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Optimization of Motor Design: Material Cost

Reductions in weight and manufacturing costs have turned out to be supplementary benefits of optimization for the copper rotor.

Material mass comparison of motors optimized for same EPACT electrical efficiency.

Example 1. Power = 5.5 kW efficiency = 89.6%
Rotor conductor Al Cu
Stator + rotor steel
final kg / starting kg 		34.5 / 45.9 27 / 35.9
Stator winding kg 7.3 4.4
Rotor cage kg 2.0 3.6
Total copper kg 7.3 8.0
7.5 / 10 kg less steel 0.7 kg more copper
Example 2. Power = 11 kW efficiency = 91.1%
Rotor conductor Al Cu
Stator + rotor steel
final kg / starting kg 		54.5 / 72.7 43 / 57.3
Stator winding kg 10.2 8.7
Rotor cage kg 3.0 5.9
Total copper kg 10.2 14.6
11.5 / 15 kg less steel 4.4 kg more copper