Quality Plan for Motor Components

Product Motor Assly

Item Description Stator Assly Item Code
QPIP No : Material
QPIP Rev No: Drawing No.
Work Instruction No. Drawing Rev No.
Sr. Parameter Description Specification / Comments Frequency
Dim / Value Unit Instrument Comments
1 Dimension Stator ID Bore gauge --- 8 nos from each lot
Stator OD Dial Vanier ---
Stack height Dial Vanier ---
Resting of End shield - Od Dial Vanier ---
PCD. for stud Dial Vanier ---
Hole dia for stud Dial Vanier ---
2 Fitment Slots size for loops Fixture Should not tight
With endshield Manual
With stud Manual
3 Performance Material CRCA Ext lab testing 0 1%
Treatment Hi-Perm
Lam. Shifting, Riveting Strength, Visual
Eccentricity & Perpendicularity Fixture
Straightness Surface plate 2%
4 Aesthetics No burs should be observed Visual 100%
No surface or corner bend Visual 100%

Quality Plan for Motor Components

Product Motor Assly
Item Description Bush Bearing Item Code
QPIP No : Material
QPIP Rev No: Drawing No.
Work Instruction No. Drawing Rev No.
Sr. Parameter Description Specification / Observation Frequency
Dim / Value Unit Instrument Observation
1 Dimension Spherical OD Dial Vanier 0.50%
ID AIR GAUGE 0.50%
Other Dim AS REQUIRED 0.50%
2 Fitment With endshield Manual Rotate smooth in cavity
With Spring Manual Step should be match
With shaft Manual Smooth rotation
3 Performance Material Ext lab test
Check oil qty (by weight?/ blotting paper) Weighing scale Oil should be sufficient
4 Aesthetics No dent marks or blow holes Visual
No damages or cracks Visual
No black dots Visual

Quality Plan for Motor Components

Product Motor Assly
Item Description End Cover assly Item Code
QPIP No : Material
QPIP Rev No: Drawing No.
Work Instruction No. Drawing Rev No.
Sr. Parameter Description Specification / Observation Frequency
Dim / Value Unit Instrument Observation
1 Dimension I D of End shield at outer edges
PCD of stud bolt w.r.t to center hole
Sq. hole for stud
Thk
Total Height
Ovality Should not oval by more then 0.5
Hole for cap grommet - ID
Hole for main wire grommet - ID
Oil cap hole ID
Name plate rivet hole ID
2 Fitment with stator
Oil catcher riveting Rivet ends should be flared correctly
oil felt Should be deep in oil
Cap grommet
main wire grommet
Oil cap fitment in catcher
Eccentricity & Square ness for stud
3 Performance Bush movement
Spring movement
4 Aesthetics Both side powder coating Should be good
No dent mark
No rusting
Zinc plating of oil catcher
Oil sleeve and cap No breakage
 Quality Plan for Motor Components
Product Motor Assly
Item Description Rotor assly with shaft Item Code
QPIP No : Material
QPIP Rev No: Drawing No.
Work Instruction No. Drawing Rev No.
Sr. Parameter Description Specification / Observation Frequency
Dim / Value Unit Instrument Observation
1 Dimension Rotor Height at skew bar VANIER
Fins height
Rotor OD
Skew width
Skew angle
b) END RING ID & HEIGHT
Shaft Od
shaft length both side
Dimple hole dist
D cut length
Dimple ID
Dimple depth
Weight of assly
2 Fitment Shaft fitment by impact test Impact ball
Shaft fitment by rotation torque
with Hylam washer
With Delran washer
with nylon spacer
With rubber washer
3 Performance Alum die casting with lamination Ext test lab
Alum purity Ext test lab
Run out w.r.t. shaft
Shaft treatment Ext test lab
4 Aesthetics Casting defects Visual
Smooth surface of rotor Visual
fins banding Visual
Rotor Damage Visual
Lacquer paint Visual
Shaft treatment Visual

Quality Plan for Motor Components

Product Motor
Item Description Motor assly Item Code
QPIP No : Material
QPIP Rev No: Drawing No.
Work Instruction No. Drawing Rev No.
Sr. Parameter Description Specification / Observation Frequency
Dim / Value Unit Instrument Observation
1 Dimension Dist of dimple from mtg points from -to
Shaft play
Shaft ends length from dimple 40 mm Vanier
Shaft side Endshield surface from mtg
surface
Shaft D cut
Shaft D length
Stud length from mtg
Stud PCD
Stud size M5
Extra washer size
Lead wire SWG
Lead Wire length
Open end
Capacitor wire length
Earthing wire length
2 Fitment With motor mtg part
With Fanblade
Capacitor with counter part
Dimple with grub screw
3 Performance High Voltage test 1000V rms
Insulation Resistance test >2M ohms
RPM at High 230/50 Hz
RPM difference b/w speeds 70 rpm
LVS 80 to 90 Volts
RPM at low 180( for pump model)
Shaft axial Play 1.5 mm
Temp rise at high 252 <70 deg
Temp rise at low 180 <70 deg
Motor running for 5min
4 Aesthetics /
Observation Extra Plain Washer, Spring washer and nut
Capacitor wire outlet Position
Earthing wire position
Name Plate data
Any abnormal noise
Main lead wire outlet position
Earthing symbol sticker
Rust proof coating on shaft
Powder coating on body
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Material Incoming

CRCA COIL ENAMELLED AL Other components

/ COPPER WIRE
IP- SP-
Stator Lamination Rotor Lamination Aluminium EC Gr Insulting Paper Insulting Tape PVC Lead wire
Sample Sample Random Sample Sample SP-
Inspection IP 01 Inspection IP 02 Inspection SP 02 Inspection SP 03 Inspection

1.Rivet hole dia & PCD
2.CB hole dia & PCD
3.ID & OD of lamination
4.Eccentricity & ovality
5.Flatness & thickness
1.ID & OD of lamination 1. Material composition 1.OD & BD 1.Dimensional Tests 1.Thickness 1.No. of strands & dia
2.Eccentricity & ovality 2.Resistance/conductivity 2.Mass transfer test 2.Water absorbtion test
3.Flatness 3.Break down voltage 2.High Voltage tests 3.High Voltage test 3.Heat test
4.Thickness 4.DC High Volt Pin Hole 4.Resistance per meter
5.Elongation

Heat Treatment
(Hi-Perm process) Material issued for
Rotor D/Cast

Inspection
Random

Stack Riveting Process Rotor Die Casting

MATERIAL RECEIVED FROM MATERIAL RECEIVED FROM SUPPLIER

MATERIAL RECEIVED FROM
SUPPLIER SUPPLIER
Inspection Inspection

1.Stack Height 1.Stack Height

2.Stack bendness 2.Rotor OD & bar skew angle
3.Burrs etc 3.Die Casting defects
4.Eccentricity & squareness 4.Rotor outness & bendness
5. Stator ID & OD 5. End rings dimensions
6. Rotor ID fitment

Process done outside Material Issued for Winding

Process
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Sheet Metal Endcover SP- Lubricating Oil SP- Sintered Bronze Bush Helical Spring SP- Woolen Felt washer

Sample Sample Sample Sample

Inspection Inspection Inspection Inspection Sample
Inspection

1.Case Height 1.Oil viscosity 1.Bush ID 1.Wire diameter 1.OD, ID & thickness
2.Hole operation position 2.Evaporation test at 2.Material composition 2.Solid Height 2.Neutralization Factor
3.Case bolt hole PCD elevated temperature 3.Nos. of turn 3.Natural wool content
4.Burrs 4.Flatness
5.Powder coating 5.Surface treatment
6.Thickness

C
Machined Rotor Shaft (Center less) Wound Stator received from
B WI- Winding Section for Varnishing
SP-
WI- Sample End Cover Sub-Assembly
Inspection
(LE & OLE type)
Lacquering of
rotor od 1.Shaft OD Varnishing
2.Linear dimension check
3.Shaft treatment
4.Sharp edge extra
5.Straightness Rollarizing of ID of
wound stator sub-
Insertion of lead assembly
grommets

A Rotor Shaft-Assy WI- SP-

Inspection
Inspection Sample Hardware like Case
bolt/Studs/bolts etc
100%
1.Rotor Run out wrt shaft Fittment of LE EndCover with 1.Surge comparision test
WI-
the Wound Stator sub-assy 2.Visual test

To FINAL assembly of motor

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Final Assembly of Motor Post Assembly of Motor

100 %
FINAL TEST SP-
Insertion of rotorshaft assy (A) into
LE cover stator assy (B)
1. Low Voltage Start Fittment of Nut/Washer other
2.Insulation Res. Test accessories as per specs
3.Surge Comp. Test
Insertion of specified case 4.Free Load Running
bolt to match above sub- 5.Pasting & scanning of NP OK Motor
assy (1-nos) Motor
Applying / pasting of rating
plate &/or connection dgm
Fittment of OLE end Rej. Motor
cover
Cleaning of motor for
removing dust/marks
Insertion of remaining
case bolt into above `

Putting motor into a

specified poly bag 1.Performance Test (AWN)
Insertion of spring washer 2.High voltage test
& screwing the nut 3.Temp Rise Test
Packing of motor into its 4.Dimesional Test
specified packing box 5.Visual Inspection
with internal packing 6. Dynamometer Test
Tightening of screw with
pneumatic tightner
Marking of model no. /
serial no. onto the box AUDIT

Rej. LOT OK LOT

Identifying & recording
the defect, dismentalling
Free running of
the motor and sending
motor to arrest infant
back the OK component
stage rej.
to their respective
stations
SP- 100% OK Motor
Inspection Motor
'HOLD' the entire lot Shipment of
for re-inspection/ motors to BUYER
dismentalling as per / storage into
1.Low volt start the decision taken shipping area
2.High voltage test
3.No-load parameters
4.Shaft endplay
5.Lock rotor test
6.Noise
7.Visual Inspection
Rej. Motor

Process done outside

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