Industrial Training Project Report

At
Marathon Electric India Pvt. Ltd.

MARATHON ELECTRIC INDIA

By
Regal-Beloit

Under the Guidance of-

Mr. Satyawan Rana
Engineer(Winding)

Submitted By:
MADHAVAN.V
Admn. No-14JE000022

SUBMITTED TO-
Department Of Electrical Engineering
Indian School of Mines,
Dhanbad. 826004

(JUNE-JULY 2016)

1
 MARATHON
ELECTRIC INDIA
PVT.LTD

INDUSTRIAL TRAINING REPORT

SIGNED BY-
Karamvir Attri
(DEPUTY GENERAL MANAGER)

2
PREFACE

Practical knowledge is of prime importance in any field of knowledge,

especially if the field is concerned with science & technology. Practical
work undertaken in addition to theoretical study greatly facilitates the
understanding of theory itself.

I am glad to present the project report on “Manufacturing of Induction

motor” for Marathon Electric India Pvt. Ltd.

This report is related to my work as a four weeks industrial trainee.

This type of training is continuously done in Marathon Electric Pvt. Ltd.,
Faridabad.

Being working on this project, it was indeed very exciting and useful
experience for me. A good confidence has been built up which will
surely help me in carrying out various activities in future career.

In this work of mine I have tried my best to make it as compact, reliable

and perfect and yet useful as possible. Every attempt has been made to
ensure that the material included represents the present state of science
and developments. Considerable thought and effort were devoted to
clarity of presentations.

In the end I wish that the report would definitely form a base for
improvement in achieving high efficiency at least partially, if not
completely.
I am highly obliged to all of those who helped me for successful
completion of the report especially to Mr. Satyawan
Rana(ASSISTANT MANAGER)

ACKNOWLEDGEMENT

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It is pleasure to record my thanks and gratitude to person and
organization whose generous help and support enable me to complete
this within stipulated time period. At the outside, I am grateful to
MARATHON ELECTRIC India Pvt. Ltd. for sponsoring this study to
me. My specials thanks are due to Mr.SATYAWAN RANA,
Mr.RAKESH DAGAR and Mr. KARAMVIR ATTRI and a host of
another official for their active help and cooperation at each stage of
study. I also received generous help and cooperation from Dealers of
company in my field area without which the study could not have
achieved its desired objectives. Lastly, I am greatly indebted to those
people who helped in completion of my project.

I wish to express my profound gratitude and regards to all faculty

members of Electrical Engineering Department for their generous help
and kind cooperation throughout the course.

Last but not least, I would like to thank my parents and friends for their
valuable contribution at every moment.

Madhavan.V
(14JE000022)

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CONTENTS

1. MEIPL PROFILE
2. TYPES OF MOTORS

3. INTRODUCTION TO 1PHASE INDUCTION MOTOR

4. MAIN STEP INVOLVED IN ASSEMBLY

5. MOTOR MANUFACTURING PROCESS

ABOUT MEIPL
Regal Beloit Corporation (USA) took over GE Motors India Pvt.
Ltd. (Faridabad) . Now it has been renamed as MARATHON
ELECTRIC INDIA PVT. LTD.

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ABOUT MARATHON COMPANY PROFILE
Since 1913, Marathon Electric has been dedicated to providing
customers with quality products for targeted applications. Headquartered
in Wausau, Wisconsin USA, the company is composed of two strategic
product lines: Motors and Generators.

MARATHON’S BRANDS

The broad categories of the Regal Beloit Corporation motor divisions

are:

 FASCO MOTOR

 LEESON MOTOR

 LINCOLN MOTOR

 MARATHON GENERATORS

 MARATHON MOTORS

 MARATHON SPECIAL
PRODUCTS
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  THOMSON TECHNOLOGY

Global Technology Center - India (GTCI)

Regal Beloit Global Technology Center - India, also known as GTCI
is located at the very heart of the city of Hyderabad, the city of pearls.
The technology center is the global hub for Engineering and Information
Technology.

GTCI has world class facility with Engineering and IT teams working
collaboratively with Regal Beloit locations globally. This center started
its operations in August 2005. Since then the technological
improvements and world class delivery has made GTCI a truly
competitive advantage for Regal Beloit Corporation

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ABOUT REGAL BELOIT

Marathon Electric is part of Regal Beloit Corporation. Regal Beloit

Corporation is a leading manufacturer of electrical and mechanical
motion control and power generation products serving markets
throughout the world. Regal Beloit is headquartered in Beloit,
Wisconsin, and has manufacturing, sales, and service facilities
throughout North America and in Mexico, Europe and Asia.

CompanyHistory

REGAL-BELOIT CORPORATION embraced the spirit of free

enterprise at its beginning in 1955 in Beloit, Wisconsin. The company
started business to produce special metalworking tools fast and shipping
them in just 24 hours after receipt of the order. Fast service, which was
unprecedented at that time in industry, remains at the core of REGAL-
BELOIT’s operating philosophy.
Five decades later, REGAL-BELOIT is much improved and
strengthened by product line diversification and 42 acquisitions. The
company nearly doubled in size in 1997 with the addition of Marathon
Electric Manufacturing Corporation of Wausau, Wisconsin. In
September 2000, REGAL-BELOIT acquired LEESON Electric
Corporation of Grafton, Wisconsin. In 2004, the company nearly
doubled in size with the acquisitions of General Electric's Commercial
AC Motors and HVAC/Refrigeration Motors and Capacitors businesses.

Today, REGAL-BELOIT operates two main groups including the

Electrical Group and the Mechanical Group. The Electrical Group
includes 6 companies that manufacture electric motors. The Mechanical
Group includes 16 companies that manufacture generators, controls,
gear products, metal cutting tools and related products.

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REGAL-BELOIT is a leading, international manufacturer of electrical
and mechanical motion control products, serving an expansive array of
markets from heavy industry to high technology.

REGAL-BELOIT’s manufacturing and service facilities are located in

the United States, Canada, Mexico, Europe and Asia. The company’s
growth and solid financial performance can be attributed, in part, to an
effective and aggressive acquisition program, which has become a
company hallmark that will continue to propel the company into the
future.
Marathon Electric: Since 1913, Marathon Electric has been dedicated to
providing quality products for customer’s individual needs. Strong
application and design engineering, solid manufacturing processes and
state-of-the-art test facilities have differentiated Marathon Electric from
the competition.
Marathon Electric Company Products:
AC Electric motors from 1/12 through 800 HP, with literally thousands
of motor configurations to choose from… single phase, three phase,
multi-speed, inverter duty, hazardous duty, severe duty, washdown, and
medium voltage…in standard, EPAct-compliant, and NEMA
Premium™ efficiency ratings.
AC Electric IEC (Metric) motors from .18 through 300 KW
AC Drives
DC Electric motors from 1/4 through 3 HP
Temperature/Vibration Monitoring devices
Generators
Air Moving Motors (Light Commercial HVAC)

Marathon Motors By Regal-Beloit offers a full line of motors to service

the Air Moving market segment. As the industry leader, several different
models are offered for all Air Moving applications to better serve the
needs
Pedestal Fan

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56 Frame Air Moving Motor

General Purpose

Full line of general purpose motors, single phase and three phases, 50
HZ or 60 HZ with voltages up to 575V. Available mountings include
welded or resilient base, C-Face and extended clamp screws. Wide range
of applications such as fans and blowers, conveyors, farm equipment,
industrial pumps, compressors and machine tools.

Food Processing Motors

Wash down Duty motors are designed for use in applications where the
motor is exposed to water and high humidity. These motors are designed
for frequent cleaning with a high-pressure spray. Some typical
applications that utilize Washdown Duty motors include food processing
plants, canneries and car washes.

Stainless Steel Motor

Agriculture

As an industry leader in
the manufacturing of motor products for severe duty applications,
Marathon Motors By Regal-Beloit offers a full line of Farm Duty
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products. From material handling to agricultural ventilation, we offer
motors to fit nearly every Farm Duty application.

Material Handling Applications

• Auger
• Center Pivot Irrigation
• Extra High Torque
• High Torque
Ventilation Applications
• Aeration Fan
• Farm Fan
• Incubator/Hatchery Fan
Marathon Electric Capabilities:
State-of-the-art test facilities.
Capable of testing motors up to 4160 volts, 1000 HP and generators up
to 13.2 KV, 3 MW

Certified by the National Voluntary Laboratory Accreditation Program

(NVLAP), Underwriters Laboratory (UL), and Canadian Standards
Association (CSA).Manufacturing and logistics operations are ISO
9001:2008 certified.Only motor manufacturer in North America,
certified by the American Bureau of Shipping-Product Quality
Assurance (ABS-PQA).Regal-Beloit truck fleet consisting of 100 trailers
that can cost effectively service customers from coast to coast.Only
motor manufacturer to be able to truly claim unlimited lead length
between a motor and drive due to Marathon’s patented MAX GUARD
insulation system.Only American motor company that operates its own
foundry, an effective way of controlling quality and lead-time on grey
and ductile iron castings.

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The major products are:
AC Drives
DC Motors
Brake Motors
Explosion Proof Motors
Pump Motors

MARATHON MOTORS IN INDIA – A GLOBAL EXPERIENCE

MARATHON ELECTRIC INDIA Pvt.. Ltd MEIPL, are leaders in

manufacturing and marketing of FHP motors in North America and have
been in this field for over a century now. Apart from FHP motors,
MEIPL product portfolio includes Cold controls, programmable
controls, drives systems, Engineering services and Integral horsepower
motors etc.

REGAL Beloit entered India by buying GE Motors India limited with

operations located in Faridabad, Haryana. MEIPL is a market leader in
India, with brand names such as AUE, COOL HOME and
MARATHON.

With MEIPL’s design, process technology, quality systems and

investments worth millions of dollars, the plant has been transformed
into a world class FHP motor production base to cater to the needs of the
global consumers.

VISION OF MARATHON ELECTRIC INDIA PVT. LTD.

Integrity – We are a company that is honest, trustworthy, candid,

transparent and fair.
High Energy – Our culture promotes a strong work ethic with high
energy teams fostering a culture of inclusion and respect for all.

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Performance – Everyone is expected to perform and our stakeholders
count on us to execute, meet commitments and continuously improve.

Types of motors

MEIPL manufactures more than 200 types. Each motor manufactured at

MEIPL comes under the classification of the below mentioned type
motors.

I. 95 Dia. Motors
These are small motors, which have 95mm as their
external diameter. These generally find their application in
the places where there is a light requirement of a motor such
as low torque and low power consumption. They are
employed in small fans such as of internal unit of split air
conditioners.

II. 100 Dia. Motors

These too are small motors, which have their external
diameter of about 100mm.Owing to low power consumption,
and low characteristics these are also employed in small
coolers or as fan of split air conditioners.

III. L Series Motors

These are typical motors and find their application only
in washing machine motors. The most distinct feature of this
motor is that the stack of the motor is square in shape with
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 reference to the outer figure whereas the inner shape is as
usual circular in accordance with the rotor. Here we do not
use any shell but end shields are used to make it. The main
advantage of this construction is that we get a high starting
torque, better cooling, low losses, which occur due to heat
and reduced lubrication problem. As the motor is fully
exposed to the external atmosphere it do not show a long run
life.

IV. Type 200 Series Motors

The type of motor we generally in the home use desert
coolers are technically described as Type 200 Motors. The
chief characteristics of this motor is that the shell of the
motor does not cover the stack of the motor, else we can say
that no shell are used but in place fully isolating end shields
are used. The stack of this type is fully exposed to the
atmosphere. The advantage of this type of construction we
get is better cooling and low temperature rise and better
efficiency. These are permanently lubricated motor. But in
the long run if the stack is not protected it gets rust and
becomes prone to less efficiency. These uses permanently
split capacitor and vary from single speed to three speeds.

V. Frame 29/39 Motors

These are the motors that are widely used in the fan
motors of air conditioners (1,1.5 and 2Ton). The fan of air
conditioners solve two purposes simultaneously
i. Cooling of internal air
ii. Cooling of external condenser fins

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 Hence the shaft of these motors extends on both sides of
the motors. The whole of the motor is shell covered and the
motor is permanently lubricated. In a way we can say that the
motor is maintenance free as no dust enters in the internal
parts of the motors and no lubrication is needed. These uses
permanently split capacitor and vary from single speed to
three speeds. Other than from their application in air
conditioner fans these are also used in Wet Rice Grinding
Machines (WRG) and in Cooler Fans also.

VI. G P Motors

These are one of the most powerful motors made at

MEIPL. The full line of general-purpose motors include,
single phase and three phase motors, operating frequency of
50 Hz. or 60 Hz. and voltages up to 575V. Available
mountings include welded or resilient base, C-Face and
extended clamp screws. These can have ventilated end
shields and the rotors are special as the end rings of the rotor
mount on themselves fins, which aid in the internal cooling.
The rotors are heavy constructed and
vary in length from 2.5’’ to 3.5’’. Special lamination rotors
are used which increase efficiency. Sometimes a fan is
mounted in the internal free space of the shaft to aid in
cooling. On the external part of the shell a box type structure
is given the manual change of speed is given. This is done by
inter changing two pairs of wires. Some motors have two
15
 capacitors; the first for starting the motor i.e. to give a high
starting torque to the motor and the second to give the
running torque to the motor. These motors are also made
permanently split capacitor type. In the two-capacitor
operation mode a governor switch is used which switches the
motor to run capacitor mode and cut offs the start capacitor
after the motor pick-ups a certain critical speed. Wide range
of applications such as Atta chakkis / Gharghanti,Surgical /
Vacuum Pumps, Wet Rice Grinders, Evaporative Desert
Coolers, Industrial Sewing Machines, Commercial Juicers,
Packaged air conditioners, Diamond / Stone Polishers,
Domestic Flour Mills, Light duty Machine tools, Lawn
movers, Floor Polisher, Coir Machine Application, Water
Coolers, Tyre changing machine, Ice cream machine fans
and blowers, conveyors, farm equipment, industrial pumps,
compressors, machine tool, big industrial fans, poultry,
industrial drills, atta-chakki etc.

VII. N F Series Motors

These are even more powerful than the GP Motors and
more durable. More or less these are identical in construction
to GP Motors. These are used in Atta-chakkis, Grass Cutting
Machines, Stone Finishing Machines, Stone Cutting
Machines (Industrial), etc.

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 INTRODUCTION TO 1-pahse INDUCTION MOTORS
A large variety of fractional HP a.c. motors are designed to operate from
1-Φ supply. Although 3-Φ motors can be designed and built in small
sizes their initial cost precludes their common use. In addition wherever
fractional HP a.c. motors are required to do useful work, for example in
homes, offices, etc.

Working principle
Conversion of electric power into mechanical power takes place in the
rotating part of an electric motor .In a.c. motors the rotor receive electric
power by induction as it happens in a transformer. That is why; such
motors are called induction motors.

Why rotor rotates

When the 3-Φ stator windings are fed from a 3-Φ supply then a
magnetic flux of constant magnitude but rotating at synchronous speed
is set up. This flux cuts the stationary rotor conductors and an emf, with
frequency same as supply, is induced in them. Its magnitude is
proportional to the relative velocity between the flux and the conductors
and Fleming’s Right Hand Rule gives its direction.

17
Since rotor bars form a close circuit, rotor current is produced whose
direction is such as to oppose the cause producing it. In this case, the
cause is the relative velocity between the rotating flux of the stator and
the stationary rotor conductors. Hence to reduce the relative speed, the
rotor starts running in the same direction as that of the flux and tries to
catch up with the rotating flux.

Slip
The difference between the synchronous speed and the actual speed of
the rotor is known as slip.
S = (Ns – N/Ns) * 100
Where Ns-N is called the slip speed
1-Phase INDUCTION MOTOR
In a 1-Phase induction motor a pulsating stator mmf is obtained. Thus
this motor with a pulsating air gap field is not self-starting.
Two different theories namely the cross-field theory and the rotating
field theory maybe adopted for explaining the running performance of
the 1-Φ induction motor.

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Rotor currents in a single-phase ac induction motor

We use the rotating field theory to analyze the motor.

According to this theory, the pulsating, stationary stator mmf wave is
resolved into two counters rotating mmf waves of equal amplitude and
moving at synchronous speeds.

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METHODS OF STARTING OF 1-Φ INDUCTION MOTOR
As already stated the 1-Φ induction motors have no inherent starting
torque. For the development of starting torque, rotating air gap field at
starting must be produced. To serve this purpose the stator of the
induction motor is provided with an extra winding known as starting
winding in addition to the main or running winding. The two windings
are placed 90 degrees electrically apart and are connected in parallel
across the 1-Phase supply.
Several methods of starting have been developed for starting the 1-Phase
induction motors. These are as follows:
1) Split phase starting
2) Shaded pole starting
3) Repulsion motor starting
4) Reluctance starting

SPLIT PHASE STARTING

1-Phase induction motors employing this method of starting are called
split phase motors. There are four types of split phase motors. They are:
• Resistor split phase motor
• Capacitor split phase motor
• Capacitor start and capacitor run motors
• Capacitor run motors
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RESISTOR SPLIT PHASE MOTOR
The two winding currents are shifted in time phase, thus creating a
rotating field, which is necessary for the production of starting torque. In
order to achieve this the main winding is designed to have lower
resistance and higher leakage reactance than auxiliary winding.
The main winding current lags the current in the auxiliary winding. This
gives rise to a rotating field and the rotor starts rotating from the
auxiliary winding to the main winding provided the poles of same
polarity are created. Interchanging the two terminals of either winding
reverses the direction of rotation.

Resistor Split Phase Motor

The starting winding is automatically disconnected at 70-80% of the
synchronous speed by means of a centrifugal switch.

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CAPACITOR SPLIT PHASE MOTOR
The time displacement between the auxiliary winding current and the
main winding current is obtained by putting a suitable capacitor in series
with the auxiliary winding.

Capacitor Split Phase Motor

The centrifugal switch disconnects the auxiliary winding at about 70-
80% of synchronous speed. For the same value of line current, this type
of motor has a higher value of torque as compared to the resistor split
phase motor.

CAPACITOR START AND CAPACITOR RUN MOTOR

Large capacitor is connected in parallel with a capacitor at the time of
starting only.
The centrifugal switch disconnects one of the capacitors automatically at
about 75% of synchronous speed leaving behind the other capacitor in
22
series with the auxiliary winding. The best starting with a high
capacitance and best running performance with a low capacitance is
obtained in such type of motors.

CAPACITOR RUN MOTORS

In this kind of motor the capacitor is kept permanently in series with the
auxiliary winding. At a desired load the capacitor and auxiliary winding
must be so designed as to result in 90 degrees time phase displacement
between the two winding currents. In such a case, the motor would
operate as a balanced 2-Φ induction motor

MAIN STEP INVOLVED IN ASSEMBLY IN MEIPL

The main steps involved from constructing a motor upto dispatch are as
follows: -

(i). STACK: - Punching and stacking of stack takes place. Then slot
paper is inserted and we get finished stack.

(ii) ROTOR: - Lamination and diecasting of rotors takes place. Then

drop on of rotor with shaft is done. Hence we get rotor
assembly.

(iii) SHELL: -Shell has been prepared through blanking, welding,

notching and painting.

(iv) ENDSHIELDS: -Finished endshields are prepared.

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(v) ASSEMBLY: - All these components are assembled to form a motor.

(vi) CMT: - (Computerized Machine Testing) Now CMT of the motor is

done.

(vii) DISPATCH: - Finally the motor has been dispatched to the

respective customer.

MOTOR MANUFACTURING PROCESS

Stack

The stack is that part of the motor on which the field windings are
placed. These are cut into sheets of small thickness and then placed one
over another to get a stack. These laminations are obtained from the
lamination department.

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 Lamination Department first cut four or five rolls horizontally from a
single steel roll having a larger width. The rolls of steel obtained after
cutting become very less in width in comparison to the bigger parent
steel rolls.

Then these cut steel rolls are feed to big die casting machines where the
laminations of the stack and rotor are simultaneously cut. According to
the cost analysis one single lamination of stack costs about Rs.1 and that
of a rotor cost about Rs.0.50. The laminations that of rotor are sent to the
vendor to fill aluminium in them.

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The slot insulation machine cuts and inserts the insulation into the stator
winding slots. The stator core is then transported to the winding shop for
injection of windings.

B. ROTOR SUB-ASSEMBLY

In these motor squirrel cage motors are used. Laminations for these
rotors are punched here and then they are sent to the vendors for
aluminum die-casting.
Rotor Rough OD Turning:

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This is the first station of rotor sub-assembly. OD of rotors after die-

casting from vendors is prepared as per the design requirements. Carbide

bits are used for rough turning.

ID Reaming:
At this station reaming operation is done on the ID of rotor. At a time
four rotors are loaded and ID is prepared as per the design specifications.
After the ID the Go/No-Go gauge checks reaming ID. In the reaming
process lubricating oil is used to remove chips from the ID of the rotor
and the fixture pads, which are formed during reaming process. Grinding
of reamers is done for a maximum of four times.

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Rotor Heat Shock Furnace and Drop On:
The heat shock furnace is maintained at the temperature of 450 degree
Celsius. The rotors are kept inside the heat shock furnace for
approximately 35 minutes. This is done to expand the ID of the rotors.
Also during heating oxidation occurs on the surface of rotor, as well as
on the joint between aluminum bars and the rotor material. In which
formation of Al2O3 and Fe2O3 takes place, which acts as insulation
between aluminum bars and the material of rotor and prevent flowing of
current in rotor laminations.

The shafts are placed inside the sleeves of the trays and when the rotors
come out of the furnace, they are held by tong and dropped on to the
shaft. After the rotors are dropped on to the shafts, the rotor shaft sub-
assembly is quenched. After quenching as the temperature of rotor shaft
sub-assembly drops down, ID of the rotor contracts and interference
fitting takes place.

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Fine OD Turning Machine:
Fine turning of rotor is done to make the OD of the rotor and to give
finish on the rotor surface. The depth of cut is less in this case as
compared to the rough OD.

Lacquering and Bearing Pressing:

Lacquering is done on the rotor OD surface to prevent it from rust.
This process is done manually. After that ball bearings are pressed on to
the shaft through interference fitting. Both hydraulic and pneumatic
pressures are used in pressing of bearings. These ball bearings are used
to reduce friction, noise as well as provide support when placed in the
end shield bore.

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C. Field
After the stacks have been filled with the slots paper they are sent to the
winding shop for the insertion of the windings in the stack slots. The
following flowchart described the process:

PROCESS DETAILS

1. Slot insulation:
In this step insulating paper is put in the slots of the stator stack so that
the wires might not touch each other, which may lead to the defect of
wire ground.

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2. Coil Winding:

Partnering with the coil injection process, most of the electric

motor industry uses the “shed” type coil winders. The principle of the
“shed” winder is that it wraps wire around a tapered coil form step and
then pushes this wire down the taper into the tooling as the next turn of
wire is wrapped above it. Stand-alone “shed” winders will wind coils
into a “transfer tool”. The operator then will use this tool to manually
transfer the coils to the injection machine.

The “shed” type winder uses short, multiple step coil forms, which
means a small flyer can be used to obtain higher winding speeds;
however, a high winding speed is not synonymous with a reduced cycle
time. Using a servomotor to drive the flyer yields great advantages over
variable frequency drives. Although both systems can provide for +/- 0
turn count, variable frequency drives can only do so by winding the final
turns at a very slow speed. Typically, a machine using a variable
frequency drive is approximately five (5) seconds slower per pole than a
machine using a servo motor drive? When winding a typical 4-pole
stator, a servomotor driven “shed” winder can produce approximately 25
more stators per hour (depending on turn count).

31
With the advent of improved machine tool controls, the “shed” type
winder has become more versatile providing the motor manufacturers
with additional savings on smaller production runs. A standalone “shed”
winder can be changed from one lamination to another within two
minutes. Stack height changes and pole configuration changes can be
made automatically.
In washer plant four winders are used as four types of
winding are used in case of LP160 double speed single-phase fractional
horsepower motor. Two of the windings are auxiliary windings and two
are main windings. These windings are placed over the star trolley.

3. Form press:
Here a form press presses the wires properly over the
stacks. The stack is placed over a fixture and then is pressed from the
top. FORM PRESS ID (internal diameter) and overhang formation on
the lead end and opposite lead end, as per specifications is done using
Form Press.

32
 4. Splice connection:
Here connecting wires are attached to the winding.
CRIMPING: the winding assembly is connected to the lead assembly
using splice connectors. This process is termed as Crimping. TOP
(thermal over load protection) is also connected during Crimping.
\
Then tapes are pasted to avoid contact between the wires and the
lead wires and also for support.
5. Taping:
After splice connection taping is done over the coils wound in the
stack so that the coil does not come out or become unraveled.
6.Lacing: At this stage thread is wound over the coils with the help of a

33
needle.

LACING: Lacing is done with a lacing cord to tightly secure the field
coil ends and keep the TOP and leads sit in to position.

7.Finishing:
At the finishing stage final touch is given to the winding by visual
inspection.

8.Final inspection / testing:

This is the last stage in the winding stage before the windings are sent
for varnishing. At this stage, with the help of a computer we can find
out if the winding is defective or not so as to prevent defective pieces
from reaching the varnish plant. But 100% defects can’t be monitored
at this stage.

TESTING: After lacing, the stator is tested for

34
  Resistance
 Rotation
 IR
 HV
 Possible shorts
 Surge.
If the stator does not satisfy the specified requirements it is
rejected, otherwise it is sent for varnish dip operation.
VARNISHING:
This involves three processes:

1. Pre-heating: The stators are loaded in hangers and

transferred to the preheating chamber where the fields are exposed
to a temperature of 90+/-5 degree Celsius. This is done to remove
the Molykote oil.

2. Dipping: The stators are then dipped in the varnish.

One most important parameter to be checked in the varnish is the
viscosity. The varnish used is a mixture of varnish and thinner in
the ratio 2:1. The viscosity of the mixture is measured using a
viscosity cup and noting the time taken by the varnish to drain out
the cup. This time must be between 15-20 sec. The temperature of
the varnish tank is 35 degree Celsius.

35
 3. Post-curing: After varnish impregnation the stator coil
assembly is post heated at a temperature of 130+/-5 degree Celsius
in the baking oven.

D.SHELL:
The shells are made from rolls of CRCA sheet. The rolls undergo
blanking i.e. cutting the rolls of steel into blanks of required dimensions.
Using a CNC lathe the ends of the shell are cut. Notching of the required
shape and at the required position is done. These unpainted shells are
then transferred to the paint shop.
PAINT SHOP
These shells undergo the following processes in
order to remove the oil layer so that the paint can adhere to the
surface of the shell.
(1) KOD: The chemical used is S-55 at a temperature of 60+/-10 degree
Celsius.
(2) DEGREASING Treatment with S-55 at 60+/-10 degree Celsius.
(3) WATER RINSE: The shells are washed in DM (dematerialized) or
industrial water at room temperature.
(4) SURFACE ACTIVATION: Surface activation of the shells is done
with Prephos-Z at room temperature.

36
(5) ZINC PHOSPHATING: The shells are treated with mixture of
phosphate S-30 and accelerator FA at 50+/-10 degree Celsius. This
forms a tough layer on the surface of the shells and enables the paint
to stay for a longer duration.
(6) WATER RINSE: The shells are again washed with DM or industrial
water.
(7) PASSIVATION: This reduces rusting.
(8) DRY OVEN: The shells are heated in an oven prior to the painting
operation. The temperature in this oven is maintained in the range of
100-130 degree Celsius.

The shells are painted with the help of a sprayer. The paint used is in the
form of a powder. In order to get a perfectly smooth and durable layer of
paint the shells are baked again. The minimum temperature maintained
is 195 degree Celsius. The shells are then individually checked to assure
that the paint layer has been uniformly and smoothly applied on the
surface of shells. The shells, which clear the check, are sent to the motor
assembly. The whole of the processes can be described with the help of
a flow chart

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 E .End Shield
Die-cast end shields are obtained from the vendor
(material is aluminium).
1) The end shields are machined according to specified internal
diameter.
2) Sleeve bearing or Babbitt bush bearing is pressed into the end
shield.
3) The end shield is further machined according to specified
outer diameter.
4) The end shield is then tested for outer and inner diameter,
concentricity, and square ness. The checked samples are sent for
assembly.
5) The parts assembled into the end shield are: -
a) Felt wick
b) Perm wick – releases oil for lubrication
c) Thrust plate – thrust washer is supported against it
d) Oil throw washer
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 e) Oil well cover
f) End cap
The end shield moves on to the rotor assembly.
F.FINAL ASSEMBLY

Materials from different units i.e. field assembly, shell assembly, end
shield assembly, rotor shaft assembly and clamp bolts, nuts and
grommet are collected. The shell is pressed on to the field. The shell
field assembly is passed through a surge test. The hexagonal nuts are
placed on the assembly tray and an end shield is assembled over it to the
shell field assembly. The rotor shaft assembly is inserted and then the
other end shield is assembled with proper adjustment. Clamp bolts are
inserted and the nuts are tightened.

The motor is checked for free rotation and noise. Then the no load test is
conducted on the motor. In this test the various parameters, resistance of
start winding, resistance of main
Winding, hipot of start winding, rotor resistance, low volts of start
winding, flat detect, watts high, hipot dynamic, high amps, are checked.
Then the motors are sent for computerized motor testing where they are
tested at different load points. The parameters checked are torque, rpm,
line voltage, starting voltage, voltage of capacitor, line current, current

39
in main and start winding, watts, efficiency, output power, power factor
and frequency.

After all the components of the motors are gathered all the components
are sent to the various assembly lines. At MEIPL there are five assembly
lines, which operate 24Hr. make more than 200 different types of
motors. At the assembly lines the components are placed in their
respective positions. Then these components are assembled by various
skilled employees to make a motor. The daily motor production of
motors sum around 2000 motors in span of 24Hr.The basic assembly
procedures are pointed below:

 Pressing of varnished fields in their respective painted shells

 Encasing of the groumet in the hole provided in the shell for
the leads to come out
 Fixing of the end shields with the rotor
 Tightening of the end shields with the help of case bolts and
nuts
 Slight hammering and adjustment of the end shields in the
axial positions so that the rotor can rotate freely
 Final inspection of the motor if it is fit for operation
 Dispatch to the Firewall Department for their packing and
their shipment to various customers
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 The Firewall Department has a great responsibility to ensure that
the motors sent are perfect and prove true in their testing and run. The
Firewall Department does the packing and the finishing of the motors.
Whole of the Department functions as follows:
STATION: 1
1. Check of Lead Damage
2. Check of Lead Cut
3. Inspection of Lead Terminal
4. Ensuring the Groumet

STATION: 2
1. Check if the Case Bolts are tight and proper
2. Inspection of End Shields
3. Ensuring End Cap
4. Ensuring Clamp Bolts

STATION: 3
Inspection of
1. Motor Assembly
2. Lead Exit
3. Name Plate
4. Rust on Shaft
5. Shaft Phosphating
6. End Play
7. Water Slinger

STATION: 4
1. Greasing of Oil on the Shaft
2. Packing

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