FACULTY OF MECHANICAL ENGINEERING,

UNIVERSITI TEKNOLOGI MARA (UiTM)

INDIVIDUAL ASSIGNMENT

Program : Bachelor of Engineering (Hons) Mechanical (EM220)

Course : Manufacturing Processes

Course Code : MEM560
Lecturer’s Name : Dr. Alhassan Salami Tijani
Group : EMD5M6B
Student’s Name : Nur Syafiqah Binti Jaafar

General Guidelines:

Scale 1 2 3 4 5
Level Very poor Poor Acceptable Good Excellent

Criteria Scale Level Achieved Marks Obtained

Qualifying requirements:
Cover - Acceptable? * Yes / No
References - Acceptable? * Yes / No
Turn-it-in Report - Acceptable? * Yes / No
CO3 Demonstrates understanding /
2
knowledge of discussed area.
Writes and observes with good
1
comprehension.
Communicates clearly in a
1
well-organized manner.
Total Marks (10%)
Havells is a manufacturer company origin from India which produce various types of domestic
appliances such as juicer, cooker, and fan (Havells, 2019). For this MEM560 individual
assignment, I choose to make research on how do ceiling fans from Havells been manufactured.
The fan that Havells company is producing consists of many designs, specifications, and types.
For example, ceiling fan, personal fan, ceiling mounting fan, etc.

Figure 1 Ceiling Fan Figure 2 Ceiling Fan Figure 3 Personal Fan

Havells is India’s most modern and largest integrated manufacturing plant for fans. They have
a manufacturing capacity of more than 6 million fans annually. These integrated manufacturing
facilities are equipped with state-of-the-art technology which includes an automated 7 tank pre-
treatment line to prepare dust and oil-free surface (India H., 2014). 7 tank pre-treatment is a
process where parts are immersed in seven tanks sequentially. It is also called zinc phosphating.
For the blade, long aluminum sheets are cut according to the size.
The corners of these blades are shaved and drilled to form holes for the rivet (Shrivastava, 2017).
The rivet will connect the blades with the motor which allows it to rotate.

The sides of the blades are smoothened, and the surface of the blade will be angled with a precise
optimum angle to improve the airflow and even out air distribution. Blade pitch is the angle of
the fan blade. The greater the angle, the higher the air the fan blades can push (Rovert, 2021).
Then those blades will be submerged into the automated 7 tank pre-treatment line. This process
will enhance the life of the blades with double glossy and shiny finishing.

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 Figure 4 7 Tank Process of painting

Figure 5 7 Powder Coating 7 Tank Process (India Q. P., 2021)

Next, this setup also comes with a conveyorized automated liquid painting setup imported from
Saints France (India H., 2014). Each fan will go through an automated process for painting.
Havells also have ultra-modern powder coating plants imported from ITW GEMA Switzerland
which is the best for solid colour fans. This process is considered the painting stage and will
minimize any dirt deposition.

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 Figure 6 ITW GEMA Switzerland

Done with the blades and aesthetic purposes, here come the technical parts. The ceiling fan
needs a motor for the fan to run. It begins with drawing out the best raw material so that
the best product can be produced. They manufacture a complete range of three-phase LV motors
and general-purpose single-phase motors. Havells has an automated CNC machining
cell with numeric controlled copper winding machines to make sure consistent quality and
perfect insulation throughout the process of mechanising copper winding (India H., 2016).

The automatic winding lines are installed from 56 to 250 frames while the electrical winding
undergoes plot installation, coil winding and coil insertion which forms electrical connection and
lacing (Shrivastava, 2017). Those processes will form a wound pack which is then impregnated
in an automated impregnation plant with a PLC control system for consistent quality. For special
applications wound packs, are impregnated with the current UV impregnation system. Automated
machines are installed for final spigot turning after the wound pack is threaded in the plater which
allows a uniform air gap. This automated setup and minimum gap between rotor and motor make
the motor more efficient and make the fan more appealing (Shrivastava, 2017).

General-purpose single-phase motors ranging from 0.25 HP to 3HP in B56 100 s frame suitable for
220 volts 50 Hertz power supply. This makes it can be used in a wide range of applications (India H.,
2016).

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 Figure - Numerical controlled copper winding machines

Figure 7 Wound Pack

Lastly, Havells’ manufacturing plant is also equipped with a conveyorized motor assembly and
testing line for ceiling fans where each motor is done polished and tested before packing (India
H., 2014). SPMs are used for fitting bearings on the sharps to ensure proper fitment and result in
no bearing noise and failure. After assembling, strict tests are conducted certifying a normal motor
movement stroke and proper insulation. Exterior dimensions will also be checked for uniform
metrology to ensure no imbalance gets embedded in the motor that would fail the operation. The
Havells’ initiative to have a greater accuracy is the shafts are made on a highly accurate CNC
machine which is EN8/C40 steel and ground to 10-micron accuracy. Havells is the only plant in
India that offers in-house winding of portable fan motors (India H., 2016).

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 Figure 8 CNC Machine

Figure 9 Motor Assembly

Figure 10 Line Testing

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 The most manufacturer uses metal for manufacturing the blades. Not to be surprised metal
blades are among the most durable and efficient. It cuts through the air with little resistance
which provides strong airflow. This makes them ideal for larger areas because the downside of
it, it might be noisy. Hence, it is not recommended in a serene place such as a
bedroom or living room despite it still does not wear well outdoor. This is because of the
moisture in the air that can make them rust easily (Rovert, 2021).

In this manufacturing process of the motor, there is a part in which the stator outer is eroded
to create the air gap to avoid humming noises. It is best that if we can lower the cost and
energy consumption by dealing with the material of the blades themselves.

Timber blades are one of the common blade materials due to their rigidity and long-life span
(Rovert, 2021). Timber or the other name is lumber, is a wood product that processes
wood which is from the fallen tree into beams and planks. It minimizes noise as it moves through
the air. Despite that, it causes a reduction in airflow. To deal with it, another material that is well
known in manufacturing blades is plastic, specifically is ABS polymer. Plastic allows
manufacturers to mould it to any shape where they can widen the design options (Rovert, 2021).
Plastic is also a lightweight material, making the installation and assembly process easier and
motor capacity lesser. This can lower the cost and energy consumption as well.

Back to the timber blades, infusion of plastic material into timber blades might help the manufacturer
achieve the best results. It can improve the airflow and at the same time no compromission of quiet
operation. Plastic infusion might help the blades easy to clean which
can prevent the timber blades from warping and being affected by the moisture from the surrounding
air (Rovert, 2021). We tend to ignore the ceiling fan hygiene, but it is important
to have a clean ceiling fan to improve the airflow which provides us better breezy feelings.

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 Figure 11 Timber

Besides that, the length of the blades can be modified. The longer the blades, the higher the motor’s
load needed (John, 2021). Higher loads can cause the motor to burn out. A specified or higher duty
motor will be needed if longer blades need to be used. For example, open space areas, great rooms,
or large spaces. But for this ceiling fan, we are focusing more on utility rooms in a house such as
a bedroom and living rooms. In this case, longer blades will not be a suitable option.

In the shaping blade process, the manufacturer can shorten the length of blades and increase the
pitch angle or blade pitch. The higher the pitch angle, the higher the ability for the blades to push
the air (Houston, 2020). Short blades might reduce the air delivery even though longer blades still
do not necessarily increase the airflow due to additional drag force that slows down the rotation.
But it will be suitable in utility spaces. A combination of the material and the length of the blade
can produce a ceiling fan with maximum results. Besides, it will produce low consumption of cost
and energy also sustainable product.

Figure 12 Blade Pitch

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References

Havells. (2019). Havells India Ltd. Retrieved from Havells Consumer Ceiling Fan:
https://www.havells.com/en/consumer/fans/ceiling-fans.html#gref
Houston, L. (2020, May 3). Ceiling Fan Pro. Retrieved from Ceiling Fan Pro Web Site:
https://ceilingfanpro.com/what-is-blade-pitch-of-ceiling-fan/

India, H. (2014, February 7). Havells Fans Manufacturing Plant Video. India.

India, H. (2016). Havells Neemrana - Induction motors manufacturing plant. India.

India, Q. P. (2021, Jun 20). Powder Coating 7 Tank Process.

John, C. (2021, July 7). Airflow Academy. Retrieved from Airflow Academy Web Site:
https://airflowacademy.com/can-you-put-longer-blades-on-a-ceiling-fan/

Rovert. (2021). Retrieved from Rovert Lighting & Electrical Web site.

Shrivastava, V. (2017, December 13). Ceiling fan Manufacturing. India.