Die-cast Copper Rotor Research Articles

Design and performance analysis of novel multiphase induction motor with die-cast copper rotors using FEA for electric propulsion vehicles applications

PurposeThe purpose of this paper is to study the development of novel multiphase induction motor (MPIM) with copper die cast rotor in the drive system of electric propulsion vehicles (EPV). It is estimated that the manufacturers are concerned about high torque,Efficiency, motor life, energy conservation and high thermal tolerance. To ensure maximum torque and efficiency with multiphase winding and copper die cast technology to increasing high thermal tolerance, life, energy conversations. On other hand, it is very important of EPV application.Design/methodology/approachThe focus of the investigation is threefold: the modified method carried out on MPIM both stator and rotor can overcome the current scenario problem facing by electric vehicles manufacture and developed perfect suitable electric motor for EPV applications. The design and simulation carried out finite element method (FEM) that was more accurate calculations. Finally developed prototype model of MPIM with copper die cast are discussed with conventional three phase Die casting Induction motor.FindingsThe paper confirmed the multiphase copper die-cast rotor induction motor (MDCrIM) is providing better performance than conventional motor. Proposed motor can bring additional advantage like heat tolerances, long life and energy conversations.Originality/valueThe experiments confirmed the MDCIM suitable for EPV Applications. The modified MDCIM of both stator and rotor are giving better result and good performance compared to conventional method.

A Hybrid Methodology for Analyzing the Performance of Induction Motors with Efficiency Improvement by Specific Commercial Measures

This paper presents a hybrid methodology to analyze the commercial measures of changing stator windings and adjusting air gap length to upgrade efficiency of typical three-phase direct-on-line induction motors with die-cast copper rotor (DCR). The calculation is carried out through combining the time-stepping and time-harmonic finite element analysis (FEA) and the circuit equivalent circuit model. Typical full-load performance of stator windings with different air gap lengths are computed by MATLAB invoking the 2D transient and eddy current field analysis in ANSYS/MAXWELL. Then, MATLAB scripts about post-processing of the FEA results are used to obtain the full-load running performance including the loss distribution and circulating current. The MATLAB scripts of circuit model built based on the FEA results is used to compare the overload and starting performance. After that, four stators with the four windings and three DCRs with different air gap of an 11 kW motor are fabricated and tested to validate the calculations. By comparing results from both calculations and measurements, it is shown that the factors of stator windings and air gap length can effectively improve the efficiency of the 11 kW DCR induction motor without the addition of extra materials. The motor with the 11/12 pitch Y-Δ series winding and 0.6 mm air gap has the best performance, in terms of efficiency, overloading capability and starting performance. Its efficiency can increase from 90% to the highest 92.35% by sole adjustment of stator winding and air gap length.

Design and Development of Rotor Quality Test System for Die-Cast Copper Rotors

It is well known in the market that the copper rotor motor can give good efficiency at par with the new era motors, and can handle higher temperatures to qualify for electric vehicle application. Being a heavy metal, die-cast copper rotor manufacturing needs absolute care for faithful rotor production. In this paper, the common faults in copper die-cast processing are identified and sufficient monitoring methods are suggested in a three-stage inspection. The final stage consists of a rotor quality test system, which detects most of the problems found in copper die-cast rotors. This rotor quality test system analysis helps to optimize the rotor manufacturing process and avoid the circumstances of fitting an inferior rotor in the motor assembly.

Fault Investigations on Die-Cast Copper Rotors

It has been known for a long time that replacement of aluminum by copper, which has an advantage in high conductivity, can be an economic solution for various applications including electric vehicle in the development of energy efficient motors. In comparison to aluminum, copper die-casting is difficult to perform due to its high density, viscosity, and melting point. Owing to these reasons, the copper die-cast rotors evince several manufacturing problems. The objective of this work is to identify the various defects in the manufacturing of copper die-cast rotor, and identify the lamination coating condition that sustains copper die-cast pressure and temperature. It evaluates the effectiveness of lamination coating on limiting the eddy current loss and the recoating process to improve in case the eddy current loss is in excess due to copper die-casting.

Analysis of End-Winding Thermal Effects in a Totally Enclosed Fan-Cooled Induction Motor With a Die Cast Copper Rotor

Thermal overload protection techniques commonly use a simplified 1st order thermal model, which does not provide accurate stator winding temperature prediction and causes frequent undesirable stoppage of the motor in the processes. This paper proposes a higher order lumped parameter thermal network model to accurately predict stator winding temperature. First, the comparison of the predicted stator winding temperature from a 1st order thermal model with a higher order thermal model is performed. Second, a comparison between the actual and the predicted stator winding temperature rise is verified for a 20 hp totally enclosed fan-cooled copper rotor induction motor that has no rotor fins on its short-circuit ring to enhance heat dissipation compared with an aluminum rotor induction motor.

On the Influence of Stator Slot shape on the Energy Conservation Associated with the Submersible Induction Motors

Problem statement: A good design of Submersible Induction Motor is required to maintain maximum efficiency level. This can be achieved in one way by optimum design of magnetic circuit. The magnetic circuit of an Induction Motor is formed by the combination of Stator core, Rotor core and air gap. In applications like Submersible Motor Pumps, the air gap cannot be minimized beyond 0.5 mm, because of the machining tolerance required, due to large core length. Now a day, the efficiency of such motor is improved by die-cast copper rotor. But the cost of such motor is more and sometimes the rotor core properties are getting changed due to high temperature during die- casting process. Approach: A new stator slot shape is proposed based on the results obtained from the iterations with Rotational Machine Expert (RMxprt) software and the performance is compared with that of the existing stator slot shape, for a 3-phase, 5 hp, 380 V, 2-pole motor The motor with both the stator slot shapes have been analyzed with the Rotational Machine Expert (RMxprt) software. Results: The magnetizing current of new design is 3.25 A, compared to the existing design of 4.67 A. The overall efficiency of the Submersible Induction Motor pump set is 5% more than that of the existing one. The discharge of the pump set has increased by about 80 liters per minute. Conclusion: The proposed stator slot dimension is suitable for more efficiency, less magnetizing current and a good power factor. This design modification does not require much cost and needs no complex manufacturing process.

Advances in Construction Techniques of AC Induction Motors: Preparation for Super-Premium Efficiency Levels

Design, material, and production techniques are evolving on AC induction motors leading to improved efficiencies over older designs. IEEE 841 and even NEMA Premium efficiency levels are now quite easy to meet and exceed. New research and production techniques will allow construction of ac motors with die-cast copper rotors, allowing even higher efficiency levels and greater longevity.

Performance Comparison of Optimally Designed Induction Motors with Aluminum and Copper Squirrel-Cages

A significant improvement in motor efficiency is expected when substituting aluminum with copper die-cast rotor in squirrel-cage induction motors due to a reduction in the rotor ohmic losses. Other performance criteria, such as starting torque, power factor, and steady-state current, may also change, and the motor may need to be redesigned to obtain optimal performance. This paper compares the performance of optimally designed squirrel-cage induction motors with aluminum and copper rotor bars with equivalent specifications. The design is optimized using three objective functions.

Copper die-cast rotor efficiency improvement and economic consideration

Significant motor efficiency improvement can be achieved by substituting aluminum with copper die-cast rotor in a squirrel cage induction motor. This paper summarizes the experiments conducted by Westinghouse Motor Company Canada Ltd. in our copper die-cast rotor induction motors project.< <ETX xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">&gt;</ETX>