Small electric motors - a few questions

Why are they so expensive? I had been thinking about upgrading my table saw motor, but apparently more than 50% of the original cost of my table saw (Ridgid TS3650) was for the motor, because the cheapest I could find in that configuration was well over $300.

What goes into an electric motor? I have a vague mental picture of coils of copper wire. Is it the copper that’s so expensive?

I had to have my motor fixed; it turns out it was only the motor’s re-set button thingy was broken. That sucker cost $50 by itself. Why is that little switch so expensive?

(Off topic, but I loved the place I took it to for repair - right in South of Market, San Francisco, inside was a dusty, dirty workshop with workbenches filled with motors in various states of repair, and a small front counter; and a proprietor who really, really likes to talk.)

Anyway, this is a whole new world for me and it certainly got me wondering what’s up with that?
Roddy

lots of iron and copper. the armature of an induction motor might have aluminum bars, but the stator windings are copper.

and yeah, I looked in the Grainger catalog and single-phase 1.5 hp motors are all about $300.

parts to keep an expensive device running are always costly.

Here’s another GQ for you: is this response supposed to be helpful in any way at all? Just wondering…
Roddy

HP seems to be a big factor in cost. I bought a 1/3 HP belt drive motor from Granger for $140 in Nov. It was a replacement for my attic fan. The retail list was $168 but I got a wholesale discount.

Interesting that the OP’s was so much more expensive.

well, it’s true, if a little curt. replacement parts are notoriously marked up. I recall an old issue of a car mag (I think it was Car & Driver) which had an article about service part prices. I think they looked at a then-$14,000 car and deduced that if one was to build the car by buying replacement parts, it would cost them over $60,000.

not really any way around it; induction motors are speed limited by the AC mains frequency, so given the same rated speed the only way to get more horsepower is to put more iron and copper in it.

As jz78817 said, copper, iron, and maybe other metals. The materials alone are expensive. Take a look in the electrical aisle at Lowes or Home Depot and see how much basic copper wire for your house costs. It ain’t cheap.

Also, whenever you make anything, there are a lot of up-front costs involved, like paying the designer(s) and devloper(s) of the product, setting up and tooling the factory, etc. Depending on the product, these costs can range from tens of thousands to many millions of dollars. I don’t know about motors, but just for giggles let’s say it costs around $500,000 or so to set up the factory. After that, it’s all labor and materials. Let’s say you spread out your up-front costs over 5 years. In that 5 years, if you make a million motors, your up-front costs work out to 50 cents a motor. But if you only make ten thousand motors, your up-front costs work out to $50 a motor. If you then have $50 of labor and materials into each motor, that’s $100 in costs just to have your motors pop off of the assembly line. Now you have to tack on overhead costs like warehousing and shipping, and maybe you’re up to $150 per motor. You need to make a profit, so you sell the motor for $200 to the retailer. He needs to make a profit too, so he sells it for $250 to the end customer.

The customer is thinking there’s only $50 worth of materials that goes into it. Why is it so expensive? I must be getting gouged! But in reality, neither the manufacturer nor the retailer is making a huge profit on the deal. They are making enough to make it worth staying in business, but not much more than that.

It costs maybe $50k to $100k to set up a line to make little plastic things. After that, the costs are a few cents at most per thing. Plastic things in low volume are expensive. Plastic things in high volume (millions of thingies) are dirt cheap.

The factory for computer chips is ungodly expensive to set up, but after that, each chip costs a few bucks at most to make. This is why there are only a couple of major CPU manufacturers. The costs up front are so huge that you have to sell millions of chips to make your money back, otherwise it’s not profitable.

Motors sold by the millions, like those in hand held power tools, are pretty cheap. Larger motors like those used in a table saw aren’t sold by the millions, and have higher material costs going into them, which is why they aren’t so cheap.

Because there aren’t many of them made. Again, it’s the setup costs plus the manufacturing costs plus the cost of warehousing and retailing the item. Plus there is some supply and demand going into it. The manufacturer doesn’t really want to sell little bit parts like this because they mostly sit in a warehouse somewhere and are then sold in very low volume, so they jack the price up. The customer is willing to pay the higher price (because otherwise they won’t have a working tool) so that’s the price that the switch settles on.

nm

I hear you, but if this was the driving economic consideration, wouldn’t most induction motors be run at nearly 3600 rpm in the US? That is, the rotor would have two poles. But the four pole, nearly 1800 rpm speed is much more common. That’s a factor of almost two, right? Assuming that their torque is dictated by the quantity of iron and copper.

Though, I dunno, maybe torque is proportional to the number of poles?

3450 for a 2-pole is common as a nameplate RPM; 3600 would be synchronous speed but induction motors need some amount of “slip” or else they’d produce no torque.

double the number of poles, halve the rotational speed. The motor RPM is largely application-dependent. For a table saw, most I’ve seen use 3450 RPM motors.

Did that shop have wooden floors?

To answer your question with a question. Why are saws, cars, and jewlery so expensive. One reason Today a stationary enginer makes over 10 times what they did when I graduated from college. Everything is expensive.