Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM)

Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM)

Clearly, Best Electric Machine (BEM) provides the best electric propulsion motor and generator system (i.e.,SYNCHRO-SYM) for the electric vehicle (EV) market with twice the performance and at least twice the peak torque density of any other electric machine system. Also, BEM provides the best practical 3D printer (i.e.,MOTORPRINTER) for the additive manufacture of axial flux electric machines with the highest performance materials, such as amorphous metal ribbon. Again, BEM provides the best EV micro distribution bus system (i.e., BM-HFMDB) with the fewest number of active electronic stages, the most efficiency, the lowest cost, and the purest waveforms. By leveraging the patents of SYNCHRO-SYM Technologies, such as SYNCHRO-SYMBM-HFMDB, and MOTORPRINTER, another original passion of BEM is to democratize the automobile industry  by providing the highest performance Universal Electric Vehicle Powertrain Chassis Module (BEM-UPM) to original equipment manufacturers (OEM) of motor vehicles, such as Toyota, GM, Ford, Tesla, etc., or to independent coach builders, such as stylish boutique EV manufacturers.

The BEM-UPM (with a standardized frame mounting interface) includes two modular suspension modules (MSM). Each MSM comprises: 1) the complete suspension frame and components (e.g., traditional independent wishbone frames and linkages) that are performance optimized, 2) the articulated driveshaft (e.g., dual velocity joints), 3) the active suspension, such as the Clearmotion (BOSE) active suspension, 4) the load leveling, wheel bearings and bushings, brake, electric motor/generator system, such as SYNCHRO-SYM, and 5) wheel and tire. The motor/generator system (e.g., preferably the magnetic gear or direct drive SYNCHRO-SYM) and 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 performance will be programmable for OEM branding. Note: The MSM is conceptually similar to in-wheel motors, such as the Protean In wheel motor and Elaphe in wheel motor, but includes the required suspension with the lowest possible unsprung weight distribution for significant performance improvement in programmable ride and stability. To universally accommodate different wheel widths with simple adjustment, the BEM-UPM comprises two MSMs that slide away or toward each other on at least two structural tube frames (for instance). Housed inside, the tubes contain banks of supercapacitors for complementing the high energy density of batteries with the high power density of supercapacitors for motoring (acceleration) or regenerative braking (deceleration).

The BEM-UPM may use MAGNAXYasa MotorsEMRAX, etc. motors with transmissions but better, the BRTEC of each superior performing direct drive SYNCHRO-SYM additionally provides motoring and regeneration torque to zero RPM and an isolated electronic power condition control between the banks of supercapacitors and the EV battery (or fuel cell) for a high power density (supercapacitors) and high energy density (battery) electric storage system of systems.  With a significant reduction in electronic stages in the system of systems, the BRTEC also provides an isolated balanced multiphase high power high frequency AC micro distribution bus system (BM-HFMDB) throughout the vehicle for universally powering multiple electric machines and a full complement of accessories along the micro distribution bus, such as a universal single or multiphase EV battery recharger, low power accessories, etc., all with the benefits of BM-HRMDB, such as fewer electronic stages, higher efficiency, and lower cost. It is conceivable that several hoses with metal braided sheaths will simultaneously distribute the high frequency “multiphase” power and cooling medium (if needed), where the braided sheath of the hoses provides the high power, high frequency Litz wire electrical power distribution in conjunction with the high pressure cooling medium distribution (e.g., 4 braided hoses for three AC phases plus neutral).

Since SYNCHRO-SYM is half the cost of other electric machine systems, BEM predicts all electric vehicles will have a SYNCHRO-SYM per wheel for torque vectoring per wheel for improved stability, direct drive (gear-less), and regeneration (to zero speed).

If placed in the front and rear of the vehicle, the self-contained (and modular) BEM-UPM (with MSMs incorporating direct drive SYNCHRO-SYMs) may provide independent, torque vectored, 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). All components of the BEM-UPM can be easily replaced for repair or maintainability. 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 of OEM components. Because electric machines are highly reliable components, the universal wheel width makes 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 drive-trains, the BEM-UPM non-recurring engineering (NRE) and volume production costs will be amortized amongst several OEM customers and vehicle models to dramatically reduce costs. With a less expensive but best performing suspension, micro distribution bus system (e.g., BM-HFMDB), and drive-train (e.g., direct drive SYNCHRO-SYMs) possible, the vehicle industry will be democratized amongst OEM and stylish boutique automobile manufacturers and artisans just as 3D printed car bodies are expected to democratize body styles amongst competitive multiple players. For instance, the BEM-UPM will allow anybody to customize their vehicles exterior and interior styles, luxury appointments, cabin styles, art, designs, warranties, deliveries, and performance styles, etc., with the best and most innovative and highest performance engineered drive-train component available, such as BEM-UPM programmed to the preferred comfort and driving brand of the manufacturer or individual designer, and comprising the highest performance electric machine system possible, or SYNCHRO-SYM, and the highest performance micro distribution bus, or BM-HFMDB, both of which are 3D Printed with the best materials by 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, etc.

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