IN-PLANT PROJECT REPORT

IN SIEMENS INDIA LTD KALWA UNIT: WMOT

DEPARTMENT: WINDING

INDEX

SR NO.

DESCRIPTION PAGE NO.

1 INTRODUCTION TO SIEMENS

2 INTRODUCTION TO MOTOR

3 INTRODUCTION TO WMOT UNIT

4 WINDING SHOP IN DETAIL

5 PROJECT

6 BIBLIOGRAPHY

INTRODUCTION TO SIEMENS

HISTORY –

Siemens was founded in Germany by Werner von Siemens in

1847. As an extra-ordinary inventor, engineer and entrepreneur,

Werner von Siemens made the first pointer telegraph and electric

dynamo, inventions that help put in spin to the industrial revolutions.

He was man behind one of the most fascinating success stories of all

time, by turning a little workshop into one of the largest enterprise.

Siemens is today a technology giant in more than 190 countries,

employing some 440,000 people worldwide. Our work in the fields of

energy, industry, communications, information, transportation,

healthcare, components and lighting has become essential parts of

everyday life.

While Werner was a tireless inventor during his days, Siemens

today remains a relentless innovator. With innovations averaging 18 a

day, it seems like the revolution Werner started is still going strong.

THE JOURNEY –

*1857 - SIEMENS was founded in GERMANY.

* 1867 - SIEMENS first linkage in India

* 1954 - Assembly and repair undertaken in a small workshop under Mahalakshmi Bridge

Mumbai.

* 1957 - Switchboards manufacture began at Worli, Mumbai.

* 1960 - Manufacture of Switch gear began at Worli, Mumbai.

* 1963 - Switch board manufacture transferred to Andheri, Chakala

* 1966 - First batch of Electric Motors produced at Kalwa.

* 1967- Centenary years of Siemens associates with India.

* 1973 - Transfer and expansion of Switchgear production at Kalwa

* 1975 - Transfer and expansion of Switchboard production at Kalwa

* 1977 - Manufacture of electronic equipment at Worli, Mumbai.

* 1984 - Manufacture of Switchboard started at Nasik.

* 1986 - Manufacture of Railway Signaling Products

* 1987 - New Industrial Electronics factory at Nasik.

* 1990- ‘Sword of honor’ from British safety council.

* 1991 - New Switchgear factory in Aurangabad.

* 1993 - Assembly workshop-Medical products Goa.

* 1995 -Launching of Mobile phones.

* 2005- Started Traction Motor Unit.

* 2007- Started Transformer factory at Kalwa.

SIEMENS IN INDIA

ABOUT SIEMENS KALWA –

The SIEMENS Kalwa plant was established in 1964 and the first batch of

electric motors was produced in the year of 1966.

SIEMENS Kalwa Works comprises of three units namely

A. Switchboard Unit

B. Switchgear Unit

C. Motor Unit

A. SWITCHBOARD UNIT –

SIEMENS switchboards have established remarkable leadership in the market.

This has come through deep understanding of customer requirements, resulting

in customer-oriented products with

user-friendly design manufactured

with latest technology, in

compliance with international

standards. The assembling of

switchboards commenced in 1954 in

a small workshop in Mumbai.

However, the manufacturing unit at

Kalwa came into existence in 1975.

PRUDUCTION SPECTRUM –

1. Circuit Breakers

2. Electric Panels

3. Potential and Current Transformers

B. SWITCGEAR UNIT –

SIEMENS switchgear unit is one, which is committed to

Provide business solutions in the field of Control Systems

and Products (CSP).The year 1973 marked the beginning

of the production of switchgears at Kalwa works.

Switchgear is a general term covering a wide range of

products used for switching and safety of various

electrical & electronic accessories. It manufactures

several forms of switching and protective devices

PRODUCT SPECTRUM –

1. Control and Limit Switches

2. Starters and Contactors

3. Push Button Indicators and

Signalling Equipments

4. HRC Fuses, Fuse Switches and

Fuse bases

5. Bimetal Thermal Overload

Relays

C. MOTOR UNIT –

SIEMENS Motors are high quality machines with economic power

consumption and are resilient enough to withstand wide voltage and frequency

applications.

The Kalwa motor works provides numerous variants of such machines.

The user-friendly designs are a proof of the fact that SIEMENS have a

considerable knowledge of its customer’s requirements. The motor factory at

Kalwa was established in 1965. A & D is a sub-division of Motors division. It

supplies standard and special products meeting specified requirements of the

customer attaining simplicity and improvement in its designs.

PRODUCT SPECTRUM –

1. AC Motors

2. Traction Motors

3. AC Generators

INTRODUCTION TO MOTORS

BASIC PRINCIPLE –

A motor is simply a device which converts electrical input to mechanical

output. The basic working principle of all the induction motors is

electromagnetic induction which occurs due to relative motion between

magnetic field and conducting material. The law which relates change in

magnetic flux with emf induced is given by Lenz Law, which states that the emf

induced due to change in magnetic field act in a direction so as to oppose the

cause of generation of that induced emf.

Mathematically it is given as

ε induced = −𝑑𝜑

𝑑𝑡

In induction motors, emf is induced due to time dependent magnetic

field which is also responsible for a time dependent magnetic flux.

A time dependent magnetic field is obtained by alternating current

flowing through conductors. The rotating flux generated by alternating current

results in relative motion between rotor conductors and magnetic flux. An emf

is induced in the conductors due to this and current starts flowing through the

shorted conductors. As the current carrying conductors are now subjected to

variable magnetic field a force is developed which provides the rotor required

torque for rotation.

MOTOR CONSTRUCTION –

1) STATOR –

A stator is the stationary part of the motor.

Stator is cylindrical in shape and is

made up of a number of laminations

0.35mm to 0.5mm thick.

The laminations are pushed into a

frame by axial key bars fitted in

dovetail slots in outer rim of the stator core.

The frames are pressed by machines of 40T, 60T or 100T according to

the frame size.

Number of laminations in one stator packet depends upon length of the

stator packet, which eventually depends upon application and

specifications of stator.

2) ROTOR –

A rotor is the rotating part of the rotor which has several shorted conductors and

it is connected to shaft which finally provides mechanical output.

Like stator, rotor is also made up of several thin laminations.

It has a number of conductors either of aluminium or of copper through

which current starts flowing due to induced emf.

3) STATOR HOUSING –

Stator housing is a robust, rugged CI frame with integral feet, used to provide

housing to stator and rotor.

The material used to make stator

housing is grey cast iron with strength 130

or 150 VHS.

It also has provision for seating of a

terminal box and earthing connections are

also provided at the bottom.

The fins provided to the

circumference of the stator housing

provide quicker dissipation of heat

generated by motor during operation.

4) SHAFT –

The shaft actually delivers the mechanical output converted from electrical

input by the motor. The rotor packet, bearing and fan are fixed on the shaft.

5) END SHIELDS –

Every motor has two end shields, one on the Driving End called as AS End

Shield and other on the Non-Driving End called as BS End Shield.

Material used for making end shield is grey

cast iron with strength 130 to 150 VHS.

The two end shields are similar in design

except for the tolerance of bore diameter where

outer rim of the bearing fits.

Like stator housing, for quicker dissipation of

heat, fins are provided on end shield also.

6) BEARINGS –

The bearing is used to connect the rotating part of motor, the shaft to the

stationary part of motor, end shield.

There are two types of bearing –

1. Roller Bearing

2. Ball Bearing

The material of bearing is the case hardened carbon steel.

Generally motors are provided with floating bearing at driving end and

fixed bearing at non driving end.

7) FAN –

Fan is one of the important components on the motor.

It is generally attached to the non-driving or

BS end of motor.

Main function of the fan is to suck the

atmospheric air through openings and throw it back

to the atmosphere.

Thermo plastic fans are generally used as

they are cheap and light weight.

INTRODUCTION TO WMOT UNIT

The motor manufacturing process can be identified as set of five integral steps –

1) MACHINE SHOP –

Cutting, Facing, center drilling, and

tapping operation on shaft is carried

on double end face centering

machine.

Turning of shaft is carried on lathe &

CNC lathe (KWS-II).

Keyway operation on shaft carried on

CNC machine (Chiron).

Grinding operation on rotor, shaft carried on cylindrical grinding

machine.

Formatted: Font: (Default) Times New Roman, 14 pt

2) PRESS SHOP –

Blanking operation on Heilbronn

Machine.

Notching and separating operation of

lamination blank.

Separating operation of lamination

blank for motors carried on notching

machines.

Notching of stator slots and rotor

blanks carried on notching machines.

Stator packeting for motor / generators carried on pressing machine.

Rotor packeting carried on TCS die-casting machine.

Rotor die-casting on TCS die-casting machine.

Shaft pressing in the rotor packet on shaft press machine.

DYNAMO COIL

BLANKING

STATOR NOTCHINGROTOR

NOTCHING

STATOR PACKETINGROTOR

PACKETING

UNWOUND STATOR

PACKETBAR INSERTION

ROTOR

DICASTING

BRAZING

WINDING SHOP M/C SHOP M/C SHOP

SHAFT

INSERTION

3) WINDING SHOP –

Coil winding on the former as per the

electrical design specification carried

on coil winding machine.

Preparation and cutting of insulation

required for the motor/generator.

Insertion of coils in the stator packet

with insulation thereby completing the

winding operations.

Testing the wound motor / generator stator packet carried in winding test

field.

Varnishing of motor / generator stator to increase the mechanical strength

and electrical properties.

4) ASSEMBLY SHOP –

Pressing of stator packets of motor /

generator into the housing carried on

pressing machine.

Balancing of rotors on balancing

machine.

Rotor insertion with bearing covers,

bearing mounted on the rotor shaft.

Line inspection to verify air gap and

fixing of fan, end shields, cir clip, fan cowl, terminal box and other small

parts, thereby completing final assembly.

VARNISHED WINDING

PACKET PRESSING

ROTOR BALANCING

ROTOR INSERTION

TERMINAL BOX

ASSEMBLY

ACCESSORIES

TESTING

5) TESTING FIELD –

Motors test field is supplied with 22 kV, 3 phase MSEB as bar. This high

voltage is stepped down to 240v and 440v with the help of 500 KVA

transformers that has two tapping for the same.

The department mainly looks after the following work:

Routine testing of 3-phase induction motors.

Type testing of 3-phase induction motors

Arrange client inspection.

Arrange routing test certificates for Motors.

Releasing of motors.

WINDING SHOP IN DETAIL

-- WORKFLOOR PLAN –

WINDING PROCESS –

1. COIL WINDING

Material Required –

Insulated copper wire which is wound on cylindrical spools kept in

storage area. The insulated copper wire can be broadly classified

based on following two criteria –

1) Diameter of the Cross Section

There are wires with three diameters generally used for coil

winding in this unit – 1.25mm, 1.40mm, 1.60mm.

2) Type of Insulation

Equipments, machines and other material –

1) Coil Winding Machine

A coil winding machine is used to obtain a coil with particular

number of turns and frames with a fixed number of conductors

per turn.

Coil spools are covered with spool covers and are placed near the

assembly for coil winding also called as Setting.

In this particular shop, there are three different assemblies for

three different machines as shown in floor plan.

In each assembly there are 12 spools on one each side that is 24

spools in total. This means that, a maximum of 24 wires can be

drawn to get 24 conductors per turn. [Provision is for 24 spools

per side]

There is a small wooden plank fixed on the assembly for every

two spools placed on either sides of assembly. The plank consists

of holes through which wire drawn from all the spools before the

plank are drawn.

All the 24 wires from different spools are held permanently by a

plank fixed at the end of this assembly so that required number of

conductors can be easily drawn through it for operation.

The machine has a motor which provides it required torque to

rotate a metal disk to which a former is attached.

A rod with angular threads on it is fitted on metal disk which has

an axis of rotation perpendicular to that of the disk.

The rod is rotated so as to move both the formers along the axis

of rotation of the rod with the help of threads and gears attached

to the small gear box on which former is mounted.

The threads are made such that the two former pieces will always

move in direction opposite to each other and their distance from

the centre of the disk will be equal.

2) Former

Former is a wooden piece which has a particular size and

particular number of slots over it.

A number is allotted to each and every former piece which is

used to identify the piece to be used for a particular type of

coil.

There are two former pieces in ones set which are exact

mirror images of each other and they are fixed on the gear

box attached to the rod.

The former rotates along with the disk and desired number

of conductors drawn through different spools get wound

over the slots provided on the former.

Distance Piece

The distance piece also has a unique number for

identification depending upon its length.

The basic function of distance piece is to maintain the

distance between two formers while the coil is being wound

over the slots.

The coil exerts a force on the former causing them to move

inwards which tried to reduce the distance between the

former resulting in undesired length of coil side.

The distance piece held tightly between the former applies

another force in direction opposite to the force applied by

windings hence balancing the same.

3) Others

Several other materials such as string, string cutter, plastic

coated tube, rotating handle are also used.

Procedure

Coil Winding types

2. COIL INSERTION

3. STATOR CONNECTIONS

4. TESTING

5. VACCUM PRESSURE IMPREGNATION