effectively eliminate the entire size, cost, and loss of the original asymmetric rotor assembly of extraneous “passive” rare-earth permanent magnets, slip-induction dependent windings, reluctance saliencies, or DC field windings and associated provisioning, such as the size, loss, cost, reliability, and maintenance issues of an extraneous multiphase slipring-brush assembly,
d) Control the full rated electric motor power with only the power of the rotor, the stator, or both, which is half (or less) of the total power rating of the electric machine and one-quarter the compounding loss and cost of the electronic controller,
e) Provide at least octuple the rated peak torque, power density, and specific power of all other machines systems because instead of quickly leading to core saturation and limited peak torque potential in all other electric motor systems, increasing torque MMF (and resulting flux) is neutralized in accordance with conservation of energy physics of a symmetric dual ported transformer topology under synchronous operation,
f) Provide leading or lagging power factor, including unity power factor,
g) Provide full electric machine control with simple control of current regardless of speed and position,
h) Double the expected performance gain from strategically applying the same performance enhancing material, windings, packaging, thermal management, electronic component, and manufacturing enhancing techniques with the same air-gap flux density, speed, and voltage design of the original asymmetric electric machine system,
j) Provide automatic, sensor-less, and instantaneous compensation to random rotor shaft or electrical line perturbations while motoring or generating without destabilizing offline delays of parametric sensing and electronic processing by an inexact control derivative of estimating FOC or DTC but instead, by embedding the essential “digital twin” of power conditioning and process control (i.e., BRTEC) into the system runtime hardware and software instead of applied as an offline tool during engineering development,
k) Provide coveted field weakening and inherent soft (or resonant) switching, which provides the highest efficiency at any speed, but with halve of the Magnetizing MMF and loss,
l) Provide comparable performance with the futuristic super permanent magnet, which is a DC field wound superconductor electromagnet, electric motor system but without the loss, cost, and size of cryogenic provisioning,
m) Eliminate permanent magnets with safety and manufacturing, life expectancy, and cogging drag issues, such as expensive, environmentally unfriendly, geopolitically sensitive rare-earth permanent magnets (RE-PM),
n) 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,
l) BRTEC inherently provides pure sinusoidal excitation, which minimizes electrical stress on electronic components.
Ironically, the same “symmetrical” electromagnetic relationships (4.1.19 – 4.1.23 of Figure 1) become the follow-on study for the asymmetric electric machine system of all other electric machine systems, which were developed because of the formidable challenges of inventing BRTEC, by deoptimizing the symmetry of an active rotor and stator assembly with the electromagnetic “asymmetry” of an active stator assembly with the single active winding set (or singly-fed) but a “passive rotor assembly” comprising slip-induction dependent windings (i.e., asynchronous singly-fed or so-called asynchronous doubly-fed asymmetric electric machines), reluctance saliencies (i.e., asynchronous and synchronous reluctance asymmetric electric machines), or rare-earth permanent magnets (PM) and DC field windings (i.e., synchronous asymmetric electric machines) under the inexact control derivative of estimating Field-Oriented Excitation Control (FOC) or Direct-Torque Control (DTC).
Never confuse the only brushless symmetric multiphase wound-rotor “synchronous” doubly-fed electric machine system, called SYNCHRO-SYM, with the so-called induction (i.e., asynchronous) doubly-fed electric machine system, which unlike SYNCHRO-SYM, is without independent and automatically exact control of the rotor and stator fluxes and therefore: a) relies on slip-induction and as a result, cannot “synchronously” operate from sub-synchronous to super-synchronous speeds with stable continuity, including zero speed and synchronous speed, b) becomes unstable with the slightest rotor or line perturbations, and c) cannot provide twice the Maximum Load Speed (MLS) of SYNCHRO-SYM for a given continuous torque, excitation frequency and port voltage, and air-gap flux density per unit of continuous power rating.
SYNCHRO-SYM → THE VERIFIED ELECTRIC MOTOR SYSTEM:
SYNCHRO-SYM‘s leap in performance was verified during at least a half century of classic electric machine study, research and publications by electric machine experts postulating the essential invention of BRTEC for automatically exact synchronous stabilization from sub-synchronous to super-synchronous speeds of two directly excited multiphase winding sets strategically placed on the rotor and stator, respectively, for the same electric machine footprint. In addition, BEM verified SYNCHRO-SYM by:
a) Lengthy analytical analysis,
b) Multiple progressive stages of prototyping, including pre-production prototyping retrofitted from off-the-shelf asymmetric induction electric motor systems, to prove the direct AC-to-AC circuit and continuous synchronous operation from sub-synchronous to super-synchronous speeds, including synchronous speed,
c) Developmental evolution of a SYNCRO-SYM computer aided design tool (BEM-CAD) that simultaneously provides side-by-side comparisons with the RE-PM and Induction electric machine system under the same electrical, such as voltage, MLS, excitation frequency, and mechanical design parameters, such as winding, material, packaging, thermal management, manufacturing, and electronic component enhancing techniques, for competitive fairness,
d) Expert scrutiny of multiple issuances of domestic and international patents, published IEEE technical articles.
e) Orchestrated empirical studies with several fiber laser companies and Metglas to verify the cutting method of the only patented electric motor 3D Printer method, called MOTORPRINTER, which is presently in fabrication for the inhouse just-in-time additive manufacture of customer specified SYNCHRO-SYM prototyping and production, instead of our typical contract manufacturing.
So, like all electric motor and generator systems, SYNCHRO-SYM is routine power scaling and manufacturing ready for any customer specification; all without considering the BEM-CAD control of the only 3D Printer method, called MOTORPRINTER, for providing the just-in-time, additive manufacture of axial-flux electric machine systems with amorphous or nanocrystalline ribbon. Also, the unique electromagnetic computer of BRTEC is considered mature technologies with no technical risk requiring more than the customary engineering solution and the legacy of at least a half century of applying high frequency electromagnetics and power conditioning that started with the switch mode power supply technology.
Present electric motor power density, efficiency, and performance innovation is limited to empirically applying a selection of available performance enhancing techniques to the same century old “asymmetric circuit and control” architecture with a passive rotor of either slip-induction dependent windings, permanent magnets, reluctance saliencies, or DC field windings, such as thermal management, manufacturing (e.g., 3D Printing), raising the maximum load speed (MLS), increasing the port voltage, incorporating better materials and physical configurations (e.g., nanocrystalline materials, printed circuit board rotors, windings and form factors). If equally applied between asymmetric electric machine contestants, the performance enhancing techniques would necessarily show similar performance improvement; but if equally applied to the patented and only “symmetric circuit and control architecture with an active rotor assembly, now called SYNCHRO-SYM, the performance enhancing techniques would necessarily double the performance improvement gain (at half the cost) as proven by a century of electric machine study, research, and publication that were reimagined to practical reality by a regiment of BEM prototyping and invention.
As a result, a truly equitable comparison must start with the same MLS under the same excitation voltage, excitation frequency, continuous torque, and performance enhancing techniques between contestants and as a result, SYNCHRO-SYM, which is without RE-PM, will always show twice the performance and octuple the peak torque capability at half the cost and half loss per unit of power rating.
Although common, it is pointless to compare real electric machine innovation, such as provided by SYNCHRO-SYM, when assessors inappropriately change the available performance enhancing technique for a particular contestant, such as raising the port voltage or maximum load speed (MLS), without allowing the same opportunity to all contestants, such as SYNCHRO-SYM, or without including the additional “compounding” loss, cost, size, and complexity of extraneous system enabling components, such as an mechanical transmission to match speed or a transformer to match port voltage.
For instance, Hitachi innocently analyzed the comparable performance of less expensive ferrite magnet electric motors versus costly, environmentally unfriendly, and geopolitically consequential rare-earth permanent magnets by unfairly multiplying the speed of the ferrite magnet motor over the rare-earth permanent magnet (RE-PM) motor but without revealing the compounding cost, size, loss, and complexity of at least the necessary extraneous high-speed electronic controller and mechanical transmission to enable the change or without revealing the comparative increase in performance of the me-too RE-PM asymmetric electric motor system with the same high speed opportunity!
QUALITATIVE PROOF of SYNCHRO-SYM BASED ON EXPERT ANALYSIS:
[Provides an expert’s analytical proof of Loss, Cost and Size between RE-PM electric machine systems and Induction electric machine systems, which was extrapolated to SYNCHRO-SYM]
SIMPLE QUALITATIVE PROOF of SYNCHRO-SYM:
[Provides a simple qualitative proof of Loss, Cost and Size between SYNCHRO-SYM, RE-PM electric machine systems, and Induction electric machine systems]
ANALYTICAL PROOF of SYNCHRO-SYM:
[Provides a precise and measurable analytical proof of Loss, Cost and Size between SYNCHRO-SYM, RE-PM electric machine systems, and Induction electric machine systems]
ONE HUNDRED and THIRTY-SIX YEARS of PRACTICAL ELECTRIC MOTOR/GENERATOR EVOLUTION AND STUDY:
[Provides a brief history of electric motor/generator system evolution, which includes SYNCHRO-SYM]
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SYNCHRO-SYM → WHITE PAPERS: