The Next Step: Further Testing and Promotion (continued) The potential for energy savings using cast copper rotors makes the copper motor rotor project of particular interest to Advanced Energy. “The Energy Policy Act of 1992 set the standards for industrial motor efficiency in our country mandating specific, minimum efficiency levels for motors between 1-200hp. The motor industry, through the National Electrical Manufacturers Association (NEMA), responded positively last June with a definition of premium efficiency when they rolled out the NEMA PremiumTM program. These motors are essentially the best you can buy from an efficiency standpoint. Copper-rotor motors may have an opportunity to raise the bar even higher,” according to Butler. Dr. John Cowie, vice president of strip, sheet and plate at CDA and program manager of the copper motor rotor project, welcomes the help of Advanced Energy, “We are now in the technology transfer phase of the project and are moving toward the promotion phase. But, before we can start the promotion, we need to partner with companies like Advanced Energy who can provide considerable assistance through their membership.” he said. From a technological standpoint, the testing of copper motor rotors at Advanced Energy will go a step further than any trials to date. “We see two potentially critical needs that have been only slightly addressed so far in regard to testing,” Butler said. “First, we want to be able to clearly demonstrate the benefits that copper has versus aluminum with regard to rotors. We would like to test multiple copper rotors alongside aluminum rotors inside a common stator. We would want to control the inputs so that the data can have as much credibility as possible. Stack length, lamination design, slot sizes, air gap, etc., need to be the same across the board between aluminum and copper, so that we can compare apples to apples. From this testing we would be able to make statements about the results that, to date, the motor-using public has never heard. Efficiency, torque, temperature rise, current unbalance and speed accuracy would all be topics for review from these tests.” Dr. Cowie hopes to begin working with Advanced Energy within the next few months. “Independent verification of our motor test results by a respected laboratory such as Advanced Energy would go a long way in convincing motor companies to invest in copper die casting equipment” he said.

Update: Copper Motor Rotor is published monthly by the Copper Development Association Inc. to provide current information of interest to those in the electric motor and related industries. CDA assumes no responsibility or liability in connection with this publication and makes no warranties of any kind with respect to the information contained herein.