build AC cast-iron frame motors at its Athens Georgia plant-available motors

range from 40 to 1500 horsepower construction begins as Rob our stock is

manufactured into a finished shaft the bar stock is cut to length and center hole
drilled the individual pieces are turned on a CNC lathe to the outer dimensions
required for a specific motor design the automated process is computer
controlled for precise repeatable park manufacturing finished shafts are grouped
by design for use later in the manufacturing cycle unmask their supplied to
Baldor with a primer paint coat already applied Athens machines at smaller
higher volume frames on a continuous transfer line process multiple machining
operations are done on a continuous basis increasing productivity [Music] all
frames are washed after machining to remove any metal shavings that could
damage the insides of a motor larger cast-iron frames are machined in a state-
of-the-art automated machining center this fully automated machine efficiently
completes all of the precision machining steps required per the motors design
the cleaned finished frame is ready to be moved to assembly [Music] cast iron
end plates are supplied to Baldor already primed and ready for precision
machining [Music] Baldor uses specialized silicon steel for its laminations that
reduce electrical losses and increase motor efficiency the coil spools are
unwound into a press that straightens the steel to the necessary flatness for
stamping finished rotor and stator laminations are punched from the same piece
of steel all waste metal is recycled heat treatment of the finished stamped
laminations is required to relieve stress in the steel this process improves the
electrical and mechanical performance of the parts computerized quality control
inspections confirm that exact design tolerances are being met during the
manufacturing process stater laminations are stacked to the required design
height and loaded into an automatic welding machine the welder compresses
the stack uniformly to minimize distortion while welding it together into one
piece the lamination stack begins the stator winding process by having slot
liners inserted these insulation liners will protect the copper wire coils from
being damaged by the lamination steel [Music] automated coil winding
equipment is used to form coil groups finished coil groups are transferred to an
automatic insertion machine that uses precision alignment to carefully insert the
coils into the line stator slots [Music] Faye's paper insulation is inserted in
between coil layers on both ends of the winding proper insulation placement is
important to ensure the long life of a motor winding [Music] coils are connected
per the electrical design requirements a careful brazing process makes the
connections secure [Music] lacing is added to increase the mechanical strength
of the winding this will prevent vibration and movement of the coils during motor
starting and operation all finished stator coils undergo a computer automated
electrical test before leaving the winding area this ensures no components were
damaged during assembly the coils were connected as the design required and
that the performance of the stator coil meets acceptable design parameters for
the part varnish is applied to the stator coating the coils and other insulation
materials when dry the stator becomes a solid unit preventing coil vibration and
movement stock motor designs use a dip and bake varnish process Athens also
offers a vacuum pressure impregnation process on custom designs the stator is
now ready for insertion into the motor frame smaller sized motors have the
stator pressed into the frame during this process the motor leads are carefully
fed through the outlet hole in the frame larger frame designs are assembled by
heating the frame so that it momentarily expands just enough to allow the stator
to drop in once inserted the stator is welded to the frame to prevent movement
Roeder laminations are stacked on a casting pin that controls skew angle and
concentricity of the lamination stack the laminations are pressed to prevent
distortion during casting that could damage the coating on the steel [Music] the
casting machine precisely controls the injection of the molten aluminum from
the bottom up into the rotor stack eliminating porosity in the casting [Music]
[Music] each caste rotor is final inspected before it is given a mark of approval
by the operator [Music] the key chaffed is pressed into the cast rotor to create
a complete rotating shaft assembly [Music] on NEMA for 40 frames and larger
the shaft is permanently welded to the rotor to prevent any movement after
assembly the shaft is checked for proper run out before it can move on to final
machining [Music] the shaft is now ready for machining to its final dimensions
computer-controlled machining is used to achieve the proper air-gap tolerance
[Music] the shaft is dynamically balanced to exact specifications this improves
motor life due to less vibration of the rotating assembly and bearings during
motor operation severe duty motors get an epoxy protective rotor coating for
harsh environments [Music] bearings are expanded by induction heating and
slid on to the motor shaft they are temporarily wrapped during final assembly to
prevent contamination all parts needed for final assembly are collected together
on trays and delivered to the assembly station where they are carefully
assembled into the completed motor [Music] impro steel bearing Isolators are
installed as standard on both ends of I Triple E 841 motors used in petroleum
processing applications [Music] [Music] mounting flanges on large frames are
machined again after final assembly to ensure the flange face is true to the
motor shaft [Music] [Music] each motor is given a routine test after final
assembly to ensure the assembled motor will perform to design requirements
custom testing is also available in the Athens test lab where witnessed and
unwitnessed full load dynamometer testing is one of many testing services
available on request motors are painted to their specification with epoxy or
lacquer finish shipping pallets are built to size providing sturdy support and
protection of stock and custom motors during shipment all motors are securely
fastened to the pallet name plates and labels are matched to the order and
mounted on the motor [Music] protective plastic covers the completed motor
and shipping labels are attached completed motors are shipped daily to
customers and Baldor distribution centers Baldor the industrial choice