Democratize The Automobile Industry With a Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM) As Only Provided With SYNCHRO-SYM Technologies:

By leveraging the patents of SYNCHRO-SYM Technologies, such as SYNCHRO-SYM, BM-HFMDB, and MOTORPRINTER, BEM will democratize automobile innovation and manufacture by providing the ultimate performing Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM) to original equipment manufacturers (OEM) of motor vehicles, such as Toyota, GM, Ford, Tesla, and independent coach builders, such as boutique manufacturers with the possible convenience of artistically 3D Printing the chassis and body style. With two SYNCHRO-SYMs replacing the typical single asymmetric electric machine system with a speed reduction gearbox, differential, and delicate RE-PMs at a lower cost, size, and loss, a truly electromagnetic drivetrain (and the only truly electromagnetic brake system with full regeneration as only provided with the high peak torque of SYNCHRO-SYM) becomes viably practical.

The BEM-UPM comprises two modular suspension modules (MSM) with a standardized frame mounting interface to the customers chassis and body style. Each MSM comprises the complete modular suspension frame and components (e.g., traditional independent wishbone frames and linkages for mechanical redundancy) that are performance optimized with the articulated driveshaft (e.g., dual velocity joints), active suspension, such as the Clearmotion (BOSE) active suspension, energy recovery and torque vectoring system, such as accelerometers, speed transducers, and control, load leveling, wheel bearings and bushings, brake, electric motor/generator system, such as SYNCHRO-SYM, and wheel and tire. The motor/generator system (e.g., preferably the magnetic gear or direct drive SYNCHRO-SYM) and mechanical parking and emergency brake assembly are located on the fixed chassis portion of the MSM for the most optimized unsprung weight distribution for best ride and dynamic stability (e.g., torque vectoring) during vehicle speed, turning, road conditions, braking, acceleration, gyroscopic effects of wheel inertia, etc. The MSM could include power steering articulation components. The MSM ride and stability performance will be programmable for OEM branding.

To universally accommodate different wheel widths with simple sliding adjustment, the two MSMs of the BEM-UPM slide away or toward each other on at least two structural tube (or rail) frames (for instance). Housed inside the tubes (or rails), banks of supercapacitors complement the high-energy density of batteries with the high-power density of supercapacitors for high power motoring (acceleration) or regenerative braking (deceleration). The same BEM-UPM can be placed in the rear of the vehicle, the front of the vehicle, or both for independent all wheel (AWD) drive. With high rate of energy recovery, such as braking, the BEM-UPM will improve the efficiency and performance of even internal combustion engine vehicles.

The BEM-UPM may use the typical electric vehicle motor systems with their gearboxes, such as MAGNAX, Yasa Motors, EMRAX, but the superior performing direct drive SYNCHRO-SYM additionally provides inherent indestructibility without the fragility and limited life expectancy of RE-PM, precise torque control to absolute zero speed (and super-synchronous speed) with virtually unrestricted peak torque potential as only provided by electromagnetic symmetry with the precision control of BRTEC, with the proprietary thermal management as only provided by MOTORPRINTER axial-flux manufacturing, and with isolated electronic power condition control between banks of the integrated supercapacitors and the EV battery (or fuel cell) for an integral high power density (supercapacitors) and high energy density (battery) electric storage system of systems.  With a significant reduction in electronic stages, higher efficiency and lower cost in the system of systems, an isolated balanced multiphase high power high frequency AC micro distribution bus system (BM-HFMDB) connects all electrical components of the BEM-UPM throughout the vehicle, which includes multiple SYNCHRO-SYMs and the full complement of accessories along the micro distribution bus, such as a universal single or multiphase EV battery recharger, low power accessories, etc. It is conceivable that several high pressure hoses with style metal braided sheaths will simultaneously distribute the high frequency “multiphase” power and the cooling medium (if needed), where the braided metal sheath of high pressure hoses simultaneously providing the high power, high frequency Litz wire electrical power distribution in conjunction with the high pressure cooling medium distribution (e.g., four braided hoses for three AC phases plus neutral).

If placed in the front and rear of the vehicle, the self-contained (and modular) BEM-UPM (with MSMs incorporating direct drive, half cost SYNCHRO-SYMs) may provide independent, non-cogging, torque vectoring, such as stability control, four way steering, and differential, four wheel drive for active four wheel power steering, regenerative braking, ABS, stability control, etc. (by at least autonomously controlling individual motors of individual wheels instead of the typical non-controllable single motor system solution with mechanical gears and differentials). All components of the BEM-UPM can be easily replaced or maintained. The BEM-UPM may comprise the best high performance off-the-shelf OEM vehicle suspension components to leverage the volume production costs and non-recurring engineering (NRE) costs. Because electric machine systems, particularly SYNCHRO-SYMs, are highly reliable components, the universal wheel width provisioning and standardized chassis interface make the BEM-UPM re-usable without obsolescence for the most flexible and open vehicle architecture.

In contrast to today’s diverse complement of OEM designed and manufactured drivetrains, the BEM-UPM non-recurring engineering (NRE) and volume production costs will be amortized amongst several OEM customers, boutique manufacturers, and vehicle models to dramatically reduce costs. With a less expensive but best performing suspension, micro distribution bus system (e.g., BM-HFMDB), and drivetrain (e.g., direct drive SYNCHRO-SYMs) possible, the vehicle industry will be democratized amongst a plethora of OEM and stylish boutique automobile manufacturers and artisans just as 3D printed car bodies are expected to democratize body styles amongst competitive players. For instance, the programmable BEM-UPM will allow anybody to customize their branded vehicles exterior and interior styles, luxury appointments, cabin styles, art, designs, warranties, deliveries, and performance styles, etc., and program their branded comfort and driving performance with the most innovative and highest performance engineered drivetrain component available, as only provided by SYNCHRO-SYM Technologies, such as SYNCHRO-SYM and BM-HFMDB under the additive manufacture of MOTORPRINTER.  Alleviated from the vehicle drive train research, design and manufacture, the BEM-UPM will also democratize the EV technical focus to battery development, vehicle control development, chassis development, etc.

Today, the typical EV has a vehicle specific and therefore quasi-UPM (e.g., perhaps in the front and rear for quasi-AWD) with a single asymmetric electric machine system comprising a speed reduction gearbox, differential gearbox, and electromechanical brake system (e.g., perhaps improved by brake-by-wire), such as promoted by Schaeffer/Vitesco. Instead, BEM will “establish a leading motion technology company in the best interest of our customers, shareholders, and employees” in accordance with our mission, “Real Innovation For Our Clean, Efficient, and Sustainable Energy Future” and with half the cost, loss, and size per unit of power rating, two SYNCHRO-SYMs can replace the single asymmetric electric machine system, gearbox, and differential off all others without a difference in cost or size while also providing independent torque vectoring per wheel with unrestrictive peak torque potential (when supported with the proper thermal management as only provided with MOTORPRINTER manufacturing) and resilient redundancy (e.g., two direct drive SYNCHRO-SYMs without the complexity of gearboxes and differentials). Also, the unrestricted peak torque, as only provided by SYNCHRO-SYM, provides the only pure electromagnetic propulsion system for full regenerating, high efficiency, non-wearable electromagnetic braking system (when mated to high power density supercapacitors) without assistance from expendable mechanical brakes that convert kinetic energy directly to frictional heat with zero percent efficiency or energy recovery (e.g., all other electric motor systems would need a multi-ratio mechanical transmission). Complemented with the high-power density ballast of supercapacitors, the two SYNCHRO-SYMs BEM-UPM provides the only truly unwearable electromagnetic brakes with expendable electromechanical brakes sized for only parking and emergency braking, all of which gives eight levels of braking redundancy and safety without hydraulics in an AWD (two BEM-UPM) vehicle.

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There are many articles about the so-called “software (SW) vehicle” but the SW Vehicle is only possible by the evolution of distributed embedded processing (or intelligence) that are specific to the electromechanical system of systems (SoS) and as a result, the SW Vehicle is actually the “interfacing” command, control, and communication (C3) and computers and intelligence (C4i), where i) “Command” is a standard control protocol with a high electromechanical response rate (i.e., effectively real time), such as change speed (and braking), change turning angle, etc., ii) “Control” is the resolution, processing, and response of sensors, control algorithms, and electromechanics, such as torque vectoring of the propulsion motors, iii) “Communication” is the bidirectional data rate, and iv) “Computers and Intelligence” is the artificial intelligence (AI) and processing algorithms.

BEM proposes its Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM) with:  1) the best electric motor propulsion system, which is the only symmetric synchronous electric machine system, called SYNCHRO-SYM,  providing twice the power density and at least eight times the peak torque density at half the cost, size, and loss per unit of power rating of any other, as proven by a century of classic electric motor and generator study, research, and publication and reimagined to practical reality by a regimen of BEM prototyping and invention, for true frictionless electromagnetic braking, electromagnetic drivetrain (with energy recovery), torque vectoring, etc., 2) the best active suspension for programmable ride, etc., 3) the best thermal management and high power density storage, such as supercapacitors, 4) a standardize vehicle mount mechanism, including accelerometers, wheel width adjustment, active ride suspension, etc., and 5) a standardized communication protocol, which leaves the style of the automobile body or the ride feel to the OEM programmable branding. For instance, the front, the rear, or both the front and rear BEM-UPMs have their own embedded processor and SW control for seamless speed (e.g., emergency and no wear electromagnetic braking), angle of steering, ride control, and torque vectoring (e.g., power steering, skid, sway, and stability control).  NOTE: Torque vectoring is the automatic controlled response mechanism for loss of wheel grip, power steering, etc. by measuring and calculating the adjustment of individual BEM-UPM wheel speed with vehicle isotropic acceleration and braking (regeneration), etc.

The OEM vehicle product life, such as the vehicle product of Cadillac, Mercedes, or boutique manufacturer, would: 1) purchase the BEM-UPM, which is the best suspension and electromagnetic drivetrain available, mostly because of the unique performance of SYNCHRO-SYM, 2) develop their branded chassis and power source, such as engine, battery, fuel cell, etc., to the standardized BEM-UPM mounting with adjustable axle width, 3) 3D Print their body style, and 4) then SW configure the BEM-UPM through BEM’s standardized C4i with their programmed brand of ride, braking, and steering feel and control response. Once the branded feel of the OEM is developed and configured into the BEM-UPM (through the standardized C4i interface), then the OEM goes on to develop the operational SW control, which commands the BEM-UPM(s) effectively in real-time, such as set speed, set steering angle, read wheel speed, read accelerometers, etc. The turn-key BEM-UPM autonomously does steering angle, torque vectoring, and speed control in accordance with its embedded measurements and algorithms with the potential of override, which leaves the OEM or boutique manufacturer to devote development to their true value added, the vehicle style, comfort, luxury, and ride.

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