INDUCTION

MOTOR
Project Review
ME3302: Automation in Manufacturing

Group 28

Dhruv Bawa - ME20B061

Putrevu Sai Satwik - ME20B138
Putumbaka Karthikeya - ME20B140

3rd Year , B.Tech Mechanical Engineering

 INTRODUCTION
 Created and patented by Nikola Tesla in 1888, An induction motor is a type of electric motor that converts
electric power into rotary motion.
 It uses the principle of electromagnetic induction which causes the rotor to turn.

 Electric current is supplied to the stator, induces a magnetic field that rotates. This rotating magnetic field
interacts with the rotor, inducing current in the rotor. The interaction of the two magnetic fields results in a
torque, turning the rotor within the motor casing.

 Since the induction motor does not use brushes like DC motors, there is less wear of the internal parts.
 Types of 3-Phase Induction Motors
Slip Ring Induction Motor
A type of induction motor where the rotor
windings are connected through slip rings
to external resistance. Low initial current,
high starting torque, improved power
factor. it is used in applications that
require high torque, cranes, and elevators.
The rotor windings consist of more
number of windings, higher induced
voltage, and less current compared to the
squirrel-cage rotor.
Squirrel Cage
Induction Motor
Squirrel cage motor is one of the types
of induction motors. As the output
shaft is connected to the rotor inner
component which is looking like a
cage. Hence it is called squirrel cage.
The two-end caps i.e, circular in shape
are joined by rotor bars.The squirrel
cage is a simple method of pulling an
electromagnetic induction effect.
 Components of Slip Ring Induction Motor

Slip Rings Stator

Stationary portion of the
Electric transmission
motor and
devices that allow energy Slip delivers a rotating magnetic
flow between two electrical
Rings Stato
rotating parts field to interact with the
r rotor

Casing
Rotor
The casing of the induction Casing Rotor The central component of
motor contains all of the the motor, and is fixed to
motor components the shaft

Bearings Shaft
Bearings Shaft
The rotor shaft is held in The motor shaft is fixed
place by bearings at either within the rotor, and rotates
end of the motor casing. with it
 Components of Slip Ring Induction Motor

Slip Rings
Electric transmission
devices that allow energy
flow between two electrical
rotating parts

● The Slip Ring” is an electromechanical device that aids in transmitting

power and electrical signals from stationary to a rotating component.
● Slip rings are also known as rotary electrical interfaces, electric rotary
joints, swivels, or collector rings.
● Sometimes, based on the application, the slip ring requires higher
bandwidth to transmit data.
● Slip rings improve the efficiency and performance of a motor by improving
system operation and eliminating wires that are dangling from motor joints.
Slip
S
Rings r
 Components of Slip Ring Induction Motor

Casing
The casing of the induction
motor contains all of the
motor components

● The casing of the induction motor contains all of the motor components,
provides electrical connections and allows for ventilation of the motor
parts to reduce heat buildup.
● The casing design often includes fins to assist with heat dissipation.
S
R
Casing
 Components of Slip Ring Induction Motor

Bearings
The rotor shaft is held in
place by bearings at either
end of the motor casing.

● The rotor shaft is held in place by bearings at either end of the motor casing.
● The bearings minimize the friction of the shaft connection to the casing, increasing
the efficiency of the motor.
● The bearings should be able to operate at low and high speeds whilst minimizing
frictional losses.
● At the same time the bearing must be economic and require absolutely minimal
maintenance Rot
Bearings
 Components of Slip Ring Induction Motor

Stator
Stationary portion of the
motor and
delivers a rotating magnetic
field to interact with the
rotor

● The stator is the stationary portion of the motor and delivers a rotating magnetic
field to interact with the rotor.
● One or more copper windings make up a "pole" within the stator, and there is
always an even number of poles within a motor.
● The electric current alternates through the poles, resulting in a rotating
magnetic field.
Stator ● The stator of this motor comprises of various slots that are arranged to support
s the construction of a 3-phase winding circuit connecting to a 3-phase AC source.
 Components of Slip Ring Induction Motor
Rotor
The central component of
the motor, and is fixed to
the shaft

● The rotor is generally constructed of copper or aluminum strips attached at each

end to a circular fixture.
● This configuration is called a "squirrel cage rotor" because of its appearance. The
magnetic field generated by the stator induces a current in the rotor, which then
creates its own magnetic field.
● The interaction of the magnetic fields in the stator and rotor results in a mechanical
to torque of the rotor.
Rotor ● In some induction motors, the copper bars are replaced with slip rings and copper
windings that behave in the same way.
 Components of Slip Ring Induction Motor

Shaft
The motor shaft is fixed
within the rotor, and rotates
with it

● The motor shaft is fixed within the rotor, and rotates with it.
● The shaft extends outside of the motor casing, and allows a connection to an
outside system to transmit the rotational power.
● The shaft is sized to the amount of torque the motor puts out to avoid
Shaft breaking the shaft.
 Components of Slip Ring Induction Motor

Slip Rings Stator

Stationary portion of the
Electric transmission
motor and
devices that allow energy Slip delivers a rotating magnetic
flow between two electrical
Rings Stato
rotating parts field to interact with the
r rotor

Casing
Rotor
The casing of the induction Casing Rotor The central component of
motor contains all of the the motor, and is fixed to
motor components the shaft

Bearings Shaft
Bearings Shaft
The rotor shaft is held in The motor shaft is fixed
place by bearings at either within the rotor, and rotates
end of the motor casing. with it
INDUCTION MOTOR - CAD
MODEL
ROTOR
STATOR
SHAFT
CASING
MANUFACTURING PROCESS OF ROTOR
 MAKING OF ROTOR – Part 1
● Die Casting: Die casting is a process used to produce the rotor body. Molten metal, such as aluminum or copper
alloys, is injected into a die (mold) under high pressure. The die is designed to shape the rotor body according to the
desired specifications.

● Surface Finish: After die casting, the rotor body undergoes surface finishing processes to achieve the desired
smoothness and dimensional accuracy. This may involve grinding, polishing, or machining operations.

● Laminations: Laminations are thin, insulated steel sheets that are stacked together to form the rotor core. The
laminations help reduce eddy current losses. The sheets are typically stamped or cut to the required shape and size.

● Slotting: Slots are cut into the rotor core to accommodate the rotor winding. These slots are precision-machined to
the specified dimensions and arrangement. The number and size of slots depend on the motor design.

● Drilling: Various holes may be drilled in the rotor for different purposes. For example, holes are drilled for mounting
bolts, balancing purposes, or to provide ventilation for cooling.
 MAKING OF ROTOR – Part 2
● Insulation: The rotor winding and core are insulated to prevent electrical short circuits. Insulation materials such as
mica, varnish, or epoxy are used to coat the winding and to insulate the laminations from each other.

● Riveting: In some designs, the rotor laminations are riveted together to enhance structural integrity and reduce
vibrations. This process involves using rivets or pins to secure the laminations tightly.

● Winding: The rotor winding consists of copper or aluminum bars that are inserted into the slots on the rotor core.
These bars are then electrically connected at one end to form short-circuited loops. The winding pattern and the
number of turns are determined by the motor design specifications.

● Balancing: The rotor is dynamically balanced to minimize vibration and ensure smooth operation. It involves
measuring the rotor's unbalance and adding or removing material to achieve the required balance. This can be done
by adding or removing weights or by machining specific areas of the rotor.

● Testing: Once the rotor is assembled, it undergoes various tests to ensure its performance and quality. These tests
may include electrical tests to check the insulation resistance and continuity of the winding, as well as mechanical
tests to verify balance, alignment, and overall functionality.
MAKING OF Rotor – Tecnomatix top view
MANUFACTURING PROCESS OF STATOR
 MAKING OF STATOR – part 1
● Die Casting: Die casting is a common method used to produce the stator frame. Molten metal, typically aluminum or
aluminum alloys, is injected into a die (mold) under high pressure. The die is designed to shape the stator frame
according to the desired specifications.

● Surface Finish: After the die casting process, the stator frame undergoes surface finishing processes to achieve the
desired smoothness and dimensional accuracy. This may involve grinding, polishing, or machining operations.

● Laminations: The stator core is typically made up of laminated sheets of electrical steel. These sheets are stamped or
cut to the required shape and size. The lamination process helps reduce eddy current losses within the stator core.

● Slotting: Slots are cut into the stator core to accommodate the stator winding. These slots are precision-machined to
the specified dimensions and arrangement. The number and size of slots depend on the motor design.

● Drilling: Various holes may be drilled in the stator frame for different purposes. For example, holes are drilled for
mounting bolts, cooling purposes, or to provide access for electrical connections.
 MAKING OF STATOR – Part 2
● Insulation: The stator winding and core are insulated to prevent electrical short circuits. Insulation materials such as
mica, varnish, or epoxy are used to coat the winding and insulate the laminations from each other.

● Riveting: In some designs, the stator laminations are riveted or bolted together to enhance structural integrity and
reduce vibrations. This process involves using rivets or bolts to secure the laminations tightly.

● Winding: The stator winding is typically made of copper or aluminum wires that are wound into the slots on the stator
core. The winding pattern, number of turns, and wire gauge are determined by the motor design specifications.

● Balancing: The stator is dynamically balanced to minimize vibrations and ensure smooth operation. Similar to the
rotor, the stator undergoes balancing processes, which involve measuring the unbalance and adding or removing
material to achieve the required balance.

● Testing: Once the stator is assembled, it undergoes various tests to ensure its performance and quality. These tests may
include electrical tests to check the insulation resistance, continuity, and performance of the winding, as well as
mechanical tests to verify balance, alignment, and overall functionality.
MAKING OF STATOR – Tecnomatix top view
MANUFACTURING PROCESS OF SHAFT
 MAKING OF SHAFT
● Raw Material Selection: The shaft is typically made of high-quality steel, such as carbon steel or alloy steel. The
raw material is selected based on its mechanical properties, such as strength and toughness, as well as its suitability
for the specific motor application.

● Cutting: The raw material is cut to the desired length for the shaft. This can be done using various cutting methods,
such as sawing, shearing, or machining operations like turning or milling.

● Turning: Turning is a machining process used to shape the shaft. The raw material is mounted on a lathe, and a cutting
tool removes material from the outer surface of the shaft to achieve the desired diameter and shape.

● Broaching: Broaching is another machining process used to create keyways or splines on the shaft. A broach tool with
multiple teeth is used to remove material in a linear motion, creating the desired profile on the shaft.
 MAKING OF SHAFT
● Heat Treatment: Heat treatment is often employed to enhance the mechanical properties of the shaft. This process
involves heating the shaft to a specific temperature and then cooling it rapidly or slowly, depending on the desired
hardness, strength, and durability. Common heat treatment methods include annealing, quenching, tempering, or
induction hardening.

● Machining: After heat treatment, additional machining operations may be performed on the shaft to achieve precise
dimensions and surface finish. This can include operations such as grinding, milling, or drilling to create threaded
holes or other features.

● Balancing: Balancing is crucial to ensure smooth operation of the motor. The shaft is dynamically balanced to
minimize vibrations. This process involves measuring the unbalance and adding or removing material from specific
locations on the shaft to achieve the required balance.

● Coating: Depending on the motor application, the shaft may undergo coating processes to improve its surface
properties. Common coatings include plating, such as chrome or zinc plating, or applying a protective layer of paint
or corrosion-resistant coating.
Making of shaft -Tecnomatix top view
 MANUFACTURING PROCESS OF Ball Bearings+Slip rings
• we’ll be outsourcing our ball bearings and slip rings from a separate vendor
and will be directly introduced in the assembly line
• This saves up setting up of additional units which were specific to their
manufacturing processes(cost cutting) and reduces the time take to make one
assembly unit of the induction motor

MANUFACTURING PROCESS OF CASING

 MANUFACTURING PROCESS OF CASING

• Sand casting: Sand casting is a method used to produce complex metal shapes by pouring molten
metal into a mold made of sand. The sand mold is created by compacting specially formulated sand
around a pattern that represents the desired shape of the casing.
• Machining: Machining involves the removal of excess material from the cast casing to achieve the
final shape and dimensions. This process utilizes various cutting tools and techniques such as milling,
drilling, and turning to shape the casing according to precise specifications.
• Surface treatment: Surface treatment is performed to enhance the durability, appearance, and
performance of the casing. It may include processes such as cleaning, deburring (removing sharp edges
or burrs), and applying coatings or finishes like painting or powder coating.
• Assembly: During the assembly process, various components of the induction motor, including the
stator, rotor, and other internal parts, are fitted into the casing. This involves aligning and securing the
components in their designated positions to ensure proper functioning and structural integrity.

Inspection and testing: Inspection and testing are crucial steps to ensure the quality and reliability
of the casing. This typically involves visual inspections, measurements, and functional tests to verify that
the casing meets the required standards and specifications.
Making of Casing -Tecnomatix top view
FACTORY LINE OF SLIP RING INDUCTION MOTOR
 TECHNOMATIX PLANT LAYOUT

VIDEO LINK FOR TECHNOMATIX PLANT SIMULATION

https://drive.google.com/file/d/1jOI9UFUhAtcGFovzPVpDWnr2rJ4IW_t5/view?usp=sharing
 TECHNOMATIX PLANT LAYOUT

VIDEO LINK FOR TECHNOMATIX PLANT SIMULATION

https://drive.google.com/file/d/1jOI9UFUhAtcGFovzPVpDWnr2rJ4IW_t5/view?usp=sharing
Time Analysis
 TIME ANALYSIS OF ROTOR
● Considering a maximum working hours of the factory is 16hrs per day.
● Maximum number of rotors obtained is 2 per layout in 1 day.
● No of rotors per month is 60 per single layout.
 TIME ANALYSIS OF STATOR
● Considering a maximum working hours of the factory is 16hrs per day.
● Maximum number of stators obtained is 2 per layout in 1 day.
● No of rotors per month is 60 per single layout.
 TIME ANALYSIS OF SHAFT
● Considering a maximum working hours of the factory is 16hrs per day.
● Maximum number of shafts can be obtained is 5 per layout in 1 day.
● But we restrict to 2 per layout to avoid extra production.
● No of shafts per month is 60 per single layout.
 TIME ANALYSIS OF CASING
● Considering a maximum working hours of the factory is 16hrs per day.
● Maximum number of cases can be obtained is 6 per layout in 1 day.
● But we restrict to 2 per layout to avoid extra production.
● No of cases per month is 60 per single layout.
Cost Analysis
 1. Raw Materials
Raw materials required to manufacture a single induction motor:

Total Cost for Raw Materials is Rs. 14700.

2. ROTOR
● Cost of Power Consumption and Machine Cost for Rotor
● Considering the cost of electricity is Rs 12/unit.
 3. STATOR
● Cost of Power Consumption and Machine Cost for STATOR
● Considering the cost of electricity is Rs 12/unit.
4. SHAFT
● Cost of Power Consumption and Machine Cost for SHAFT
● Considering the cost of electricity is Rs 12/unit.
5. Casing
● Cost of Power Consumption and Machine Cost for CASING
● Considering the cost of electricity is Rs 12/unit.
 5. Bearings +Slip Rings

● Cost of slip rings – Rs 2400

● Cost of Bearing(6210-2RS-HQ1)- Rs.2000
 COST ANALYSIS

Let’s say factory produces 300(60*5 Layouts) motors per month.

Selling price for each motor is Rs 30000.(7HP Induction Motor)
Manufacturing Cost = Labor Cost + Maintenance Cost + Raw Materials + Power
Consumption

Manufacturing cost per each motor= 14700+7029.56+1095= Rs 22824.56(approx)

Taking 30% markup, Final price of 1 motor=Rs 30000
Raw Materials + Power Consumption = 15800/motor = 47,40,000/month
Labour + Maintenance Cost = 2108870( 16 workers per layout with Rs 20000/month)
Selling Price = 90,00,000/month
Profit = 2151130/month.
Total Machine Cost + Land Cost = 102300000.
Time Taken to recover the Investment = 3.96Yrs.(Break even)
No. of units sold before investment is recovered= 14,256 units
  Alignment of Rotor – Stator – Shaft assembly:
 This is important as the opposite may lead to undesirable vibrations and
heat generation. We use rotary balancing to check for vibrations here.
Additionally, the casing is equipped with fins to allow adequate heat
transfer to prevent rise in temperature which may lead to a fire in the
assembly.

 Ball Bearings Quality check :

 The Bearing’s load-carrying capacity is tested to prevent it from
Quality failing during operation. The bearings are graded on the basis of their
roundness, size and surface smoothness characteristics.
Control  Final Assembly Quality check:
 Once the induction motor is assembled it undergoes a series of tests to
ensure it meets the standards.
 The motor is run at its synchronous speed to check if any unwanted
vibrations are produced or not.
 Torque characteristics of the slip rings are analysed under different
loading conditions to test its failure limit. – using oscilloscope and
Hipot tester (usually done on one unit of the batch as it is very time
 JACK SIMULATION – TESTING FACILITY

https://drive.google.com/file/d/10qKrOnzPy2bG15zidUT_j7xsNPTEgliG/view?usp=sharing
JACK SIMULATION - VIDEO
  Cost analysis:
 Faced a problem while estimating the costs of different
operations and machinery required for production. Ex:
calculating which model of the machine will be suitable
Challenges for industrial standards

Faced  Tecnomatix:
 Because of the constraint on the total number of units
allowable in the plant layout for student license, we
couldn’t completely show the video simulation of our
assembly unit.
  Introduction of our product(Induction Motor)
 Dhruv Bawa, Putrevu Sai Satwik
 Cad+Line Diagrams - Putrevu Sai Satwik
 Manufacturing Proceses - Putumbaka Karthikeya
 Assembly line - Putumbaka Karthikeya, Dhruv Bawa
CONTRIBUTIO  Tecnomatix Plant layout - Putumbaka Karthikeya, Putrevu Sai
NS Satwik
 Time Analysis - Putumbaka Karthikeya, Dhruv Bawa
 Cost Analysis- Putumbaka Karthikeya, Putrevu Sai Satwik
 Quality Control- Dhruv Bawa
 Jack simulation – Dhruv Bawa, Putrevu Sai Satwik