Program Background

This technology seeks to offer longer lasting, more efficient pumps that will be important to weapons systems and defense ground support facilities. The efficiency is being assessed with an overall systems perspective i.e. both addressing the motor and the pump efficiencies independently, as well as their coupling to provide optimum performance for a given application.

Hypothesis

The motor uses copper in the squirrel cage rather than the more conventional use of aluminum, in order to reduce motor losses by about 40%. Improved induction motor efficiency is being achieved through the use of die cast copper rotor motors. The Copper Development Association, in partnership with motor manufacturers and diecasters, has developed this technology and demonstrated it to be sound.

Learn more about Copper Motor Rotor technology.

Anticipated Results

Product demonstrations; improved parts availability; strengthened capabilities of the U.S. pump and motor supply chain; and reduced life cycle costs of motor/pump combinations and other copper-based components within DoD. These benefits are applicable to both in service legacy weapon systems as well as in-theatre ground systems and facilities. DoD should be expected to: reduce component lead times, increase qualified US component suppliers, increase motor service life and increase pump component life.

Demonstration Site

A large chill water pumping facility at Ft. Bragg has been selected as one of the demonstration sites. A 75 HP, 1800rpm motor has been designed by Baldor and the laminations are presently being manufactured. V-Forge is increasing the size capability of their copper rotor die casting machine to produce the large rotor for this motor, which will be among the largest die-cast copper rotors ever produced.