Copper-rotor induction-motor: Strong alternative to rare earth motors for EV traction

Malcolm Burwell SAE 2012 Powertrain Electric Motors Symposium for Electric and Hybrid Vehicles Detroit 23 April 2012

The challenge for electric traction motors: Rare earth cost-levels and cost-volatility

3000

Permanent Magnet Motor Materials (rare earths)

Ne Oxide Dy Oxide

2500

Dysprosium Oxide
2000

Neodymium Oxide
$ per kg
1500

Copper (for reference)

1000

$1200/kg

500

$130/kg $7/kg
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Source: metal-pages.com, Kidela Capital

2001 2002

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Copper rotor induction motor history

Vehicles with copper rotors

1990

2000

2005

2010 2012 2013

Rotor manufacturing

Die-casting of copper rotors Fabrication of copper rotors Tier-1 suppliers

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Performance/cost analysis: Two similar HEV motors

Toyota Prius with THS II (PM) motor

Outer stator diameter Outer rotor diameter Axial core length Active material weight RMS line voltage @ 6000rpm

Permanent Magnet Motor 269mm 161mm 84mm 30kg 544V

Copper Rotor Induction Motor 269mm 180mm 84mm 35kg 600V

Comparison of Different Motor Design Drives for Hybrid Electric Vehicles Motor Design Ltd. 2011 Popescu et al 4 | Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Performance/cost analysis: The two HEV motors perform similarly

Permanent magnet motor (Prius THS II) Torque (Nm) Torque (Nm)
560

Copper rotor induction motor

Peak power 82kW

400

Peak power 50kW

60 600

Speed (rpm)

5000

60 600

Speed (rpm)

5000

<80% 80-90% 90-92% 92-95% 95-96%

Efficiency
5 | Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Comparison of Different Motor Design Drives for Hybrid Electric Vehicles Motor Design Ltd. 2011 Popescu et al

Performance/cost analysis: The permanent magnet motor costs more

Cost of active materials (magnets, copper, iron) in each HEV motor

2008 2012

Permanent magnet motor (Prius THS II) $242 $763

Copper rotor induction motor $129 $146

Comparison of Different Motor Design Drives for Hybrid Electric Vehicles Motor Design Ltd. 2011 Popescu et al 2012 updates from metal-pages.com

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Manufacturing fabricated rotor

Laminations

End rings & brazing paste Rotor bars

Components

Assemble - Induction braze - Bead blast - Balance

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Manufacturing die cast rotor

Laminations Copper pellets

Die tooling

Components
8

Die cast

Quench

Balance

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Todays supply chain resources

Advice and Introductions EV Motor Manufacturing AC Propulsion (US) Tesla Motors (US) Hyosung (KR) Yulon (TW)

Rotor Casting

Outsourced Motor Design MIT (US) Motor-Design (UK) WEMPEC (US)

Akashi (JP) Remy (US) Vforge (US) Fukuta (TW) Favi (FR) Kienle + Spiess (DE) Ramco (US) THT (US) Yunnan Copper DieRotor Fabrication casting (CN)

| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Copper rotor induction motor video: Comments from todays suppliers

www.copperalliance.org/motor

10 | Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012

Copper-rotor induction-motors: Strong alternative to rare earth motors for EV traction

For more information please contact: malcolm.burwell@copperalliance.org robert.weed@copperalliance.us

To view the video of industry comments on the copper rotor induction motor go to: www.copperalliance.org/motor

11 | Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012