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French Die Caster Offers Copper Motor Rotors
(continued) About 10 years ago, a large pump manufacturer asked FAVI if it would be possible to die cast copper motor rotors. Grundfos, based in Denmark, was seeking an alternative to aluminum rotors for use in its submersible pumps, where corrosion resistance is important. Copper was clearly the preferred material because its corrosion resistance and electrical conductivity are both significantly higher than for aluminum. As readers of this newsletter know, die casting copper is anything but simple, but FAVI engineers were able to draw upon their extensive experience with copper alloys to make the process work. Nevertheless, bringing copper rotors to commercial production took nearly 10 years. Today, FAVI supplies rotors in a variety of configurations based on customer specifications. Included among its client listings are a growing number of European industrial equipment manufacturers. Some, like Grundfos, are looking for better corrosion resistance, while others are more interested in high electrical efficiency or the more compact size (for equivalent power) that copper makes possible. Short Delivery Time 
After receiving an enquiry, FAVI engineers work with customers to design the rotor. Size and slot configurations are optimized to achieve the required electrical, magnetic and mechanical characteristics commensurate with dimensional constraints. Modeling and computer-aided design facilitates the process, enabling the prediction of induction and flux density for various slot designs and of temperature and stress distribution in conceptual rotors (Figure 2). Such state-of-the-art design tools shorten the interval from initial enquiry to production to as little as two months.
FAVI's comprehensive service includes design and assembly of all tooling. In addition, prototype rotors are tested at a 3,000 sq ft research facility supported by the company at the Graduate School for Electronic and Electrical Engineering (École Supérieure d'Enginieurs en Electrotechnique et Electronique, ESIEE) in nearby Amiens. Equipment includes two fully instrumented test stands, at 11kW and 75kW, to evaluate rotor performance and quality. Tests can be conducted according to several international standards, including IEC 34-2, CSA C390-98, CEI 61972 and IEEE 112-1996 (B). In terms of quality control and assurance, the company is fully certified under ISO 14001, ISO 9002, and ISO 9001 version 2000, as well as EAQF 94, QS 9000, QSE and OHSAS 18001. MORE >> |
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