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Induction Motors with Die-Cast Copper


Rotors

February 2006

Contents
1 Introduction 2

2 Benefits 2
2.1 Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Flattening the efficiency curve . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Thermal budget . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Torque-speed characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9 Environmental performance . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Improved steel properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Issues 10
3.1 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Higher start-up current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Rotor inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Applications 11

5 Conclusion 11

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www.leonardo-energy.org Motors with Die-Cast Copper Rotor

1 Introduction

The main advantage of using copper for the rotor of an induction motor is efficiency im-
provement. Since copper has a higher conductivity than aluminum (57 MS/m compared
to 37 MS/m), it is a natural choice. However, its high melting point and the resulting
high cost for die casting was for a long time a major barrier. Several technological break-
throughs in copper die-casting have been recently achieved, removing this barrier and
clearing the way for industrial production.
Today, regular production at medium volume already exists. About 250,000 units with
die-cast copper rotors are in use. The efficiency of these motors improves on average
around 3% compared to motors with aluminum rotor. This corresponds with a global
annual electricity savings potential of 108 Twh1 .
A survey among manufacturers, users, researchers, engineers and members of associations,
reveals that the copper rotor motor has now become a familiar technology (82%). A
majority agree the technology is ready for mass production (74%). In addition to higher
efficiency (42%), lower heat production (24%) and reduced cost (11%) of motors with
die-cast copper rotor are seen as major advantages. The main application domain is
for industrial low voltage induction motors of 1 up to 100 kW, but the technology has
potential as well for fractional kW motors.

2 Benefits

2.1 Cost

Using copper instead of aluminum can yield significant cost savings. This might be
surprising, given the higher price per liter of copper (21.4 e/l compared to 4.6 e/l for
aluminum). But the difference in conductivity turns out to be the decisive factor.
When designing a motor with die-cast copper rotor, two different ways exist to benefit
from the higher conductivity of copper. If all the other parameters of the motor are kept
the same, using copper instead of aluminum leads to a higher efficiency. In this case, the
higher cost of the motor will be compensated by a lower running cost, resulting in net
cost savings after the pay-back period.
Another possibility is to design a copper rotor motor with the same efficiency as its
aluminum counterpart. In that case, the higher conductivity allows for a lighter and
smaller rotor. This is because with a copper rotor, also the steel parts of the rotor and
stator can be made smaller, as well as the windings, the shaft and the housing of the
motor. The savings made by this reduction of volume are much higher than the cost

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premium for the copper rotor motor, as can be seen on table 12 . For a 15 horsepower
motor, the resulting cost reduction is 16.4%, for a 7.5 horsepower motor it amounts even
to 22.6%.

Magnetic Rotor Shaft + Cost reduction


Motor category Steel Windings Conductor Housing Total $ %
15 hp
Copper rotor 85 39 18 47 189
Aluminum rotor 107 46 5 68 226 37 16.4
7.5 hp
Copper rotor 53 20 11 32 116
Aluminum rotor 68 33 4 45 150 34 22.6

Table 1: Estimated variable motor cost comparison (all figures in $)

2.2 Efficiency

Simply changing the rotor conductor material from aluminum to copper already leads to
a higher efficiency. When high efficiency is the purpose for choosing a copper rotor, in
most cases other modifications are carried out as well, such as improving the steel quality
and modifying the rotor conductor bar shape. Table 2 shows test data and performance
characteristics of standard efficiency aluminum rotor models, compared to high efficiency
copper rotor designs (400 V, 50 Hz, 1.1 up to 37 kW). For these motors, improved magnetic
steels (4 W/kg loss instead of 8 W/kg) have been used.

Rotor conductor Al Cu Al Cu Al Cu Al Cu
Rated power, kW 1.1 1.1 5.5 5.5 11 11 37 37
Power factor 0.77 0.79 0.83 0.83 0.83 0.81 0.87 0.85
Power consumed, W 1435 1334 6485 6276 12590 12330 40700 39900
Efficiency, % 75.9 82.8 84.8 88.12 87.6 89.9 91.1 93.2

Table 2: Test data and performance characteristics [Kimmich, 2005]

Using a motor with die-cast copper rotor makes it possible to achieve the highest efficiency
level Eff1 without major design problems and without increasing the volume of the motor.

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Motor Motor
Losses Cost

CCR

Cost
Loss

Motor

Past Present Future

Figure 1: Induction motor efficiency, technology and cost [Deivasahayam, 2005]

2.3 Flattening the efficiency curve

In addition to the higher efficiency at nominal value, an induction motor with die-cast
copper rotor has also the advantage of a flatter efficiency curve. This is especially valuable
for industrial motors with intermittent loads. As shown on figures 2 and 3, the efficiency
drop at partial load and at more than 100% load is smaller for copper rotor motors.

95%

90%

85%

80%
Efficiency [%]

75%

70% DT90S4
DTE90S4
DV132S4
65%
DVE132S4

60%
0% 20% 40% 60% 80% 100% 120% 140% 160%

Figure 2: Efficiency vs load, 1.1 and 5.5 kW

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96%

94%

92%
Efficiency [%]

90%

11 kW Al
88%
11 kW Cu
37 kW Al
86%
37 kW Cu

84%
0% 20% 40% 60% 80% 100% 120% 140%
P/Prated

Figure 3: Efficiency vs load, 1.1 and 37 kW

2.4 Volume

If the higher electrical conductivity of copper is not completely used for improving effi-
ciency, the rotor can be made smaller. This has a positive effect on the complete design
of the motor. Since the rotor is the inner part of the motor, reducing its volume leads to
an even higher reduction in volume for the stator, the windings, and the housing of the
motor.

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100

90

Relative volume (ARM = 100) 80


74
70 68
66
63
61
60
53
50

40

30

20

10

0
2.2 4 9.2 15 30 55
Power [kW]

Figure 4: Volume of housing of copper rotor compared to aluminum rotor motors

A copper rotor motor will also heat up less than its aluminum equivalent, as a result of
which less cooling facilities are required, making it possible to further reduce the volume
of the motor.

2.5 Weight

The reduced volume will lead to a reduced weight of the motor. The rotor will increase in
weight due to the higher density of copper (8.92 kg/l compared to 2.70 kg/l for aluminum),
but this is more than compensated by the reduction in steel weight in rotor and stator,
in stator windings, and motor housing.

2.6 Thermal budget

Copper has a higher electrical conductivity and a higher thermal capacity than aluminum
(3.39 kJ/(kg*K) compared to 2.43 kJ/(kg*K)), leading to a significantly lower tempera-
ture rise during operation, as demonstrated in table 3.

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Rotor conductor Al Cu Al Cu Al Cu Al Cu
Rated power, kW 1.1 1.1 5.5 5.5 11 11 37 37
Power factor 0.77 0.79 0.83 0.83 0.83 0.81 0.87 0.85
Power consumed, W 1435 1334 6485 6276 12590 12330 40700 39900
Efficiency, % 75.9 82.8 84.8 88.12 87.6 89.9 91.1 93.2
Temparature rise, K 61.1 27.8 80.0 61.3 75.0 62.1 77.0 70.4

Table 3: Test data and performance characteristics [Kimmich, 2005]

As a result, the rotor requires less ’thermal budget’. So other parts are allowed to heat up
more, or less cooling facilities are required (e.g. cooling fins), leading to a more compact
and lighter machine that fits more easily into hermetic systems.

2.7 Torque-speed characteristics

At start up, the torque of a copper rotor machine is lower than for an aluminum rotor
motor, but at running speed, the reverse is true. In other words, in a copper rotor motor,
the maximum torque shifts to a higher speed. This makes the technology very useful in
applications such as pumps which need high torque at high speed.

120.0

100.0
M [Nm], I [A]

80.0

60.0

40.0
Current - Cu
Torque - Al
20.0
Current - Al
Torque - Cu
0.0
0 200 400 600 800 1000 1200 1400 1600
n [min-1]

Figure 5: caption

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2.8 Reliability

Studies that confirm the reliability of the copper rotor motors are not available because
the technique is still relatively new and even conventional motors have a relatively long
life expectancy. But can be expected that reliability would be higher due to the following
effects:
• the higher strength of copper
• the lower temperature difference during operation
• the positive influence of the die-casting operation on the surrounding steel

2.9 Environmental performance

Again, the better conductivity of copper can be used in two ways. Either the efficiency is
kept the same; in that case the copper rotor motor has a better environmental performance
because it requires about 20% less material. Or the efficiency is improved, resulting in a
much larger (absolute) improvement in environmental performance in the use phase.

2.10 Improved steel properties

Coppers melting temperature is 1083◦ C, compared to 660◦ C for aluminum. So when die-
casting a copper rotor, the temperature of surrounding steel parts becomes significantly
higher than when die-casting aluminum. This changes the structure of the steel and
influences its characteristics. Unlike what one would expect, this influence is positive.
The higher the die-casting temperature, the more energy-efficient the steel becomes, and
the higher its electromagnetic permeability3 .

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30W/kg

25W/kg

20W/kg
without heating
550°C
Specific losses è
15W/kg 650°C
750°C
800°C
10W/kg
920°C
1100°C
5W/kg

0W/kg
0.0T 0.5T 1.0T 1.5T B è 2.0T

Figure 6: Improved steel characteristics with rising processing temperature

2.0T

1.8T

1.6T

1.4T

1.2T
without heating
1.0T 550°C
0.8T 650°C
750°C
0.6T 800°C
B è

920°C
0.4T 1100°C
0.2T

0.0T
100A/m 1000A/m H è 10000A/m

Figure 7: Improved permeability with rising processing temperature

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3 Issues

3.1 Recycling

A copper rotor is a composite material. This makes recycling complicated, but it is


certainly not impossible. Techniques have already been developed to separate and recycle
the copper from the rotor.

3.2 Starting torque

The copper rotor motor has the advantage of a high torque at running speed. But the
starting torque is lower than in aluminum rotor motors (85 Nm instead of 90 Nm in a 5.5
kW motor). This is beneficial for gear box life, but for certain applications, it can be a
problem. A modified design of the rotor slot can increase starting torque to an adequate
value.

3.3 Higher start-up current

The higher conductivity of copper, i.e. its lower electrical resistance, will result in a higher
start-up current (7.5 times the nominal current for a 7.5 kW copper rotor motor, instead
of 6.5 times for its aluminum counterpart). The use of a soft starter can be used to avoid
that this higher current affects the electricity system. Also, since motors are increasingly
being driven by inverters, inrush and starting currents become less of an issue.

3.4 Rotor inertia

The higher density of copper (8.92 kg/l compared to 2.70 kg/l for aluminum) results in a
higher weight of the rotor (whereas for the complete motor, the compactness of the rotor
will result in a lower weight). Consequently, the inertia momentum of the rotor is higher.
This improves the motor’s efficiency, but can be an problem in certain applications, for
example machines that frequently switch direction at high speed.

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4 Applications

Hereby a list of applications where copper rotor motors have been applied, or are being
considered:
• Agricultural pumps (efficiency, torque)
• Water circulation pumps (efficiency, torque)
• Oil well pumps (efficiency, torque)
• Airport baggage handling (low volume)
• Rolling curtains (low volume, high speed)
• Aeronautic applications (low volume, high speed)
• Refrigeration compressors (high efficiency)
• Ceiling conveyor belt (low weight)

5 Conclusion

Industrial production of induction motors with die-cast copper rotors is a fact today. As
of end 2005, over 250 000 copper rotor motors are in operation.
The main advantages of this new technology are higher efficiency, or for the same efficiency,
lower volume, weight and cost.
For more information, visit www.copper-motor-rotor.org.

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Acknowledgement

This brochure has been developed with the help of a group of experts providing input and
reviewing documents:
Ned Brush, Consultant, United States
M Deivasahayam, Mehala Machines, India
Martin Doppelbauer, SEW Eurodrive, Germany
Stefan Fassbinder, Deutsches Kupferinstitut, Germany
Sigrid Jacobs, Arcelor, Belgium
Dale Peters, Consultant, United States

Notes

1
Annual global electricity consumption = 15000 TWh. Of which 40% or 6000 TWh is industrial
consumption. Of which 60% or 3600 TWh is used by motor systems. A savings of 3% on 3600 TWh =
108 TWh.
2
Based upon data from manufacturers, and independent technical sources.
3
This effect has already been demonstrated on lower-grade steels, on which the graphs in figures 6
and 7 are based. It still remains to be confirmed for higher grade steels, for which the trend is expected
to be the same, but the effect smaller.

References

[Deivasahayam, 2005] M Deivasahayam, Energy Conservation through Efficiency Im-


provement in Squirrel Cage Induction Motors by Using Copper Die Cast Rotors,
EEMODS 2005, Heidelberg, September 5-7
[Kimmich, 2005] R Kimmich and others, Performance Characteristics of Drive Motors
Optimized for Die-cast Copper Cages, EEMODS 2005, Heidelberg, September 5-7
[Parasiliti, 2004] F Parasiliti and others, Three-Phase Induction Motor Efficiency Im-
provements with Die-Cast Copper Rotor Cage and Premium Steel, SPEEDAM 2004,
Capri, June 16-18
[Parasiliti, 2005] F Parasiliti and M Villani, Design Strategies and Different Materials
for High Efficiency Induction Motors. A Comparison, EEMODS 2005, Heidelberg,
September 5-7

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