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TECHNICAL RESEARCH (BET-3)

Ingente, Eliakim
B.
BET-HVACR3a
Doctor Bilomar
Floresca
Fabrication of cost-effective Fan motor winding separator and extractor

In Partial Fulfilment

Technical Research

BET3

Presented to

Prof. Dr. Bilomar Floresca

Powerplant Engineering Department

Technological University of the Philippines Manila

Ayala Blvd. Ermita, Manila

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 CHAPTER I

Problem and Its Setting

Introduction

Most of the things around the human environment are functioned by

machines wherein motors are used to generate power in it. In Heating Ventilating

Air-conditioning refrigeration industry, motors are widely used for it serves as the

heart of the entire machinery used in HVAC industry. When motors are partially

defected, it can be serviceable, but if it is all burned up or varied, it is no use unless

it is all be junked out or recycled for future industrial applications, recondition and

repurposing. The magnetic wires in motor are removed and recycled, but the core

(iron ring shape that supports the winding and coils comprises the rotor along with

the shaft) (reverso) are used again as a base support for the new rewind coils. In

line with the redundant usage of motors, the researchers have come up with the

ideology of making a tool that mitigates the removal of junk or burned up copper in

the core of an electric motor.

Electric motor is widely used at this present time; Electric motor is an

electrical machine that converts electrical energy to mechanical energy. Motors are

operated by so called magnetic field and an electric current in a wire winding to

generate force in the form of torque on motor’s shaft (Wikipedia). Most of the

motors in the present circumstances are made up of copper, and for the sake of the

motor’s economic affordability, most present fabricated motors are made up of

aluminum.

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 In many instances, motors when burned up are soon be winded. Before

the motors are to be winded, the very first process is to remove the windings from

the motor core and rewinding process are as follows. Many technicians as well as

scrappers tend to struggle removing motor windings from its core, it takes time and

much more laborious. In congruence with this matter, the researcher ought to

fabricate a cost-effective or budget-friendly tool that is handy for most of

technicians as well as scrappers and rewinders.

Objectives of the study

The main objective of this study is to develop a puller or extractor of magnetic

copper and aluminum windings using locally available materials.

Specifically, this study aims to:

1. Lessen rewinding process by means of easily extracting busted or burned-out

motor windings from motor core.

2. Easily remove magnetic wires from the core of electric motor.

3. Test the efficiency and effectiveness of the extractor on pulling magnetic wires

on electric fan motor.

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Significance of the study

The verdict and authenticity of this study will benefit the following:

Technician. This research study will benefit the technicians, for it gives

them the mitigation on removing magnetic wires on the core of electric motor.

Rewinders. This study benefits the rewinders by easily accumulating motor

cores from electrical shops.

Junkshop owners. This research study will allow junkshop owners to

achieve a less hassle job on separating the motor core and the magnetic wires.

Copper Recyclers. This research study will allow copper recyclers to make it

easier to recycle and repurpose copper wires unto a new fine copper that is soon be

used for electrical purposes.

Scope and Limitation

This research aims to design and fabricate a cost-effective or budget-

friendly tool that mitigates the processes in removing or extracting copper and

aluminum wires from electric motor cores. This research is composed of tests and

processes that deals with the struggles of most of technicians, rewinders as well as

scrappers.

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 Chapter II

Review of Related Literature

The electric motor's world impact before light bulbs

Trolleys and the connected power systems were very expensive to build but

transported millions of people to work in the 1880s. Until the growth of the power

grid in the 1890s most people (middle and low classes) even in cities did not have

the electric light in the home. It wasn't until 1873 that the electric motor finally

achieved commercial success. Since the 1830s thousands of pioneering engineers

have improved motors and created many variations. See other pages for more

detail on the electric motor's vast history.

How motors work

Electric motors can be powered by alternating (AC) current or direct current

(DC). DC motors were developed first and have certain advantages and

disadvantages. Each type of motor works differently but they all use the power of

the electromagnetic field. We will talk about the very basic principle of

electromagnetic fields in motors before you can move on to the different types of

motors. AC electric motors use a secondary and primary winding (magnet), the

primary is attached to AC grid power (or directly to a generator) and is energized.

The secondary receives energy from the primary without directly touching it. This is

done using the complex phenomena known as induction. (EdisonTechCenter)

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Types of alternating current motors

Alternating currents power these electric motors. The AC motor is generally

made up of two basic parts: an outside stator with coils through which runs an

alternating current that produces a rotating magnetic field, and an inside rotor that

is attached to the output shaft and produces a second rotating magnetic field. The

rotor’s magnetic field may be made by permanent magnets, reluctance saliency, or

DC or AC electrical windings. This article looks at the two most common types of AC

motors: induction and synchronous.

Induction Motors

Induction motors, also known as asynchronous motors, use

electromagnetic induction from the stator’s magnetic field to create the electric

current in the rotor to produce torque. These electric motors do not run at

synchronous speed with the current, hence their name. They use the

electromagnetic induction phenomenon for transforming the electric power into

mechanical power. Induction motor rotors are the most common type of AC motor

and are used for various types of pumps, compressors, and other machines.

Single Phase Motors

Single phase motors have one stator. They don’t have the unique rotating

magnetic field that poly or multi-phase motors have. The winding of the stator

generates a field which pulsates instead of rotates. When the rotor is at rest, the

expanding and collapsing stator field creates currents in the rotor. The currents

create a rotor field opposite in polarity to the stator’s field. The opposite polarity

applies a turning force to the upper and lower parts of the rotor. Since this force

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goes through the center of the rotor, it remains equal in each direction, resulting in

the rotor remaining stationary. If the rotor starts turning, it continues to rotate in

the direction in which it is started, since the momentum of the rotor aids the

turning force in that direction. Single phase motors are used in low power

applications such as domestic appliances like ceiling fans, mixer grinders, and

portable power tools.

Polyphase Motors

Polyphase motors can be two or three phase motors. They are similar to

single phase induction motors in operation, but both single phase and polyphase

motors operate with rotating magnetic fields. Their rotating magnetic fields are

created by a two or three phase current that flows through two or more groups of

coils. The rotating magnetic fields produce torque. Polyphase motors are used for

applications that require high power, such as power drives for compressors,

hydraulic pumps, air conditioning compressors, and irrigation pumps.

Synchronous Motors

Synchronous motors operate at a speed that is synchronized with the

supply current frequency. This means at the motor’s steady state, the rotation of

the shaft synchronizes with the frequency of the supply current. The rotation period

of the shaft is equal to the number of AC cycles. Synchronous motors have stators

with multiphase AC electromagnets on them. These electromagnets produce a

magnetic field which rotates in time the line current. The rotor with either

permanent magnets or electromagnets turns in step with the stator field at the

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same rate, creating the second synchronized rotating magnetic field of an AC

motor.

Reluctance Motors

Reluctance motors have a rotor consisting of a solid steel casting with

projecting toothed poles. Their starting process is similar to an induction motor, but

then it runs like to a synchronous motor. Usually, they have fewer rotors than

stator poles, minimizing torque ripple and preventing the poles from all aligning,

because that position cannot generate torque. Reluctance motors have a range of

horsepower ratings, from a few watts to about 22 kW.

Hysteresis Motors

Hysteresis motors have a rotor that is made up of a ring of a semi-

permanent magnetic material such as high-carbon steel. Hysteresis, the way the

rotor’s magnetic flux lags behind the external magnetizing force, and the eddy

current of the motor produce the motor’s torque. These motors have a good

starting torque and are very quiet. However, their efficiency is low, and they are

restricted to small power ratings. Applications included tape recorder capstan drives

and motion picture cameras and recorders. (Thomasnet)

Coil winding technology

In electrical engineering, coil winding is the manufacture of

electromagnetic coils. Coils are used as components of circuits, and to provide the

magnetic field of motors, transformers, and generators, and in the manufacture of

loudspeakers and microphones. The shape and dimensions of a winding are

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designed to fulfill the particular purpose. Parameters such as inductance, Q factor,

insulation strength, and strength of the desired magnetic field greatly influence the

design of coil windings. Coil winding can be structured into several groups regarding

the type and geometry of the wound coil. Mass production of electromagnetic coils

relies on automated machinery. (Wikipedia)

Motor Core

A core is a path of magnetic flux. It is made of iron. Moreover, a core used to

combine two magnets with magnetic flux is called a yoke. There is a difference in

accessory ingredients between iron for mechanical structures and that for cores.

Iron for mechanical structures contains carbon (C), while iron for cores is mixed

with silicon (Si) and called silicon steel. A motor has a stator core and a rotor core,

and a magnetic circuit is established through the air gap between them. Since the

magnetic pole of the stator core configuring the magnetic circuit of winding-field DC

motors is excited by direct current, the core does not need to be laminated; soft

steel is used instead. On the other hand, laminated core is used for a rotor core

configuring the armature circuit as the flux changes with rotation. Also, permanent

magnets are often used for the magnetic pole of compact DC motors. Cores for the

stator of synchronous motors and the stator and rotor of induction motors are

excited by alternating current, therefore laminated core is used for each of them.

(Nidec)

Hydraulic and Mechanical Pullers

A complete line of pullers with the widest range of sizes, capacities and

styles. Whether your application requires mechanical or hydraulic, Enerpac can

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satisfy your requirements. Made of high strength steel alloys, you can depend on

Enerpac pullers to provide years of trouble-free operation, even in the harshest

environments. These hydraulic pullers provide a simple solution for removing shaft

mounted items such as bearings, gears, sleeves, wheels, sprockets and eliminate

time-consuming and unsafe hammering, heating or prying. Damage to parts is

minimized through the use of controlled hydraulic power. (Enerpac)

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 Chapter III

METHODOLOGY

This chapter presents the development of the research, the procedure in the

assembly of the components or parts as well as the steps of testing and evaluating

the tool’s functionality.

Research Design

This research was designated on developmental research which in generality

focused on developing a prototype of a motor copper extracting tool. In creating a

prototype, the researcher will prove the workability of the project through a

functional model. The functionality and the capability of the proposed project will be

determined through experimental method wherein tests and experiments takes

place.

Project Design

The electric fan motor extractor or puller is a manually operated mechanical

tool that is used to extract the stators from motor core for future rewinding

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process. The puller is made out of locally available materials; MS plates, deform

bar, flat bar, square bar, cold rolled shafting, bearing.

Figure 1: Electric fan motor extractor and puller

Figure 2: Motor stator clamp

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 Figure 3. Motor coil extractor

Project Development

The following is the operational procedures for the project:

Firstly, the defected motor will be placed to the motor clamp where the other

side of the stator would be sawed up and lose the tight endings of the poles of the

motor.

Secondly, once the other side of the motor coils are sawed up, the extractor

will now be placed to the gaps of the stator where it is now pulled so that the coils

are extracted from the motor core.

Evaluation Procedure

The following is the evaluation procedure:

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 The project will be evaluated by only 1 respondent with 10 different sizes of

square electric fan motor; Asahi, Standard, Fukuda, Mitsu, Camel, special sized

electric fan motors except orbit (circular core) fan motor, Industrial motors. It will

be evaluated by the different criteria based on the following: Functionality,

Durability, Safety, and Workability. A demonstration on how the prototype will be

functioned is presented to the panel of evaluators. The specifications of the project

were discussed and emphasize its limitations.

Table 1

Likert scale

Numerical Scale Descriptive Rating

5.0 Excellent

4.0 Very Good

3.0 Fair

2.0 Poor

1.0 Very Poor

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