CHAPTER 1: INTRODUCTION

Col. R. E. B. Crompton founded R.E.B. Crompton & Company in 1878. The company was merged with F.A.
Parkinson in 1927 to form Crompton Parkinson Ltd. Greaves Cotton and Company, established by James Greaves
in 1859, was appointed as their concessionaire in India. In 1947, just before India's independence, Lala Karam
Chand Thapar, an Indian industrialist, bought Greaves Cotton when the company was put up for sale. With this
acquisition, Karam Chand Thapar gained control of several associated companies such as Crompton Parkison
Works, Greaves Cotton and Crompton Parkinson Company. The name Crompton Greaves Limited was adopted
on 2 August 1966, following a court-directed amalgamation of Greaves Cotton and Crompton Parkinson Ltd.

Over the years, the company has evolved into one of India's largest private sector enterprises. After the acquisition
of the Belgium-based Pauwels Trafo/Pauwels Group in May 2005, Crompton Greaves was ranked amongst the
world's top ten electrical transformer manufacturers. The company subsequently acquired companies outside
India. These include Ganz (Hungary), Microsol (Ireland), Sonomatra (France), MSE Power Systems (USA), and
ZIV (Spain).

Crompton Greaves is a part of the US$4 billion Avantha Group, and is headquartered in a building CG House at
Worli, Mumbai. In 2009 Crompton Greaves adopted a new brand identity and is since known as CG.

CG is fast emerging as a first choice supplier of high quality, smart electrical, industrial and consumer products
and solutions all over the world.

As one of the world`s leading engineering corporations, CG provides end-to-end solutions, helping its customers
use electrical power effectively and increase industrial productivity with sustainability. CG was established in
1937 in India; and, since then the Company has been a pioneer and has retained its leadership position in the
management and application of electrical energy.
Our unique and diverse portfolio ranges from transformers, switchgear, circuit breakers, network protection &
control gear, project engineering, HT and LT motors, drives, Power Automation Products and turnkey solutions
in all these areas; thus enhancing the many aspects of industrial and personal life. This portfolio has been
structured into 3 SBUs - Power Systems, Industrial Systems and Automation. For details please refer to the panel
on the right.
Since 2005, CG has embarked upon an ambitious globalization strategy, growing both organically and
inorganically, and drawing into its fold leading international companies such as Pauwels, Ganz, Microsol,
Sonomatra, MSE and PTS. Consequent to this globalization, CG now enjoys manufacturing bases in
Belgium, Hungary, Indonesia, Ireland, France, UK and US, in addition to more than twenty manufacturing
locations in India, employing more than 8000 employees worldwide with diverse nationalities and cultures. A

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worldwide marketing network of more than 150 representatives spans the globe, offering the entire range of CGs
products, solutions and services.

CG has been aggressively investing in R&D, product certifications, product quality, productivity enhancement
and operational excellence. CG`s Global R&D center, located in India, has been recognized for its innovation
and received the prestigious "National Award for the Best R&D Efforts" for its outstanding achievements in the
Electrical Engineering Sector in 2008. CG`s R&D strategy aligns with the Company`s Global Vision, and focuses
on creating platform technologies, shrinking product development cycle time and enhancing CGs Intellectual
Property capital.
To unify our global focus, all CG facilities across the world have taken actions to ensure that customers receive
consistent "One World Quality", for all CG products and solutions in all parts of the world.
Thanks to its well-structured and validated business model, CG is well positioned to provide its customers with
technology-driven, value-added solutions, leveraging a broad product portfolio on the one hand, and enhancing
the entire value-chain quality, delivery, and services on the other hand.

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CHAPTER 2: PRODUCTS OF CROMPTON GREAVES

Fig 1: Some Products of Crompton Greaves

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Power Systems

Transformers and Reactors

Switchgear Products-MV/HV/EHV/UHV
Instrument Transformers-MV/HV/EHV/UHV
Power Quality Solutions
T&D Systems/Engineering Solutions
Mobile Substations
Protection Control & Automation
Services for Power Systems
Transformer & Switchgear Components
LV Switches & Panel Products

Industrial Systems

Motors: High/Low Voltage AC&DC

Generators/Alternators
Traction Motors/Alternators/Control Electrics
FHP/Commercial Motors
Drives and Automation
Stampings and Laminations
Services for Industrial Systems

Automation System

Power Line Carrier Communication(PLCC)

Control Panels
Numerical Protection IED'S or Relays
Smart Grid products (Smart Energy meters, Data concentrator Units)
Substation Automation Solutions
RTU's based solutions
Relay Panels
Routers

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Consumer Products

Fans
Appliances
Lighting
Pumps
Home Automation
Integrated Security Systems
Wiring Accessories

CG offers products, services and solutions through multiple revenue streams comprising two business
segments, viz. Power Systems and Industrial Systems.

Power Systems, includes transformers, switchgear, circuit breakers, vacuum interrupters, network protection & control
gear, as well as design, servicing, and execution of turnkey T&D and substation projects and solutions. This is the
largest business which is now well entrenched throughout the world. It is a high value, high turnover business with a
strong global footprint, contributing to approx. 70 per cent in consolidated revenue. The facilities are located in different
parts of Belgium, Hungary, India, Indonesia, Ireland, UK and US.

Industrial Systems is engaged in the business of power conversion equipment; a wider spectrum of High and Low
Tension rotating machines (motors and alternators), stampings, as well as railway transportation & signalling products.
Industrial Systems is largely India focused with a very strong market presence and market leadership position in many
segments. It also caters to foreign markets through its facilities in Hungary and exports. Its product portfolio includes
motors & generators ranging from 20W to 30MW. We enjoy a market leadership for AC Motors and the second position
in AC Generators and DC Motors in India. We are the largest manufacturers of Low Tension motors in India offering
a range of AC and DC motors ranging from 0.18kW to 4MW in various standards and customized configurations to
respond to the exacting demands of the industry.

CG offers a wide range of high and low voltage motors (rotating machines). The range includes safe and hazardous area
motors, energy efficient motors as well as motors for special applications like brake motor, re-rolling mill, cement mill,
oil-well pump etc. Our range also includes DC Motors and Traction motors. Our motors are available in various
standards and customized configurations to respond to the exacting demands of the industry:

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1. High Voltage Motors
CG offers wide range of High Voltage Motors from 2 to 24 Poles up to 25 MW range in various enclosures like Closed
Air Circuit Water Cooled (CACW), Closed Air Circuit Air Cooled (CACA), Totally Enclosed Tube Ventilated Motors
(TETV), Screen Protected Drip Proof (SPDP), Totally Enclosed Fan Cooled (TEFC) to meet various industrial
requirements of any specific application.
2. Low Voltage Motors
CG offers wide range of Low Voltage motors in cast iron and aluminium constructions conforming to International
Electro technical Commission (IEC) and NEMA MG1 Standards, CG also offers custom built motors with complete
solutions, engineered for special and critical applications.
3. Energy Efficient Motors
Efficient use of energy enables commercial and industrial facilities to minimize production costs, increase profits, and
stay competitive. The majority of electrical energy consumed in most industrial facilities is used to run electric motors.
Energy-efficient motors now available are typically from 2 to 6 percent more efficient than their standard motor
counterparts.
4. Motors for Hazardous Areas (HV)
CG offers high voltage motors suitable for hazardous area. These motors are designed to suit the ignitable atmospheres
present in hazardous Locations such as Zone1, Zone 2 or Class1 Div. 1 and 2. Motors are suitable for various
temperature classes & gas groups.

5. Motors for Hazardous Area (LV)

CG has the largest manufacturing range of low voltage motors suitable for hazardous area. These motors are designed
to suit the ignitable atmospheres present in hazardous Locations such as Zone1, Zone 2 or Class1 Div 1 and 2. .

6. DC Motor
We offer entire range of World Class DC Motors in IEC frame up to 710, for various application for constant and
variable speed requirements.

7. FLP Motor
CG offers wide range of low voltage Flameproof Squirrel Cage & Slip Ring electric motors for operation in
hazardous and hostile environments, ranging from 0.37 kW to 355 kW. These Flameproof Motors are licensed
by a European notified body (BASEEFA) and Indian notified body (ERTL/DGMS/DGFAS&LI).All relevant
products fully comply with the requirements of the ATEX & CE Directives.

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 CHAPTER 3: GENERAL INFORMATION

ELECTRIC MOTORS
An Electric motor is a machine which converts electrical energy into mechanical energy.

PRINCIPLE OF OPERATION
Current carrying conductor placed in a magnetic field, experiences a mechanical force whose direction is given
by Flemings Left-hand rule and whose magnitude is given by

F = BIL Newton

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 CHAPTER 4: AC MOTOR

4.1 AC motor
An AC motor is an electric motor that is driven by an alternating current. It consists of two basic parts, an outside
stationary stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor
attached to the output shaft that is given a torque by the rotating field.

4.2 Types of AC motor

Depending on the type of rotor used:
Synchronous motor
This rotates exactly at the supply frequency or a submultiple of the supply frequency. The magnetic field on the rotor is
either generated by current delivered through slip rings or by a permanent magnet.
Induction motor
This turns slightly slower than the supply frequency. The magnetic field on the rotor of this motor is created by an
induced current.

4.3 HISTORY
In 1882, Serbian inventor Nicola Tesla identified the rotating magnetic induction field principle and pioneered the use
of this rotating and inducting electromagnetic field force to generate torque in rotating machines. He exploited this
principle in the design of a poly-phase induction motor in1883. In 1885, Galileo Ferraris independently researched the
concept. In1888, Ferraris published his research in a paper to the Royal Academy of Sciences in Turin.
Introduction of Tesla's motor from 1888 onwards initiated what is sometimes referred to as the Second Industrial
Revolution, making possible both the efficient generation and long distance distribution of electrical energy using the
alternating current transmission system, also of Tesla's invention (1888). Before widespread use of Tesla's principle of
poly-phase induction for rotating machines, all motors operated by continually passing conductor through a stationary
magnetic field (as in homo-polar motor).Initially Tesla suggested that the commutators from a machine could be
removed and the device could operate on a rotary field of electromagnetic force. Professor Poeschel had realized that
the induced rotating Magnetic field would start the rotor of the motor spinning, but he did not see that the counter
electromotive force generated would gradually bring the machine to a stop. Tesla later obtained U.S. Patent0, 416,194,
(December 1889), which resembles the motor seen in many of Tesla's photos. This classic alternating current electro-
magnetic motor was an induction motor.

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 CHAPTER 5: INDUCTION MOTORS

Most AC motors are induction motors. Induction motors are favored due to
their ruggedness and simplicity. In fact, 90% of industrial motors areinduction motors. Induction motors are the
workhorses of industry and motors up to about500 kW (670 Hp) in output are produced in highly standardized frame
sizes, making them nearly completely interchangeable between manufacturers (although European and North American
standard dimensions are different).Very large induction motors are capable of tens of megawatts of output, for pipeline
compressors, wind-tunnel drives, and overland conveyor systems.

5.1 PRINCIPLE OF OPERATION

Based on rotating magnetic induction field principle, the rotating andinducting electromagnetic field force
generates torque in rotating machines. Conversion of electrical power into mechanical power takes place in
the rotating part of the motor. In Induction motors rotor receive electric power by induction in exactly the same way as
the secondary of a 2-winding transformer receives its power from the primary. That is why such motors are known
induction motors. One means of creating a rotating magnetic field is to rotate a permanent magnet. If the moving
magnetic lines of flux cut a conductive disk, it will follow the motion of the magnet. The lines of flux cutting the
conductor will induce a voltage, and consequent current flow, in the conductive disk. This current flow creates an
electromagnet whose polarity opposes the motion of the permanent magnet Lenzs Law. The polarity of the
electromagnet is such that it pulls against the permanent field.

Fig 2: Rotating magnetic field produces torque in conductive disk

Nicola Tesla conceived the basic principles of the poly-phase induction motor in 1883, and had a half horsepower (400
watts) model by 1888. Tesla sold the manufacturing rights to George Westinghouse for $65,000.Most large (> 1 Hp or
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1 kW) industrial motors are poly-phase induction motors. By poly-phase, we mean that the stator contains multiple
distinct windings per motor pole, driven by corresponding time shifted sine waves. In practice, this is two or three
phases. Large industrial motors are mostly 3- phase motors.
Conversion of electrical power into mechanical power takes place in the rotating part of the motor. In Induction motors
rotor receive electric power by induction in exactly the same way as the secondary of a 2-winding transformer receives
its power from the primary. That is why such motors are known induction motors. One means of creating a rotating
magnetic field is to rotate a permanent magnet. If the moving magnetic lines of flux cut a conductive disk, it will follow
the motion of the magnet. The lines of flux cutting the conductor will induce a voltage, and consequent
current flow, in the conductive disk. This current flow creates an electromagnet whose polarity opposes the motion of
the permanent magnet Lenzs Law.
For a 3-phase induction motor, stator windings when supplied with 3-phase currents, produce a magnetic flux, which is
of constant magnitude but revolves (or rotates) at synchronous speed (given by Ns= 120f/p). This revolving magnetic
flux induces an e.m.f in the rotor by mutual induction. The stator in (Figure 3) is wound with pairs of coils corresponding
to the phases of electrical energy available. The 2-phase induction motor stator above has 2- pairs of coils, one pair for
each of the two phases of AC. The individual coils of a pair are connected in series and correspond to the opposite poles
of an electromagnet. That is, one coil corresponds to a N-pole, the other to a S-pole until the phase of AC changes
polarity. The other pair of coils is oriented 90 in space to the first pair. This pair of coils is connected to AC shifted in
time by 90 in the case of a 2-phase motor. In Tesla's time, the source of the two phases of AC was a 2-phase alternator.

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 CHAPTER 6: CONSTRUCTION

An Induction motor consists essentially of two main parts:

1. A stator and
2. A rotor
Both are assembled together as one assembly, rotor known as an armature, a stator containing windings connected to a
poly-phase energy source as shown in Figure below:

Fig 3: Stator and Rotor

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 CHAPTER 7: STATOR

It is made up of a number of stampings, which are slotted to receive the windings. It is wound for a definite number of
poles, (The no. of poles P, produced in the rotating field is P = 2n where n is the no. of stator slots/pole/phase).
The exact no. of poles being determined by the requirements of speed. Greater the no. of poles, lesser the speed and
vice versa.
A 2-pole (pair of N-S poles) alternator will generate a 60 Hz sine wave when rotated at 3600 rpm (revolutions per
minute). The 3600 rpm corresponds to 60revolutions per second.

Fig 4: Addition of field poles decreases speed

A similar 2-pole permanent magnet induction motor will also rotate at 3600 rpm. A lower speed motor may be
constructed by adding more pole pairs. A 4-pole motor would rotate at 1800 rpm, a 12-polemotor at 600 rpm. The style
of construction shown (Figure 4 (above)) is for illustration. Higher efficiency higher torque multi-pole stator induction
motors actually have multiple poles in the rotor. For a 3-phase induction motor, stator windings when supplied with 3-
phase currents, produce a magnetic flux, which is of constant magnitude but revolves (or rotates) at synchronous speed
(given by Ns= 120f/p). This revolving magnetic flux induces an e.m.f in the rotor by mutual induction. The stator in
(Figure 3) is wound with pairs of coils corresponding to the phases of electrical energy available. The 2-phase induction
motor stator above has 2- pairs of coils, one pair for each of the two phases of AC. The individual coils of a pair are
connected in series and correspond to the opposite poles of an electromagnet. That is, one coil corresponds to a N-pole,
the other to a S-pole until the phase of AC changes polarity. The other pair of coils is oriented 90 in space to the first
pair. This pair of coils is connected to AC shifted in time by 90 in the case of a 2-phase motor. In Tesla's time, the source
of the two phases of AC was a 2-phase alternator. The stator in has salient, obvious protruding poles, as used on Tesla's
early induction motor. This design is used to this day for sub-fractional horsepower motors (<50 watts). However, for
larger motors less torque pulsation and higher efficiency results if the coils are embedded into slots cut into the stator
laminations.
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 Fig 5: Stator frame showing slots for windings

The stator laminations are thin insulated rings with slots punched from sheets of electrical grade steel. A stack of these
is secured by end screws, which may also hold the end housings. Generally a wound stator is called as a field (or stator
field) in terms of production, the plant or place where whole process of insulation and insertion of winding and other
processes takes place is called as passing line i.e. where fields are produced. Following processes are carried out at
passing line:

7.1 INSULATION
Insulation paper which is a good quality mica sheet is inserted into the slots of the stator at slot insulator
machines.
Stator core is built from high-quality low-loss silicon steel laminations and flash-enameled on both sides.
Insulation paper is inserted into the slots accordingly as the stack height, slot width, shape and dimensions,
generally stack heights varies from 18mm to 500mm. A wide range of insulating machines is available in the
market.
General check points for insulation are proper checking for stack height, diameter and other mechanical
dimensions of stator core, besides insertion of slot paper should be uniform and of equal height with no
shifting down from its original position.

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 Fig 6: Insulating Machine

7.2 WINDING
The coils are wound on an external fixture, and then worked into the slots. Insulation wedged between the coil periphery
and the slot protects against abrasion.
In Figure, the windings for both a two-phase motor and a three- phase motor have been installed in the stator slots. The
coils are wound on an external fixture, and then worked into the slots. Insulation wedged between the coil periphery
and the slot protects against abrasion. Actual stator windings are more complex than the single windings per pole in
(Figure 7 (above)). Comparing the 2- motor to Tesla's 2- motor with salient poles, the number of coils is the same.
In actual large motors, a pole winding, is divided into identical coils inserted into many smaller slots than above. This
group is called a phase belt.

See (Figure 8) the distributed coils of the phase belt cancel some of the odd harmonics, producing a more sinusoidal
magnetic field distribution across the pole. The slots at the edge of the pole may have fewer turns than the other slots.
Edge slots may contain windings from two phases. That is, the phase belts overlap.

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Fig 7: Stator with (a) 2- and (b) 3- windings.

Fig 8: Winding Structure

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A brief description of various types of windings along with the machines used is given below:

Concentric Winding
There are many features like the automatic stack height adjustment and the graphical user interface based on MS
Windows. The A-Winder (model of winding machine) is available in a single spindle and a dual spindle:

Fig 9: Single Spindle Winder

Wave Winding
Its a distributed or non-distributed coil (also known as split phase and non-split phase winding). The waves are formed
directly during the winding process which saves space and guarantees an optimal winding result. The coils are wound
on an external fixture, and then worked into the slots. Insulation wedged between the coil periphery and the slot protects
against abrasion. Actual stator windings are more complex than the single windings per pole.
After this lead or cables connection are made to the field Winding and insulation tapes are applied according to the
specifications as per E.I. chart.

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 Fig 10: Types of Wave Windings

Loose-Tooth / Bobbin Winding

As the demand for higher slot-fill-factors reaches the limits of conventional winding/inserting technologies, more and
more motor makers start wind directly on the single stator teeth that are assembled afterwards or bobbins that are
assembled into segmented stators. To ensure a maximum fill-factor, the wires are exactly positioned to prevent the
problem of twisted wires.

Fig 11: Winding machine-SWK

7.3 INSERTION
Wound coils are inserted into the stator slots at insertion machines along with the wedge paper for insulation of coil
periphery from stator laminations and adjoining coils. A great care is taken for proper insertion of wedge paper into the
slots.

7.4 FORMING
The best winding and insertion still doesn't make the perfect stator, Forming process is another focal point in the
production process. Processes carried at this stage are such as expanding lamellas, to final forming of I.D., O.D. and

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heights of the winding head, scratch wire detection. After this lead or cables connection are made to the field Winding
and insulation tapes are applied according to the specifications as per E.I. chart.

Fig 12: Forming press-ZFM-K

7.5 LACING
Lacing or knotting is done at the machine for finally tightening the all the loose wires of coil winding. The end turns are
laced with a "diamond stitch pattern. Both sides are laced at the same time and a real knot is being tied at the end. After
this process the wound stator looks like in figure and then the final process is carried out on field where final inspection
is done for visually detecting and removing the defects on account of following:
Loose wires/wiring, Lacing or knotting problem.
Wedge paper problem, shifted down wedge paper.
Slot paper.
Cables or connecting lead length and proper application of insulation tape.
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This is the most critical and important stage of passing line from point of view of quality control. At this stage the
responsibility lies wholly on operator as there is no intervention of machinery and the defects have to be detected
visually and removed manually.

7.6 COMPUTERIZED WINDING TEST

Computerized winding tester is the most comprehensive quality control method for in-plant testing process industries.
It is extremely effective as a diagnostic tool to evaluate and detect any windings fault that may exist. It can be used to
detect the following in the windings:
Turn to turn short circuits
Coil to coil short circuits
Phase to phase short circuits
Reverse coil connections
Open coils
Grounded coils
Defective insulation

The following tests are performed by the computerized winding tester:

Resistance test:
The Resistance test is performed on the Main and Auxiliary windings. All the resistance measurements are corrected to
the ambient temperature (25 C) using the temperature sensors. It checks wrong turn count, poor connections,
mislabelled leads, and incorrect wire size.

AC Hi-Pot test:
The AC hi-pot test detects if there is a breakdown to ground or between windings which would otherwise go undetected
using average current measurement techniques. This measures the resistive portion of the leakage current, rather than
the total current.

Surge test:
The high voltage surge test checks for insulation problems between turns, coils, and phases of the winding. Surge tests
can also detect other faults which change the inductance of a winding such as reversed coils. The surge test also has the
ability to detect corona caused by weak insulation in addition to actual insulation breakdown.

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 Rotation test: The rotation direction test determines the rotation of the stator whether it is clockwise or anti-clockwise.
This test uses the Hall-effect type sensors.

To manufacturers this means that the faulty windings can be isolated and repaired at every stage of manufacturing thus,
ensuring quality and saving in material and labour costs.

Fig 13: Manual Surge Comparison tester

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 Fig 14: Computerized Winding test machine

7.7 VARNISHING
Finally the Wound stator i.e. the field after being properly checked goes for varnish plant where penetrating coat of
good insulating varnishes are applied on windings to protect them from action of vibration, heat, water, oil, dirt and acid
fume would soon cause a complete failure of field or rotor circuits. Without a coating of insulating varnish, slot papers
would soon become brittle and crack or soggy from moisture and the enamel covering of wires would chip and flake.
When properly applied and treated, insulating varnish provides a solid film protective covering. At varnish plant there
are two stations Loading (here fields are loaded for varnish process on to the hangers) and Unloading station (fields are
unloaded from the hangers), the whole process takes almost about 4 to 5 hours. At both loading and unloading stations
thorough inspection of fields is done to detect visually for:
Wedge paper problem.
Loose wires or wiring in varnished fields (at unloading station)
Without marking.
Knotting/lacing problem.
Lead cut/unequal length/terminal damage. From the point of view of quality control the inspection made at varnish
stations for defect is most crucial, since the varnished fields are passed on for assembly line and if rejection is made on
basis of above problems during any stage of assembly line results in wastage of resources, manpower and time.

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 CHAPTER 8: ROTOR

The rotor consists of a shaft, a steel laminated rotor, and an embedded Copper or aluminium squirrel cage, As compared
to a DC motor armature, there is no commutator. This eliminates the brushes, arcing, sparking, graphite dust, brush
adjustment and replacement, and re-machining of the commutator. They are of two types as follows:

8.1 Squirrel-cage Rotor

Almost 90% of induction motors employ this type of rotors because of simple and rugged construction and almost
indestructible. The rotor consists of a cylindrical laminated core with parallel slots for carrying the rotor conductors,
which are not wires but consists of heavy copper bars.
One bar is placed in each slot; rather the bars are inserted from the end where semi-closed slots are used. The rotor bars
are brazed or electrically welded or bolted to two heavy and stout short-circuiting end-rings.

Fig 15: Laminated rotor with (a) embedded squirrel cage, (b) conductive cage removed from rotor

The squirrel cage conductors may be skewed, twisted, with respect to the shaft. The misalignment with the stator slots
reduces torque pulsations.

8.2 Phase-wound Rotor

Motors employing this type of rotors are called wound motors or as Slip-ring motors. This type of rotor is provided
with 3-phase, double layer, distributed winding consisting of coil as used in alternators. The rotor is wound for as many
poles as the no. of stator poles and is always wound3-phase even when the stator is wound two-phase. Rotor Stack
laminations are die casted to form a rotor stack in which shaft along with end rings is inserted in to this by process of
Drop-on, and then this shaft-rotor assembly is allowed to cool.
After this process this shaft-rotor assembly is passed on for Rotor test.

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8.3 ROTOR TEST
Rotor Test System is designed to evaluate the Electromagnetic properties of squirrel cage rotors. The test system consists
of Mechanical and Display unit, interconnected by cable. The test set operates on the basis of inductive measurement,
it accept a wide range of rotors, from small type to pump rotors which have long shaft. It can be operated with minimum
efforts.
HOW THE EQUIPMENT WORKS?
The test set operates on the basis of electrical & magnetic effects caused by the circulation of induced currents into the
winding of a rotor, which is made to turn at a constant speed, with in a magnetic field produced by a permanent magnet.
The induced magnetic field produced by permanent magnet, acts on one slot at time. However, the direction of magnetic
fields is such that the turns of a moving coil cut the lines of force normally. The induced currents, which are proportional
to the field intensity distance of magnet from the rotor, on the speed of rotation(constant) & on the rotor characteristics,
produce magnetic fields, the symmetry of which enable a clear observation of the turns in the short-circuited condition.
A fixed probe subjected to the magnetic fields produced by the rotor under test, provides the signals, which after being
amplified, are applied to picture tube. The induced e.m.f cause voltages to appear between the commutator laminations&
the amplitude, shape & recurrence of these voltages permits the location of faults in the rotor winding.

Fig 16: Rotor Tester machine

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APPLICATIONS
Broken or interrupted rotor bars.
Poor or missing connections to the rotor end rings.
Rotor bar resistance measurement.
A short circuit between two or more bars.
Error in the relative position between commutator & slots.
Non-uniformity between lamination of the commutator.
Deviation of the skew angle.

8.4 QUALITY
After this, shaft-rotor assembly is passed on to for I.D. (Internal Diameter) Reaming and O.D. (Outer diameter)
Reaming, which is done with help of Micrometre. This is again a very important stage from point of view of Quality
Control, since the responsibility lies wholly on operator.

8.5 LACQUERING
The next step is that of lacquering and painting the shaft-rotor assembly, this is done manually by applying a good
quality resin based lacquer which is done with help of brush, the lacquer used for the purpose is generally oil mixed
shellac based compound, which forms a thin and a highly elastic insulation layer on the rotor surface.

Fig 17: Rotor with Mounted Shaft

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 CHAPTER 9: ASSEMBLY

After all above mentioned processes shaft-rotor assembly, stator (Field winding) from passing line along with
miscellaneous parts such as follows:
Nuts
Clamp Bolts
Gourmet (Conduit Adapter)
Shells brought to the assembly line which is the final stage of production, the major processes carried here are as
follows:

9.1 Shell Field Pressing

Here the shell is pressed on to the field, i.e. the stator is inserted into the shell. After this the
Conduit Adapter (Gourmet) is inserted into the punched hole made in the shell along with insertion of Elfie which is a
special adhesive used to hold gourmet in the place tightly.

9.2 Assembly of Motor

Here the Rotor-shaft Assembly is inserted into the Stator-shell assembly, along with the end shield casing; the bolts are
inserted always in diagonally opposite manner, the connecting leads are taken out from Conduit adapter.

9.3 Running of Motor

Here the Motor is tested by running it on the input supply voltage and current which is a little higher than that specified
by customer requirements.

9.4 Noise Testing

This is a most important stage of assembly line from point of view of Quality control, basically it is a Inspection Stage
where all assembled motors are tested for Noise limit, the whole arrangement is enclosed inside the sound proof glass
walls, with two operators employed on the noise testing Machine.
The Noise, Resonance & Vibration Test System runs on the Windows operating system as well as user-friendly software
package. It has built-in signal conditioning, an A/D converter for sensor measurements, relays for digital I/O control
and powerful application software for noise, resonance and vibration testing. It is intended for use on AC and DC motors
directly on the production floor.

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9.5 Tests Performed

9.5.1 Noise
Noise testing analyses audible noise, generated by a motor, by doing a frequency analysis and comparing it to an
envelope based on a median of setup motors. The analysis must have a certain percentage of data points fall within this
envelope or the part will fail. There are six different ranges available for noise - 1000 Hz, 2000 Hz, 3000Hz, 5000 Hz,
7000Hz and 10,000.

9.5.2 Vibration & Resonance

Resonance testing analyses a combination of audible noise and vibration, generated by a motor, by doing a frequency
analysis and comparing it to an envelope based on a median of setup motors. This method tests for resonance by making
contact with the motor body and determines at which frequency and amplitude the motor is resonant. The resonant
frequency is much larger than other frequencies generated within the motor. Resonance is processed the same as noise
and uses the same ambient noise cancellation feature as for noise. Resonance is measured in Rones. There are four
ranges available for Resonance - 500 Hz, 1000Hz, 2000 Hz and 3000 Hz.

9.5.3 Ambient Cancellation Technique

Cancellation testing technique identifies the ambient noise, resonance and vibration levels on the factory floor and then
separates them from the noises, resonance's and vibrations created by the motor-under-test. This is done each time a
motor is tested, allowing for ambient sampling on every motor.

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9.6 Collection Methods

9.6.1 Resonance Acoustic Probe

The vibration data is collected using an Exclusive Resonance Acoustic Probe. This unique probe breaks up air
movements and ambient noises into white noise. The sound channels used are specifically designed for the motor-
under-test. A combination of highly repeatable transducers and Noise Cancellation Software eliminates 90% - 95% of
ambient factory noise and vibrations. The Resonance Acoustic Probe converts mechanical movement from the motor
and motor casing into sounds. The diaphragm controls the movement of air (the vibration) down the chamber into the
collection device. The tester is then able to look at the frequencies generated by the movement of the motor before
these noises and vibrations are dispersed into the air. This probe eliminates the contamination of other frequencies that
could have been picked up along the way.
Only the true readings are displayed. The Resonance Acoustic Probe is equipped with spring-loaded constant
pressure transducer. This transducer was developed exclusively for noise &vibration analysis and is highly repeatable.
Special emphasis is placed on the location of these transducers. The transducers position is isolated from the holder
(transducer) and the motor test fixture to ensure that the vibration picked up is from the motor.

9.6.2 Microphone
The use of microphones (even high-end products costing thousands of dollars) will not guarantee getting good
broadband frequency data. In fact, higher-end microphones also pick up movements and ambient conditions, resulting
in poorer data.

Fig 18: Noise Testing System

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Some of common problems/faults encountered from quality point of view if a digital noise testing system is not used:
Opinions vary shift to shift as well as person to person.
All Operators have their own opinions of a good versus bad parts.
Factory noise levels from 60-85dB.
No data is available on defects and or returns.

9.7 NLT (No Load Test)

This is an Inspection stage of Production Control, at this stage various tests are performed on assembled motor out of
which No Load is most important one both from production and quality point of view, a short description of all the tests
are given as below:

9.7.1 No-Load Test (AC or DC)

Performed for Voltage, Current, Power, Power Factor, Speed (RPM) &Direction. The No Load test is performed by
unloading the shaft of the motor as much as possible or applying it as close to zero torque as possible. A regulated AC
voltage is applied to the motor leads and motor voltage, current, wattage and direction are monitored. A low voltage
start test will also be done prior to these no-load tests. Three types of no load tests can be provided: disconnected,
inferred no-load and measured no-load.

9.7.2 Load Point Test (AC or DC)

Performed for Voltage, Current, Electrical Power, Power Factor Speed (RPM), Direction, Torque, Mechanical Power
and Efficiency. As many different load steps as needed can be programmed for a given motor-under-test, or a continuous
speed vs. torque curve can be generated. To measure a specific Load Point, the dynamometer is set to control in either
speed mode or torque mode, depending on customer preference. If the dynamometer is controlling speed (speed mode
testing), then a speeds established by the dynamometer and torque is produced based on the capabilities of the motor. If
the dynamometer is controlling torque (torque mode testing), then a load is established by the dynamometer and speed
is produced based on the capabilities of the motor. In either case, once the desired point is established, the tester can
measure speed, torque, voltage and current (amps) depending on how the individual tester is configured. The most
commonly used single load point is the full load point. This means that the speed selected is the motors rated speed (if
speed mode testing is used) or the load selected is the motors rated torque (if torque mode testing is used). Then any
data gathered is full load data. As many load points as desired can be gathered.

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9.7.3 Locked Rotor (AC)
Performed for Voltage, Current, Electrical Power, Power Factor, Torque, Direction. Another common load point is
known as Locked Rotor or Stalled Torque. A full current is applied to a Hysteresis Brake, Dynamometer, or by
simply clamping or locking the motor shaft and energizing the motor. More torque is produced by the
Dynamometer/Brake than the motor can produce. In this state the shaft cannot turn, simulating the rotor being locked
or blocked. This test is very hard on a motor. There is a large amount of current that flows into the rotor, causing it to
heat up rapidly. As a result, this test must be performed very quickly. A motor, with a locked rotor, draws up to six or
seven times its rated current (sometimes more). The power supply used must be capable of regulating the motor voltage
adequately during rapid changes in current to ensure the proper voltage is maintained when the data is being taken.
Locked rotor torque testing is important. If the motor cannot produce enough torque to overcome the friction in the load,
as it sits without rotating, the motor can be energized but it will not start the load. If the motor remains in this state for
very long it will overheat and fail. This criteria indicates whether or not a motor may be more likely to suffer from
nuisance tripping during motor starts and determines whether the motor exceed the National Electrical Manufactures
Associate (NEMA) locked-rotor current limit. This performance measurement can help indicate the reliability of the
motor.

Standard Features:
Fast Model Changeover
Shaft Rotation Detection
DC Resistance Testing at 100mA to 1 Am
50 / 60 Hz
Temperature Compensated DC Resistances to 25C
AC HI pot Testing
Industrial Computer with Backup Hard Drive
CDR/W
Intel Processor
Nine-Lead Connections for 5-Speed Motors with Start Winding or Three Phase Dual Voltage Motors
High Current DC Resistance Testing 10 Amps to 50 Amps for 0.1 micro OHM Resolutions
High Voltage HI pot up to 10KV
12-Lead Connections
Thermal Overload Continuity Testing

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After this stage the assembled motor is passed through firewall test, from where it is passed on to for final packaging,
where name plated is placed on the motor casing, and it is packed after oiling the shaft, so as to prevent it from rusting
in a palette of 175 motors each.

9.8 SCAT
This is an inspection stage of quality control; here six motors are randomly selected from a palette of 175 motors and
selected tests are performed on motor which are same as that done at NLT and Noise testing. Motors which do not pass
this test are sent back to concern point of production line where the failure took place.

Fig 19: Faults Occurring In Motors

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CHAPTER 10: PROCESS LAYOUT AND MAIN COMPONENTS

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 Fig 20: Motor Parts

END SHIELD SHELL

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ROTOR SHAFT ASSMEBLY FIELD

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 CONCLUSION

After the completion of industrial training we enhanced competitiveness in our respective area of specialization. We
tried to relate the experience in the workplace with knowledge learned in the institute & applied the knowledge on the
job under supervision.
Here, we gained the experience & knowledge that can be used for suitable jobs without delay after studies.
We learned to hone soft skills appropriate to the work environment and also get improvised in communication skills.
We assessed career ability, knowledge & confidence as well as enhanced our marketability to be more competitive.
With experience, knowledge & skills acquired during industrial training we will be better prepared to face working
world.

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 REFERENCES/BIBLIOGRAPHY

www.electrical4u.com

Textbook of Electrical technology- Volume 2 B.L.THAREJA, A.K. THAREJA

www.wikipedia.org
Daily Report Diary.
Electrical Machines by P.S. Bimbhra
Power System by J.B. Gupta and Power system by V.K. Mehta
Electric Machines by Ashfaq Husain

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