Industry Visit Report

Industry Visit Report

Name of the Industry:

1. AG ELECTRIC MOTOR, KARAD

2.CRYOTECH, TASWADE

3. POWER ENGINEERS, KOLHAPUR

Submitted by,
Mr. Rahul Rajendra Kondaval
Roll No:63
In
B. Tech Final Year, Track I
Under The Guidance of
Mr. N.R.Kulkarni

Department of Electrical Engineering

SANJAY GHODAWAT UNIVERSITY, KOLHAPUR

October 2021

Track I_ELE_2021-22 1
Industry Visit Report

Department of Electrical Engineering

CERTIFICATE

Industry Visit Report

Submitted by,

Mr. Rahul Rajendra Kondaval

Roll No:63

In
B. Tech Final Year, Track I (2021-22)

IUI Cell coordinator Internship Guide H.O.D

Date:

Place:
Acknowledgement

Track I_ELE_2021-22 2
Industry Visit Report

It is my pleasure to be indebted to various people, who directly or

indirectly contributed in the development of this work and who influenced my
thinking, behaviour and acts during the course of study.
I express my sincere gratitude to director of SGU, HOD of Electrical
Dept. & my guide for providing me an opportunity to undergo industrial
training.
I am thankful to Mr. Shridhar Ramdurgkar Sir for his support,
cooperation and granting me permission for doing training in his company for
constant period. Also I am thankful to Aadarsh sir, Masurkar sir, Jadhav sir &
Ashwini madam for their guidance & all other members who contribute in this
training work.
Lastly, I would like to thank the almighty and my parents for their moral
support and my friends with whom I shared my day-to-day experience and
received lots of suggestions that improved my quality of work.

Index

Track I_ELE_2021-22 3
Industry Visit Report

Sr. no. Content Page no.

1. AGE ELECTRICALS, KARAD 5-12

2. CRYOTECH, TASAWADE 13-25

3. POWER ENGINEERS, KOLHAPUR 26-28

1. AG ELECTRIC MOTOR, KARAD

 Company Name : AG Electro Services, Karad

 Address : Plot no.6, Koyana
Industrial Estate, Pune
Bengluru Highway - NH4,
karad.
Dist: Satara
State: Maharashtra, India.

Track I_ELE_2021-22 4
Industry Visit Report

 Quality Policy :
AG ELECTRO SERVICES is committed to Enhance
Customer Satisfaction by providing Products & Services to satisfy applicable
Requirements and Customer Requirements by carrying out continual
improvement in effectiveness of quality management system.

 Date of Establishment : 1992

 Major Products :

 Manufacturer & Exporter of Freight Elevators Motors

 Vibrator Motors
 Motors for hazardous locations
 Pump Motors
 Motors for tools
 Brushless Motors
 Door & Car Gate Motors
 Hermatic Motors

Track I_ELE_2021-22 5
Industry Visit Report

 Motors for dairy & floor cleaning applications

 Copper brazed rotors & Die cast rotors
 Wound stator
 Rotor assembly & complete motors

 AGE’S Esteemed Customers :

 The Pelle Co.Ltd.Canada
 Emcan Electric Motors
 Acquires Technologies
 Lexon Winders, Pune
 Atlas Copko, Nashik

 Achievements :
 CSA International Approval

Introduction to Induction Motor

The induction motors are basically AC motors. They can operate on

either single phase or three phase ac supply; however the singe phase induction
motors find very limited area of application. In almost 85% application three
phase induction motors are preferred. Depending on type of rotor, the induction
motors are classified into two types. Slip ring induction motors and squirrel
cage induction motors.
Induction motors are referred to as ‘asynchronous motors’ because they
operate at a speed less than their synchronous speed. Synchronous speed is the
speed of rotation of the magnetic field in a rotary machine, and it depends upon
the frequency and number poles of the machine. The induction motor always
runs at speed less than its synchronous speed.

 Constructional details:
Induction motor is having two main parts: 1) stator & 2) rotor.

Track I_ELE_2021-22 6
Industry Visit Report

Fig.1.1 constructional details of stator &

rotor

1) Stator:
As the name suggest it is the stationary part of motor. This part is made up
of silicon steel stamping i.e. thin sheets. The stampings are slotted. The slots are
formed on inner side of the stator. In these slots three phase winding is
accommodated. This winding may be star or delta connected.The three ends of
this windings are brought out into the terminal box where three phase ac supply
is connected.

2)Rotor:
The rotor is the rotating part of the induction motor. The type of rotor is the
squirrel cage rotor & wound rotor. The rotor comprises of a cylindrical
laminated core with axially placed parallel slots for carrying the conductors.
Each slot carries a copper, aluminium, or alloy bar.

 Working principle of induction motor:

The working of an Induction Motor can be summarized as, the stator

winding produces magnetic field and due to electromagnetic induction a current
is induced in rotor which produces torque. No electrical connection exists
between rotor and stator which differentiates it from other motors, as it works on

Track I_ELE_2021-22 7
Industry Visit Report

Faraday’s law of Electromagnetic Induction.

The AC power supplied to the stator creates a magnetic field which is
changing over time due to AC oscillations. This changing magnetic field
produces changing magnetic flux that induces a current in rotor windings in
accordance with Faraday’s law. This current will generate a magnetic field to
oppose the stator magnetic field in accordance with Lenz’s law. To oppose this
change, the rotor will start rotating in the direction of changing magnetic field
of the stator.
In this way when three phase supply is applies to stator winding rotating
magnetic field is produced. Due to this rotor starts rotating. Here electricity is
induced by induction rather than direct connection, that’s why it is called
induction motor.

 Types of induction motor:

The types of induction motors can be classified depending on whether they
are a single phase or three phase induction motor.

 Single Phase Induction Motor :

The types of single phase induction motors include:

1. Split Phase Induction Motor

2. Capacitor Start Induction Motor
3. Capacitor Start and Capacitor Run Induction Motor
4. Shaded Pole Induction Motor

 Applications:
These are used in low power applications and widely used in domestic
applications as well as industrial. And some of those are mentioned below:
 Pumps
 Compressors
 Small fans
 Mixers
 Toys
 High speed vacuum cleaners
 Electric shavers
 Drilling machines

Track I_ELE_2021-22 8
Industry Visit Report

 Three Phase Induction Motor :

The types of three phase induction motors include:

1. Squirrel Cage Induction Motor

2. Slip Ring Induction Motor

 Applications:
Induction motors are used in industry and domestic appliances because
these are rugged in construction requiring hardly any maintenance, that they are
comparatively cheap, and require supply only to the stator. Some of the
applications are given below:
 Lifts
 Cranes
 Hoists
 Large capacity exhaust fans
 Driving lathe machines
 Crushers
 Oil extracting mills
 Textile

 Process Flow Chart :

Track I_ELE_2021-22 9
Industry Visit Report

Fig.1.2 General process flow chart for

motor manufacturing
Figure 1.2 illustrates a basic ac motor manufacturing process flow.
Laminations are generated as the first step. Such laminates are divided into
rotors and stators. Laminations of stators, shown in Fig. 1.3, are then piled into a
core, and the core is wound with copper or aluminium wire, forming a wound
stator core. Some kind of outer housing is made, and that is then wrapped
around the center of the wound stator, making an assembly of the wound stator.
The assembly of the wound stator is then sent to motor assembly.
The rotor laminations in Fig. 1.4 are also stacked and then aluminium
die cast into a rotor casting. A shaft is then produced, and this is assembled into
the rotor. Then bearings are placed making it a rotor assembly. The rotor
assembly is sent to motor assembly.

Fig.1.3 Stator Lamination Fig.1.4 Rotor Lamination

There are two end frames that are produced and sent to the motor assembly.The wound
stator assembly, rotor assembly, two end frames, and assorted parts are assembled into a
full motor during the final process. The motor is then checked for shipping, painted, and
packed.

Track I_ELE_2021-22 10
Industry Visit Report

2. CRYOTECH, TASWADE

 Company Name : Cryotech Pvt. Ltd

 Address : C57, Karad
industrial area, karad midc,
Taswade
Dist: Satara State: Maharashtra, India.

 Manufacturing Process :
1.Stack making process:

Track I_ELE_2021-22 11
Industry Visit Report

Stack making is nothing but the process of

lamination joining together according to required height of stack.
In this industry different process are used for stack making.

Fig.2.1 classification of stack making

 Auto-stacking
An auto-stacking machine is used for this. The first instrument is
inserted into the unit according to the model. Stack material is selected
according to design details, i.e. thickness & height. According to
specifications, roll wound material is taken by computer. The distance
sensor is positioned between the AC drive and the machine in order to
correctly tackle the material strip and avoid any damage The number of
laminations is calculated according to stack height & thickness and it is
given to the batch counter. The rotary encoder for counting rotations is
located at the top of the unit. PLC is used for general process
management.

 Welding:-
Welding is the method of connecting metal pieces to the point of
melting by heating the surface. "Tic Welding" is used in this industry. It
is the method of arc welding that uses tungsten electrodes to create
welds. The weld area and electrode are shielded by inert gas, i.e. argon,
from oxidation or other ambient pollution. So here, when dc supply is
applied, the tungsten electrode behaves as a cathode and the work piece

Track I_ELE_2021-22 12
Industry Visit Report

acts as an anode. When the filler material is used, the tungsten rod is
heated and the weld is formed on the workpiece. At the same time, the
argon gas cylinder provides the gas for this phase to create a shield

 Riveting:-
Riveting is a mechanism that can be used to connect pieces
together by means of a rivet called a metal part. The rivet is used around
adjacent surfaces to connect pieces. Generally, it is used to connect a
number of metal plates. The basic configuration of the rivet includes the
head, middle cylindrical body & tail.

2. Coil winding process :

In electrical equipment, coils are used to provide magnetic fields.
There are two types of engine that are based on the supply of data,
i.e. single phase and three phase engines. The single-phase motor
consists of a main & auxiliary coil, while the high- speed & low-
speed coil is a three-phase motor. Formers & separators are required
for this process. Consideration is given to specifications such as
gauge, number of turns, resistance, weight & thickness. The coil is
constructed from copper or aluminium. Dual-coated, single-coated,
polyester & aluminium are available in four coil grades. Coil
winding is achieved using two methods:-

a) Manual winding machine:

Fig.2.2 Manual winding machine

Track I_ELE_2021-22 13
Industry Visit Report

Manual attempts are important in this process. The number

of turns is chosen according to the design. On top of the unit,
which counts rotation, one counter is fixed. The unit is made up of
one handle that must be shifted according to the number of turns
b) Auto winding machine:

Fig.2.3 Auto winding machine

Auto winding is mostly the preferred technique because it offers
advantages such as improved efficiency, better control of consistency and
decreased waste. We need to send the computer program in the auto winding
machine & the machine will run according to the commands.
3. Stator winding process:
After the stack making & coil winding, the parts which
are required for stator manufacturing are ready. For stator winding
manual winding is preferred & for that skilled labours are
required.
Manual winding process is carried out as follows:
Slot paper insertion

High speed coil insertion

Outer paper insertion

Pressing using bullet gauge

Separator insertion

Insertion of low speed coil & outer

Track I_ELE_2021-22 14
Industry Visit Report

Pressing

Lacing at bottom side

Lead wire insertion & connection

Brazing

Resistance checking

Sleeve insertion

Lacing at top side

Fig.2.4 Flow of stator winding process
According to the flow diagram stator winding process is carried out.
At start, slots of stack are filling with slot paper. Coils are placed in slot. After
each coil outer paper is placed to avoid short circuit of coil. After each layer
different shapes of separators are used to provide insulation between two layers.
Sleeves are inserted. Connections are made & starting ends are taken out. Lead
wire is connected for connection purpose.

4)Varnishing process :
Varnishing is the method used to insulate pollutants from
the windings to make the windings rigid & tight & dissipate heat. The
Vacuum Pressure Impregnation (VPI) approach is applied here.
Vacuum Pressure Impregnation (VPI) is a method for sealing porous
materials with varnish or resin using vacuum and pressure. The
method is as follows:

 Preheating
The equipment in an oven that heats and allows moisture to
evaporate. This helps the resin better penetrate the material.

 Dry Vacuuming
Remove the equipment from the oven and place it into a
vacuum chamber, which removes air and any remaining
moisture.

Track I_ELE_2021-22 15
Industry Visit Report

 Filling
Fill the chamber with resin, coating the part and filling in all the
gaps and pores in the piece of equipment.

 Wet Vacuuming
Reduce the vacuum levels and hold it for a set period of time.

 Pressure
Increase pressure within the chamber using dry air, nitrogen, or other
gases. This allows for even deeper penetration of the resin.

 Draining
Then vent the pressure, drain the chamber of excess resin, and remove the part.

 Curing
Finally, the equipment is placed into an oven to cure the resin.
2)Assembly :

 The wound stator assembly, rotor assembly, two end frames, and
assorted parts are assembled into a full motor during the final
process. The cycle is as follows:
 The stator and rotor are linked to the front and back cover here.
 Broaching & bearing rotor pressing is done before this assembly.
Broaching is the method of making the pressing of the rotor clear &
bearing with press fit & push fit. After stator and rotor is assembled
one wiser is placed on rotor bearing for fitting rotor tight & to avoid
movement of rotor.
 The air distance between the stator and the rotor should be
between 0.25 and 0.45 mm..25mm to 0.45mm.
 Seal tight is used to tight the motor assembly & avoid moisture
contaminants.

Inspection Process
Inspection of motors is carried out in following three
ways i.e. visual inspection, mechanical inspection & electrical
inspection.

Track I_ELE_2021-22 16
Industry Visit Report

Fig.2.5 Inspection Process

1) Visual checking
Visual inspection is carried out for pinching, outer paper & outer paper
turn.

2)Mechanical checking
In mechanical checking, the parameters like inner diameter, outer
diameter & stack height are checked.

3)Electrical testing
In this resistance checking is done and different types of test
are carried out such as surge test, HV test & VAW i.e. no load test.

Surge Test :
This testing is done on the kit which is shown in fig.5.3. on this
kit different parameters like current, voltage & resistance is also
checked. One master piece of model is placed & it is consider as
ideal. By comparing the model with the master piece test is carried
out. If test is ok then characteristic appears is same. If it is not ok
waveform appears is distorted.

Fig.2.6 Kit for surge test

Track I_ELE_2021-22 17
Industry Visit Report

a) HV test
For High Voltage testing kit is available. In this test high voltage i.e.
1850kv is applied to motor for 1 second. After this terminals of wire should be
connected to ground surface for discharging dc current.

b) VAW testing

Fig.2.7 kit for HV & VAW test

This testing is carried out on above kit. The constant 220 v is applied &
current of three phases & power of motor is checked for high speed & low
speed. And these readings are comparing with standard ratings.

Track I_ELE_2021-22 18
Industry Visit Report

3.POWER ENGINEERS, KOLHAPUR

 Company Name : Power Engineers,Kolhapur

 Address : W - 24 / 25, MIDC, Gokul Shirgaon,Kolhapur
Maharashtra 416234.
 Date of Establishment : 1977

 Quality policy

Track I_ELE_2021-22 19
Industry Visit Report

Power Engineers is committed to Enhance Customer Satisfaction by providing

Products & Services to satisfy applicable Requirements and Customer Requirements by
carrying out continual improvement in effectiveness of quality management system.

 Major Products

 Distribution Transformer
 Hermetically Sealed Transformer
 Power Transformer
 Furnace Transformer
 Convertor Transformer
 Special Transformer

 Certification

 ISO9001 TUV SUD

 NABCB
 IS 1180

 Scope

 Design
 Manufacture
 services

 Introduction to Transformer

Track I_ELE_2021-22 20
Industry Visit Report

A transformer is a device used in the power transmission of electric energy. The

transmission current is AC. It is commonly used to increase or decrease the supply voltage
without a change in the frequency of AC between circuits. The transformer works on basic
principles of electromagnetic induction and mutual induction.

 Constructional details:

Fig 3.1 constructional details of Transformer

 Working principle of Transformer :

The transformer works on the principle of Faraday’s law of electromagnetic

induction and mutual induction.There are usually two coils primary coil and secondary coil on
the transformer core. The core laminations are joined in the form of strips. The two coils have
high mutual inductance. When an alternating current pass through the primary coil it creates a
varying magnetic flux. As per faraday’s law of electromagnetic induction, this change in
magnetic flux induces an emf (electromotive force) in the secondary coil which is linked to the
core having a primary coil. This is mutual induction.

 Types of Transformer :

Track I_ELE_2021-22 21
Industry Visit Report

 Applications:

 The transformer used for impedance matching.

 The transformer used for isolate two circuits electrically.
 It is used to increase or decrease the alternating voltages in elecic power applications.
 The transformer used in voltmeter, ammeters, protective relay etc.
 The transformer used for step up low voltage in case of measurement.
 The transformer used for step down high voltage for safety.
 The transformer used in rectifier.
 It is used in voltage regulators, voltage stabilizers, power supplies etc.

 Process Flow Chart

Track I_ELE_2021-22 22
Industry Visit Report

Fig.3.2 General process flow chart for Transformer

manufacturing

Track I_ELE_2021-22 23
Industry Visit Report

Conclusion :
From this training I got the information about how the industry is functioning in & out.
From the industrial training I understood the actual process of manufacturing of motor and its
testing. In industry I got the chance to work in different sectors which enhances my practical
knowledge. It’s my esteemed chance to think and learn beyond the education. AGE has helped me
to secure necessary training sessions and procure sufficient knowledge on motor construction. I
understood the safety precaution that must be taken during the testing of motor. The overall
information regarding motor is understood here by visualizing & analyzing. Our theoretical aspects
are visualized here practically.

Track I_ELE_2021-22 24
Track I_ELE_2021-22 25