Copper Rotor Technology for High Efficiency Motors

  • András Bárdos
  • Csaba Walczer
  • Zoltán Kéri
  • Imre Selmeczi
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)


The asynchronous motor technology offers an easy solution for the e-traction. Two types of induction motor could be differentiated according to the used squirreled cage materiel, namely aluminium and copper. The copper rotor motor is being developed by many OEMs as a premium solution. The economical way to produce rotors for induction motors is the casting, independent of the applied squirrel cage material. High pressure die casting is the casting process attaining the highest productivity. The cast parts are near net shaped and often are they used unmachined in their as-cast condition.

The actual industrial demands, due to the used very high motor rpm, require parts with improved physical properties, i.e. high tensile strength with good electrical conductivity in very narrow slots. Just only the pressure die casting technology is ready to fulfil the mentioned requirements.

In the case of copper rotor, two manufacturing technologies are still in the race, namely the fabricated and the cast squirrel cage. Just only with the casting technology is possible to fill the newly developed very narrow rotor slots. Today it is possible to cast 1.3 mm thin slots with a stack length of 200 mm.

At present, the Breuckmann group is developing in Hungary together with the University of Miskolc and Öntögepszerviz Kft. a casting system and a manufacturing cell for large-volume production of rotors with high process reliability. In the foreseeable future, the company will offer economically advantageous solutions for the industrial production of rotors for asynchronous motors.


Copper rotor Cast rotor High motor rpm 



This work was supported by the European Union within the frames of the Széchenyi 2020 Program (GINOP-2.2.1-15-2016-00002) and by the European Union within the frames of the Horizon 2020 Program (H2020-SMEInst-2016-2017; 806095; HPC-rotors).

The authors would like to thank Kristóf Bodnár, János Erdélyi, Dániel Molnár, Dorottya Somfai and László Varga, for their collaboration and the excellent common work.


  1. 1.
  2. 2.
    U.S. Department of Energy. Accessed 29 Dec 2017
  3. 3.
  4. 4.
    International Annealed Copper Standard (1913)Google Scholar
  5. 5.
    Pawlek, F., Reichel, K.: The effect of impurities on the electrical conductivity of copper. Z. Metallkunde 47, 347–356 (1956). I. The Electrical Conductivity of Pure Copper, its Maximum Value and its Controls by ImpuritiesGoogle Scholar
  6. 6.
    Bargel, S.: Werkstoffkunde, pp. 272–281. Springer, Berlin (2004)Google Scholar
  7. 7.
    Ingenieurbüro für Elektro-Maschinenbau Hompage. Accessed 04 Dec 2017
  8. 8.
    Bárdos, A.: Der Asynchronantrieb: Neue Perspektiven durch innovative Gießtechnologie, Forum Elektromobilität, Berlin 1–2 März 2016Google Scholar
  9. 9.
    Yamazaki, K., Kato, S.Y.: Iron loss analysis of interior permanent magnet synchronous motors by considering mechanical stress and deformation of stators and rotors. IEEE Trans. Magn. 50(2), 909–912 (2014)CrossRefGoogle Scholar
  10. 10.
    Bárdos, A.: Anwendung von Kupfergusstechnologie und Vorteilen im Motorenbau. ATB Expertentag, Nordenham (2014)Google Scholar

Copyright information

© Springer International Publishing AG, part of Springer Nature 2018

Authors and Affiliations

  • András Bárdos
    • 1
    • 3
  • Csaba Walczer
    • 2
  • Zoltán Kéri
    • 3
  • Imre Selmeczi
    • 4
  1. 1.Breuckmann GmbH & Co. KGHeiligenhausGermany
  2. 2.Breuckmann Hungary Kft.Egyetemváros, MiskolcHungary
  3. 3.Faculty of Material Science and Engineering, Institute of Metallurgical and Foundry EngineeringUniversity of MiskolcEgyetemváros, MiskolcHungary
  4. 4.Öntögépszerviz Kft.BudapestHungary

Personalised recommendations