SYNCHRO-SYM

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SYNCHRO-SYM

Only Practical Brushless, Symmetric, Synchronous Doubly-Fed Electric Motor or Generator System

Our Mission –

Innovate For Our Clean, Efficient, and Sustainable Energy Future!


BOTTOM LINE UP FRONT:


Step 1: Simply remove the non-optimal asymmetry of the “passive rotor assembly,” which comprises slip-induction dependent windings, reluctance saliencies, DC field windings, or rare-earth permanent magnets (RE-PMs) and their associated provisioning, such as brushes, sliprings, RE-PM structural and thermal reinforcements, conventional or superconductor electromagnets, etc., and the inexact, full power rated control derivative of an estimating flux-oriented excitation controller (FOC) from the ubiquitously applied asymmetric electric motor circuit and control architecture.

Note: When optimally designed: i) with the same continuous Maximum Load Speed (MLS), air-gap flux density, excitation frequency, port voltage, and continuous torque, ii) with the same material, winding, electronic component, manufacturing, and packaging enhancing techniques, and iii) without considering the compounding loss, cost and size of the FOC, the passive rotor assembly reasonably consumes up to half of the asymmetric motor real estate, operating loss, such as core, electrical, and friction loss, or cost but cannot independently contribute additional working power to the electromechanical energy conversion process along with the universally essential “active stator assembly” of all electric motors, which comprises the directly excited (e.g., bidirectional) multiphase winding set (or active winding set) that determines the overall power rating of the asymmetric electric motor, while reasonably consuming the other half of the electric motor real estate, loss, or cost.

Step 2: Replace the “passive rotor assembly” with the optimal symmetry of an “active rotor assembly,” which comprises another similarly rated active winding set as found on the universally essential active stator assembly, which is only possible by replacing the estimating FOC with the automatically exact, synchronous stabilization of a half power rated 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 additional working power to the electromechanical energy conversion process along with the “active stator assembly,” while consuming the other half of the electric motor real estate, operating loss, such as core and electrical, or cost.

Result: In accordance with the governing Law of Conservation of Energy, the symmetric (and synchronous) circuit and control architecture of SYNCHRO-SYM effectively: a) eliminates the entire loss, cost, and size of the “passive rotor assembly,” b) doubles the continuous power density (per unit of continuous power rating of the original asymmetric electric motor or generator system within the same packaging (less any RE-PMs) by advantageously placing two similarly power rated active winding sets on the rotor and stator, respectively, to inherently maintain the same electric motor port voltage, excitation frequency, continuous torque, air-gap flux density, and footprint of material, cost, and loss), c) halves the overall cost (per unit of continuous power rating), d) halves the overall loss (per unit of continuous power rating), e) provides octuple the peak controllable torque (per unit of continuous power rating) by neutralizing the torque current generated flux, e) provides leading, lagging or unity power factor adjustment at any speed, including zero speed, f) provides the coveted field weakening capability, and g) eliminates the need for exotic materials, such as rare earth permanent magnets, with the associated geopolitical consequences and inefficiency of cogging drag.


Without the need to critique the Pros and Cons of cost, loss, size, or manufacturability of available material, winding, electronic component, and packaging enhancing techniques that all electric motor manufacturers empirically leverage to enable the publicized price-performance of their “me-too” century old asymmetric electric motor system circuit and control architecture, such as the high power-density of the Koenigsegg Quark E-Motor system package, Magna, Linear Labs, Infinitum, MAGNAX, Tesla Carbon Wound, etc., retrofitting the same “me-too” asymmetric electric motor system package with the pinnacle circuit and control technology of SYNCHRO-SYM will double the publicized power density, halve the cost, octuple the “peak torque,” and eliminate any RE-PMs by brushlessly and stably fitting another active winding set within the same packaging.

Only SYNCHRO-SYM opens the next chapter in e-mobility with the pinnacle of electric motor or generator circuit and control architecture.


DETAILS:

All electric motor and generator systems (i.e., electric machine systems) follow the classic textbook 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), which comprises the inherent symmetry of two “directly excited (i.e., bidirectional and without slip-induction dependency) multiphase winding sets (i.e., active winding sets)” 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, but 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 real time emulation excitation control or BRTEC TM) in order: a) to eliminate the size, loss, cost, reliability, and maintenance issues of an extraneous multiphase slipring-brush assembly, b) to avoid the asymmetric instability of relying on slip-induction excitation, particularly about synchronous speed where slip-induction ceases to exist, c) to 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, d) to provide direct and independent phase and amplitude control of the rotor and stator torque and magnetizing MMF (and resulting fluxes) to exactly satisfy synchronous operation by embedding the essential “digital twin” of power conditioning and process control (i.e., BRTEC) instead of applied as a tool during engineering development, e) to control 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 machine and one-quarter the compounding loss and cost of the electronic controller, f) to provide at least octuple the rated peak torque of all other machines systems because increasing torque MMF (and resulting flux) on each side of the air-gap, which quickly leads to core saturation in all other electric motors, are neutralized in accordance to conservation of energy physics of a dual ported transformer, and g) to provide automatic, sensor-less, and instantaneous compensation to random rotor shaft or 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 without wasteful shaft damping. In contrast, 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 as postulated during the classic electric machine study, by deoptimizing the symmetry of an active rotor and stator assembly with the “asymmetry” of a “passive rotor assembly” comprising slip-induction dependent windings (i.e., asynchronous singly-fed or so-called asynchronous doubly-fed asymmetric electric machines), reluctance rotor saliencies (i.e., asynchronous and synchronous 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).


Never confuse the only brushless symmetric multiphase wound-rotor doubly-fed “synchronous” electric machine system, called SYNCHRO-SYM, with the so-called induction (i.e., asynchronous) doubly-fed electric machine systems, which unlike SYNCHRO-SYM, is without independent and automatically exact control of the rotor and stator fluxes and therefore, a) cannot “synchronously” operate from sub-synchronous to super-synchronous speeds with stable continuity, including zero speed and synchronous speed, b) becomes unstable with slight 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 (i.e., twice the continuous power density) per unit of continuous power rating.


It follows that with over a hundred years of practical electric motor application and risk mitigation, all magnetic electric motors are: a) straight-forward, b) must simultaneously obey the empirically derived electric machine laws of physics, such as Ampere Circuital Law, Faraday’s Law, and Lorentz force Law that were generalized and integrated with time by Maxwell Equations, c) obey the comparison tradespace between all electric machine systems, and therefore, d) must be compatible with the same present or future electric machine material, winding, packaging, construction, electronic component, thermal management, and manufacturing enhancing techniques and as a result, the symmetric multiphase “synchronous” doubly-fed electric machine entity of SYNCHRO-SYM has no risk without the customary engineering solution.


With the same material (less RE-PMs), packaging, winding, electronic component, manufacturing, and thermal management enhancing techniques, only SYNCHRO-SYM provides twice the maximum load speed (MLS) or constant-torque range as any other electric motor system that is optimally designed to the same continuous torque, voltage and frequency of excitation, and air-gap flux density, which is clearly tantamount to twice the power density, half the loss, and half the cost per unit of continuous power rating in accordance with the electric machine laws of physics, such as Faraday’s Law, Ampere Circuital Law, Lorentz Force Law, and Maxwell Equations.

Electric Airplane Propulsion, Anybody?


Without relying on slip-induction for operation, with continuously stable operation at or about synchronous speed, and with real time emulation control (BRTEC) of the rotor and stator torque and magnetizing MMFs of two active winding sets strategically placed on the rotor and stator, respectively, SYNCHRO-SYM is the pinnacle in electric machine circuit and control architecture, which is the symmetric multiphase wound-rotor “synchronous” doubly-fed electric machine system in accordance with the definitions and constraints provided in COMPARISON TRADESPACE BASELINE BETWEEN ALL ELECTRIC MOTOR AND GENERATOR SYSTEMS.”


The double price-performance 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.


Since BMW prefers the traditional brush-slipring, RE-PM free passive DC field wound rotor, synchronous electric machine system in their 5th generation e-drive (2022), why not go the next step with the brushless, RE-PM free, “active” multiphase wound rotor, “synchronous” doubly-fed electric machine system of SYNCHRO-SYM that provides twice the power density and octuple the peak torque at half the cost and loss (per unit of continuous power rating)?


Providing a more obvious comparison with the axial-flux formfactor of similar adjacent stator and rotor disks, (1) remove the “passive rotor disk” assembly (with rotor bearing assembly) of any axial-flux asymmetric electric motor or generator system, which cannot contribute working power to the electromechanical energy conversion process but evenly shares in the entire electric motor real-estate, cost, or operating loss, such as friction, core, and electrical loss, along with the universally essential active stator assembly of all electric motor and generator systems that does contribute working power to the electromechanical energy conversion process, and (2) remove the inexact, estimating field-oriented excitation controller (FOC) of the asymmetric electric motor system, which compounds the size, loss, and cost of the “motor system” but cannot contribute working power to the electromechanical energy conversion process, and then (3) replace the “passive rotor disk” assembly with another similar “active stator disk” assembly (with the addition of the rotor bearing), which synchronously and independently contributes an additional increment of working power to the electromechanical energy conversion, and (4) replace the full-rated FOC with the exact synchronous stabilization control of a half-rated brushless, sensorless, and multiphase real time emulation control (BRTECTM) and as a result, the original axial-flux “asymmetric” electric machine system package becomes an axial-flux “symmetric, synchronous” doubly-fed electric machine system of the patented SYNCHRO-SYM.

By the symmetric and synchronous power magnification of two active winding sets advantageously stationed on the rotor and stator, respectively, which inherently maintains the same electric motor footprint of material, cost, and loss of the original non-optimal asymmetric electric machine system with a single active winding set on the stator, then SYNCHRO-SYM effectively: 1) doubles the contiguous constant-torque speed range (i.e., Maximum Load Speed) for a given continuous torque, pole-pair count, excitation frequency and voltage, and air-gap flux density by stably and synchronously operating from sub-synchronous to super-synchronous speed, which is tantamount to double the power density, half the cost, and half the loss of the original asymmetric electric machine package (per unit of power rating), 2) eliminates the entire size, cost, and loss of the original asymmetric rotor of extraneous “passive” rare-earth permanent magnets, slip-induction dependent windings, reluctance saliencies, or DC field windings and associated provisioning, 3) provides coveted field weakening with halve of the Magnetizing MMF loss by sharing Magnetizing MMF between the rotor and stator active winding sets on each side of the airgap, 4) provides octuple the controllable peak torque (and peak power density) by holding the air-gap flux density constant and under the core flux saturation with increasing torque current in accordance with the conservation of energy physics of a dual ported transformer topology, 5) provides leading or lagging power factor, including unity power factor, 6) eliminates inefficient cogging drag of RE-PMs, 7) doubles the expected 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 and voltage of the original asymmetric electric machine system, 8) uniquely favors the employment of wide bandgap (WBG) power semiconductors, such as SiC MOSFET devices, by neutralizing their 2-3x extra cost while at least doubling their exceptional performance (see section The Power Transfer Effectiveness of The Electronic Controller of ELECTRIC MACHINE DESIGN DISTINCTIONS & CONSTRAINTS), and 9) comparably performs 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.


With at least 50 years of classic theoretical electric machine study and verification that reasonably assumed the “passive rotor” or “active stator” of the “me-too” asymmetric electric motor system consumes similar cost, size, or loss, such as core, electrical, and friction losses, with the compounding effects of electronic control, only the patented “symmetric circuit and control” technology of SYNCHRO-SYM with automatically exact, brushless, sensorless, and multiphase real time emulation control of both the rotor and stator magnetizing and torque fluxes (or MMF) for continuously stable “synchronous” operation provides double the power density (and  octuple the peak torque) at half the loss and cost per unit of continuous power rating of the asymmetric electric machine system by at least effectively eliminating the extraneous size, cost, and loss of the “passive rotor” with extraneous RE-PMs, slip-induction windings, reluctance saliencies, or DC field windings and associated provisioning.


With at least 50 years of classic theoretical electric machine study and verification, only the patented “symmetric circuit and control” technology of SYNCHRO-SYM with available cooling means provides at least octuple (i.e., eight times) the available peak torque (and peak power density) of the century old, me-too, asymmetric electric machine circuit and control architecture of all others within the same packaging (less RE-PMs), including the so-called superior continuous torque (SCT) e-motor of Mahle.

Gearless or Direct Drive Electric Vehicles, Anybody?


SYNCHRO-SYM‘s leap in performance was verified during at least the last sixty years of classic electric machine study 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. More recently, BEM verified SYNCHRO-SYM: a) by lengthy analytical analysis, b) by several progressive stages of prototyping, including pre-production prototyping by retrofitting off-the-shelf electric machines, and more importantly, c) by the development 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 and mechanical design parameters for competitive fairness, such as winding, material, packaging, thermal management, manufacturing, and electronic component enhancing techniques. 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 interface advantage to 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, with over a half century of applying switch mode power supply and electronic power conditioning, the essential high power, high frequency electromagnetics for the unique electromagnetic computer of BRTEC are considered mature technologies with no technical risk requiring more than the customary engineering solution.


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]

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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]

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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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