The benefits of a copper cage rotor
Why put a copper cage rotor into your electrical traction motors and other embedded devices ?
Electrical vehicle performance
Just replacing the aluminium rotor of an induction motor by a copper cage rotor improves the motor performance.
Energy losses in electrical systems are mainly caused by the electrical resistance of conductive materials that are used. Thanks to copper’s good conductivity (97% IACS +/- 3%), energy efficiency improves. FAVI’s rotor technology gives major advantages for the improvement of motor efficiency.
Integrated into an asynchronous motor, the FAVI copper cage rotor increases the power/weight ratio, up to 4 kW per kg of an on-board motor.
In the automotive industry, car manufacturers are always looking to maximize power from the smallest possible size of motor. This weight saving, produces a higher mileage/kilometer ratio per electrical recharge.
Savings
An induction motor equipped with the ‘FAVI DIE-CAST COPPER ROTOR’ achieves better than 90% efficiency.
Thanks to its optimized design and ease of industrialization, the production costs of this motor are significantly lower than those of a permanent-magnet motor.
Reliability and lifespan
Electrical asynchronous motors have been used in many applications in the railway transport industry for years (e.g tramways, subways, high-speed trains, TGV). It is a proven solution in terms of reliability and lifespan (no efficiency loss of the motor over time). Integrating a FAVI copper cage rotor into an asynchronous motor increases the motor efficiency without compromising its robustness.
Applications
Hybrid and electric vehicles
Electric drivetrain , starter-alternator , power-steering motor
Trains, Tramways
Rail traction motor
Electric forklift
Electric forklift motor
INDUSTRIAL KNOW-HOW
As an industrial subcontractor, we study, industrialize, and produce die-cast copper rotors.
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Research & development
Typical projects are :
- Researching and developing specific alloys, to meet new technical or economic constraints, customer specifications or simply to open up new markets.
- Developing innovative technologies in product processing.
- Developing and optimizing products and industrial processes, guarantees continuous improvement of product quality and economic performance.
These innovations result from proactive meetings, listening to our partners at their centers of excellence e.g. technical centers, professional schools and universities.
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Product development
As your industrial development Partner, our Design team proposes the optimization of your product, through die-casting, machining and assembling. All requirements and quality issues relating to the product and manufacturing process are taken into account, to guarantee top product preformance from Day 1 of production.
Our Design office is experienced in the latest STATE OF THE ART Equipment :
- CAD
- Finite Elements Analysis
- Rheology
- Rapid prototyping in 3D, either machined from a block of the chosen metal, or from the initial samples.
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Product validation
Our test laboratory validates products and materials :
- Through material structural analysis and metallurgical testing.
- Through physical static or dynamic testing,to validate product function and resistance.
- Through specific bench testing on request.
FAVI has been recognized in July 2015 as being able to carry out tests and provide results according to the car manufacturers’ required standards. This is known as ‘Self-Certification’.
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Industrial resources
Our industrial departement manages, develops and uses ‘Best Practise’ production and quality methods.
We manufacture foundry, cutting tools, machining, assembly machines and control devices. A real advantage for industrializing your products giving continuous improvement throughout the manufacturing process.
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Production
Our core industry for 60 years : pressure die casting.
It is through this expertise that we are able to inject and control pure copper at 1300°C.
Up to now, we have produced more than 1,5 million die-cast copper rotors, whilst carrying out the entire manufacturing process : design, tooling, die-casting and machining.
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Metal and alloys
Cu97 Pure Copper
The copper used to inject the rotors with has an excellent 97% IACS (+/-3%) electric conductivity.
Our 'mini-factory' organization
At FAVI, our challenge is to place our customers at the centre of attention for each one of our employees, who organize production in our autonomous and independant mini-factories. Each mini-factory is dedicated to one customer or product and piloted by a team leader. All back-up services, such as Sales, QC and maintenance are closely integrated to favour reactivity, proactivity and communication.
Latest News
EVENTS 30 January 2023
FAVI will exhibit at GLOBAL INDUSTRIE 2023 (GILYON23)
FAVI will exhibit at GLOBAL INDUSTRIE 2023 (#GILYON23) from March 7 to 10, in Eurexpo LYON. Come meet us on booth 6H120!
EVENTS 28 February 2020
FAVI will exhibit on the MIDEST 2020 trade fair during the “Global Industrie” event in Paris
FAVI will exhibit to the MIDEST 2020, the International Fair for Subcontracting, from March 31 to April 3, in Villepinte (Paris). Midest is one of the 4 shows of the “Global Industrie” event. Come meet us on booth 6H111! More information and tickets here