With the numerous advantages, it is not surprising that a number of copper foil manufacturers are evaluating induction motors with cast copper rotors for future vehicles. Because the CDA and the ICA recognize the global nature of the automobile industry. They’ve developed a network of centers of technical expertise and partners to help engineers and designers, including facilities worldwide.
Automotive manufacturers view their choices for reducing emissions and fuel consumption, the electrical propulsion becomes more attractive. Initially, IPM - Internal Permanent Magnet motors have been a popular motor design. They also provide high peak efficiency and high torque density, but there are some cons. The stator losses can really be significant. They require expensive controllers and also they might as well rely on rare earth magnet materials. So, a potential alternative to the IPM is none other than the induction motor. They have been used successfully in the production of vehicles.
They have a comparable peak efficiency and torque density and a rugged, durable design. The induction motors do not suffer a drag loss when the motor turns and don’t lose efficiency during low-torque, high-speed conditions, which makes them well suited for hybrid as well as plug-in hybrid applications according to the best copper sheet manufacturers.
Copper foil manufacturers you replace an aluminum rotor with a copper rotor, it will increase the benefits of an induction motor. Copper rotor bars, as well as the end rings, reduce electrical losses, that lead to a smaller and more efficient motor. The automotive engineers had experimented with the fabricated copper rotors but they are continuously looking for a high production, efficient process, like die to cast.
The die casting copper is more challenging than die casting aluminum due to copper melting temperature. It is much higher. The ICA - International Copper Association, Ltd. and the CDA - Copper Development Association Inc. had realized the need to improve casting technology and had conducted extensive research on casting copper rotors for the industrial applications. They quickly saw the need to share this information with all the automotive engineers and they’re actively promoting cast copper rotors to the next level - transportation industry.
In addition to the increased competencies, copper rotors can also provide an economic benefit over aluminum rotors. Even though the raw material cost for aluminum might be less than copper, the motor along with a cast copper rotor can be 15 to 25% smaller than an equivalent motor with the aluminum rotor. As a result, the organization will get considerable savings just by reducing the amount of electrical grade lamination steel as well as the number of stampings. The great heat conduction properties of copper can make thermal management far easier, that can be another source of cost reduction for the entire system.
Copper has always been recognized as the most preferred material by copper sheet manufacturers for conducting electricity. And that is why it is used globally in motor windings. At present, the copper industry provides a great help to designers and engineers to bring improved technology to the motor rotor for electric and hybrid vehicles.