Cost-Effective Manufacturing
Smaller is Better
A
NovaTorque motor that produces a given amount of output power is roughly 40%
smaller than an induction motor with an equivalent power rating, so it
requires less steel and copper. Less steel and copper means it costs
less, especially given recent increases in the price of lamination steel and
copper wire.
The picture shows a typical pool pump motor, 0.75HP single phase induction motor (big motor). Next to it is a 0.75HP NovaTorque motor (60mm frame). The NovaTorque motor provides the same power, costs less to manufacture, and offers over 90% efficiency. The big motor is only about 50% efficient.
Less Wasted Material
The NovaTorque geometry uses laminations that have a parallelogram shape and therefore can be produced with almost no waste material. A lower scrap rate means lower costs. By contrast, radial motors use circular laminations with large punch-outs; these shapes have the fundamental problem of wasting more steel than is used in the final motor.
Field Poles
The field poles of NovaTorque motors lend themselves to several innovative low-cost manufacturing techniques. These proprietary processes have far lower tooling costs than the traditional lamination equipment used for radial motors.
Windings
A key advantage of the NovaTorque geometry is that the copper wire can be easily wound into a compact coil either on the field pole or pre-wound on a bobbin. The winding machine used is simple and a low-cost capital investment, while radial motors require very expensive winding machines to lay the wires in the stator slots. Plus, no end turns are required for NovaTorque windings, reducing the amount of copper needed.
Magnets
The cost of magnets has traditionally been a barrier to more widespread use of permanent magnet motors. However, the cost of magnets has dropped dramatically in recent years. Plus, because of the flux concentration characteristics of the conical hub in NovaTorque motors, it is possible to use low-cost ceramic magnets. In addition, NovaTorque motors can use thinner magnets than conventional PM motors, further cutting magnet costs.
Electronic Drive Modules
The costs of electronic drive modules, which are required by PM motors but not by induction motors, have come down substantially and are no longer as large a factor as they once were. The drive modules used by NovaTorque motors are completely standard. Based on all previous cost trends in the electronics industry, we anticipate the cost will drop further as PM motors become more widely used and volumes increase.