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Copper-Rotor Motors Boost Efficiency Motor manufacturers have known for some time that replacing the aluminum conductor structure of the rotor with copper would significantly increase the electrical energy efficiency of the motor and, therefore, significantly reduce lifetime operating costs. For this reason, some special purpose motors and many very large motors are built with copper rotor structures by a costly and slow fabrication process. Notably, the level of energy efficiency being achieved through the CDA copper motor rotor project exceeds the efficiency of currently produced motors and any efficiency guidelines in place by the Consortium for Energy Efficiency, the U.S. Department of Energy, or the National Electrical Manufacturers Association. In fact, the project’s efficiency tests show that motors with copper conductor bars in the rotors yield overall loss reductions of from 15% to more than 20%, compared to their aluminum counterparts, for the same lamination and rotor designs, according to CDA’s Dr. John Cowie, manager of the copper motor rotor project. For this reason, some special purpose motors and many very large motors are built with copper rotor structures by a costly and slow fabrication process. The potential total energy savings in applying copper to the rotors of medium-power motors are a significant national consideration. The DOE has determined that electric motor systems account for 23 percent of all electricity consumed in the United States, nearly 70 percent of which is consumed in the manufacturing sector. CDA expects integral horsepower motors with copper rotors to become the replacements of choice for end users when they are available. According to Dr. Cowie, replacement copper rotors should begin to become available sometime next year. CDA is partnering with a rotor manufacturer for fabricating 100 rotors to go into service early next year. |
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