SYNCHRO-SYM Technologies

– SYNCHRO-SYM: Only Practical Brushless, Symmetric, Synchronous Doubly-Fed Electric Motor or Generator System –

Our Mission:

Real Innovation For Our Clean, Efficient, and Sustainable Energy Future!

SYNCHRO-SYM

SYNCHRO-SYM → BOTTOM LINE UP FRONT:

– Whatever performance/price another so-called new EMS may claim for a given design specification, such as the Donut Motor system (Donut Lab), DC Field Wound Synchronous motor systems (ZF), or Raxial-Flux motor system (Koenigsegg), simply retrofitting the same EMS package with the optimal symmetric circuit and control technology of SYNCHRO-SYM will verifiably magnify the original performance/price claim by at least 2-8x (while eliminating the harm of any RE-PMs)! –

SYNCHRO-SYM → SHOW ME (RETROFIT):

To provide a more obvious comparison, consider the axial-flux formfactor of any electric motor system (EMS) 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 electromagnetic 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 (A-EMS), and also, remove its inexact, full power rated offline 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” for primary torque and working-power production, 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 also compounds the size, loss, and cost (including frictional losses) 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 electromagnetic symmetry of another “active stator assembly” disk that has a rotor bearing assembly (i.e., essential active rotor 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 (BRTEC^TM).

Note: Unlike the passive rotor assembly, the “active rotor assembly” of only the symmetric synchronous doubly-fed electric motor circuit and control architecture (S-EMS), called SYNCHRO-SYM, stably, wirelessly, independently, and synchronously contributes an additional increment of working power (or twice the working power overall) to the electromechanical energy conversion process along with the “active stator assembly” with virtually the same total loss, cost, and size per unit of power rating

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 regimen of BEM prototyping and invention has already proven the unique brushless, symmetric, and synchronous circuit and control architecture of SYNCHRO-SYM with two “active” winding sets on the rotor and stator, respectively, which inherently preserves 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 per unit of power rating as the original asymmetric circuit and control architecture and packaging 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).

For instance to achieve the same performance as an axial-flux SYNCHRO-SYM with the same custom selection of available optimizing material, winding, electronic control, thermal management, and packaging performance enhancing techniques, which all other electric machine system manufacturers must leverage to improve their advertised performance but 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 electronic motor controller with double the power rating and excitation frequency, a step-up transformer to double the supply voltage, and robust winding insulation 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,” which includes electronic controller, in order to double the continuous torque at the same port voltage and MLS speed as SYNCHRO-SYM.

This simple retrofit between any A-EMS and SYNCHRO-SYM conveniently shows:

Like the original A-EMS, SYNCHRO-SYM follows the same material, winding, packaging, and electronic component enhancing techniques and as a result, is straight-forward ready,
Like the original A-EMS, SYNCHRO-SYM follows the same operation, design, construction, and manufacture and as a result, is straight-forward ready,
Like the original A-EMS, SYNCHRO-SYM uses off-the-shelf components (but without RE-PMs) and as a result, is straight-forward ready,
Like the original A-EMS, 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 the original A-EMS, 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 the original A-EMS, only the symmetric circuit and control architecture of SYNCHRO-SYM with two similarly rated active winding sets advantageously placed on the rotor and stator, respectively, inherently provides: i) the same packaging footprint and materials (less RE-PMs), ii) universal single AC, multiphase AC, or DC operation, iii) coveted field weakening for extended speed range, electronic control reliability, and highest efficiency at any speed, iv) efficient clogless motoring and generating (i.e., no RE-PMs), v) inherently indestructible without the fragility and limited life expectancy of RE-PM but with the precision control of BRTEC and the proprietary thermal management as only provided by the just-in-time, additive manufacture of MOTORPRINTER, vi) “comprehensive” leading, lagging, or unity power factor compensation over the entire speed range, vii) “comprehensive” regeneration over the entire speed range, viii) best utilization of emerging wide bandgap electronic semiconductor switches with a symmetric circuit and control technology that doubles their expected performance with half their expected amount of material, such as copper, & cost per unit of power rating, ix) the reliability and resiliency of BRTEC with inherent resonant switching, x) the direct AC-to-AC power conversion of instantaneous, sensorless, multiphase, and automatic electromagnetic computing (i.e., BRTEC) with inherent active filtering, which eliminates the DC Link Stage of FOC with banks of large, expensive, inefficient, and delicate low frequency, high power capacitors, xi) the unique power conditioning method of BRTEC inherently provides pure sinusoidal excitation, which minimizes electrical stress on electronic components, insulation, etc., xii) best utilization of the axial-flux form factor by conveniently and proportionally placing the compact electromagnetic computer of BRTEC within the otherwise wasted annulus of the electric motor axial flux core, which physically provides the same rotor and stator assemblies (less software programming), and xiii) a simple and highly effective demand based cooling method for another level of system power density and component inventory reduction, all of which are inherent to SYNCHRO-SYM under the additive manufacturing of MOTORPRINTER and the design control of BEM-CAD,
But unlike the original A-EMS, the modularized, axial-flux SYNCHRO-SYM is: i) with the same rotor and stator disks with the exception of software configuration (as only provided by the symmetric circuit and control architecture and the additive manufacture of MOTORPRINTER under BEM-CAD), ii) is without the safety and handling issues of RE-PMs, iii) is without the componentized assembly logistics of the typical remotely mounted electronic controller, such as FOC, and iv) as a result, can be conveniently field assembled or field stackable lengthwise for incrementally higher power rating or smaller diameter, direct drive applications.

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SYNCHRO-SYM → THE ONLY GAME CHANGER FOR THE ELECTRIC PROPULSION WORLD:

In keeping with our mission statement, “Real Innovation for Our Clean, Efficient, and Sustainable Energy Future,” BEM patented the only 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-old” 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.
Although the performance of all electric machine systems is dependent on the whole system approach, such as materials, windings, and packaging techniques, only the circuit and control architecture of SYNCHRO-SYM doubles the performance gain
No permanent magnets, such as expensive, environmentally unfriendly, geopolitically sensitive rare-earth permanent magnets (RE-PM), with safety, manufacturing, life expectancy, and associated cogging and torque ripple, which were shown to increase electric vehicle power requirements by up to 5% without a shaft-axle decoupling means
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)
Octuple the peak torque potential (per unit of continuous power rating) for highly reliable less complex, and low maintenance gearless (direct drive) electric vehicles because torque MMF on each side of the air-gap is neutralized (i.e., zero torque inductance)
Inherently provides zero torque MMF inductance because the Torque MMF on each side of the air-gap is cancelled and as a result, torque current response is instantaneous, which surpasses the response of a RE-PM electric motor that is considered the lowest Torque MMF inductance.
Double the effective material utilization with two “active” winding sets within the same form and fit packaging, which equates to half the iron loss and material cost per unit of power rating
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 of SYNCHRO-SYM 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
Inherently provides pure sinusoidal excitation, which minimizes electrical harmonic and common mode stress on electronic components
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

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 MOSFETs 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 an additional increment of “working power” to the electromechanical energy conversion process along with the universally essential “active stator” assembly for primary torque and working-power production within 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 & amount of materials, 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, provides at least octuple the expected peak torque, halves the expected cost, halves the amount of material, such as copper & no RE-PMs, and halves the expected loss per unit of power rating from applying the same performance enabling material, winding, electronic component, such as emerging wide bandgap power semiconductors (WBG), cooling, and packaging techniques to any other electric motor or generator system!

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!

Our Distinctive Value Proposition: SYNCHRO-SYM is the only electric motor system (EMS) with the optimal electromagnetic symmetry of an “active rotor” with another “active winding set” that stably contributes at least an additional increment of working power to the electromechanical energy conversion process along with the active stator. All other electric motor systems, including so-called “breakthrough airplane propulsion electric motor systems,” have the non-optimal electromagnetic asymmetry of a “passive rotor” with rare-earth permanent magnets, reluctance saliencies, conventional or superconductor field windings, or slip-induction windings that effectively wastes half of the EMS real-estate, loss, and cost without stably and independently contributing additional “working power” to the electromechanical energy conversion process!! When considering the rotor reasonably consumes half of the total EMS loss, cost, and size with compounding effects of stator, electronic control, etc. included, SYNCHRO-SYM immediately delivers at least twice the power density, half the loss, and half the costs per unit of package power rating of any other EMS and without considering the additional performance enabling as only possible with the 3D Printing method of MOTORPRINTER!!

The symmetric EMS circuit and control technology (S-EMS), as only provided by SYNCHRO-SYM, with the “doubly-fed electromagnetic symmetry” of a) the universally essential active stator with an independently excited multiphase winding set (i.e., active winding set) for torque and power production, b) an active rotor for additional torque and power production, and c) an enabling brushless real-time emulation (i.e., automatic) control means for smooth stable operation from sub-synchronous, such as absolute synchronous speed, to super-synchronous speeds, such as at or about synchronous speeds, is the foundational theoretical study for all electric machine systems (EMS). For Example, the S-EMS becomes the theoretical study for the asymmetric EMS circuit and control technology (A-EMS) of all others by deoptimizing the doubly-fed electromagnetic symmetry of two active winding sets on the rotor and stator, respectively, in the same EMS package footprint, instead with the singly-fed asymmetry of the active stator for torque and power production but a “passive rotor” with permanent magnets, DC field windings, reluctance saliencies, or slip-induction windings, which reasonably wastes half of EMS real-estate by not producing any torque or power, and an estimating derivative of field-oriented control for stable control to synchronous speed. In consideration, the S-EMS and A-EMS necessarily leverage the same legacy packaging techniques, construction, and design specification!

With the same packaging & design specification, with no permanent magnets to damage, and no core saturation limit, no other EMS can approach the power density, specific power, efficiency, or low cost of SYNCHRO-SYM circuit and control technology!

Today: Only SYNCHRO-SYM “Total System” Power Density reaches over 200 KW/L, Specific Power reaches over 50 KW/Kg, Efficiency reaches over 98%, and Cost is halved per unit of power rating with the same design specification and electric machine packaging and performance enhancing techniques as today’s A-EMS but incredibly with the compounding size, loss, and cost of the electronic controller “extraordinarily” included in the specifications and without precious rare-earth permanent magnets or superconductor electromagnets!

Tomorrow: Only SYNCHRO-SYM will continue to more than double the advertised performance gain with half the cost and amount of material, such as copper and no RE-PMs, per unit of power rating of any present or future electric machine system packaging and performance enhancing techniques available to all, such as the performance and cost of emerging wide-bandgap semiconductor (WBG) switches, by “uniquely” enabling the rotor to be at least an additional “working power and torque” contributor to the electromechanical energy conversion process along with the universally essential active stator! It follows, the fully electromagnetic SYNCHRO-SYM will be the only electric motor system of choice when superconductors become a practical reality!

Soon: When fabrication is completed (circa late 2025), MOTORPRINTER will eliminate the typical, highly capitalized, exploited offshored labor, industrial factory for electric motor manufacture while providing inhouse, just-in-time, programmable additive manufacture of any size SYNCHRO-SYM with seamless incremental production scaling, high capacity thermal management, and convenient power stacking!

– Several electric vehicle propulsion motor manufacturers admirably prefer the traditional “passive DC field-wound rotor” synchronous electric motor system for enhancing performance and for the ethical reason of eliminating RE-PMs with harmful exploited labor, human rights, environmental, geopolitical consequences, such as the E-Motors from ZF, Mahle, Vitesco, and BMW’s 5^th 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 that provides at least 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)? –

Click here for The Simple Truth (Part 1)
– SYNCHRO-SYM Versus Others –

Click here for The Simple Truth (Part 2)
– SYNCHRO-SYM: Pinnacle of Electric Motors –

Click here for The Simple Truth (Part 3)
– Comparison Trade Space –

**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 electromagnetic 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 symmetry of two “directly excited” (i.e., bidirectional and without slip-induction dependency) “multiphase winding sets” (i.e., active winding sets) or doubly-fed 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 knowingly 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 contiguously stable operation, regardless of rotor or line perturbations from sub-synchronous to super-synchronous speeds 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 or about zero speed where slip-induction torque angle approaches zero,

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.

In accordance with the COMPARISON TRADE SPACE BETWEEN ALL ELECTRIC MOTOR AND GENERATOR SYSTEMS:

BEM says there are only two distinct categories of electric machine systems (EMS) for comparison purposes: a) the Asymmetric EMS (A-EMS) with the “asymmetry” of an “active stator” comprising a directly excited multiphase winding sets (or active winding set) for torque and power rating but a “passive rotor” of either slip-induction windings, reluctance saliencies, DC field windings or RE-PMs and excitation control by a derivative of field-oriented control (FOC), such as Direct Torque Control (DTC) and b) the Symmetric Synchronous EMS, as only provided by SYNCHRO-SYM, with the “symmetry” of an “active stator” and “active rotor” with active winding sets, respectively, to preserve the same electric machine footprint as the A-EMS but only realized by a brushless real time emulation controller (BRTEC)
The air-gap flux density of any EMS is determined by the flux saturation limit of the core material and not by the limited residual flux density potential of any RE-PM with flux density non-ideally inversely proportional to coercivity or the unlimited flux density potential of any electromagnet with flux density ideally directly proportional with MMF and as a result, all optimally designed electric machine systems have similar air-gap flux density, similar effective air-gap area, and similar active winding set design for the same torque, synchronous speed, excitation frequency, voltage, and power rating.
The single air-gap axial-flux electric machine footprint has adjacent rotor and stator disks with similar size, loss, and cost, where total loss includes friction, electrical, and core losses, total cost includes bearings, core materials, electronic components, etc., and total size includes the rotor disk, stator disk, and the electronic excitation controller.
Total electric motor size, cost, and loss Basis (per unit of power rating) is the size, loss, and cost divided by the total rated electromechanical power conversion rating.
All EMS design also involves control, structural and mechanical design anomalies, such as physical slots along the air-gap for rare-earth permanent magnets (RE-PM) or winding placement, material properties, such as flux saturation properties that limit air-gap flux density, end-turns, frame, thermal management, bearing assembly, friction, such as windage and stray losses, electronic control, etc., which will realistically compound the EMS size, loss, and cost beyond the expectations of electromagnetic physics design. For instance, winding slots consume about the same area as the effective air-gap area and as a result, halving the constant torque speed range with the same power by doubling the number of pole-pairs to double the torque with the same MMF will increase the total air-gap area of any EMS by approximately 33% (e.g., the same effective air-gap area with twice the slots with double the slot area). If SYNCHRO-SYM is designed for the same constant torque speed with double the torque by doubling the pole-pairs (slots) for the same speed, power, voltage, frequency of excitation, and effective air-gap area as any asymmetric EMS (A-EMS), the power density of SYNCHRO-SYM will be an impressive 1.5x the A-EMS (instead of 2x for the passive rotor disk replacement example) with the cost and loss reduced by 0.66x (instead of the 0.5x for the passive rotor disk replacement example) per unit of power rating.

It follows that only the Symmetric circuit and control technology of an axial flux SYNCHRO-SYM has:

a) The same active rotor and stator disks (as provided by the manufacture of MOTORPRINTER under BEM-CAD design control) with the same active stator winding set as the A-EMS but with integral BRTEC sections instead of the necessarily componentized FOC and as a result, each disk has the same loss, cost, and size as the active stator disk of the A-EMS without including the compounding loss, cost, and size of FOC

b) Twice the power rating, half the cost, half the loss, half the size per unit of power rating of the A-EMS, because SYNCHRO-SYM with two similar active winding sets of the A-EMS has twice the power as the A-EMS with the same packaging, material, loss, cost, size, voltage, and electronic components by replacing the FOC with a BRTEC

c) Octuple the peak torque as the A-EMS, because the symmetric EMS circuit and control architecture of SYNCHRO-SYM is effectively a dual ported transformer topology and therefore, in accordance to conservation of energy, torque MMF (beyond magnetizing MMF for establishing air-gap flux density) on each size of the air-gap are neutralized and regardless of torque current magnitude, a) torque MMF can increase substantially (8x) without leading to the immediate core saturation experienced by the A-EMS, b) torque MMF inductive reactance approaches zero, and c) with air-gap flux density remaining constant, air-gap flux density can be designed closer to the core’s saturation limits, all of which are essential for direct-drive (i.e., gearless) electric propulsion, full electromagnetic & regenerative braking, and rapid torque vectoring response!

d) 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, by introducing another duplicate stator disk (for twice the power rating with the same excitation voltage & frequency, and torque design,

e) 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,

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,

i) Uniquely favor 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,

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, 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,

o) Inherently provides a unique multilevel circuit and control architecture

p) Inherently provides pure sinusoidal excitation, which minimizes electrical harmonic and common mode stress on electronic components

q) Without the safety and handling issues of RE-PMs or the modularized assembly logistics of the typical remotely mounted electronic controller of asymmetric electric machine systems, the modularized axial-flux SYNCHRO-SYM with the same rotor and stator disks with the exception of software configuration (as only provided by the symmetric circuit and control architecture and the additive manufacture of MOTORPRINTER under BEM-CAD) can be conveniently field assembled or field stackable lengthwise for incrementally higher power rated applications or smaller diameter, low speed, direct drive, high power applications, which otherwise, must be shipped fully assembled with the rotor locked and with exotic shipping and mounting logistics, particularly for high power, low speed applications, such as winding turbines.

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: a) relies on slip-induction and as a result, cannot operate from sub-synchronous to super-synchronous speeds with stable continuity, including synchronous speed where slip-induction ceases to exist or zero speed where slip-induction torque angle randomly approaches zero, 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.

“Simple” Concept of Operation

Electric Machine System Trade Space and Physics

**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 and contiguously stable stabilization from sub-synchronous to super-synchronous speeds, including synchronous speed where slip-induction ceases to exist or zero speed where slip-induction torque angle approaches zero, 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 with the evolution of a modular hardware and software control system architecture provides continuous synchronous operation from sub-synchronous to super-synchronous speeds, including synchronous speed and zero 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 (i.e., asymmetric electric machine systems) 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 improving thermal management, improving manufacturing (e.g., 3D Printing), raising the maximum load speed (MLS) by increasing the port voltage, or incorporating better materials and physical configurations (e.g., nanocrystalline materials, printed circuit board rotors, windings and form factors). However, 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 expected performance improvement gain and octuple the expected peak torque gain at half the cost and half the cost (per unit of power rating) as proven by a century of electric machine study, research, and publication that were reimagined to practical reality by a regimen of BEM prototyping and invention.

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 match the speed of the motor to the speed of the load or without revealing the comparative increase in performance of the same-old RE-PM asymmetric electric motor system with the same high speed opportunity!

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 in accordance with Electric Machine System Trade Space and Physics]

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 in accordance with U]

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]

Why Choose SYNCHRO-SYM?

Why The Name SYNCHRO-SYM?