Design and Development of Rotor Quality Test System for Die-Cast Copper Rotors

It is well known in the market that the copper rotor motor can give good efficiency at par with the new era motors, and can handle higher temperatures to qualify for electric vehicle application. Being a heavy metal, die-cast copper rotor manufacturing needs absolute care for faithful rotor production. In this paper, the common faults in copper die-cast processing are identified and sufficient monitoring methods are suggested in a three-stage inspection. The final stage consists of a rotor quality test system, which detects most of the problems found in copper die-cast rotors. This rotor quality test system analysis helps to optimize the rotor manufacturing process and avoid the circumstances of fitting an inferior rotor in the motor assembly.