development and testing of die cast copper
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DEVELOPMENT AND TESTING OF
DIE CAST COPPER ROTORS
MARCH 2004
Project Report Prepared
By
INTERNATIONAL COPPER PROMOTION COUNCIL (INDIA)
Project Executed by ICPC(I) with Assistance
from SIDBI
Project Team
S.MAHADEVAN - Project Consultant
G.RANGANATHAN - Technical Consultant
V.KRISHNAMOORTHY - Project Assistant
C.NARAYANAN - Project Assistant
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 2
TABLE OF CONTENTS
PAGE NO.
a) Preface 1
b) Organizations and project team 3
1.0 Introduction and background 6
2.0 Need for the study 12
2.1 Executive Summary 12
2.2 Technology opportunity 12
2.3 Choice of Coimbatore Cluster 13
2.4 Expected benefits 13
3.0 Project objectives 15
3.1 Technology related objectives 15
3.2 Market related objectives 16
4.0 Summary of approach 17
4.1 Project technical approach 17
4.2 Manufacturer – Partners 17
4.3 Categories of Products 19
4.4 Testing and confirming methodology 20
4.5 Strategic partners 21
5.0 Detailed approach 23
5.1 Technology related approach 23
5.2 Market assessment dimensions 24
5.3 Project time schedule 25
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 3
6.0 Project findings and summary 26
6.1 Rotors conditions summary 26
6.2 Factory test results 26
6.3 SITARC test results 27
6.4 Field test results 27
6.5 Performance comparison summary 27
6.6 Market assessment details 29
6.7 Project time schedule summary 33
6.8 Over all conclusions 35
7.0 Conceptual approach of Phase II 36
A-I Annexure I – Rotor Condition report
A-II Annexure II – Factory Test Comparison
A-III Annexure III – SiTARC Test Report
A-IV Annexure IV – Field Test Report
A-V Annexure V – Bar Chart Details
A-VI Annexure VI – Rotor Weight and Cost Report
A-VII Annexure VII – Feedback From Manufacturer-Partners
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 4
PREFACE
AC Induction motors have played a leading role in the growth and improvement
of all spheres of Industries, Agriculture and Domestic uses, all over the world and in
India. Presently in India out of the total electric power generated, more than 70% is used
by AC Induction motors.
The Technology and efficiencies have been improving over the years through
materials, Designs and the process of manufacture.
The use of Die Cast Copper Rotors in Electric Motors is a recent technological
development that has captured the attention of manufacturers and the advocates of
Energy efficiency around the world.
This project is undertaken to test the performance of Indian Die-cast copper
Rotors towards evaluating the suitability of this technology upgrade for the Indian
market, and in particular for the Motor and pump cluster in Coimbatore. The purpose of
the project is to advance the concept to the market and the project was conceived in 2
phases. The I phase which is completed and covered in this report is focused in carrying
out exhaustive tests in assorted ratings, types and quantities of die cast copper rotors to
confirm the performance, results and advantages.
The impetus for development of this project has come from International copper
promotion council (India) and the project team.
Nexant, under US Aid energy conservation and commercialisation project (ECO)
rendered all help in encouraging and developing the concept.
The support extended by SIDBI/TBSE helped in carrying out the I phase, and
they also provided guidance and valuable suggestions continuously through their
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 5
Coimbatore office.
The help and co-operation extended by the following participating Industries
were very valuable without which the project could not have been successful.
i. M/s.Stark Motors, Coimbatore
ii. M/s.Jaghas Engineering Equipments, Coimbatore
iii. M/s.Archana Industries, Coimbatore
iv. M/s.Suguna Machine works (P) Ltd. Coimbatore
v. M/s.Suguna Industries (Unit II), Coimbatore
vi. M/s.Pilot Industries, Coimbatore
The help and guidance provided by all strategic partners and in particular
SITARC, NSIC, SIEMA and CODISSIA were very useful. We are happy to record that
the success of Phase I is in tune with International Experiences shared in the recent
ELROMA-2004 at Delhi. This provides encouragement to proceed with phase II which
can make the technology popular in the market, to the advantage of both manufacturer
and users, apart from helping towards energy efficiency and energy conservation.
S.MAHADEVAN
G.RANGANATHAN
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 6
ORGANISATIONS AND PROJECT TEAM
INTERNATIONAL COPPER PROMOTION COUNCIL (INDIA) [ICPC(I)]
ICPCI is the Indian Centre of the International copper Association Ltd. (ICA).
The principal objective of the ICPCI, a non profit, non commercial organization, is to
promote the beneficial consumption of copper. ICPCI is responsible for guiding the
policy and the finding of the initiatives and promotional activities to expend the use of
copper nationally. ICPCI supports scientific studies relating to role of copper in human
health, safety, energy - efficiency and the environment. ICPCI works in tandem with
various industries to promote the use of EE motors that help improve performance and
boost Industrial productivity and energy servings.
Small Industries Development Bank of India (SIDBI)
Small Industries Development Bank of India was established in April 1990 under
an Act of Indian Parliament as the principal financial institution for promotion, financing
and development of industry in the small scale sector in India and coordinating the
functions of other institutions engaged in similar activities. The Banker (May 1999
issue), London has ranked SIDBI 23rd in terms of Assets and 24th in terms of capital
among the top 50 development banks of the world.
The main provider of term finance and development services to the units in the
small scale sector, SIDBI, which has its head office in Lucknow, channelizes assistance
through three routes - Indirect Assistance, Direct Assistance and Development and
support services. Indirect Assistance is extended by way of refinance to primary lending
Institutions (PLIs), re-dismantling of bills of these institutions as well as through letter of
credit (LOC) in some of them. These PLIs numbering nearly 1000 have about 65,000
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 7
outlets all over the country. Direct Assistance is provided by the Bank through its
Regional Offices and Branches in the form of tailor - made schemes, targeting specific
groups or activities of small scale Industries.
The Bank's development and support services cover soft loans, grants and corpus
support, which are provided to non-governmental organisations, technology institutions,
management institutions, industry associations etc. which act as implementation
agencies for various promotional programmes of SIDBI. SIDBI has memorandum of
understanding with research and development institutions, government organisations,
International Agencies and Industry Associations to foster such programmes.
NEXANT INC. (USA)
Nexant Inc. a Bechtel Technology consulting company is a premier provider of
experience based management and technology consulting services to Governments,
electric utilities, energy producers, oil and gas companies and end users world wide.
Nexant is the prime contractor for energy conservations and commercialisation (ECO)
project which is a joint project of Government of India and the United States Agency for
International Development (USAID). ECO aims to systematically address the market,
technical, economic, financial, regulatory policy and international barriers that has thus
for limited the implementation of end use energy efficiency practices and technologies in
India.
PROJECT TEAM AND ORGANISATION
The organisation for the project in corporates all groups necessary to secure rapid
validation and promotion of project results. The project management team working
under ICPCI includes Mr.S. Mahadevan, a motor/pump marketing expert,
Mr.G.Ranganathan, Technical expert on motor and pumps and two recent engineering
graduates for the performance testing and other follow up.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 8
Mr.S.Mahadeven is currently connected with the ICPCI market promotion
program for energy efficient motors and transformers. He is recently retired from a 36
year career in marketing motors. He spent 12 years with Bharat Bijlee as Deputy General
Manager and Southern India Regional Manager. Earlier he spent 22 years with the
General Electric Company of India in Marketing and servicing of motors and pumpsets,
holding positions of Product Manager, Territory Manager, Senior Manager and Regional
Manager. His experience focuses on product development strategies pertaining to motors
and pumpsets, training and development of marketing teams etc.
Mr.G.Ranganathan has had a distinguished career in the motors and pumps
industry since 1960. In a 20 year career until 1980 with M/s.Coimbatore Premier
Corporation, he was technical manager responsible for manufacture of Electric motors,
pumps, starters and switches in a unit employing 300 workers and 15 engineers. From
1980 to 1998, he had successive management positions at GEC Alsthom including
manager development and quality control, Manager Quality Assurance and head of GEC
Alsthom's Coimbatore unit. Some of his responsibilities include design, development
and manufacturing and obtaining ISI marketing license for all types of motors and
pumps. Since 1998 he has been active as a technical consultant to many of the motors
and pumps producers in the Coimbatore cluster. He has been closely involved in the
establishment and accreditation of testing laboratories of SITARC and a regional testing
laboratory of the state government.
The engineering students V.Krishnamoorthy and C.Narayanan have both
completed their degree in Electrical Engineering. They conducted the testing program
for PDC copper die-cast motors, under Mr.Ranganathan's supervision as their final year
project.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 9
1.0 INTRODUCTION AND BACKGROUND
The motor and pump industry is vital supplier to the Indian economy,
particularly to industry and agriculture. All of industry uses pumps and motors as a vital
means of production; all of irrigated agricultural production also relies on pumps. Taking
electricity consumption as an indicator, electric motors account for more than 70% of
industrial electricity consumption, pumps account for a third of that amount, and pumps
account for all of agricultural electricity use. Pumps are also an unseen but important
aspect of domestic life, providing for water supply in homes as well as public water and
sewerage works.
Despite its vital and pervasive role in the economy, the Indian motor and pump
industry stand at a critical juncture due to increasing materials costs, suppressed demand
and depressed prices, and GOI policy that is expected to raise product quality standards,
particularly in establishing new standards and procurement requirements for energy-
efficient motors. These pressures have severely damaged some of the dominant
manufacturers in the industry and also resulted in closure of many small scale units.
The small - and medium - scale manufacturers of motors and pumps are
particularly critical to the economy, yet are more exposed to these difficulties. In 1997,
this sector supplied 43% of the total Indian Market for AC low-tension motors up to 37.5
kw, and the majority share of smaller size motors, which are the workhorses of industry.
This sector supplies more than 95% of pumps for agriculture. Most of these
manufacturers have limited product lines, no market influence, limited resources and
technical expertise, and hence have little recourse to changes in the supply and demand
dynamics of their business. The recent and expected changes include the following:
� Overall motor and pump sales have been in recession in recent years, following
an average 5% annual growth rate from 1985/86 to 1995/96. IEEMA reported
that annual production of low-tension AC motors declined from 1996/97 to
2001/02 (from 3, 023 MW to 2,566 MW, while numbers of motors remained flat
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Copper Die Cast Rotor Project, Coimbatore. 10
at 35 lakhs in both years).
� Raw material costs for motor and pump manufacturing have increased
significantly. The price of pig iron increased to Rs.11, 000 per tonne in February
2003 from Rs.9, 000 per tonne in January 2002 and today it has gone to
Rs.28, 000/tonne. The price of metallurgical coke rose to Rs.10, 000 per tonne in
February 2003 from Rs.8, 200 per tonne in January 2002 and today it has gone to
Rs.1, 800/tonne. All these with have gone up steeply further at the time of
preparing this report.
� Finished product prices for pumps and motors have not risen in the same period;
rather there is downward pressure on prices. The small and medium-scale
manufacturers are the low-cost suppliers to the market. Very few have the brand
recognition required to set prices without the risk of losing sales. In the current
market, most suppliers must cut prices to win sales, even as margins are already
razor-thin.
� GOI is in the process of establishing new standards for energy - efficient (EE)
motors, which the small-medium manufacturers are ill-positioned to meet. The
aim is to establish a market for EE motors in key economic segments, through a
program of initiatives and incentives. The largest motor manufacturers are
already able to produce motors to this standard. This situation poses a potential
lost opportunity for the small scale sector, and a potential threat of lost market
share to the large manufacturers and to foreign competition.
The developments in energy efficiency standards deserve further explanation.
Energy efficiency was established as a National priority in 2002. The GOI established
the Bureau of Energy Efficiency (BEE) to mobilize EE efforts, including the
establishment of EE standards for certain products and programs for EE improvement in
key industries, among other initiatives.
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Copper Die Cast Rotor Project, Coimbatore. 11
Motors is one of the first product categories selected for new standards, and BEE
is currently working with IEEMA, BIS, SIEMA and others to establish a motor EE
standard, compliance procedures, testing and labeling protocols, etc. for this year. The
new standard is being set according to the International definition of EFF 1, EFF2 and
etc,. Ultimately, this is expected to be a mandatory standard. BEE will establish EE
motor labeling conventions and a promotion program.
In parallel, BEE will stimulate the demand for EE motors in several important
markets via separate initiatives, aimed to set mandatory targets, create financing
incentives, and establish procurement practices that will favour EE products. For
example:
� Industry - Each of India's eleven most energy-intensive industries will have
mandatory EE improvement targets and practices. Together they comprise a
significant share of the industrial motor market, and EE motors will feature in
their compliance strategies.
� Agriculture - Utility Demand Side Management (DSM) programs are currently
in the pilot stages for EE pumpset financing programs. BEE will support
expansion of these programs to other states, and may seek to require that
government financing of pumpsets specify that EE standards are met.
� Government buildings - GOI has set 30% EE improvement targets for all
government buildings, and BEE is developing lifecycle costing procurement
practices that would favour procurement of EE motors and equipment using EE
motors.
These policies will favour the growth of EE motor manufacturers in these
markets, at the expense of producers of standard motors. If these policies are successful,
manufacturers of standard motors could be left to compete over a shrinking market
driven only by cost, while EE motor (and pump) manufacturers would expand into high
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 12
value markets.
Currently, only the large manufacturers produce EE motors. To meet the EFF 1
standard, manufacturers generally employ a range of improvements in materials,
manufacturing methods and quality control that collectively reduce the motor's losses
and boost its operating efficiency to the required standard. The improvements include
specialized steel alloys in the stator laminations, greater copper content in the stator
windings and core, improved resins and varnishing practices, better temperature control
in the baking/curing process, and overall improved attention to quality control.
While small and medium-scale manufactures could follow the same approach, their
mode of operation poses difficulties. The wide range of improvements may require an
unreasonable level of investment, and the quality control improvements may be difficult
to sustain except in the best-managed units. In this scenario, the development of the EE
motor market share provides an opportunity for only a few, and a threat for many in the
SME motor and pump cluster. However, the die-cast copper rotor may offer a solution to
this situation.
TECHNOLOGICAL OPPORTUNITY
US tests of motors using die-cast copper rotors have demonstrated reduction in
losses of 10-20% in a variety of motor sizes compared to motors using the standard, die-
cast aluminium rotors. This translates to an efficiency gain of 2-3 percent, which is
equivalent to all the efficiency gains of the past years due to improvements in materials
and manufacturing practices.
These gains are the result of a persistent effort since the 1980s to boost motor
efficiency levels in the United States. By the 1990s, improvements in materials and
manufacturing practices were achieving diminishing levels of improvements, and
National legislation had established a higher standard than EFF 1 to apply as the
minimum efficiency level at which motors could be produced and sold. Policy-makers
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Copper Die Cast Rotor Project, Coimbatore. 13
and technocrats sought to raise the bar further, which led to R&D to solve the problems
in die-casting of copper rotors. The US government and Copper Development
Association sponsored research to select a die material capable of casting mass
production-level quantities of copper rotors under the thermal stress conditions imposed
by copper's high melting temperature. By 2001, a suitable die material had been selected.
Two US manufacturers have begun commercial-level production of die-cast copper
rotors in 2003/2004, incorporate them in motor assemblies, and market the products as
super-premium motors, exceeding EFF 1 motors by several percentage points.
Perfect Die casting (PDC) of Surat, Gujarat, has developed the capability to die-
cast copper rotors in small size ranges, suitable for motors up to 7.5 hp. PDC had an
interest in copper die-casting since the early 1990s, but could not solve the metallurgical
difficulties of the process. PDC's persistence led to contact with the Copper
Development Association, which shared its research findings and manufacturing
insights. PDC began producing die-cast copper rotors in small quantities in 2002, but has
not yet found demand for the product.
This is the opportunity that the proposed project seeks to develop. Mumbai-based
International Copper Promotion Council (India) supported a small-scale test of several
PDC rotors in 2002. These motors, manufactured and incorporated into open well
submersible pumps by Jahgas Engineering of Coimbatore, showed good improvement
when the aluminium rotor was replaced by the PDC die-cast copper rotor. These first
tests demonstrated that the PDC rotors provide similar levels of performance
improvement as in the US trials. However, their limited number is not sufficient as a
basis for adoption of the technology by more manufacturers.
Coimbatore Motor and Pump Manufacturing Cluster
The pump and motor manufacturing cluster in Coimbatore accounts for nearly
50% of Indian production: about 1.4 lakhs of pumps each month. There are 1600 SSI-
registered companies in the cluster, of which about 600 are foundries that produce
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Copper Die Cast Rotor Project, Coimbatore. 14
castings for pumps and motors. The number of stable, active manufacturers of finished
pumps and motors is more than about 200.
NSIC study estimates there are 30 producers of die-cast aluminium rotors in
Coimbatore, but that they supply only 10% of the rotors used by the cluster. The
remaining rotors are purchased primarily from local traders who source them from
various Indian locations. Hence, there is opportunity for developing local capability for
copper die-casting without disrupting the existing producers, though the limited degree
of local non-ferrous die-casting capability may suggest insufficient expertise to support
technology upgradation to copper die casting. Nevertheless, most Coimbatore producers
are already purchasing rotors from outside the cluster, so the existence of a local copper
die-caster may not be necessary to their adoption of the die-cast copper rotor. These
issues will be assessed further in the market assessment component of the proposed
project.
Coimbatore manufacturers are known for their entrepreneurial aptitude, and are
rapid adopters of technology developments once the business merits are proven. For
similar reasons, energy-efficient motors have made greater market in roads in South
India than in other parts of the country. This is an apt location for the proposed project. If
the die-cast copper rotor performance tests prove the benefits of technology upgradation
in important market segments, the leading manufacturers of the cluster will adopt it, and
the others will follow quickly. This is evident in the enthusiastic support for the project
by industry associations SIEMA and CODISSIA, and in the ease with which the project
team has found manufacturer partners to participate in the project.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 15
2.0 NEED FOR THE STUDY
2.1 EXECUTIVE SUMMARY
The use of die-cast copper rotors in electric motors is a recent technological
development that has captured the attention of motor manufacturers and advocates of
energy efficiency around the world. The project is to test the performance of Indian die-
cast copper rotors toward evaluating the suitability of this technology upgrade for in
Indian market and particularly for the motor and pump manufacturing cluster of
Coimbatore.
2.2 TECHNOLOGICAL OPPORTUNITY
A copper die-cast rotor offers superior performance to the conventional,
aluminium die-cast rotor that dominates the Industry, but until recently the technology
for copper rotor die-casting has not been economical. North American demand for ever
higher efficiency levels in electric motors has lead US metallurgists to develop die
material suited to the thermal stress of die-casting at copper's high melting temperature.
One Indian manufacturer, Perfect Die-cast of Surat, has kept pace with the American
Technology developments in copper die-casting and has produced a few copper rotors
that tested positively in trials last year.
This project was conceived as it was felt necessary to prove the concept among
selected manufacturers, in fairly large numbers and in rotor sizes corresponding to the
largest markets and will results in atleast 50 energy - efficient motors operating in Indian
industry and Agriculture. The project will provide vital data in support of a subsequent
program (Phase II) for technology upgradation and market development that will benefit
the Coimbatore motor and pump industry cluster as well as similar clusters in other parts
and the Indian economy in general. The phase II concept is described at the end, under
point 7.0.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 16
2.3 CHOICE OF COIMBATORE CLUSTER
Coimbatore is one of the well known motor and pump clusters in India, with
market share of around 50% in pumpsets, and around 10% in the supply of motors for
various uses. Motors and pumps manufacture has commenced in Coimbatore with 2/3
manufacturers over 65 years ago, before which they were one of the earliest users of
motors imported from U.K. then. This is interesting considering the fact that the A.C.
motors technology has been commercialised world wide only 100 years ago.
It is estimated that about 500 motor and pump manufacturing units are in
existence in the organised sector and an equal number in the unorganised sector.
Coimbatore is well known for its small industries and dynamic entrepreneurs. Southern
Indian Engineering Manufacturer's Association (SIEMA) of Coimbatore founded in
1952 by eminent industrialists is doing an excellent work in rendering technical support
and all round help to improve quality, productivity profitability and greater contribution
to GDP of the nation. Coimbatore District small Industries Association (CODISSIA)
highly successful and well known association since 1969 has a membership of more than
4000 small scale units of all types.
Coimbatore has been identified by the Government of India as a Centre for the
implementation of Industrial cluster Development scheme for the motor and pump
industry considering all the above and the infrastructure available.
2.4 EXPECTED BENEFITS TO THE COIMBATORE MOTOR AND PUMP
CLUSTER
The technology upgrade of this project offers important potential benefits to the
Coimbatore motor and pump manufacturing cluster, which holds a high potential for the
National and International Markets. Competition is generally stiff, but has worsened as
raw material costs have increased considerably since 2002, while prices have remained
almost the same. Concurrently GOI standards for motor efficiency are being upgraded.
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Copper Die Cast Rotor Project, Coimbatore. 17
While the large market players are able to produce motors to this standard, small and
medium - scale motor producers may face difficulties and miss this opportunity to sell to
a higher value market. The die-cast copper rotor offers the following opportunities for
Coimbatore motor and pumps manufacturers.
� Production of EE motors (Eff1 standard) by small and medium - scale
manufacturers. The copper die-cast rotor alone is expected to achieve sufficient
efficiency improvement to reach Eff2 and Eff1 standards without other costly
upgrades to materials and manufacturing practices. If the small and medium -
scale sector is thus enabled to produce EE motors, compliance with GOI EE
standards become feasible on a National scale and the market would grow
rapidly.
� Reduction of manufacturing cost: Optimisation of motor and pump design
around this copper rotor's performance advantages, may allow a net reduction in
material cost, despite the higher cost of the die-cast copper rotor. Certain other
costs for aluminium rotors such as for dynamic balancing may be saved due to
the metallurgical advantages of the die-cast copper rotor. International
experience with regard to this cost reduction is about 7%.
� Creation of new, valued products: The copper rotor's performance attributes may
enable production of products for the domestic market and other products where
reduced size or enhanced performance at the same size meet a market need.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 18
3.0 PROJECT OBJECTIVES
3.1 TECHNOLOGY RELATED OBJECTIVES
The objective of the project is to assess die-cast copper rotors as a prospect for
technology upgrade to benefit producers of motors and pumps in the Coimbatore cluster.
This experience will later be used in other clusters and areas involved in manufacture of
motors and pumps. The project focuses on the performance of motors with these rotors
incorporated in the most important product types that the cluster produces. It will assess
technically the various benefits derived by replacement of rotors with die-cast copper
rotors without any design change of the slots, in the phase I. The objective in a nutshell
is to prove the feasibility, technical superiority and the durability of the end products. If
the rotors are proven to provide the benefits that are expected, this project will be a basis
for strategic development of product design by manufacturers around this improved
component that is for a strategy for technology upgrade in the cluster.
This project will lead into and support a phase 2 effort for Technology
upgradation aimed to:
1) Develop and promote product design modifications by which motor and pump
manufacturers in Coimbatore can best improve the range and competitiveness through
incorporation of CDC rotors in their products
2) Develop multiple supply sources of CDC rotors, capable of large scale
production.
3) To try and develop at least certain sizes of Industrial motors of Eff2, Eff1 and
premium efficiency levels to International standards as demonstration for encouraging
manufacturers in Coimbatore cluster and elsewhere for offering products for the
domestic and export markets.
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Copper Die Cast Rotor Project, Coimbatore. 19
3.2 MARKET RELATED OBJECTIVES
Market assessment of copper die-cast rotors will be undertaken with components
of
a) Cluster characterisation with the help of study made by NSIC on the
Coimbatore cluster.
b) Economic assessment of costs of Die-cast copper rotors under mass
production conditions.
c) Die-casting capability assessment
d) Feed back assessment from participating manufacturers and consumers
e) Market size and rate of growth assessment for die-cast copper rotors.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 20
4.0 SUMMARY OF APPROACH
4.1 PROJECT TECHNICAL APPROACH
Technical approach to the project in summary is to test die-cast copper rotors in
most common motor and pump product categories, in sufficient numbers to establish
confidence in the test results. All the rotors will be procured from Perfect Die-cast, based
on rotor designs and stampings provided by six partner manufacturers. These partner
manufacturers were selected based on the types of motors and pumpsets chosen for the
tests and the interest and co-operation expressed by them. These designs will be
unchanged from those currently used by them for aluminium or copper bar rotors. The
manufacturers will incorporate the die-cast copper rotors into motor/pump assemblies
and the project team will conduct performance tests at their respective factories in the 1st
step. A portion of the motors will be subject to more extensive series of performance
tests at the SITARC laboratory. Once these tests are complete, the motor/pumps will be
installed in a select group of consumer sites. Their performance and endurance under
working conditions will also be tested and compared to conventional products. The
project team will assess consumer and manufacturer reaction to the new products.
4.2 MANUFACTURER - PARTNERS
In April 2003, the project management team conducted a series of meetings in
Coimbatore towards developing the project technical approach, obtaining insights from
leading stake holders and commitments from manufacturers who would participate in
the project. Six manufacturing units were selected as project partners as follows.
M/s.Jaghas Engineering Produce submersible pumps for the Agricultural,
domestic and industrial markets. They are known for the high quality of products and
they participated in the earlier trials of CDC rotors in 2002.
M/s.Pilot Industries produce mini-monoblock pumps and various other sizes of
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Copper Die Cast Rotor Project, Coimbatore. 21
monoblock and jet pumpsets for the domestic market. They showed interest to
participate to examine prospects of increasing the discharge or head of its existing
pumps by using CDC rotors or possibly in developing new products.
M/s.Suguna is a leading group with a number of manufacturing units in the
cluster, producing monoblock pumps, submersible pumps, motors and various other
products for the domestic market as well as for the export markets. They are high-quality
producers with a history of early adoption of technology upgrades. They are expected to
begin production of EE motor and improved efficiency pumps as soon as BEE
establishes the efficiency and market guide lines.
M/s.Stark Motors produce 3 phase AC Industrial Motors for the Industrial
Market. Stark Motors have already established a reputation for high quality motor
performance and has supported quality testing and related technology upgrade
opportunities in co-operation with members of the project management team.
The manufacturer partners have each agreed to participate in the project in the
following manner:
� Procurement support: Provide drawings and stampings as a basis for procuring
CDC rotors from perfect die-cast. These will be according to the motor design
specifications that the manufacturers use currently in their products.
� Product Assembly: Upon being supplied with CDC rotors, the manufacturer
will assemble them into their products (motors or pumps).
� Testing support: At the manufacturing facility, the manufacturer will support
the testing procedures to be performed along with the project team - A) the
products that incorporate the CDC rotors and B) an identical number of products
of the same specification that incorporate standard rotors. The manufacturers will
provide pumps and motors selected by the project team for testing at external
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Copper Die Cast Rotor Project, Coimbatore. 22
testing laboratory such as SITARC.
� Field testing support: At the conclusion of testing, the manufacturer will assist
the project team in selection of consumers for installation of motors/pumps that
incorporate the CDC rotors, under arrangement in which the consumers agree to
field testing by the project team. It is assumed that the products shall be sold to
the consumers on terms established by manufacturers.
� Communication of project results: The test results and findings of the project
will be made public through report by the project team and shall not be
considered proprietary information for the sole benefit of the manufacturer
partners.
It is also proposed that at the commencement of the project each of the
manufacturers shall sign a memorandum of understanding with the project manager
(ICPCI), committing to these elements of participation.
4.3 SELECTED PRODUCT CATEGORIES FOR ROTOR TESTING
In consultation with manufacturer - partners the project team has selected 4
product categories in which to test the die-last copper rotors, and key motor ratings
(sizes) within those categories. The selected types and ratings represent the dominant
products that are marketed by the Coimbatore motor and pump cluster, and those
expected to benefit most from the use of die-cast copper rotors. They also cover all the
three segments of industrial, agricultural and domestic uses. The categories are described
as follows:
Industrial motors in 4 ratings - single phase 1 hp, 3 phase 2 hp, 3 hp and 5 hp
ratings - All of these motors typically use aluminum die-cast rotors and the copper die-
cast (CDC) rotors are expected to provide a significant boost in efficiency levels. The
selected motor ratings represent the largest markets for industrial motors and are
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 23
expected to provide for the greatest levels of efficiency improvement. First 2 ratings of
this category will be supported by Suguna units and the other 2 ratings by Stark Motors.
2 pole mono-block pump of 5 hp rating. This is one of the largest selling pumps
for the Agricultural market. They use Aluminium die-cast rotors most commonly and
good efficiency gains are expected from CDC rotors. Suguna will support the tests in
this category.
� Submersible pumps in 2 ratings - single phase 1 hp and 3 phase 5 hp -
submersible pumps typically use copper bar rotors based on an earlier
manufacturing technology, assembling copper bars with end rings and brazing
the copper at each end. In this case the CDC rotors might provide superior
performance with small efficiency improvements than with aluminium rotors.
These are selected for tests and they can provide ease of manufacture and
consistency apart from efficiency improvement. Single phase ratings in this
category will be supported by Jaghas Engineering and 3 phase rating by Archana
Industries (Suguna Group).
� Mini mono-block pump of 0.5 hp rating. This is a typical product used in very
large scale for water pumping in residential buildings. The existing product uses
aluminium die-cost rotor. Pilot Industries will support the tests in this category.
The project plans to test 10 CDC rotors in each of this ratings and categories.
Given the 4 categories in which there are a total of eight products, it is planned to test 80
CDC rotors.
4.4 TESTING AND CONFIRMING METHODOLOGY
All the manufacturer-partners have testing facilities in their factories for routine
and load tests which will be used for testing of all motors and pumps assembled with
CDC rotors and an equal number with their conventional rotors. This means that in each
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 24
of the rating 10 products each with CDC rotors and conventional rotors (total 20) will be
tested. From out of them, 2 each with CDC rotor and conventional rotors (total 4 in each
rating) will be selected for exhaustive testing in the neutral laboratory SITARC. Apart
from tests for efficiencies, tests will also be conducted for assessing various other
parameters like currents, torques and temperature rise etc., as CDC rotors have many
other advantages other than efficiency improvements. After the test results are confirmed
at SITARC, field tests will be conducted for confirming the endurance and also to obtain
comparative results with the conventional motors/pumps. At least one or two in each of
the 8 ratings will be field tested initially and more tests later after the products are sent
by the manufacturers to various customers.
4.5 STRATEGIC PARTNERS: SIEMA, CODISSIA, NSIC, SiTARC
The project has the support of four strategic partners that are influential in the
Coimbatore cluster, as well as the advisory support of the International Copper
Promotion Council (India) and Nexant, USAID's contractor for the Energy Conservation
and Commercialization (ECO) Project. The strategic partners and their respective roles
are described as follows.
SIEMA (Southern Indian Engineering Manufacturers' Association)
SIEMA has grown into an influential organization, and its membership is
precisely the group that may benefit most from the use of copper die-cast rotors. Its
members are manufacturers of electric motors, mono-block pump sets, submersible
pumps and other pumps, diesel engines, and other engineering products. SIEMA has
been noted for its awareness creation among members in quality control, and is currently
involved actively with BIS in the development of standards for agricultural pumpsets
and with BEE and IEEMA in the development of motor efficiency standards. SIEMA
has agreed to assist the project team with promotion and information dissemination at
the conclusion of the project, and will later be an important partner in developing a
strategy for technology upgradation in the cluster.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 25
CODISSIA (Coimbatore District Small Scale Industries Association)
CODDISSIA has offered to assist in promotion of the project results and
CODISSIA's support and advisory assistance are particularly important to the project in
terms of developing the later strategy for achieving technology transfer among the
smaller - scale units in the cluster.
NSIC (National Small Industries Corporation)
NSIC has agreed to assist the project in assessing the Coimbatore cluster as a
market for technology upgrade incorporating die-cast copper rotors. NSIC has already
conducted a market assessment of the Coimbatore motor and pump cluster, seeking
opportunities to upgrade productivity and quality levels, improve export earnings, and
improve profits. Die-cast copper rotors may offer a means to achieve some of these
objectives, and hence the project provides a confluence of objectives. The market
assessment team working in the project will coordinate closely with NSIC.
SITARC (Small Industries Testing and Research Centre)
The project will use SITARC's extensive testing facilities for the detailed
performance tests conducted in each product category. For the selected motors and
pumps, SITARC will conduct the tests on a fee basis. SITARC has a comprehensive
testing facility for motors and pumps as per the ISI standard, and is recognized by BIS.
SITARC is also recognized for its research and development activities in pumpsets, and
may offer valuable advice on the subject of how pumpsets may be redesigned to
optimize performance and cost of manufacturing, taking advantage of the performance
benefits of the die-cast cooper rotors.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 26
5.0 DETAILED APPROACH
5.1 TECHNOLOGY RELATED APPROACH
The project will be carried out step-wise in nine major activities, as described
below and portrayed in the project schedule:
� Obtain MOUs with the manufacturer – partners: The manufacturer partners
have shown enthusiasm for the project in meetings, assisted in defining the
products and ratings in which the rotors will be tested, and committed verbally to
the scope described of their role in the project. However, prior to committing
funds to purchase the rotors, the project team will prepare MOUs for the
manufacturers to sign, to be sure that the extent of respective roles are
understood and that activities may proceed without difficulties.
� Prepare drawings and stampings: The manufacturer - partners will prepare the
drawings and stampings needed by Perfect Die Cast to cast the rotors.
� Procure rotors: The project technical team will coordinate between PDC and
each manufacturer as required, and will prepare work orders and transportation
of the finished rotors. Six weeks is provided for the procurement period, because
PDC has not yet produced die-cast copper rotors in this quantity, and may
require additional time if some of the designs pose any difficulties. PDC is
expected to send the finished rotors on a continuous basis over this period, in
batches corresponding to each rotor design. This will allow the subsequent steps
to proceed for the first sets of motor pumps types.
� Assemble motors and pumps: The manufacturer - partners will assemble the
motors or pumps as the finished rotors are received. Initial testing at the
manufacturing site will begin very shortly thereafter.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 27
� Conduct testing: This is the most time consuming and costly element of the
project. As each motor / pump is assembled, the project technical team
(Mr.Ranganathan and the two engineering graduates) will conduct bench tests of
motor performance using the quality control facilities in place at the
manufacturers units. Each of the manufacturer has on-site instrumentation
required to obtain ISI certifications, which will support testing of many
performance parameters. For each category, an equal number of pump/motors
with conventional and die-cast copper rotors will be tested. These test results will
be tabulated and the product that best approximates the mean of the sample will
be sent to SITARC for more accurate and comprehensive testing using their
equipment.
� Install copper rotor units at customer premises: At least 50 of the pumps and
motors that incorporate the die-cast copper rotors are expected to be installed at
consumer premises and tested for performance in the field. This is provided that
the bench test results are positive. The manufacturer-partners will assist the
project team to select consumers who are willing to participate in the project,
understanding the each product may be considered a prototype and that they are
participating in an R&D project.
� Field testing: The installed die-cast rotor products will be tested at the consumer
premises by the project technical team and compared to tests performed on
similar, standard products.
5.2 MARKET ASSESSMENT
A market assessment of CDC rotors will also be undertaken which will have the
following components.
a) Cluster characterization with the help of NSIC who have successfully
done lot of work on Coimbatore Cluster of motor and pumps.
b) Economic assessment of costs and impact under mass production
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 28
conditions
c) Copper die-casting capability assessment - the capabilities that require
being built up and the needs that are to be met are to be assessed.
d) Market feedback assessment - feedback will be obtained and analysed
from the manufacturers - partners and the consumers participating in the
project.
5.3 PROJECT SCHEDULE
The duration of the project is planned as 6 months but as stated elsewhere in the
report, the supply of CDC rotors in time will decide the total duration. It is also planned
that the field tests will be carried out to confirm performance and endurance on each of
the ratings initially in a few sites and will be monitored further after the motors / pumps
are reached to end customer by various manufacturers in their normal course.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 29
6.0 PROJECT FINDINGS AND SUMMARY
6.1 ROTOR CONDITIONS SUMMARY
As originally anticipated there were some initial technical problems faced by
Perfect Die-cast which was subsequently over come by them and supplies completed
satisfactorily. There were delays on account of this which is reflected in the project times
schedule dealt later.
Annexure 1 (2 sheets) provide the details of number of rotor supplied in each
rating and the quantities rejected due to defects.
The over all accepted 87%.
Rejected rotor 13%
Further analysis shows that the percentage accepted is actually better to the
extent of 96%, if one item of Jaghas Engineering is removed which was in process
initially when there were some technical problems in melting, as conveyed by PDC
during discussions. This confirms that the technology adopted for CDC rotors is fairly
reliable, but only needs to be tuned for mass production.
6.2 FACTORY TEST RESULTS
After assembling and checking, exhaustive tests were conducted at the respective
manufacturing partner factories on all motors/pump assembled with CDC rotors and
equal number assembled with conventional rotors.
Annexure 2 (16 pages) detail the factory test results summary for all 8 ratings of
motor chosen for the project. This stage of the project also consumed more time than
planned as it had to be tuned with the supply of rotors and supply of other components.
There were also delays as the respective factories had market pressures of suppliers and
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 30
the tests had to be scheduled without disturbing their normal production requirements.
The tests were carried out to the full satisfactories of the team and result tabulated
illustrates the various parameters and comparative performances.
6.3 SITARC TEST RESULTS
Complete test results given by SITARC are given in the Annexure 3.
Though there are some small variations in the results both in the positive and
negative the overall performance of CDCR motors are found satisfactory and prove the
gains and performance established in factory test results.
The tests carried out in the same stator with CDCR and aluminium die-cast rotor
as given in the annexure also establish the efficiency gains and performance variations as
proved in other tests.
6.4 FIELD TEST RESULTS
Comparative field test results along with comments are given in Annexure 4 for
various ratings that are carried out. Analysing one of the tests for one of the most
common rating of 0.5 hp motor incorporated in mini-monoblock pumpset, it is seen that
the over all efficiency improvement on site conditions is 3.5% with reduction of
pumping time by 10%.
6.5 PERFORMANCE COMPARISON SUMMARY
All the bar charts detailing the comparative performance of different ratings of
motors are given in the Annexure 5.
While understanding the comparison of performance it is to be noted that the
motors are tested with copper die-cast rotors and conventional rotors without any change
in the rotor slot configuration and rotor stamping stacks. Much better results were
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 31
reported as per international experience by designing and manufacturing dedicated
designs for copper die-cast rotors.
a) Efficiency improvement in CDCR motors vary from 1.36% to 3.44%.
The improvement can be considered as 2.8% as most of the results are
around this.
b) Temperatures rise reduction in CDCR motors vary from 3.52˚C to
17.2˚C. The reduction can be taken as 7.5˚C as most of the results are
around this figure.
c) Next important dimension is slip or the variation in full load speed
or R.P.M. The reduction in slip in CDCR motors vary from 0.77% to
3.35%. The reduction can be taken as 2% reduction in slip.
d) The starting current increase is from 2.77% to 19.45%. In most of the
cases it is between 7.5% to 11%. Hence the starting current increase can
be taken as 10%.
e) Starting torque decrease is between 0% to 33.33% and the decrease can
be taken as 17%.
f) Full load current variation is seen between -1.3% to - 5.7%. Hence the
decrease of full load current can be taken as 4% as most of the figures are
around this.
g) Full load power factor changes between +1.3% to - 4.7%. As can be seen
from the bar chart most of the readings are around `0'. Hence the
variation can be taken as 0 or negligible.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 32
6.6 MARKET ASSESSMENT DETAILS
a) Cluster characterisation
Coimbatore is one of the most important motor and pump cluster in the country
with probably the first electrical motor driven pump having been manufactured here
about 65 years ago. They were users of these pumps even earlier imported from Europe.
NSIC provided lot of details of their study of the cluster and discussion were also had
with leading and experienced manufacturers in this area who provided valuable
information. Summing up details of the cluster as relevant to our project and study -
i. It has a total of around 1000 units in the organised and unorganised
sector involved in manufacture of motors and pumps and components.
ii. It caters to about 45% to 50% of motor driven clear water pumps
required by the domestic market. It caters to around 10% of the motors
market catering to industrial and other uses.
iii. When it comes to stator and rotor, more than 75% is sourced from
outside places like Bangalore, including die-casting with Aluminium.
iv. In terms of quality of manufacture and productivity, a large potential
remains to be tapped with appropriate and latest technology. Some of the
enterprising units have adopted improved technology and methods of
manufacture to tap quality conscious Indian and Export markets.
v. Government of India has also identified this motor and pump cluster for
development.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 33
b) Economic assessment of costs of rotors
Rotors costs details and weight details are given in Annexure 6. The following
are some of the obstacles in assessing economic costs of rotors under mass production
conditions.
i. Presently the technology and productivity is limited.
ii. Replacement of Al. with copper will certainly increase costs unless
dedicated products are designed by optimisation of materials.
iii. Copper prices are varying very violently at present due to market
conditions and assessment may not be realistic.
However with various details gathered and tabulated including weights and
costs, the end product price may go up by 5% to 7.5% with die-cast copper rotors in
place of conventional rotors. Along with this possible increase the efficiency
improvement and life improvements due to reduced temperature rise are to be
considered.
However it is to be noted that the purpose of the project with efficiency and
economy to be evaluated together, could be successfully attempted at the end of phase 2.
As a direction for putting to use the technical opportunity with CDC rotors,
i. Dedicated products could be planned with higher and premium efficiency
in 3 phase industrial motors, where the domestic and overseas markets
are expected to be ready to pay a better price for better performance and
efficiency.
ii. Dedicated, cost effective and reliable motors and pumps could be
produced to the cost conscious agricultural and domestic markets.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 34
c) Copper die casting capability development
In order to build up enough capacities to meet the demand that can pick up
substantially as we go along, we have had discussions with M/s.Perfect Die Cast, a few
Die-cast aluminium rotors manufacturers in Coimbatore and Bangalore as well as some
of the experts in the area of non-ferrous metals and copper melting and casting.
During ELROMA, meetings and discussion were co-ordinated with experts from
U.S. and some of the Indian Companies who were interested. With all the above
preliminary efforts the following require attention and further efforts:
i) The expertise available with PDC can produce fairly reliable CDC rotors
and PDC can be helped to improve and streamline facilities for mass
production at least to the extent of 5000 to 10000 rotors per month.
ii) The conventional melting and die-casting technology used by the
Aluminium die-cast rotor producers does not seem suitable to adopt for
copper die-casting as many efforts in this direction have failed. PDC
seems to be using only conventional method for melting of copper, but
have developed innovative method for copper die-casting which is
guarded as secret by them at present.
iii) Some of the latest methods used internationally for melting and casting
copper under controlled conditions, seem to hold some possible solutions
and one of the Indian companies has also agreed for trials. In the phase II.
We plan to pursue on this and in this direction.
iv International experience recorded is that the performance and advantages
of CDC rotors do not vary with process variables. This is a very
favourable point for proceeding with some trials as detailed in the earlier
paragraphs.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 35
d) Feed back assessment from participating manufacturers and consumers
The reaction of participating manufacturers is very positive with regard to this
technology though they have reservations about costs and availability. All of them
expressed inclination to proceed with CDCR for atleast some of their range of products
to develop energy efficient and cost effective products.
The consumers particularly the Industrial customers showed high level of
satisfaction with regard to efficiency improvements. They may be willing to pay a
nominal extra to the energy efficient products.
e) Market size and rate of growth assessment for die cast copper rotors
Historically the A.C. squirrel cage Induction motors were only invented and
manufactured initially with copper bar rotors. Aluminium die-cast rotors were a big leap
forward as it greatly helped through ease of manufacture for mass production and
consistent and durable performance. With die-cast copper rotors becoming feasible, the
entire range of A.C Squirrel cage motors of both single phase and 3 phase could adopt to
CDC rotors, if not immediately, over a period of time. In terms of over all Indian
Production as gathered from various published informations and projections, covering
both organised and unorganised sectors and covering both single phase and 3 phase
motors with pumps and loose motors for various applications (other than appliances) is
around 15 million per annum. Estimates of 3 phase motors out of this is around 3 million
with average rating of about 5 kw or 7.5 HP. Balance 12 million comprise of single
phase motors with average rating of 0.50 kw or 0.75 HP.
CDC rotors are feasible for the entire requirements. Even assuming a demand of
1 to 2% to start with, the requirements could be 2.0 lakh rotors per annum.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 36
The adoption process will solely depend on dedicated designs addressing
different performance and characteristics as well as costs, economy and the availability.
Proper projections and growth should be attempted after completion of phase II
of this project which is expected to show some more positive directions.
6.7 PROJECT TIME SCHEDULE SUMMARY
The original time schedule fixed was 6 months commencing from August 2004.
As it was felt even then, the delivery of CDC rotors will actually decide the total time
duration of this project.
Apart from more than 1 months delay in supply of CDC rotors by Perfect Die-
cast, there were also delays in the respective factories which have actually resulted in a
delay of over 2 months. The activity wise time taken is given in the chart in the next
page. There are also delays in completing field tests of the full quantity originally
planned and it has been completed with samples in each of the ratings. The project team
however hopes to keep in touch with various manufacturing partners in order to monitor
performance of more number of motors with CDC rotors going into the market.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 34
Project Schedule of various Activities
Tests Month 1
August '03
Month 2
Sept 03
Month 3
Oct 03
Month 4
Nov 03
Month 5
Dec 03
Month 6
Jan 04
Month 7
Feb 04
Month 8
March 04
1. Obtain M.O.U.s
2. Drawing preparation
3. Rotors procurement
4. Assembly of products
5. Factory testing
6. SITARC Testing
7. Field testing
8. Market Assessment
9. Reporting
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 35
6.8 OVER ALL CONCLUSIONS
The summed up findings and conclusion are given below which encourage to
proceed with phase II, which can consolidate the gains of the new technology and also
enable propagation in large scale.
i) The quality and performance of the Indian made CDC rotors are reliable
ii) The efficiency gain and losses reduction mainly due to rotor loss
reduction are appreciable
iii) The cooler motors by over 7.5˚C is encouraging
iv) The RPM increase due to slip reduction helps increase productivity and
also to design and offer better products.
v) The starting current increase is to be tackled with suitable slot design.
vi) Reduction of starting torque need not be a concern as in many
applications this reduction may not matter.
vii) Power factor remaining without any charge is also encouraging as
actually some small drop in power factor was anticipated.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 36
7.0 CONCEPTUAL APPROACH FOR PHASE II
With completion of phase I and analysis of all results and findings, very bright
prospects are seen for die-cast copper rotors to be adopted in fairly large scale in all
categories of motors for improvements of efficiencies and performance. It can contribute
to develop varieties and cost effective products as well.
� In summary it can be stated that the opportunity identified with the CDCR
Technology for opening new dimensions in the design of AC Motors is proved.
This can help to focus the Designs of AC Motors to higher efficiency levels,
different performance characteristics and even attempt cost reduction with
optimum use of materials.
� In order to move fast towards making the proven opportunity a commercial
reality, it is necessary to create awareness, appreciation and mental readiness and
need among Manufacturers, End users and the Intermediaries.
� Though it is a good point that Technical Capability is available in India, the
capacity built is small, as the demand has not yet picked. Another problem is that
the technique formulated is kept a trade secret. From broad information gathered
on the technology, it looks based on old and conventional practices with some
innovation.
� If very large demands is to be addressed which is a definite possibility, it is
necessary to identify and help build capacities and economics based on latest
methods of copper melting and casting. The possibilities are seen in making
successful trials on discussion with some of the metallurgists of companies
involved with copper and castings adopting latest technologies.
� In order to speed up the `commercial reality' process, it is also necessary to go
about evolving dedicated designs and manufacture certain ratings to demonstrate.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 37
� Both Motors for Industrial use and Pumping sets incorporating motors can be
chosen for the purpose of evolving designs for demonstration. In case of
Industrial Motors, it can be Premium Efficiency, Eff1 and Eff2 level Motors as
per Indian and International Standards performance and dimensions. In case of
pumpsets, it can be economical designs with saving of materials or designs for
higher performance.
� Some preliminary work is already being carried out about phase 2 and it will be
very effective to undertake phase 2 immediately. This can also help the
manufacturers of all sizes and capacities to meet the higher Efficiencies and
performances being formulated by BEE.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 38
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore. 39
ROTOR CONDITION REPORT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
ROTORS CONDITION REPORT
SI.NO. COMPANY
NAME
RATINGS
(ROTOR DETAILS)
QUANTITY
RECEIVED
ACCEPTED
QUANTITY
REJECTED
QUANTITY
SI. NO. OF
REJECTED
ROTOR
1 PILOT
INDUSTRIES
0.5HP/0.37kW,Mini Mono block,
1Φ (AL3,ø:54mm,CL:50mm) 9 8 1 9
2 JAGHAS ENGG.
EQUIPMENTS
1.0HP/0.75kW,
4" submersible, 1Φ (V4,ø:48mm, CL:160mm)
10 3 7 1,2,4,5,7,9,10
2HP/1.5kW, Mono block,3Φ (SC90/2P,ø:76mm,CL:85mm)
10 9 1 5
3 SUGUNA
MACHINE
WORKS (P) LTD. 5HP/3.7kW, Mono block,3Φ
(1112/2P,ø:95mm,CL:110mm) 10 9 1 8
4 SUGUNA UNIT II 1HP/0.75kW,1Φ
(161M,ø:109mm,CL:89mm) 10 10 --- ---
5 ARCHANA
INDUSTRIES
5HP/3.7kW, 6" submersible, 3Φ (V6,ø:76mm,CL:180mm)
10 10 --- ---
3HP/2.2kW,3Φ (1100/4P,ø:95mm,CL:90mm)
10 10 --- ---
6 STARK
MOTORS 5HP/3.7kW,3Φ (1112/4P,ø:109mm,CL:125mm)
8 8 --- ---
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
ROTOR CONDITION
8
3
9 9 10 10 108
1
7
1 1 0 0 0
0
0
2
4
6
8
10
12
PILOT CL:
150mm
JAGHAS
CL:160mm
SMW
CL:85mm
SMW
CL:110mm
SUGUNA
CL:89mm
ARCHANA
CL:180mm
STARK
CL:90mm
STARK
CL:125mm
NO
.OF
RO
TO
RS
ACCEPTED ROTORS REJECTED ROTORS
ACCEPTED
ROTORS
87%
REJECTED
ROTORS
13%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FACTORY TEST COMPARISON
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
SLNO.
NAME OF THE COMPANY MOTOR RATINGS PAGE NO.
1 ARCHANA INDUSTRIES
5HP/3.7kW, 6" submersible,3Φ
1
2 JAGHAS’ ENGINEERING EQUIPMENTS
1.0HP/0.75kW,4" submersible,1Φ 3
2HP/1.5kW, Mono block,3Φ
5
3 SUGUNA MACHINE WORKS (P) LTD.
5HP/3.7kW, Mono block,3Φ,
7
4 PILOT INDUSTRIES
0.5HP/0.38kW,Mini Mono block 9
5 SUGUNA INDUSTRIES UNIT II
1HP/0.75kW,1Φ
11
3HP/2.2kW,3Φ
13
6 STARK MOTORS
5HP/3.7kW,3Φ
15
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : CS30208 - DIE CAST COPPER ROTOR
MOTOR SI.NO : CS30211 - COPPER FABRICATED ROTOR
COMPANY NAME: ARCHANA INDUSTRIES.
ROTOR DETAILS: V6, øøøø:76mm, CL:180mm PLACE: COIMBATORE NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
DIE CAST Cu. 415 4.67 696 2998
Copper fabricated 415 4.50 784 2976
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
DIE CAST Cu. 415 8.52 4832 2893 76.25 0.79 3.56
Copper fabricated
415 8.96 5072 2824 72.81 0.79 5.86 100 %
Comment
about DIE
CAST Cu.
-- Current
decreases by 0.44 A
Power decreases by
240 Watts
Speed increases by
69 rpm
η increases by
3.44% --
Slip decreases by 2.30
DIE CAST Cu. 415 7.17 3728 2922 74.31 0.72 2.61 75%
Copper 415 7.27 3872 2877 71.49 0.74 4.08
MOTOR RATING: 5HP/3.7kW, 6"""" submersible, 3ΦΦΦΦ
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
fabricated
Comment
about DIE
CAST Cu.
-- Current
decreases by 0.1 A
Power decreases by
144 Watts
Speed increases by
45 rpm
η increases by
2.82%
Power factor decreases by
0.02
Slip decreases by 1.47
STARTING TORQUE: RATED TORQUE OF THE MOTOR: 11.87 N-m / 1.21 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
DIE CAST Cu. 39.60 145.24
Copper fabricated 35.51 172.98
Comment about DIE CAST
Cu. Current increases by 4.09 A Torque decreases by 30.64
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT REDUCED VOLTAGE OF 353 V ROTOR TYPE
Winding by Resistance Method
DIE CAST Cu. 18.99º C
Copper fabricated 22.61º C
Comment about Cu. Rotor Temperature rise decreases by 3.62º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : CDR1 - DIE CAST COPPER ROTOR
MOTOR SI.NO : CFR1 - COPPER FABRICATED ROTOR
MOTOR RATING : 1.0HP/0.75kW,4"""" submersible,1ΦΦΦΦ COMPANY NAME: JAGAHAS’ ENGINEERING EQUIPMENTS.
ROTOR DETAILS: V4, øøøø:48mm, CL:160mm PLACE: COIMBATORE NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
DIE CAST Cu. 240 4.70 740 2985
Copper fabricated 240 4.44 700 2983
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
DIE CAST Cu. 240 5.8 1320 2876 57..3 0.95 4.13
Copper fabricated
240 6.0 1380 2819 54.46 0.96 6.03 100 %
Comment
about Die cast
Cu.
-- Current
decreases by 0.20 A
Power decreases by
60 Watts
Speed increases by
57 rpm
η increases by
2.84%
Power factor decreases by
0.01
Slip decreases by 1.90
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE: RATED TORQUE OF THE MOTOR: 2.37 N-m / 0.24 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Copper die cast 18.5 50
Copper fabricated 18.0 50
Comment about Cu. Die cast Current increases by 0.50A --
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT RATED VOLTAGE OF 240 V ROTOR TYPE
Winding by Resistance Method
Copper die cast 11.27º C
Copper fabricated 16.0º C
Comment about Cu. Die cast Temperature rise decreases by 4.73º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 7511 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 7510 - DIE CAST Al. ROTOR
COMPANY NAME: SUGUNA MACHINE WORKS (P) LTD.
ROTOR DETAILS: SC90/2P, øøøø:76mm, CL:85mm PLACE: COIMBATORE
NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 415 2.14 264 2996
Al. 415 1.98 280 2995
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 415 3.31 1824 2949 82.54 0.77 1.70
Al. ROTOR 415 3.39 1856 2926 81.14 0.76 2.47 100 % Comment
about Cu.
Rotor
-- Current
decreases by 0.08 A
Power decreases by
32 Watts
Speed increases by
23 rpm
η increases by
1.50%
Power factor increases by
0.01
Slip decreases by 0.77
Cu. ROTOR 415 2.90 1440 2955 79.19 0.63 1.50
Al. ROTOR 415 2.91 1456 2940 77.80 0.70 1.99 75% Comment
about Cu.
Rotor
-- Current
decreases by 0.01 A
Power decreases by
16 Watts
Speed increases by
15 rpm
η increases by
1.39%
Power factor decreases by
0.07
Slip decreases by 0.49
MOTOR RATING : 2HP/1.5kW, Mono block,3ΦΦΦΦ
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE: RATED TORQUE OF THE MOTOR: 4.77 N-m / 0.486 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 31.50 406.18
Al. ROTOR 29.25 442.17
Comment about Cu. Rotor Current increases by 2.25 A Torque decreases by 35.99
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT REDUCED VOLTAGE OF 353 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 16.50º C 39.65º C
Al. ROTOR 13.50º C 36.80º C
Comment about Cu. Rotor Temperature rise increases* by 3º C Temperature rise increases* by 2.85º C
* Die cast copper rotor doesn’t have cooling fins.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 7516 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 7514 - DIE CAST Al. ROTOR
MOTOR RATING : 5HP/3.7kW, Mono block,3ΦΦΦΦ COMPANY NAME: SUGUNA MACHINE WORKS (P) LTD.
ROTOR DETAILS: 1112/2P, øøøø:95mm, CL:110mm PLACE: COIMBATORE
NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 415 2.63 320 2997
Al. 415 2.74 440 2994
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 415 6.86 4256 2947 87.09 0.86 1.35
Al. ROTOR 415 7.28 4496 2925 83.99 0.86 2.50 100 % Comment
about Cu.
Rotor
-- Current
decreases by 0.42 A
Power decreases by
240 Watts
Speed increases by
22 rpm
η increases by
3.10% --
Slip decreases by 1.15
Cu. ROTOR 415 5.43 3232 2960 85.99 0.83 1.35
Al. ROTOR 415 5.71 3408 2935 82.19 0.83 2.18 75% Comment
about Cu.
Rotor
-- Current
decreases by 0.28 A
Power decreases by
176 Watts
Speed increases by
25 rpm
η increases by
3.80% --
Slip decreases by 0.83
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE:
RATED TORQUE OF THE MOTOR: 11.87 N-m / 1.21 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 54.99 173.97
Al. ROTOR 49.80 260.95
Comment about Cu. Rotor Current increases by 5.19 Torque decreases by 86.98
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT REDUCED VOLTAGE OF 353 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 24º C 66.75º C
Al. ROTOR 35º C 80.10º C
Comment about Cu. Rotor Temperature rise decreases by 11º C Temperature rise decreases by 13.35º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 0328390 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 0328391 - DIE CAST Al. ROTOR
MOTOR RATING : 0.5HP/0.38kW,Mini Mono block, 1ΦΦΦΦ COMPANY NAME: PILOT INDUSTRIES
ROTOR DETAILS: AL3, øøøø:54mm ,CL:50mm PLACE: COIMBATORE NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 240 1.5 188 2989
Al. 240 1.44 190 2990
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 240 2.25 508 2911 76.19 0.94 2.97
Al. ROTOR 240 2.38 533 2856 72.74 0.93 5.48 100 % Comment about
Cu. Rotor -- It takes lesser
current by 0.13 A
It takes lesser power by
25 Watts
Speed increases
55rpm
It gives more η 3.45 %
Power factor increases by
0.01
Slip decreases by 2.51
Cu. ROTOR 240 1.84 404 2935 72.45 0.91 2.16
Al. ROTOR 240 1.94 429 2898 69.03 0.92 3.89 75% Comment about
Cu. Rotor -- It takes lesser
current by 0.1A
It takes lesser power
25 Watts
Speed increases 37 rpm
It gives more η 3.42 %
Power factor decreases by
0.01
Slip decreases by 1.73
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE:
RATED TORQUE OF THE MOTOR: 1.21 N-m / 0.12Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 8.21 36.48
Al. ROTOR 7 48.64
Comment about Cu. Rotor Current increases by 1.21 Torque decreases by12.16
PULL OUT TORQUE:
ROTOR TYPE % OF TORQUE
N-m
Cu. ROTOR 194.98
Al. ROTOR 172.49
Comment about Cu. Rotor It has more torque BY 22.49
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT RATED VOLTAGE OF 240 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 10º C 44.84º C
Al. ROTOR 13º C 51.93º C
Comment about Cu. Rotor Temperature rise decreases by 3º C Temperature rise decreases by 7.09º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 48822 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 42414 - DIE CAST Al. ROTOR
MOTOR RATING : 1HP/0.75kW,1ΦΦΦΦ COMPANY NAME: SUGUNA INDUSTRIES UNIT II
ROTOR DETAILS: 161M,øøøø: 109mm, CL: 89mm PLACE: KALAPATTI, COIMBATORE. NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 240 5.04 180 1498
Al. 240 4.8 180 1491
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 240 6.8 1010 1470 74.52 0.62 2.01
Al. ROTOR 240 6.9 1020 1442 73.16 0.62 3.87 100 % Comment about
Cu. Rotor -- Current decreases
by 0.1 A
Power decreases by
10 Watts
Speed increases by
28rpm
η increases by
1.36 % --
Slip decreases by 1.86
Cu. ROTOR 240 6.1 780 1475 71.34 0.53 1.69
Al. ROTOR 240 6 800 1447 70.19 0.56 3.55 75% Comment about
Cu. Rotor -- Current decreases
by 0.1A
Power decreases by
20 Watts
Speed increases by
28 rpm
η increases by
1.15 %
Power factor decreases by
0.03
Slip decreases by 1.86
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE: RATED TORQUE OF THE MOTOR: 4.77 N-m / 0.49Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 35.2 221.08
Al. ROTOR 33.5 308.49
Comment about Cu. Rotor Current increases by 1.70 Torque decreases by 87.41
PULL UP & PULL OUT TORQUE:
ROTOR TYPE % OF PULL UP TORQUE
N-m
% OF PULL OUT TORQUE
N-m
Cu. ROTOR 189.80 342.10
Al. ROTOR 307.37 413.27
Comment about Cu. Rotor Torque decreases by 117.54 Torque decreases* by 71.17
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT RATED VOLTAGE OF 240 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 25.5º C 50.50º C
Al. ROTOR 40.0º C 58.31º C
Comment about Cu. Rotor Temperature rise decreases by 14.5º C Temperature rise decreases by 7.81º C
* In this comparison, Pull out torque of Copper rotor is less.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 69083 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 69120 - DIE CAST Al. ROTOR
MOTOR RATING : 3HP/2.2kW, 3∅∅∅∅, 415 V COMPANY NAME: STARK MOTORS
ROTOR DETAILS: 1100/4P, OD: 95mm, CL: 90mm PLACE: COIMBATORE NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 415 2.57 240 1498
Al. 415 2.63 240 1496
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 415 4.48 2600 1451 85.88 0.81 3.24
Al. ROTOR 415 4.72 2660 1411 83.55 0.78 5.91 100 % Comment about
Cu. Rotor -- Current
decreases by 0.24 A
Power decreases by
60 Watts
Speed increases by
40 rpm
η increases by
2.33 %
Power factor increases by
0.03
Slip decreases by 2.67
Cu. ROTOR 415 3.73 1960 1465 84.15 0.73 2.37
Al. ROTOR 415 3.83 2040 1433 82.82 0.74 4.44 75% Comment about
Cu. Rotor -- Current
decreases by 0.1A
Power decreases 80 Watts
Speed increases by
32 rpm
η increases by
2.33 %
Power factor decreases by
0.01
Slip decreases by 2.07
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE:
RATED TORQUE OF THE MOTOR: 14 N-m / 1.43 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 26.72 242.41
Al. ROTOR 20.90 268.84
Comment about Cu. Rotor Current increases by 5.82 Torque decreases by 26.43
PULL OUT TORQUE:
ROTOR TYPE % OF TORQUE
N-m
Cu. ROTOR 408.83
Al. ROTOR 340.53
Comment about Cu. Rotor Torque increases by 68.30%
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT RATED VOLTAGE OF 415 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 30º C 57.68º C
Al. ROTOR 43º C 68.77º C
Comment about Cu. Rotor Temperature rise decreases by 13º C Temperature rise decreases by 11.09º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PERFORMANCE COMPARISON
MOTOR SI.NO : 69079 - DIE CAST COPPER ROTOR
MOTOR SI.NO : 68840 - DIE CAST Al. ROTOR
MOTOR RATING : 5HP/3.7kW,3ΦΦΦΦ, 415 V COMPANY NAME: STARK MOTORS
ROTOR DETAILS: 1112/4P, øøøø:109 mm, CL:125 mm PLACE: COIMBATORE NO LOAD TEST:
ROTOR TYPE VOLTAGE
V
CURRENT
A
POWER
W
SPEED at 50Hz
rpm
COPPER 415 3.40 300 1499
Al. 415 3.48 360 1495
LOAD TEST:
LOAD
ROTOR TYPE Voltage
V
Current
A
INPUT
POWER
W
SPEED
At 50Hz
% OF
η
POWER
FACTOR
%OF
SLIP
Cu. ROTOR 415 7.45 4344 1469 85.97 0.81 2.06
Al. ROTOR 415 7.43 4544 1429 83.01 0.85 4.71 100 % Comment
about Cu.
Rotor
-- Current
increases by 0.02 A
Power decreases by
200 Watts
Speed increases by
40 rpm
η increases by
2.96 %
Power factor
DECREASES by 0.04
Slip decreases by 2.65
Cu. ROTOR 415 5.90 3280 1473 85.54 0.78 1.78
Al. ROTOR 415 5.88 3400 1443 82.56 0.80 3.81 75% Comment
about Cu.
Rotor
-- Current
increases by 0.02A
Power decreases by
120 Watts
Speed increases by
30rpm
η increases by
2.98 %
Power factor decreases by
0.02
Slip decreases by 2.03
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
STARTING TORQUE: RATED TORQUE OF THE MOTOR: 23.75 N-m / 2.42 Kg-m
ROTOR TYPE CURRENT
A
% OF TORQUE
Cu. ROTOR 39.11 168.37
Al. ROTOR 32.74 205.21
Comment about Cu. Rotor Current increases by 6.37 Torque decreases by 36.84
PULL OUT TORQUE:
ROTOR TYPE % OF TORQUE
N-m
Cu. ROTOR 350.73
Al. ROTOR 294.16
Comment about Cu. Rotor torque increases by 56.57
TEMPERATURE RISE TEST:
TEMPERATURE RISE AT RATED VOLTAGE OF 415 V ROTOR TYPE
Core by Thermo meter Method Winding by Resistance Method
Cu. ROTOR 30º C 61.78º C
Al. ROTOR 32º C 68.93º C
Comment about Cu. Rotor Temperature rise decreases by 2º C Temperature rise decreases by 7.15º C
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
SITARC TEST REPORT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 1
MOTOR RATING : 0.5 HP/0.37kW, 1φ, 240 V, Mini Monoblock MOTOR NUMBER : A-5 Al. ROTOR C-8 Cu. ROTOR MANUFACTURE NAME : PILOT INDUSTRIES, 14-B, Valluvar Nagar, Lakshmipuram, Coimbatore – 641 004.
� 0422-2591822, 2598913
INSTALED DATE : 02/03/04 FIELD LOCATION : Mr.Senthil kumar,
Venkata lakshmi nagar, Thanneer pandal road, Coimbatore – 641 004.
� 0422-2512972
FIELD CONDITION (Apprx. values) :
� Tank size : 1.20 × 1.88 × 0.60 m3
� Suction head : 2.50 m
� Delivery head : 7.50 m
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA Al. ROTOR
MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 0.5 HP/0.37kW 0.5 HP/0.37kW --
DATE 02/03/04 02/03/04 --
VOLTAGE 238 V 237 V --
CURRENT 1.8 A 1.7 A Current
decreases by 0.1 A
INPUT WATTS 0.37 kW 0.35 kW Power decreases
by 0.02 kW
POWER FACTOR
0.863 0.848 Power factor decreases by
0.015
FREQUENCY 49.7 Hz 49.4 Hz --
TANK CAPACITY 1353.6 lit. 1353.6 lit. --
TIME TAKEN 32 Min 50 Sec 29 Min 51 Sec Time decreases by 2 Min 59 Sec
DISCHARGE 0.687 lps 0.755 lps Discharge
increases by 0.068 lps
kWh 0.201 0.174 kWh decreases by 0.027 kWh
OVER ALL EFFICIENCY
18.20 %
21.70 %
Over all efficiency increases by
3.50%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 2
MOTOR RATING : 1.0 HP/0.75kW, 4" Submersible, 1φ, 240 V
PUMP DETAIL : 10 Stage, Cup type
(Same Pump for both the Motors)
MANUFACTURE NAME : JAGHAS’ ENGINEERING EQUIPMENTS,
Ammankulam Road, P.N.Palayam,
Coimbatore – 641 037.
� 0422-2211443, 2216144, 2216288
INSTALED DATE : 04/03/04
FIELD LOCATION : Ms. Jayalakshmi,
204-B, “Sastha Vihar”,
Text tool Layout,Singanallur,
Coimbatore – 641 005.
� 0422-2577575
FIELD CONDITION :
� Tank size : (1.85 ×1.17× 0.68) m3 + (1.85 × 0.96 × 0.68)
m3
� Delivery head : 35 m
� Water level : 8 m
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA COPPER
FABRICATED ROTOR MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 1 HP/0.75kW 1HP/0.75kW --
DATE 04/03/04 04/03/04 --
VOLTAGE 228.5 v 227 V --
CURRENT 6.8 A 6.5 A Current
decreases by 0.3 A
INPUT WATTS 1.44 kW 1.34 kW Power decreases
by 0.1 kW
POWER FACTOR
0.928 0.908 Power factor decreases by
0.02
FREQUENCY 49.10 Hz 49.4 Hz --
TANK CAPACITY 2,679.54 lit 2,679.54 lit --
TIME TAKEN 49 Min 42 Sec 37 Min 54 Sec Time decreases
by 11 Min 48 Sec
DISCHARGE 0.898 lps 1.178 lps Discharge
increases by 0.28 lps
kWh 1.169 0.838 kWh decreases by 0.331 kWh
OVER ALL EFFICIENCY
22.0 % 31.02 % Over all efficiency
increases by 9.02%
Note: The huge efficiency improvement is due to the existing older fabricated copper rotor motor.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 3
MOTOR RATING : 1.0 HP/0.75kW, 4” Submersible, 1φ, 240 V
PUMP DETAIL : 10 Stage, Cup type
(Same Pump for both the Motors)
NAME OF THE COMPANY: JAGHAS’ ENGINEERING EQUIPMENTS,
Ammankulam Road, P.N.Palayam,
Coimbatore – 641 037.
� 0422-2211443, 2216144, 2216288
INSTALLED DATE : 25/03/04
FIELD LOCATION : Mr. Suresh,
Kalapatti road,
Coimbatore – 641 035.
FIELD CONDITION :
� Tank size : (0.78 × 0.78× 0.83) m3
� Delivery head : 46 m
� Water level : 8 m
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA COPPER
FABRICATED ROTOR MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 1 HP/0.75kW 1HP/0.75kW --
DATE 25/03/04 25/03/04 --
VOLTAGE 220.7 v 232.9 V --
CURRENT 6.2 A 6.1 A Current
decreases by 0.1 A
INPUT WATTS 1.33 kW 1.36 kW Power increases
by 0.03 kW
POWER FACTOR
0.954 0.945 Power factor decreases by
0.09
FREQUENCY 49.3 Hz 49.4 Hz --
TANK CAPACITY 505 lit 505 lit --
TIME TAKEN 10 Min 9 Sec 8 Min 40 Sec Time decreases by 1 Min 29 Sec
DISCHARGE 0.898 lps 0.971 lps Discharge
increases by 0.073 lps
kWh 0.221 0.192 kWh decreases by 0.029 kWh
OVER ALL EFFICIENCY
28.72 % 32.89 % Over all efficiency
increases by 4.17%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 4
MOTOR RATING : 1 HP/0.75kW, 1φ, 240 V MOTOR NUMBER : 508973 - Al. ROTOR 509377 - Cu. ROTOR NAME OF THE COMPANY: SUGUNA INDUSTRIES UNIT II Kalapatti Road,, Coimbatore – 641 035.
� 0422-2591822, 2598913
INSTALLED DATE : 27/03/04 FIELD LOCATION : 37, SIDCO,
Coimbatore – 641 021.
� 0422-2673293 FIELD CONDITION (Apprx. values) :
� Application type : Compressor
� Tank size : 25 lit
� Pressure : 10 Kg
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA Al. ROTOR
MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 1HP/0.75kW 1 HP/0.75kW --
DATE 27/03/04 27/03/04 --
VOLTAGE 231.4 V 235.6 V --
CURRENT 6.5 A 6.6 A Current increases
by 0.1 A
INPUT WATTS 0.90 kW 0.86 kW Power decreases
by 0.04 kW
POWER FACTOR 0.594 0.559 Power factor
decreases by 0.035
FREQUENCY 49.1 Hz 49.2 Hz --
TANK CAPACITY 25 lit. 25 lit. --
TIME TAKEN TO DEVELOP A
PRESSURE OF 10 Kg 6 Min 8 Sec 6 Min 1 Sec
Time decreases by 7 Sec
kWh 0.084 0.080 kWh decreases by
0.004 kWh
ENERGY CONSUMED IN 15 Min FOR MAINTAINING A
PRESSURE OF 10 Kg
0.222 kWh
0.212 kWh
kWh decreases by 0.010 kWh
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 5
MOTOR RATING : 2.0 HP / 1.5kW, 3-φ, 415 V, Monoblock.
MOTOR NUMBER : A1 - Al. ROTOR C1 - Cu. ROTOR
NAME OF THE COMPANY: SUGUNA MACHINE WORKS (P) Ltd.,,
Vizhankurichi, Thaneer pandal road,
Peelamedu,
Coimbatore – 641 004.
� 0422-2512711
INSTALLED DATE : 28/03/04
FIELD LOCATION : Mehala Towers,
36, Harvey Road,
Tirupur – 641 602,
� 0421-2203880
FIELD CONDITION :
� Tank size : 2000 lit
� Delivery head : 25 m
� Suction head : 2 m
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA DIE CAST
ALUMINIUM ROTOR MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 2 HP/1.5kW 2HP/1.5kW --
DATE 28/03/04 28/03/04 --
VOLTAGE 445.67 v 462.17 V --
CURRENT 3.87 A 3.7 A Current
decreases by 0.17 A
INPUT WATTS 2.171 kW 2.413 kW Power increases
by 0.242 kW
POWER FACTOR
0.727 0.815 Power factor increases by
0.088
FREQUENCY 49.30 Hz 49.20 Hz --
TANK CAPACITY 2000 lit 2000 lit --
TIME TAKEN 16 Min 33 Sec 13 Min 43 Sec Time decreases by 2 Min 50 Sec
DISCHARGE 2.01 lps 2.43 lps Discharge
increases by 0.42 lps
kWh 0.5988 0.551 kWh decreases by 0.0478 kWh
OVER ALL EFFICIENCY
24.5 % 26.65 % Over all efficiency
increases by 2.15%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 6
MOTOR RATING : 5.0 HP / 3.7kW, 3-φ, 415 V, Monoblock.
MOTOR NUMBER : A2 - Al. ROTOR C3 - Cu. ROTOR
NAME OF THE COMPANY: SUGUNA MACHINE WORKS (P) Ltd.,,
Vizhankurichi, Thaneer pandal road,
Peelamedu,
Coimbatore – 641 004.
� 0422-2512711
INSTALLED DATE : 03/04/04
FIELD LOCATION : 37, Pappampatti,
Palani – 624 621.
� 04545-260324
FIELD CONDITION :
� Tank size : 10000 lit
� Delivery head : 3 m
� Suction head : 7 m
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA DIE CAST
ALUMINIUM ROTOR MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
RATING 5 HP/3.7kW 5HP/3.7kW --
DATE 03/04/04 03/04/04 --
VOLTAGE 377.5 v 389 V --
CURRENT 7.0 A 6.7 A Current
decreases by 0.3 A
INPUT WATTS 3.77 kW 3.86 kW Power increases
by 0.09 kW
POWER FACTOR
0.824 0.855 Power factor increases by
0.031
FREQUENCY 49.60 Hz 49.50 Hz --
TANK CAPACITY 10000 lit 10000 lit --
TIME TAKEN 14 Min 14 Sec 12 Min 52 Sec Time decreases by 1 Min 22 Sec
DISCHARGE 11.71 lps 12.93 lps Discharge
increases by 1.22 lps
kWh 0.894 0.824 kWh decreases
by 0.07 kWh
OVER ALL EFFICIENCY
30.45 % 32.84 % Over all efficiency
increases by 2.39%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD TEST REPORT- 7
MOTOR RATING : 5 HP / 3.7kW, 3φ, 415 V MOTOR NUMBER : A1 - Al. ROTOR C1 - Cu. ROTOR NAME OF THE COMPANY: STARK MOTORS Kalapatti, Coimbatore – 641 035.
� 0422-2627672, 2627612
INSTALLED DATE : 08/04/04 FIELD LOCATION : Saranya textiles,
Thaneer pandal road, Coimbatore – 641 004.
� 0 98422 50596 FIELD APPLICATION TYPE: Doffing
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FIELD PERFORMANCE COMPARISON
DATA Al. ROTOR
MOTOR
DIE CAST COPPER
ROTOR MOTOR COMMENT
VOLTAGE 347.3 V 344.7 V --
CURRENT 3.7 A 3.73 A Current
increases by 0.03 A
INPUT WATTS 1.87 kW 1.62 kW Power
decreases by 0.25 kW
POWER FACTOR 0.840 0.727 Power factor decreases by
0.113
FREQUENCY 49.5 Hz 49.5 Hz --
ENERGY CONSUMED IN ONE HOUR
1.95 kWh
1.68 kWh
kWh decreases by 0.27 kWh
ENERGY CONSUMED IN A YEAR @ 24
Hrs/Day 17082 kWh 14716.8 kWh
kWh decreases by 2365.2 /
year
Cost / Year @ Rs. 4.95 / kWh
Rs.84555.90 Rs.72548.20 Net saving per
year is Rs. 12007.70
INITIAL MOTOR COST Rs.6857.00 Rs.7567.00 Cost increases by Rs.710.00
PAYBACK PERIOD of EXTRA INVESTMENT
@ Rs. 4.95/ kWh ---- 23 days ---
PAYBACK PERIOD FOR THE CAPITAL
COST ---
236 Days (Apprx. 8 months)
---
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
BAR CHART DETAILS
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
EFFICIENCY COMPARISON
0.5 HP MONOBLOCK
45.3
56.5
63.1
48.2
59.7
66.5
40
45
50
55
60
65
70
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
5 HP STARK MOTORS
84.8
86.3 8685.6
87.3 87.4
75
77
79
81
83
85
87
89
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
3 HP STARK MOTORS
82.6
86.3 8685.6
87.3 87.4
75
77
79
81
83
85
87
89
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
5 HP MONOBLOCK
82.5
85.386
85.2
87.788.6
75
77
79
81
83
85
87
89
91
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
2 HP MONOBLOCK
75.6
81
83.1
75.9
81.3
83.5
75
76
77
78
79
80
81
82
83
84
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
1 HP SUBMERSIBLE MOTORS
36.5
48.5
54.7
37.2
50.6
59.1
30
35
40
45
50
55
60
65
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
Copper fabricated rotor Copper die cast rotor
5 HP SUBMERSIBLE MOTORS
71.6
75.877.2
74.1
78.579.8
60
65
70
75
80
85
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
Copper fabricated rotor Copper die cast rotor
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
1 HP SUGUNA MOTORS
62.964.9
68.7
60.5
64.9
70.2
50
55
60
65
70
75
50 % LOAD 75 % LOAD 100 % LOAD
EF
FIC
IEN
CY
(%)
ALUMINIUM ROTOR COPPER ROTOR
PERFORMANCE COMPARISON
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
NO LOAD CURRENT VARIATIONS IN %
8
-4.01
2.29 2.28
53.77
-5.85
-1.94
-8
-6
-4
-2
0
2
4
6
8
10
0.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB
% V
AR
IAT
ION
� Here the negative percentage indicates that the copper rotor motor draws
lesser current than the aluminium rotor motor at no load condition.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
No load current variation
In % -4.01% to +8% -5.85 % to +3.77%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
� Here the negative percentage indicates that the power consumed by the copper
rotor motor is lesser than the aluminium rotor motor at no load condition.
� Zero percentage indicates that the power input for aluminium rotor and copper rotor motor are same.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
No load input power
variation In % 0% to -27.27% -11.22 % to +5.71%
NO LOAD INPUT POWER VARIATION CHART
-27.27
-16.66
0 0
-11.22
5.71
-5.71-4.84
-30
-25
-20
-15
-10
-5
0
5
10
0.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB
% V
AR
IAT
ION
IN
NO
LO
AD
PO
WE
R IN
PU
T
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
Full load current variation
In % -5.7% to -1.3% -4.91 % to -3.33%
FULL LOAD CURRENT VARIATION CHART
-5.46
-2.35
-5.7
-1.31
-3.53
-1.3
-4.91
-3.33
-6
-5
-4
-3
-2
-1
00.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP
SUB
1 HP
SUB
% D
EC
RE
AS
E I
N F
UL
L L
OA
D C
UR
RE
NT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
Full load slip variation
In % -3.35% to -0.77% -2.3 % to -1.9%
FULL LOAD SLIP VARIATION CHART
-2.51
-0.77
-3.35
-1.86
-2.3
-1.9
-2.65
-1.15
-4
-3.5
-3
-2.5
-2
-1.5
-1
-0.5
00.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB
% D
EC
RE
AS
E O
F S
LIP
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
% Variation in full load
power factor -4.7% to +1.3% 0 % to -1.04%
FULL LOAD POWER FACTOR VARIATION CHART
1.3
0
-4.7
0.24 0 0
-1.04-0.7
-5
-4
-3
-2
-1
0
1
2
0.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB
% V
AR
IAT
ION
IN
FU
LL
LO
AD
PO
WE
R F
AC
TO
R
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
% Variation in starting
current 3.72% to 19.45% 2.77 % to 11.51%
STARTING CURRENT VARIATION CHART
7.5 7.6910.42
19.45
3.725.07
11.51
2.77
0
5
10
15
20
25
0.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB% IN
CR
EA
SE
IN
ST
AR
TIN
G C
UR
RE
NT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
% Variation in starting
torque -33.33% to -8.14% 0 % to -17.71%
STARTING TORQUE VARIATION CHART
-25
-8.14
-33.33
-17.95-15.13
-28.33
-17.71
0
-35
-30
-25
-20
-15
-10
-5
00.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP
SUB
1 HP
SUB
% D
EC
RE
AS
E I
N S
TA
RT
ING
TO
RQ
UE
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
PULL UP TORQUE VARIATION CHART
-25.6
-9.94-12.14
-38.24-45
-40
-35
-30
-25
-20
-15
-10
-5
00.5 HP MONO
BLOCK
5 HP STARK 3 HP STARK 1 HP SUGUNA
% D
EC
RE
AS
E I
N P
UL
L U
P T
OR
QU
E
PULL OUT TORQUE VARIATION CHART
5.7
2
-17.22
-7.5
-20
-15
-10
-5
0
5
10
0.5 HP MONO
BLOCK
5 HP STARK 3 HP STARK 1 HP SUGUNA
VA
RIA
TIO
N O
F P
UL
L O
UT
TO
RQ
UE
IN
%
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
Aluminium die cast to
copper die cast
Copper fabricated to
copper die cast
Degree Variation in
temperature rise -17.2 ˚ C to +0.4˚ C -4.73˚ C to -3.52˚ C
TEMPERATURE RISE VARIATON CART
-7.09
0.4
-5.2-7.15
-17.2
-3.52-4.73
-7.81
-20
-15
-10
-5
0
5
0.5 HP
MONO
BLOCK
2 HP
MONO
BLOCK
5 HP
MONO
BLOCK
5 HP
STARK
3 HP
STARK
1 HP
SUGUNA
5 HP SUB 1 HP SUB
DE
GR
EE
VA
RIA
TIO
N IN
TE
MP
ER
AT
UR
E R
ISE
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
ROTOR WEIGHT AND COST REPORT
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
ROTOR WEIGHT REPORT
Al ROTOR
DIE CAST COPPER
ROTOR
SI..
NO.
COMPANY
NAME
RATINGS
(ROTOR DETAILS)
ROTOR
STAMPING
WEIGHT
Kg.
Al. WEIGNT
(Approx.)
Kg.
ROTOR
WEIGHT
Kg.
Cu.
WEIGHT
(Approx.) Kg.
ROTOR
WEIGHT
Kg.
1 PILOT
INDUSTRIES
0.5HP/0.38kW,Mini Mono
block, 1Φ (AL3,ø:54mm,CL:50mm)
0.583 0.132 0.715* 0.337 0.920**
2 JAGHAS ENGG.
EQUIPMENTS
1.0HP/0.75kW,4"
submersible,1Φ (V4,ø:48mm, CL:160mm)
0.867 0.509
(cu. Fabricated) 1.376 0.522 1.389
2HP/1.5kW, Mono block,3Φ (SC90/2P,ø:76mm,CL:85mm)
2.000 0.400 2.400* 1.051 3.051**
3 SUGUNA
MACHINE
WORKS (P) LTD. 5HP/3.7kW, Mono block,3Φ,
(1112F/2P,ø:95mm,CL:110mm) 3.700 0.850 4.550* 2.126 5.826**
4 SUGUNA UNIT II 1HP/0.75kW,1Φ
(161M,ø:109mm,CL:89mm) 4.600 0.500 5.200** 1.300 5.900**
5 ARCHANA
INDUSTRIES
5HP/3.7kW, 6" submersible,3Φ (V6,ø:73mm,CL:180mm)
2.466 1.404
(cu. Fabricated) 3.870 1.789 4.255
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
* Rotors with cooling fins
** Rotors without cooling fins
ROTORS COST REPORT
AL / FABRICATED Cu.
ROTOR MOTOR
DIE CAST COPPER ROTOR
MOTOR
SI.NO. COMPANY
NAME
RATINGS
(ROTOR DETAILS) Die cast Charges
for Al Rotor
(Material Cost
inclusive)
Price
Of the
Motor
Die cast Charges
for Cu Rotor as
per PDC - Surat
(Material cost
inclusive)
Price
Of the
Motor
1 PILOT
INDUSTRIES
0.5HP/0.38kW,Mini Mono block,
1Φ (AL3,ø:54mm,CL:50mm) 27.00 1680.00 300.00 1953.00
2 JAGHAS ENGG.
EQUIPMENTS
1.0HP/0.75kW,
4" submersible, 1Φ (V4,ø:48mm, CL:160mm)
128.00 6640.00 639.00 7151.00
2HP/1.5kW, Mono block,3Φ (SC90/2P,ø:76mm,CL:85mm)
60.00 5860.00 695.00 6495.00
3 SUGUNA
MACHINE
WORKS (P) LTD. 5HP/3.7kW, Mono block,3Φ
(1112/2P,ø:95mm,CL:110mm) 129.00 7710.00 779.00 8360.00
3HP/2.2kW,3Φ (1100/4P,ø:95mm,CL:90mm)
3.450 0.500 3.950* 1.450 4.900**
6 STARK
MOTORS 5HP/3.7kW,3Φ (1112/4P,ø:109mm,CL:125mm)
6.230 0.870 7.100* 2.970 9.200**
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
4 SUGUNA UNIT II 1HP/0.75kW,1Φ
(161M,ø:109mm,CL:89mm) 82.50 4250.00 820.00 4987.50
5 ARCHANA
INDUSTRIES
5HP/3.7kW, 6" submersible, 3Φ (V6,ø:76mm,CL:180mm)
345.00 12900.00 804.00 13359.00
3HP/2.2kW,3Φ (1100/4P,ø:95mm,CL:90mm)
102.50 5192.00 797.00 5886.50
6 STARK
MOTORS 5HP/3.7kW,3Φ (1112/4P,ø:109mm,CL:125mm)
159.00 6857.00 869.00 7567.00
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
FEEDBACK FROM MANUFACTURER-
PARTNERS
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
International Copper Promotion Council (India)
Copper Die Cast Rotor Project, Coimbatore.
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