Demonstration Meeting Successful A wide spectrum of industries and businesses were represented — from motor manufacturers to research and development organizations and from academicians to die casters. All were given a comprehensive overview of the project and were able to view actual rotor casting. The U.S. Department of Energy (DOE), the Copper Development Association Inc. (CDA), and research labs, Formcast and Trex Enterprises (formerly Thermotrex), sponsored the demonstration. “DOE asked CDA to hold the event because the technology is on the verge of commercialization. We needed to maximize exposure through a large meeting,” explained Cowie. Following a welcome address from CDA president and CEO, Andy Kireta, Sr., Scott Hutchins of DOE explained the government’s involvement in the program. Dr. Dale Peters, a consultant to CDA and former manager of the copper motor rotor project, reviewed the project’s history and current objectives. He detailed the project from an engineering perspective by explaining the limitations inherent in die casting copper. Figure 1. Tests of an Optimized Copper Motor Rotor Losses 40% Total Losses 23% Temperature Rise 41% Efficiency +1.6% 90.9% vs. 92.5% Stator windings and iron core were modified from standard motor design to gain best possible results. The data in Figure 1 illustrates the improvements achieved when a motor is designed specifically to use copper rotors. Dr. Cowie described the trials performed by the copper motor rotor team that led to the success of the project thus far. Dr. Edwin Brush, a consultant to CDA from BBF & Associates, spoke more specifically about the science of die-casting copper rotors. Darryl Van Son, also a CDA consultant, detailed the testing procedures and revealed the results of tests performed by four different manufacturers, who all found a marked increase in motor efficiency using the copper rotor. (See Figures 1 and 2.) CDA consultant and die designer, Dr. Ruedi Beck of DieTec Ruedi Beck GmbH detailed the die requirements for casting of copper, such as venting, speed of fill and pressure requirements. MORE >>

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.