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Copper-rotor induction-motor: Strong alternative to rare earth motors for EV traction Malcolm Burwell SAE 2012 Powertrain Electric Motors Symposium for Electric and Hybrid Vehicles Detroit – 23 April 2012
The challenge for electric traction motors: Rare earth cost-levels and cost-volatility
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 2
Source: metal-pages.com, Kidela Capital
0
500
1000
1500
2000
2500
3000
Ne Oxide Dy Oxide
Neodymium Oxide
Dysprosium Oxide
Copper (for reference)
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Permanent Magnet Motor Materials (“rare earths”)
$1200/kg
$130/kg $7/kg
$ per kg
Copper rotor induction motor history
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 3
1990 2000 2005 2010 2012 2013
Die-casting of copper rotors Fabrication of copper rotors
Vehicles with copper rotors
Rotor manufacturing
Tier-1 suppliers
Performance/cost analysis: Two similar HEV motors
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 4
Comparison of Different Motor Design Drives for Hybrid Electric Vehicles
Motor Design Ltd. – 2011 – Popescu et al
Permanent Magnet Motor
Copper Rotor Induction Motor
Outer stator diameter 269mm 269mm Outer rotor diameter 161mm 180mm Axial core length 84mm 84mm Active material weight 30kg 35kg RMS line voltage @ 6000rpm 544V 600V
Toyota Prius with THS II (PM) motor
Efficiency <80% 80-90% 90-92% 92-95% 95-96%
Torque (Nm) Torque (Nm)
Speed (rpm) Speed (rpm)
Copper rotor induction motor
400
560
60 60 600 600 5000 5000
Performance/cost analysis: The two HEV motors perform similarly
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 5
Comparison of Different Motor Design Drives for Hybrid Electric Vehicles
Motor Design Ltd. – 2011 – Popescu et al
Peak power 50kW
Peak power 82kW
Permanent magnet motor (Prius THS II)
Performance/cost analysis: The permanent magnet motor costs more
Cost of active materials (magnets, copper, iron) in each HEV motor
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 6
Permanent magnet motor (Prius THS II)
Copper rotor induction motor
2008 $242 $129 2012 $763 $146
Comparison of Different Motor Design Drives for Hybrid Electric Vehicles
Motor Design Ltd. – 2011 – Popescu et al 2012 updates from metal-pages.com
Manufacturing – fabricated rotor
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 7
Components - Assemble - Induction braze - Bead blast - Balance
End rings & brazing paste
Rotor bars
Laminations
Manufacturing – die cast rotor
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 8
Components - Die cast - Quench - Balance
Copper pellets
Die tooling
Laminations
Today’s supply chain resources
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012
Remy (US) Fukuta (TW) Ramco (US)
AC Propulsion (US) Tesla Motors (US) Hyosung (KR) Yulon (TW)
Akashi (JP) Vforge (US) Favi (FR) Kienle + Spiess (DE) THT (US) Yunnan Copper Die- casting (CN)
MIT (US) Motor-Design (UK) WEMPEC (US)
Rotor Casting
EV Motor Manufacturing
Rotor Fabrication
Outsourced Motor Design
Advice and Introductions
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Copper rotor induction motor video: Comments from today’s suppliers
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 10
www.copperalliance.org/motor
| Copper-rotor induction-motors: Strong alternative to rare earths for EV traction - 23 April 2012 11
For more information please contact:
To view the video of industry comments on the copper rotor induction motor go to: www.copperalliance.org/motor
Copper-rotor induction-motors: Strong alternative to rare earth motors for EV traction
