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A Little Luck and a Lot of Ingenuity Yield Copper Rotor Success
(Continued)  “We made a most encouraging achievement recently when we achieved a 2.5% gain in efficiency versus an aluminum die cast rotor. The company that contracted with us is continuing their tests on the rotors we made and are very interested in copper cast rotors,” Ajmearwala said. (see Figure 2).
“Submersible cast copper rotors are an attractive alternative to fabricated copper rotors, as the fabrication process is a very complicated and costly procedure. These rotors often reach the length of 1100 mm,” Ajmearwala said. Cowie explained that, due to the complexity of manufacture, fabricated rotors sometimes vibrate, causing premature failure. This is mainly due to misalignment, partly as a result of the air gap between the end ring and laminations. “With a cast copper rotor, there is no room for the air gap. This results in a smooth working rotor with far better conductivity and a much longer working period,” Ajmearwala said. He also reports improved motor efficiency, due to lower starting torque and a 40 percent increase in a pump's water output. While not yet in full production, Perfect Diecast has gained the interest of motor companies from Bombay to Europe. “Almost every part of our success in copper motor rotors can be initially attributed to CDA,” Ajmearwala explained. However helpful technological support can be, the ingenuity displayed by Mr. Ajmearwala and his team is the secret to their copper die casting success. “It seems that very soon the market will see a new super-premium-efficiency motor which will start a new revolution in motors,” he said, explaining his enthusiasm and undaunted efforts. |
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