BLDC CEILING FANS MANUFACTURING/ ASSEMBLY REPORT

SCOPE : Ceiling fans are available in different colours and sizes to suit every need. Fans are used in
domestic as well commercial establishments. In Indian climatic conditions Fans have become a necessity
for every house hold as well in commercial establishments. Currently Ceiling Fans widely in use have
been manufactured using a single phase capacitor type induction motor. With the advancement in
technology a new concept has been introduced in Ceiling fans viz. BLDC ( Brush Less Direct Current). The
Fan motor consists of a copper wound stator with 16/18 poles, a permanent magnetic ring of similar
number of poles and a electronic circuit plate ( Driver/ Card) designed to suit fitment inside the Ceiling
Fan Body assembly. The electronic Card contains magnetic pole sensors to drive the motor. Hence there
is less friction resulting in lower heating and improved performance leading to power saving with longer
life. The market size is huge and ever expanding. Besides open market there is always scope in
government purchase program.

List of major Components:

1. Body & Cover set of alimunium casting
2. M.S.Shaft 1 No.
3. Stampings
4. S.E. Copper Wire
5. Ball Bearings 2 Nos
6. Aluminium Blades 3No./ No.
7. Show cup/ fittings rings
8. Cannopy 2 Nos
9. Down Rod
10. Card Board Packing Box including Thermocole support.
11. Hardware ( Different size of screws, nuts & Bolts)
12. Single core PVC Coated wire for connections.
13. Insulating Varnish
14. Powder for Powder Coating
Plant & Machinary : 1. Lathe Machine 4 ft for machining of stamping stack & other operations – 1 No.
2. ¾” Drill machine pillar type - 1 No.
3. Hand Press / Hydraulic Press for pressing Stator – 1 No.
4. Arbour Press for Bearing Pressing
 5. Grease gun to size
6. Powder coating plant
7. Electrical Panel for Testing

8. Techometer for speed measurement

9. Cardboard box Packing Machine

10. Screw Drivers,Scissor, Spanners, Plier, pullers & few Jigs & Fixtures etc.

11. Tables & stools for creating assembly & testing line.

12. Bins & Pellets for storage of material.

13. Coil winding machine

Manufacturing Process :

Body & Cover set are purchased from outside ( Bought out complete ) machined & Hole-Tapped
complete. These are subjected to inspection & then powder coated as required.

Aluminium Blade sets are also bought out complete and powder coated as required

Stampings are fitted in Shaft in stack of 12/14mm & wound & varnished after outer finishing of the
stack as per size.

Magnetic Ring is checked for finishing and a layer of Lacquer applied to the inner surface of the ring.

Bearings fitted on the Shaft, electronic card placed in place and final Assembly of the Fan completed.

Idle motor is run on 220 volts AC and results noted. Random testing of the motor on load fitted with
blades is also carried out.

Final Stage :

Each motor is subjected to ‘Run-in’ test for at least 30 minutes and test results noted. Motors are
selected on random basis and subjected to run test on load and results noted.

Each motor is cleaned with silicon polish and packed in polyethene bag . Finally each motor along with a
downrod and a remote is packed in card board box provided with thermocole support and kept in
finishing room for final dispatch.