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Copper Motor Rotor (CMR)


Technology

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Milind Raje International Copper


Promotion Council (India)

Dr Sandeep Garg
UNDP GEF
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Project Partnership
Under overall flagship of Bureau of Energy Efficiency ( BEE )

funding from
Common Fund for Commodities ( CFC )
Global Environment Facility ( GEF )
United Nations Development Program ( UNDP)
and in partnership with
Non Ferrous Technology Development Center

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( NFTDC )

International Copper Association (ICA / ICPCI) developed


technology for copper die cast rotors

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Project Partnership-Why?
Demonstration of Indian Capabilities
Trial of New Technologies
Improvement of Motor Efficiencies
Harmonization of Global Motor Standard
Indigenization of Technology because of New
Developments
Mitigation of Climate Change

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Current Status of the Project


Presentation is for adoption and information
Dissemination
Indian Capabilities exists.
Contact Points for Technology Assessment
www.nftdc.res.in
Contact Point: Mr D Lokeswara Rao, Project Director

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IEC Energy Efficiency Classes


IEC 60034-30 (Published 21 October 2008)

Premium Efficiency

IE3

NEMA Premium

High Efficiency

IE2

Eff 1

EPAct

Standard Efficiency

IE1

Eff 2

Below Standard Efficiency

Eff 3

Rating Plate new !


IE3 93.4%
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Testing method new !


Low uncertainty

Overview of Energy Efficiency Regulation

New Standards on Horizon

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Advantages with Copper


Improved Performance
Higher Efficiency energy savings
Reduced temperature rise Better operation and longer life

Increased power density


Reduced size Less power to space ratio ( compact)
Reduced active material content Material cost reduction

New Applications .

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EV/HEV Vehicles
Corrosion resistance and higher flux density
Very high torque motors (Cu alloys)

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Barriers to CMR technology


adoption
Cu die casting

Process know how


Equipment
Related capital costs
Motor re-design capabilities

Existing standards of frame sizes


Requirements of other performance parameters
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Objective and Strategy

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Objective:
Address copper die-cast technology migration
barriers faced by the motor manufacturers
Strategy:
Establish an Enabling Technology Centre

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Enabling Technology Centre (ETC)


Establishment of an ETC to Adapt copper die-casting technology for creation of
low cost local facility
Develop motor re-design capability with testing &
validation facilities
Transfer technology (total solution)

Market development for CMR motors


Improve energy efficiency standards
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Adopt CMR technology for niche applications

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Integrated Centre

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Enabling
Technology
Centre
1) Processes

Advanced Test
Centre
Test Facilities
Test methods

2) Equipments
Accreditation
Test services

3) Motor
Design

Technology
Training

Dissemination
Training
Technology Transfer

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Pre Project Scenario


2 to 3 die casters were only in operation for copper rotor
die casting in India with horizontal presses.
No vertical presses were used

The other alternative technology of fabricated copper rotors


was used by the industry for a limited purpose.
NFTDC was chosen by International Copper Association
(ICA) for this project on the basis of its well known
expertise in the technology of OFE Copper and other high
quality copper alloys in India
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Die Casting of Copper Rotors Basic issues


Porosity in cast rotors
Die life
Hot Metal handling techniques

Problems and issues are common world over


but
the solutions are unit specific
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Basic Issues : 1

Porosity in cast rotors


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Reasons for porosity


Dissolved gases
Pick up of gases during melting
Entrapped air in die cavities and rotor slots
Poor venting of gases from dies and rotor slots
Under fills
Characteristics of metal
Low temperature
Poor Die design
Low pressure die casting
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Challenges associated with Physical


properties
Property

Aluminum

Copper

Melting Point

660

1083

64%

Poor die life


Need for high cost tools

Density

2.770g/cc

8.94g/cc

223%

Die casting pressures


Issues of porosity

Heat Capacity

917J/kg/k

386 J/kg/k

58%

390 KJ/kg

205 KJ /kg

47%

238w/m/k

397 w/m/k

67%

2.5 mNs/m2

3.9 mNs/m2

56%

Latent Heat of
Fusion
Thermal
Conductivity
Viscosity
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Variance

Seriously affects the


castability

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Basic Issues : 2

Die Life
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Heat checking
How others handled the problem
Use of super alloy inserts

Nickel based alloys such as Inconel 617 & 718


Tungsten based alloys such as Anviloy 1200

Pre heating of dies to 6000 C

ETC approach
Surface modification through die coating technologies
Low cost Ceramic and other inserts
Preheating of dies etc to 3000 C
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Re design the of dies


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Basic Issues : 3

A unique Melt control & Transfer system


Melting under controlled atmosphere
Minimum exposure of liquid metal.
No Ladles
Clean metal Out put :
No oxide inclusions
Controlled discharge of molten
metal

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Copper with electrical conductivity from 99% to 100 % IACS

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Die casting of Copper rotors


Made easy
A Unique die design was developed
and being patented
Minimal Heat checking problems to
dies
Minimum time delay for shot after
pouring the metal into the press cavity
A customized die design for gas/hot air
venting
Porosity in die cast rotors has been
kept in control

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Same Die Casting Presses used by conventional die casters for casting
Aluminium rotors are used.
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Work done for Process Optimization


100 die casting trials
600 rotors cast for both

internal process optimization

supplies for actual end users

Rotor for 0.5 hp to 50 hp motors were cast


In a size range of :

50mm dia to 220mm dia


and a length of 55mm to 300mm

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Work done for Process Optimization

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Rotors were cast for 4 different customers from different


regions and applications.
Rotors for Motors of industrial, textile and submersible
applications were supplied.
Die cast rotors were supplied to replace the fabricated
rotors

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Motors identified for Re-Design &


development
Submersible pump set motors

Industrial motors ( 2kw to 11kw) Standard, Textile


loom etc.
Electric Vehicle motors motors ( 6kw to 35kw)
Fractional horsepower motors (0.25kw to 0.75kw)
Ceiling fan motors

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Motors test set up Design


validation

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3-Phase Power analyzer


(PM3000A)

Torque Display

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Bellow couplings

Torque
Transducer

Eddy Current
Dynamometer

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Rotor Test Setup

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D. Lokeswara Rao

Software26developed in Labview

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Rotor Test Results

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Available now for Technology Transfer

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Cost effective End to End Technology Solution


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Process Know how + Indigenous Equipments at very affordable cost

Pilot production with customer rotor, to show first hand experience and confidence

50-110mm dia x 80 to 200mm CL

150 to 220mm dia x 150 to 400 mm CL

Fractional Hp to 50 Hp

Ease of adoption and modification of existing equipments


(Al Rotor to Cu Rotor)
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Read More
Copper Motor
Rotor Technology
There is a need for technology developments to address the energy shortages through improved efficiencies
in electric motors and also use the technologies for special applications. Copper die cast rotor technology is
one such technology intervention. This article describes copper die cast rotor technology and the technology
Centre for facility developed at the Enabling Technology Centre (ETC) established at Hyderabad.
- Milind Raje & KN Hemanth Kumar

ne of the ways to address the


problem of energy shortage is
to reduce demand mainly by
increasing end use efficiency. In order
to address the issue there is continuous
improvements in the standards and the
regulations on energy performance.
While global energy performance
standards
are
enhanced
and
harmonized, Bureau of Indian Standards
has also revised its standard for energy
efficient motors in harmonization with
the global standards. Different
countries have also introduced
regulations based on these standards
to ban sale & manufacture of the low
efficiency motors in their countries. In
India also Bureau of Energy Efficiency

82!August 2012!Electrical India

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are developing such regulations based


on the new standards. To compliment
these regulatory measures, end user
involvement is also done through
awareness creation and capacity
building to adopt high efficiency
motors. The technology developments
and its commercialization are also
important aspects.
Squirrel cage induction motors are
the mostly used motors at present.
Squirrel cage induction motors took a
share of over 75% of the total middle
and small motors. Currently, squirrel
cage induction motors are widely
applied in industries, agriculture,
national defence, commerce, public
facilities and transportation, becoming

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THANK YOU !!!

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