Die Casting Copper Rotors - Copper Development Association

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Motor TestsRotor I 2 R Losses (Watts)HPkWPolesAlCuDifferenceReduction4 3 4 221 92 129 - 58%5 3.7 4 - - - - 38%15 11 4 262 157 104 - 40%25 19 4 410 292 118 - 40%
Motor TestsTemperature RiseAICuDifference Percent15 HP (11kW) Motor 64.9C 59.5C - 4.5C - 7%25 HP (18.5 kW) Motor 79.9C 47.2C - 32.7C - 41%? Affects life expectancy of the motor? For every 10 degrees C hotter a motor runs,life can be reduced in half? <strong>Copper</strong> rotors could increase life expectancy? Similar results have been seen in premium efficiencymotors since their introduction 20 years ago
Page 1 and 2:
Die Cast Copper Motor RotorWorkshop
Page 3 and 4:
IntroductionProgram initiation - Ba
Page 5 and 6:
IntroductionObjectives? Development
Page 7:
IntroductionAdvantages to motor per
Page 10 and 11:
Cracking -Thermal Expansion & Contr
Page 12:
Die Materials TestingH-13 tool stee
Page 22 and 23:
Predicted Temperature Profiles
Page 24 and 25:
The Die Casting ProcessSystem desig
Page 26 and 27:
The Die Casting ProcessInductotherm
Page 28 and 29:
The Die Casting ProcessApplying dry
Page 30 and 31:
The Die Casting ProcessTransferring
Page 32 and 33:
The Die Casting ProcessEjecting cop
Page 34 and 35:
Testing Die MaterialsDr. John G. Co
Page 36 and 37:
Testing of Die Materials - H-13 Ste
Page 38 and 39:
Testing of Die Materials - H-13 Ste
Page 40 and 41: Testing of Die Materials - H-13 Ste
Page 42 and 43: Testing of Die Materials - H-13 Ste
Page 44 and 45: Testing of Die Materials - CVD-W on
Page 46 and 47: Testing of Die Materials - InconelV
Page 48 and 49: Testing of Die Materials - InconelP
Page 50 and 51: Testing of Die Materials - TZM & An
Page 52 and 53: Testing of Die Materials - TZM & An
Page 54 and 55: Testing of Die Materials - Nickel A
Page 56 and 57: AlloyDie Materials TestingNickel-ba
Page 58 and 59: AlloyDie Materials TestingSuperallo
Page 60 and 61: Die Materials TestingConclusions -
Page 62 and 63: Die Casting Copper RotorsMaster die
Page 64 and 65: Die Casting Copper RotorsLarger Ind
Page 66 and 67: Die Casting Copper RotorsArbor (Man
Page 68 and 69: Die Casting Copper RotorsAssembled
Page 70 and 71: Die Casting Copper RotorsInserting
Page 72 and 73: Die Casting Copper RotorsCopper pel
Page 74 and 75: Die Casting Copper RotorsPouring co
Page 76 and 77: Die Casting Copper RotorsEjecting r
Page 78 and 79: Die Casting Copper RotorsWater-quen
Page 80 and 81: Die Casting Copper RotorsCross-sect
Page 82 and 83: Rotor Steel Specification for Coppe
Page 84 and 85: Capabilities for Future Die Casting
Page 86 and 87: Motor Test ResultsMr. Darryl Van So
Page 88 and 89: Diminishing ReturnsLossesWe arehere
Page 92 and 93: Motor TestsCopper rotor consistency
Page 94 and 95: Motor TestsRotor Cost Implications?
Page 96 and 97: 15 kW Motor - Past, Present and Fut
Page 98 and 99: Principles of die casting technolog
Page 100 and 101: Abbreviations for die castingA = ar
Page 102 and 103: Gate velocity v MAV MA=____________
Page 104 and 105: Metal flow rate Q mm AQ M=? ?t Fm p
Page 106 and 107: Runner cross section A kA KA K= 1.6
Page 108 and 109: Sankey diagram
Page 110 and 111: Heat Conduction Q IQ l= ? w* A w* (
Page 112 and 113: The three cooling areas
Page 114 and 115: Insulation material
Page 116 and 117: Insulation material
Page 118 and 119: Electrical heaters
Page 120 and 121: Electrical heaters
Page 122 and 123: The shot sleeve design
Page 124 and 125: The die design
Page 126: The die design
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Die Casting Copper Rotors - Copper Development Association

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