Analysis of Copper Vs Aluminum Winding Motors

Swapnil Desai,Sandesh Desai,Surendra Sangare,Anil Yadav

Electrical Engineering Department, Theem College of Engineering Boisar, India.
swapnildesai912@gmail.com
Electrical Engineering Department, Theem College of Engineering Boisar, India.
desaisandesh60@gmail.com
Electrical Engineering Department, Theem College of Engineering Boisar, India.
surendrasangare001@gmail.com
Electrical Engineering Department, Theem College of Engineering Boisar, India.
ay000081@gmail.com

ABSTRACT: In this paper, we are comparing the many parameters of the winding
materials and improve the motor efficiency as well as reduce the cost of the motor. We can
reduce the manufacturing cost by using the designed aluminum material windings instead
of copper material winding for several appliances and limited rating motors. It is essential
to gain a new motor with the equal characteristics and the same power efficiency while
decreasing conductor material price and thus the rate per motor unit. For this purpose, we
analyze two motors, one with copper winding and one with aluminum winding. The learning
focuses on mechanical and electrical characteristics, in order to evaluate the rated and
starting torque values for the shaft at some stage in speed function. Another vital parameter
is the motor temperature in continuous function. A variety of equipment manufacturers have
currently replaced the motor stator winding material from copper (Cu) to aluminum (Al) to
decrease the product cost in the competitive international appliance market. Although
discount in the motor price can be achieved, a noticeable increase in the failure charge due
to stator insulation breakdown will be observed.
Keywords— stator winding, temperature, cost-effectiveness, motors, energy efficiency

Introduction
In small electric powered motors are used for a huge vary of activities. Many of them are
single segment motors. Motors are used in household appliances, small, electric driven
pumps, fans, etc. It is estimated that the 90 % of electric motors are beneath 0.75 kW. An
essential variety of these are used for special services. The small motors are manufactured
for devoted applications in extended production. This way the motor manufacturers can
decrease the manufacturing costs. The motor’s price depends on its energy and efficiency.
In this paper we are analyzing 75W induction motor. In order to gain the minimum price,
motors are chosen which admire two important features
• The most of electricity requested by using the user • Energy efficiency.
OBJECTIVES OF STUDY

1. Substitute material for copper winding with economical aspects.

2. Study and reduce the losses and noise in both the windings.
3. Study temarature variations for different parameters.
Overview

 Copper or Aluminum Stator Winding

Copper and aluminum are used as conductor substances in induction motors manufacture.
The contemporary density of copper is greater with 30% than aluminum’s. Although the
aluminum charge is lower than copper’s, in reality in a 1/3 ratio, some professionals think
about that copper is top of the line because the copper resistivity is with 63% larger than
aluminum’s. Considering these facts, the usage of aluminum in stator winding for induction
motors is pretty acceptable. Another situation is given via the steel resources. In case of
copper, the very best stage of request was 25.5106 tone/year in 2012. There sources of copper
are estimated to final for round thirty more years, barring taking into account the
recycling process. It is very challenging to predict the metal’s prices in the future, but, based
on the amount of resources, the electrical equipment producers expects that the aluminum
rate will increase slower in the future.

Methodology
I. Designing of the motor.
For designing the motor we need to know the physical parameters of the winding material
used in the motor.
Table 1. Physical Property of Wire Material
Physical Property Aluminum Copper
Resistivity,Ω- /m 0.03 0.01665
Mass Density,kg/ 2.7 8.88
Expansion Coefficient,µm 23.862 16.73
Thermal Conductivity,w/mk 210 398
Tensile strength,MPa 46.5 124
Melting Point, 660 1084.86
Specific Heat,J/kg k 904 384.5

The volume of aliminum wire motor designed is increased by 62% from the copper motor
it is why the conductivity of aluminum is 60% of copper and slots area must be increased.

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International Journal Of Advanced and Innovative Research ISSN: xxxx-xxxx
Vol. 1, No. 1, Juny 2017, pp. xx-xx

The material cost of the aluminium wire motor is less then the copper wire motor because
of the present high value of copper.

Table 2. Desing Factors Of Motors

Design Factors Copper Wire Aluminum Wire
Wire Material Copper Aluminum
Length (m) 47.53 48
Stator Diameter (mm) 50.8 51
Air Gap 0.375 0.4
Number of Stator Slots 12 12
Stator slot area (mm) 28.066 44.54

II. Analysis of Motor.

A. Mesurement of losses in induction motor

We similuate the losses and the efficency by using the eqivalent circuit method.
The efficiency test is performed following the IEEE standard 122B method [4],[5]

Fig. 1. Equivalent cicuit of motor

 Test Result.

Table 3. Test Result of Motors

Motor method Copper loss Copper loss Core loss Efficiency
(stator) (Rotor) [w] [%]
[w] [w]
Aluminum ECM 4.73 1.40 2.06 87.01
wire motor
Friction losses: 1.05 Stray Losses:0.50
ECM 4.62 1.90 2.09 86.6

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 Copper Friction losses: 0.76 Stray Losses:0.52
wire motor

ALUMINUM WIRE MOTOR

Friction Stray load
Losses, losses, 0.5
1.05

Stator
core losses,
losses, 4.73
2.06

Rotor
losses, 1.4

Fig. 2. Losses in aluminum winding motor

Fig. 3. Losses in copper winding motor

B. Measurement of Noise Level

The noise level of this two motor is important considering their utilization in
home appliances. The noise level of these motors measured by sound meter.
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International Journal Of Advanced and Innovative Research ISSN: xxxx-xxxx
Vol. 1, No. 1, Juny 2017, pp. xx-xx

45
40
35
30
Noise [dB]

25
20
15
10
5
0
0 2500 5000 7500 10000 12500 15000 17500 20000
Frequency[Hz]

Copper winding noise Aluminium winding noise

Fig. 4. Noise level in aluminum and copper winding motor

The noise level of motor with aluminum winding is smaller than the motor with
copper winding.

C. Heating Test of Motor’s windings

An important problem in electric motor operation is insulation class, and implicitly, the
temperature of the winding.

120

100
Temperature

80

60

40

20

0
0 25 50 75 100 150
Time [min]

Copper Winding Aluminum winding

Fig. 5. Temperature variation in aluminum and copper winding motor

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The temperature of the aluminum winding is greater than copper winding but it is in
permissible limits.
CONCLUSION
In this paper, design of 75W induction motor using aluminum wire motor and copper wire
motor. The performance of aluminum wire motor and copper wire motor is almost same. We
use more aluminum than copper for same rating but the cost of the aluminum is less than
copper and winding material cost is decrease by 85%. The efficiency of aluminum winding
motor is greater than copper winding motor. The noise level of aluminum winding motor is
less than copper winding motor. The temperature variation in aluminum winding is
greater than copper winding but these does not much effect on the operation. After
considering all the above factors the aluminum winding motor is more efficient than copper
winding motors for small applications.
REFERENCES
 Mariana Iorgulescu, Study of Single Phase Induction Motor with Aluminum versus
Copper Stator Winding
 Pil-Wan Han, Yon-Do Chun, The Study To Substitute Aluminum For Copper As a
Winding Material in Induction Machine
 Wiliam R. Finley, Mark M.Hodowanec, Selection of Copper vs. Aluminum Rotors
for Induction Motor
 Daewoong Choi, Tae-June Kang, Stator Insulation Quality Assurance Testing For
Appliance Motor With Aluminum Winding

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