development and testing of die cast copper

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



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



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



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



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



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.



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.



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



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.



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



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



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



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.



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.



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.



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.



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.



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.



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



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



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



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



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.



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.



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.



� 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



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.



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



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



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.



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.



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.



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.



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.



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.



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



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.



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.



� 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.



ROTOR CONDITION REPORT


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 --- ---



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%



FACTORY TEST COMPARISON



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



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



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


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




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%


0.01





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 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




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


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%


0.07


MOTOR RATING : 2HP/1.5kW, Mono block,3ΦΦΦΦ




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



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.






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% --


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% --




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




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






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 %


0.01


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 %


0.01




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












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


Cu. Rotor -- Current decreases

by 0.1 A

Power decreases by

10 Watts

Speed increases by

28rpm

η increases by

1.36 % --


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 %


0.03




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


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




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.






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


Cu. Rotor -- Current

decreases by 0.24 A

Power decreases by

60 Watts

Speed increases by

40 rpm

η increases by

2.33 %


0.03


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 %


0.01




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


PULL OUT TORQUE:


N-m

Cu. ROTOR 408.83

Al. ROTOR 340.53

Comment about Cu. Rotor Torque increases by 68.30%












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


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 %


0.02





ROTOR TYPE CURRENT

A

% OF TORQUE

Cu. ROTOR 39.11 168.37

Al. ROTOR 32.74 205.21


PULL OUT TORQUE:


N-m

Cu. ROTOR 350.73

Al. ROTOR 294.16

Comment about Cu. Rotor torque increases by 56.57









SITARC TEST REPORT



FIELD TEST REPORT



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



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%




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,


� 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




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 --


decreases by 0.3 A


by 0.1 kW

POWER FACTOR


0.02


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




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.




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,


� 0422-2211443, 2216144, 2216288

INSTALLED DATE : 25/03/04

FIELD LOCATION : Mr. Suresh,

Kalapatti road,


FIELD CONDITION :

� Tank size : (0.78 × 0.78× 0.83) m3


� Water level : 8 m




DATA COPPER

FABRICATED ROTOR MOTOR

DIE CAST COPPER

ROTOR MOTOR COMMENT


DATE 25/03/04 25/03/04 --

VOLTAGE 220.7 v 232.9 V --


decreases by 0.1 A

INPUT WATTS 1.33 kW 1.36 kW Power increases

by 0.03 kW

POWER FACTOR


0.09


TANK CAPACITY 505 lit 505 lit --





OVER ALL EFFICIENCY


increases by 4.17%




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,


� 0422-2673293 FIELD CONDITION (Apprx. values) :

� Application type : Compressor

� Tank size : 25 lit

� Pressure : 10 Kg




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


by 0.04 kW

POWER FACTOR 0.594 0.559 Power factor

decreases by 0.035


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




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,


� 0422-2512711


FIELD LOCATION : Mehala Towers,

36, Harvey Road,

Tirupur – 641 602,

� 0421-2203880

FIELD CONDITION :



� Suction head : 2 m




DATA DIE CAST

ALUMINIUM ROTOR MOTOR

DIE CAST COPPER

ROTOR MOTOR COMMENT


DATE 28/03/04 28/03/04 --

VOLTAGE 445.67 v 462.17 V --


decreases by 0.17 A


by 0.242 kW

POWER FACTOR

0.727 0.815 Power factor increases by

0.088







OVER ALL EFFICIENCY


increases by 2.15%




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,


� 0422-2512711


FIELD LOCATION : 37, Pappampatti,

Palani – 624 621.

� 04545-260324

FIELD CONDITION :



� Suction head : 7 m




DATA DIE CAST

ALUMINIUM ROTOR MOTOR

DIE CAST COPPER

ROTOR MOTOR COMMENT


DATE 03/04/04 03/04/04 --

VOLTAGE 377.5 v 389 V --


decreases by 0.3 A


by 0.09 kW

POWER FACTOR

0.824 0.855 Power factor increases by

0.031






kWh 0.894 0.824 kWh decreases

by 0.07 kWh

OVER ALL EFFICIENCY


increases by 2.39%




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




DATA Al. ROTOR

MOTOR

DIE CAST COPPER

ROTOR MOTOR COMMENT

VOLTAGE 347.3 V 344.7 V --


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


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)

---



BAR CHART DETAILS



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



5 HP STARK MOTORS

84.8

86.3 8685.6

87.3 87.4

75

77

79

81

83

85

87

89


EF

FIC

IEN

CY

(%)


3 HP STARK MOTORS

82.6

86.3 8685.6

87.3 87.4

75

77

79

81

83

85

87

89


EF

FIC

IEN

CY

(%)




5 HP MONOBLOCK

82.5

85.386

85.2

87.788.6

75

77

79

81

83

85

87

89

91


EF

FIC

IEN

CY

(%)


2 HP MONOBLOCK

75.6

81

83.1

75.9

81.3

83.5

75

76

77

78

79

80

81

82

83

84


EF

FIC

IEN

CY

(%)




1 HP SUBMERSIBLE MOTORS

36.5

48.5

54.7

37.2

50.6

59.1

30

35

40

45

50

55

60

65


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


EF

FIC

IEN

CY

(%)

Copper fabricated rotor Copper die cast rotor



1 HP SUGUNA MOTORS

62.964.9

68.7

60.5

64.9

70.2

50

55

60

65

70

75


EF

FIC

IEN

CY

(%)





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%



� 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.


copper die cast


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




copper die cast


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




copper die cast


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




copper die cast


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




copper die cast


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




copper die cast


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



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

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copper die cast


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



ROTOR WEIGHT AND COST REPORT



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


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**


(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



* 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


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


6.230 0.870 7.100* 2.970 9.200**




(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


159.00 6857.00 869.00 7567.00



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development and testing of die cast copper

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