DEPARTMENT OF MECHANICAL

ENGINEERING
Visca, Baybay City, Leyte, PHILIPPINES
Telefax: (053) 565-0600 local 1029
Email: coe@vsu.edu.ph
Website: www.vsu.edu.ph

MEng – 135 DC – AC Machineries

CHALLENGE PROJECT: SHEAR CUTTING MACHINE REHABILITATION

Members:

Albios, Hannie Mae O.

Arguilles, Joshua C.

Avila, Josephine Jan F.

Cabarubias, Jasper

De La Cruz, Von Diosequim M.

Gonzales, Christine Grace A.

Gubalane, Victorino S. III

Jandumon, Ian Cesar I.

Jubay, Jayclien J.

Matuguina, Miko L.

Mayaman, Charles Vincent

Muñez, Jhuniel G.

Pole, Johann Christian G.

Roxas, Luis Manuel L.

Triste, Queen C.
i. TABLE OF CONTENTS

Introduction .......................................................................................................................................................... 1
Objectives ............................................................................................................................................................ 2
Theoretical Background ................................................................................................................................ 3 - 6
System Design and Construction ............................................................................................................... 7 - 15
Schematic Diagram............................................................................................................................................ 7
Materials .................................................................................................................................................... 7 - 12
Experimental Methodology ...................................................................................................................... 12 - 13
Processes ................................................................................................................................................ 13 - 15
Assessment .................................................................................................................................................... 15
Results and Discussions ................................................................................................................................... 16
References ......................................................................................................................................................... 17
I. Introduction

Induction motors are commonly utilized in industrial and commercial settings for their dependable and
efficient operation. In order to achieve optimal performance, it is important to have an effective electrical power
distribution system that enables the smooth flow of electrical energy to the motor. The power connection
arrangement within this system plays a vital role in ensuring the efficient and safe operation of induction
motors. A well-constructed power connection arrangement can decrease electrical losses, reduce the
likelihood of equipment damage, and prevent unanticipated shutdowns. The most widely used power
connection arrangement for induction motors is the delta-wye configuration, which has a unique arrangement
of power connections that provide several advantages over conventional wiring methods.

Wye-Delta connections are commonly used in power distribution systems because they allow the voltage
to be stepped down while maintaining a balanced three-phase load. The delta connection allows for a higher
voltage output, while the wye connection provides a lower voltage but allows for greater flexibility in balancing
the loads. The utilization of delta-wye wiring in industrial and commercial settings to power up motors is
widespread. This wiring configuration stands out due to its distinctive power connection arrangement that
offers numerous benefits compared to conventional wiring methods. It is a crucial aspect in ensuring motors
operate efficiently and safely, making it a vital component in electrical power distribution systems. The delta-
wye starter is a popular method for managing electric motor starting current. It is often utilized in industrial
applications that demand a strong beginning torque, such as shear cutting machines.

A shear cutting machine is a type of industrial machine used to cut or shear various types of materials
such as sheet metal, paper, plastic, and fabric. The machine consists of a sharp blade or blades that are used
to cut the material as it passes through the machine. In a shear cutting machine, the motor is typically used to
drive the cutting blade, which requires a significant amount of power and torque. Depending on the size and
capacity of the machine, it is possible for a shear cutting machine to use an induction motor, but it is not the
only type of motor that can be used but, in this project, an induction motor is utilized.

Shear cutting machines are used in a variety of sectors to cut materials. To overcome the early resistance
of the material being cut, the motor utilized in these machines must have a high beginning torque. This project
will dwell into the importance of delta-wye wiring in powering motors and its effect on motor operation, and
analyze the basic principles of this wiring with its usage in various industrial and commercial environments. By
evaluating the pros and cons of this wiring configuration, this project will provide a thorough understanding of
its significance in the electrical power distribution system. The goal of this project is to create a delta-wye
starter for a shear cutting machine motor. The starter will be designed to deliver the appropriate starting torque
to the motor while controlling the beginning current to protect the motor and other components. The project
will include designing and building the starter, as well as testing and assessing its performance with the motor.

1
II. Objectives

• Power up a three-phase three horsepower induction motor that will drive the shear cutting machine
equipped with two emergency stops, three phase breaker and indicator lights that will activate upon
operation of the machine

• Provide a comprehensive understanding of the importance of delta-wye wiring in powering up motors

and its impact on motor performance

• Take advantage of the unique arrangement of power connections offered by the delta-wye configuration

• Ensure efficient and safe operation of the shear cutting machine by providing a proper flow of electrical
energy to the motor

• Reduce electrical losses and minimize the risk of equipment damage through a well-designed power
connection arrangement

• Improve power factor and reduce voltage stress on the motor, leading to an extended motor life and
improved overall performance

• Provide a path for fault current to flow, allowing protective devices to quickly and safely disconnect the
power in the event of a fault

• Balance the distribution of power to the motor, reducing the risk of electrical overloads and ensuring
consistent operation

2
III. Theoretical Background

The analysis of the voltage and current relationships between the three phases of the motor in a
delta-wye connection is an essential aspect of understanding the behavior of electrical motors. This
analysis is performed using mathematical models that are based on the laws of electrical circuits, including
Kirchhoff's laws and the law of conservation of energy. In a three-phase electrical system, voltage and
current are distributed among three separate phases, each 120 degrees out of phase with the others.
These phase relationships can be represented using complex numbers, which allow for the representation
of both magnitude and phase information. The mathematical models used to describe the delta-wye wiring
configuration in electrical motors involve the analysis of these complex numbers to determine the voltage
and current relationships between the three phases.

Figure 3.1 Three-phase “Y” connection has three voltage sources connected to a common point

The laws of electrical circuits, including Kirchhoff's laws and the law of conservation of energy,
are fundamental principles used to describe the behavior of voltage and current in electrical circuits.
Kirchhoff's voltage law (KVL) states that “The sum of voltages around any closed loop in an electrical
circuit is equal to zero”. Kirchhoff's current law (KCL) states that “The sum of current entering and leaving
a node in an electrical circuit is equal to zero”. These laws are used to describe the relationships between
the voltages and currents in the delta-wye wiring configuration in electrical motors. The law of conservation
of energy states that the total energy in a system is constant and cannot be created or destroyed. This
law is also important in the analysis of electrical motors, as it is used to determine the relationships
between the electrical energy supplied to the motor and the mechanical energy generated by the motor.

The delta-wye wiring configuration is widely used in three-phase electrical motors to distribute
voltage and current among the three phases of the motor. The theoretical frameworks used to explain this
wiring configuration are based on electrical circuit theory and the theory of electromagnetic induction.
These theories describe how electric currents and voltages interact in the motor to generate torque and
mechanical power.

Electrical circuit theory provides the foundation for understanding how electric currents and
voltages interact in an electrical circuit. This theory is based on the laws of electrical circuits, including
Kirchhoff's laws and Ohm's law, which describe the relationships between the voltages and currents in an
electrical circuit. By using these laws, it is possible to analyze the behavior of the voltage and current in a
delta-wye wiring configuration and determine how they interact to generate torque and mechanical power
in the motor. The theory of electromagnetic induction is another important aspect of the theoretical
frameworks used to explain the delta-wye wiring configuration. This theory describes how a changing
magnetic field induces an electric current in a conductor. In an electrical motor, the interaction between
the magnetic fields generated by the current flowing in the coils and the magnetic fields generated by the
rotor creates a force that causes the rotor to rotate. This interaction between the electrical and magnetic
fields generates the torque and mechanical power in the motor.

3
 Figure 3.2 Interaction between the Electrical and Magnetic Fields

The combination of electrical circuit theory and the theory of electromagnetic induction provides
a comprehensive understanding of how the delta-wye wiring configuration operates in an electrical motor.
By analyzing the voltage and current relationships between the three phases of the motor, it is possible
to determine how they interact to generate torque and mechanical power. This understanding is critical
for optimizing the performance of electrical motors and ensuring that they operate efficiently and reliably.
Force diagrams are a useful tool in understanding the interactions between the electrical and mechanical
forces in delta-wye wired motors. They show how the forces are distributed along the rotor and stator of
the motor and the relationships between the current, voltage, and power in the motor.

A delta-wye wired motor is a type of induction motor that uses a delta-connected stator winding
and a wye-connected rotor winding. In a delta-wye wired motor, the electrical forces are generated by the
magnetic field created by the stator winding and the mechanical forces are generated by the rotor winding.
The force diagrams in delta-wye wired motors can be used to show the distribution of forces along the
rotor and stator. For example, in a rotating magnetic field, the magnetic field generated by the stator
winding interacts with the magnetic field generated by the rotor winding. This interaction results in an
electrical force that acts on the rotor, causing it to rotate.

Figure 3.3 Electrical Force in Induction Motor

The force diagrams also illustrate the relationships between the current, voltage, and power in
the motor. The voltage applied to the stator winding generates a magnetic field, which in turn generates
an electrical force in the rotor winding. This electrical force drives the rotor, causing it to rotate. The current
flowing in the stator winding is proportional to the voltage applied, while the current flowing in the rotor
winding is proportional to the mechanical force acting on it. The power in the motor is the product of the
voltage and current, and it is proportional to the mechanical power generated by the rotor. The electrical
power input to the stator winding is equal to the mechanical power output of the rotor, so the efficiency of
the motor can be calculated by comparing the electrical power input to the mechanical power output.

4
 Free body diagrams are used to describe the forces acting on different components of a motor
and to visualize the interactions between these forces. In the case of delta-wye wired motors, free body
diagrams are used to represent the forces acting on the rotor and stator, and how these forces interact to
generate torque and mechanical power in the motor.

Figure 3.4 Rotor and Stator Forces in Induction Motor

A free body diagram of the stator would show the magnetic force generated by the stator winding,
the gravitational force acting on the stator, and any other external forces acting on the stator. The magnetic
force generated by the stator winding is proportional to the current flowing in the winding and the magnetic
field generated by the winding. Next is a free body diagram of the rotor would show the electrical force
generated by the interaction between the magnetic field generated by the stator winding and the magnetic
field generated by the rotor winding, the mechanical force generated by the rotor winding, and any other
external forces acting on the rotor.

The electrical force generated by the interaction between the magnetic fields is proportional to
the current flowing in the rotor winding and the magnetic field generated by the rotor winding. The
interaction between the electrical and mechanical forces generates a torque that causes the rotor to rotate,
generating mechanical power. The mechanical power generated by the rotor is proportional to the torque
generated and the speed of rotation.

In a delta-wye connection of an induction motor, the stator windings are connected in either a
delta (Δ) or wye (Y) configuration. In a delta connection, the stator windings are connected in series to
form a closed loop. This configuration provides a high starting torque and is commonly used in applications
where a high starting torque is required. In a wye connection, the stator windings are connected in a Y-
shape and are connected to a neutral point. This configuration provides a lower starting torque but
provides a higher breakdown torque. The delta-wye connection is commonly used in high-performance
motor drives and variable frequency drives (VFDs) where the speed of the motor can be adjusted to match
the load requirements. In these applications, the stator windings are connected in a wye configuration and
the output of the VFD is connected to the delta configuration.

In many circuit applications, we encounter components connected together in one of two ways
to form a three-terminal network: the “Wye” (also known as the “star”) configuration, and the “Delta”
configuration. The delta-wye wired motor is an induction motor that operates on the principle of
electromagnetic induction. The motor consists of a stator and a rotor. The stator is the stationary part of
the motor that contains the windings, while the rotor is the rotating part of the motor that contains the
magnetic field. In a wye-delta wired motor, three-phase electrical power is supplied to the stator winding.
The stator winding is connected in a delta configuration, which provides a balanced distribution of
electrical power to the motor. The three-phase electrical power supplied to the stator winding generates
a rotating magnetic field.

The rotor winding, which is connected in a wye configuration, interacts with the magnetic field
generated by the stator winding. This interaction generates an electrical force that drives the current
flowing in the rotor winding. The current flowing in the rotor winding generates its own magnetic field,
which interacts with the magnetic field generated by the stator winding. The interaction between the
magnetic fields generates a torque that causes the rotor to rotate, generating mechanical power. The
mechanical power generated by the rotor is proportional to the torque generated and the speed of rotation.

5
 The working principle of a wye-delta wired motor is based on the interaction between the
electrical and magnetic fields in the motor. The three-phase electrical power supplied to the motor is
transformed into a rotating magnetic field, which generates torque and mechanical power in the motor.
The delta-wye wiring configuration allows for the efficient distribution of electrical power to the motor,
providing stable and reliable operation. The delta-wye wired motor is a popular choice for many industrial
applications due to its high efficiency, reliability, and versatility.

Figure 3.5 The Wye Network and Delta Network

Wye Configuration: Delta Configuration

𝐿𝑒𝑡 𝑅𝐴 = 𝑅𝐵 = 𝑅𝑐 𝐿𝑒𝑡 𝑅𝐴𝐵 = 𝑅𝐵𝐶 = 𝑅𝐴𝐶

1 1 1
𝑅𝑇 = 𝑅𝐵 + 𝑅𝐶 = +
𝑅𝑇 𝑅𝐵𝐶 𝑅𝐴𝐵 +𝑅𝐴𝐶

1 𝑅𝐴𝐵 +𝑅𝐴𝐶 +𝑅𝐵𝐶

𝑅𝑇 = 𝑅𝐶 + 𝑅𝐶 =
𝑅𝑇 𝑅𝐴𝐵 𝑅𝐵𝐶 +𝑅𝐴𝐶

𝑅𝐵𝐶 (𝑅𝐴𝐵+ 𝑅𝐴𝐶 )

𝑅𝑇 = 2𝑅𝐶 𝑅𝑇 =
𝑅𝐴𝐵 +𝑅𝐴𝐶 +𝑅𝐵𝐶

𝑅𝐴𝐵 (2𝑅𝐴𝐵 )
𝑅𝑇 =
3𝑅𝐴𝐵

2
𝑅𝑇 = 𝑅𝐴𝐵
3
It is possible to convert a delta network into a functionally equivalent wye network, and it is also
possible to convert a wye network into a functionally equivalent delta network. “Functionally equivalent”
means that the overall electrical behavior of the converted network is identical to the overall electrical
behavior of the original network. In other words, if the original network is connected to the system at
terminals A, B, and C, we can remove the original network and connect the converted network to terminals
A, B, and C without changing the behavior of the system. At this point we know what a delta–wye
conversion is. It is proven by these equations that the Wye connection contains a lot of resistance than
the Delta connection hence it should be the first one to engage in motor systems. It turns out that
converting a delta network to a wye network, or a wye network to a delta network, can facilitate the analysis
of a larger circuit that includes a delta or wye network.

6
 IV. System Design and Construction

Figure 4.1 Schematic Diagram

Insert Schematic Diagram here.

Materials

Metal enclosure boxes, also known as electrical circuit boxes or panel boxes, are commonly
used in a variety of applications to house electrical equipment and protect it from environmental hazards.
Metal enclosure boxes are essential components for housing and protecting various types of electrical
equipment across a wide range of applications.

Electrical Circuit box

7
 Industrial plug socket connectors are used to provide electrical power to industrial equipment
and machinery. They are designed to withstand the harsh environments and heavy usage typically
encountered in industrial settings. The term "three-phase" refers to the three alternating currents that are
used to provide power to the equipment, while the number of cores and holes in the connector determines
the specific configuration. Industrial plug socket connectors are essential components in providing power
to industrial equipment and machinery, and the specific configuration and rating of the connector must be
chosen based on the requirements of the equipment being powered.

Industrial Plug Socket Connector

A wire tray, also known as a cable tray, is a type of containment system used to support and
protect electrical cables and wires in commercial and industrial settings. It is designed to provide a safe
and organized way to route cables and wires throughout a building or facility. Wire trays are an important
component of electrical systems in commercial and industrial settings, providing a safe and organized
way to route and protect cables and wires. The specific type and configuration of wire tray used will depend
on the requirements of the building or facility, and should be chosen based on safety codes and standards.

Wire Tray

A thermal overload relay is an electrical protection device that is designed to protect electric
motors from damage caused by overheating. It is a type of relay that uses a bimetallic strip or an electronic
sensor to detect overheating, and then interrupts the power supply to the motor to prevent damage.
Thermal overload relay is an important component of electrical systems that use electric motors. It protects
the motor from damage caused by overheating and can help to extend the motor's lifespan. The specific
type of thermal overload relay used will depend on the motor's characteristics and the requirements of the
application.

8
 CNC JR28s-25 Thermal Relay

The Allan Transformer 220V-12V DC 2A / 12v2a is a type of power supply transformer that is
commonly used to convert high-voltage AC power from the mains supply (220V) to low-voltage DC power
(12V DC) with a maximum output current of 2 amps. It is designed to provide a stable and reliable source
of DC power for a wide range of electronic devices and appliances, including LED lighting systems,
routers, and other low-power devices. The "2A" or "12v2a" in the name refers to the maximum output
current of the transformer, which is 2 amps. The specific use and application of the transformer will depend
on the requirements of the device or equipment being powered.

Allan Transformer

The MY4NJ is a type of power relay that can be powered by a 12V, 24V, or 220V coil. It is commly
used in industrial control systems and other applications that require a reliable and durable switching
solution. The relay is mounted on a DIN rail and has a 14-pin configuration with 4PDT (4 Pole Double
Throw) contacts, which means that it has four sets of normally open (NO) and normally closed (NC)
contacts that can be switched between two positions. The MY4NJ relay also comes with a socket that can
be easily mounted onto a DIN rail, making it simple to install and replace. The specific use and application
of the MY4NJ relay will depend on the requirements of the system or device it is being used with, but it is
commonly used in control panels, automated machinery, and other industrial systems.

Coil Power Relay DIN Rail Mounted with Socket

9
 A circuit breaker is an electrical device that is designed to automatically interrupt the flow of
electrical current in a circuit when it detects a fault or overload condition. It is a safety device that is
commonly used in electrical systems to protect against electrical fires, equipment damage, and other
hazards. Circuit breaker is an essential component of electrical systems that help to protect against
electrical hazards and damage. The specific type and rating of circuit breaker used will depend on the
characteristics of the circuit being protected and the requirements of the application.

3P Circuit Breaker

The ST3PA-B is a type of power on delay timer relay that is designed to control the timing of the
power-on sequence in an electrical system. It is commonly used in control panels, automated machinery,
and other industrial systems. The timer relay can be powered by an AC 220V supply and is equipped with
a knob that can be used to control the delay time. ST3PA-B timer relay is an important component of
electrical systems that require precise timing control during the power-on sequence. The specific use and
application of the relay will depend on the requirements of the system being controlled, but it is commonly
used in control panels, automated machinery, and other industrial systems.

Timer Relay

A pilot light LED indicator is an electrical component that is used in control panels and electrical
enclosures to indicate the status of a device or system. The pilot light is typically installed on the front of
a panel or enclosure and provides a visual indication of the state of the system being monitored. It is a
simple yet important component of electrical control systems that provides a clear visual indication of the
status of a device or system. The specific use and application of the pilot light will depend on the
requirements of the system being monitored, but it is commonly used in a wide range of applications, such
as motor control, machine automation, and process control.

10
 Pilot Light LED Indicator

A 10A Off Switch Emergency Stop Push Button is a safety device that is used to quickly shut
down a machine or system in case of an emergency. The push button is typically installed in a prominent
location on the control panel or machine and is designed to be easily accessible to the operator. 10A Off
Switch Emergency Stop Push Button is an important safety component of industrial machines and
systems that helps to protect operators and equipment from damage in case of an emergency. The
specific use and application of the push button will depend on the requirements of the system being
controlled, but it is commonly used in a wide range of applications, such as machine automation, process
control, and motor control.

Emergency Stop Push Button

A push button spring return is a type of electrical switch that is designed to be mounted on a
control panel or enclosure and is used to control the operation of a machine or system. The push button
is typically constructed with a round, cylindrical body and a button that is spring-loaded to return to its
original position when released. Push button spring return is a simple yet important component of
industrial control systems that provides a reliable and convenient way to control the operation of machines
and systems. The specific use and application of the push button will depend on the requirements of the
system being controlled, but it is commonly used in a wide range of applications, such as motor control,
machine automation, and process control.

Push Buttons

11
 A CNC CJX2s AC Contactor is an electrical component that is used to control the operation of
electric motors and other electrical loads. The contactor is designed to be mounted on a DIN rail and is
typically used in industrial control systems, such as CNC machines. CNC CJX2s AC Contactor is an
important component of industrial control systems that provides a reliable and convenient way to control
the operation of electrical loads. The specific use and application of the contactor will depend on the
requirements of the system being controlled, but it is commonly used in a wide range of applications, such
as machine automation, process control, and motor control.

CNC CJX2s Magnetic Contactor 3Phase

Experimental Methodology

The main reason of this project is to create the motor control panel of the shear cutting machine.
In such case, the machine hasn’t been operational for quite a long time. Researchers carefully crafted the
experimental methods in order for their objectives and plans are feasible given on a limited time frame.
The shear cutting machine enables the use of an induction motor which converts electrical energy into
mechanical energy then transmits from the motor through a rotating shaft thus providing energy to cut
sheet metals through its blades.

The flow diagram below indicates the plans and processes in attaining the desired result of this
project.

Final
Motor
Preemptive Testing
Wiring Controls
Procedural Testing of and
Installation Testing and
Initial Planning, Electrical Sealing
of Electrical Tuning
Inspection Discussion Wirings
Components
of the and
Condition Research
of the
Machine

12
 Initial Inspection of the Machine

Initial inspection of the machine was conducted to initialize whether the machine and the motor
itself is still in good condition. It is the crucial step in developing certain actions and plans in order to
rehabilitate the machine which is the main goal of this project. Continuity testing on the motor will be
conducted through the use of a multi tester. It a process in which the electrical continuity of the motor and
its windings is inspected to ensure that there is no break or it is not shorted. If such a motor's continuity
test is successful, it means that the electrical circuit in the motor is complete, with no open circuits or
breaks in the motor windings. This means that the motor windings are undamaged and that electric current
can flow freely through them. If the continuity test fails, it indicates that the motor windings have an open
circuit or a break, which could be caused by physical damage, overheating, or insulation failure. This could
result in the motor not working or working inefficiently, necessitating repairs or replacement of the faulty
components.
As a result, a successful continuity test indicates that the motor windings are in good condition
and can function properly, whereas a failed continuity test indicates that further investigation is required
to identify and repair any motor faults and it can derail or diminished the objectives of this project.

Procedural Planning, Discussion, and Research

Procedural planning is where process of creating a detailed set of instructions or procedures that
describe how a specific task or activity should be carried out. In this project a breakdown of task and
materials will be prepared in so that a smooth flow of activities will be recorded and conducted. Identifying
the tools, materials resources required to complete each step. Proper materials which in compliance with
quality standard is ensured to assure longevity of the machine and can perform on the specified tasks
with ease and hassle free.

Research is preceded upon planning to gather vital information on set of specifications and
materials should the researchers acquire. Budget and the resources needed is also dependent on the
students’ reach. However careful selection of materials is a top a priority to ensure quality of the project
without breaking too much on the bank.

Wiring Installation of Electrical Components

Delta-wye configuration is aligned with the project to control the motor of the shear cutting
machine. This type is desirable because it reduces the motor's starting current. When a large motor is
started, it can draw a very high current, which can damage the motor and other electrical system
equipment. The delta-wye starter reduces current by first starting the motor in a delta configuration, which
applies full voltage across the motor's three windings. When the motor reaches a certain speed, the starter
changes to a wye configuration, which applies a lower voltage across the windings. This reduces the
starting current of the motor and prevents damage to the motor and other electrical system components.

Processes

The processes involved in achieving the objectives of the delta-star wiring configuration of the
shear cutting machine included carefully selecting the appropriate motor, designing and implementing the
wiring configuration, and conducting rigorous testing and evaluation to ensure that the machine met its
performance objectives. In addition, ongoing maintenance and calibration of the machine were necessary
to ensure that it continued to perform optimally over time.

Shearing machines are versatile tools used to cut sheet metal and other alloys. After carefully
deciding on the right motor, planning and putting in place the wiring arrangement, and putting the machine
through thorough testing and assessment

13
 Delta wye configuration is fitted upon the control system with the diagram given below.

Preemptive Testing of Electrical Components

This process is a proactive approach that involves testing of electrical wirings before any problem
arises or before any load such as the motor is connected. This is done to identify potential electrical
hazards and prevent accidents and damage to the equipment. The goal of preemptive testing is to identify
any issues that could lead to a failure or malfunction in the future and take corrective action before they
occur. This can help to avoid costly downtime, equipment damage, and even safety hazards. This process
can include a variety of different tests, depending on the type of component being tested and the specific
concerns that need to be addressed.
By visual inspection of the materials and electrical components, the researchers may identify
physical defects on the items that is purchased such as cracks, corrosion and discoloration. Afterwards,
functionality testing will be conducted to see if the materials are functioning correctly or it performs to its
optimum performance. Electrical testing follows as this is where the voltage, resistance and continuity of
the wirings are inspected.
This process is the most time consuming of all the processes involve because it is where
problems are mostly found, material incompatibility and other factors that may affect the workings of the
system. However, such is proceeded as the crucial part for which trouble shooting may be involve to
ensure safety and success of the project.

Motor Controls Testing and Tuning

Motor controls testing is the step in which the researchers verify and test the performance of the
motor control system being developed optimizing its performance to the right consistency to ensure
smooth delivery of power and performance. This process involves subjecting the motor control system to
different loads starting from a small 3KW motor to the big boy motor which is 5.5 KW to verify whether the
theories are best fitted for the system or is it capable of handling the required load for such application.
The specification of the motor of the shear cutting is listed as follows.

14
 Hitachi Ltd. Tokyo Japan Induction Motor
Type EFOUP Form KK
kW 5.5 Volts 200
Poles 4 Cycles 60
Rating CONT. RPM 1750
Rotor K2 Amps 21
Temperature 65℃ Code H
Rise
Ambient 40℃ Bearing 630BHL
Temp
Vibration Insulation E
Class Class
Date 1973 Rule JLS 0Z004
MFG No. D36203Z (NOT Phase 3
SURE)

After such testing, the process of tuning the motor will be conducted. This will involve adjusting
the defaulted parameters to its specified requirement for usage as the main driver of the shear cutting
machine. The adjustment of the time delay will be considered to know when the motor will shift to wye
connection to forbade the speed of the shear cutting machine for optimal and safety of operation.

Final Testing and Sealing

The final testing and sealing of a motor control system takes place before the system is put into
operation. During this stage, the entire system is thoroughly tested to ensure that it meets the required
specifications and is ready for use. Following testing, the system is sealed to prevent unauthorized
tampering or modifications. An inspection is carried out to ensure there is no lose wire nor a damage
component may be present for such can affect the entire performance of the machine that may also cause
severe damage to the machine and safety hazards to its users
To assess the performance of the shear cutting machine, several experimental tests were
conducted. These tests included measuring the current draw of the motor during startup, as well as
monitoring the torque output of the motor. In addition, the shear cutting machine was tested under various
loads to evaluate its cutting capacity and efficiency.

Assessment

The assessment of the shear cutting machine involved comparing its performance with that of
other machines on the market, as well as evaluating its ability to meet the specific needs of the intended
application. This assessment involved taking into consideration factors such as cutting speed, accuracy,
and reliability, as well as any potential maintenance or repair needs.

A 3-phase, 3-horsepower induction motor is utilized in order to rehabilitate and continuously

operate a shear-cutting device. The rehabilitation of the said device will not be completed without the
assistance of these components; dual emergency stops, a delta-wye starter, a three-phase breaker, and
an indication flashing light that turned on while the machine was operational. The machine's energy
efficiency may be increased by including a variable frequency drive that will let the motor speed be
changed. A controller can also be used to automate the shear machine's operation even more, making
the cutting process to be exact, precise, and effective. The relays and other parts needed to power the
motor will also need to be housed in a control box.

This control box should have a magnetic starter with overload protection and be linked to the
machine by a flexible conduit. It should also include a power switch with an "on" and "off" position for
convenience of its use. Lastly, for safety reasons, all wiring must be placed in accordance with current
electrical codes. To guarantee that the shear machine runs effectively and safely, all required parts should
be installed correctly and double checked for security. A variable frequency drive, control panel, circuit
breaker, and all electrical wiring should be included. Each of the components should also be fitted in
accordance with the instructors and other advisers in order to ensure complete compliance with safety
requirements. With these factors taken into account, the installation of the shear machine should be
completed efficiently and in a timely manner

15
V. Results and Discussions

The experimental methodology processes were utilized as the basis for developing the motor
control system of the shear cutting machine during the project's implementation. This included planning,
researching available resources, wiring the components, and troubleshooting issues, resulting in the
collection of observable data. The project aimed to provide power and ease to users of the shear cutting
machine, and it also provided researchers with a lifelong learning experience in motor control systems.

During the first part of the implementation of the project, the idea of creating a control system for
the shear cutting machine was brought up by our dearest instructor. The ease of having a control system
for which with one tap we can simply turn on and off this big hunky machine was inevitable. As per
observation and history, the machine was short lived and was used manually overtime by the students
because of the lacking control system and within that limitation a lot of students struggled on specific task
that required the use of this machine.

The feasibility of this project was mainly dependent on the condition of the machine and its motor.
An initial inspection on the machine is conducted to foresee if rehabilitation is attainable or not given its
current state. The motor is also inspected as to which this is the main driver of this machine. A continuity
test is conducted as for us to know if there are certain defects on the internal windings of the motor, or
there could be damaged which can’t be physical seen without the use of proper equipment. After many
years of dormant sleep, the test yields possible result as to which there were no possible defect on the
windings given the resistance and continuity test that is conducted. With the yield result, the next step is
preceded. Certain discussions are made on what theories and practices that would best fit on the motor
given its specifications. The components are discussed and the budget are being divided among the group
of students qualified for the task. With careful consideration on the components and its specifications,
orders were made overseas that has taken almost two to three weeks of anticipation. It was discussed
that the branding of these electrical components should be identical to ensure proper and smooth
operation.

However, with such extent there are components that were not used because of incompatibility
and mishaps on the researcher’s side. Miscommunication and lack of knowledge became a hindrance to
such group work. Upon arrival of all electrical components, wiring installation was preceded. It is the
strenuous process that this project offers for which lacking of proper tools and proper equipment were not
obtained by the students because of insufficient funding. With skills developed from personal experiences
wiring installation preceded on time given the limitations discussed. AWG 18 automotive wires were wired
unto the relays and smaller electrical components. The AWG 14 wires were installed on the main contactor
which deals higher current capacity. After wiring and installation of electrical components to the control
box, testing is done with the use of multimeter to ensure proper connection between relays and wire slots
before connection to the main electrical outlet. Minor delays were noticeable because of mishaps in wiring
connection. However, such were addressed automatically and solved sensible of its use. With the control
system, being operational and ready for testing of a load. It was intended to use first smaller load before
the big one to ensure smooth operation and for safety precautions. The use of a 3-kilowtt motor is utilized
which yield positive results afterwards. After seeing all are functional and are compatible with the given
load, the motor was connected and is being tested after years of being stagnant.

At first load up, as electrical current passes through the components down to the motor it created
a powerful torque which was odd given on the set of specifications, the starting configuration and the timer
delay that was set to counter such outcome. With this mishap in the project the main breaker of the main
line broke forcing a delay in testing. Then discussions were made to know what was the problem at that
very moment, research was then again conducted to investigated the main cause of this perpetuating
event. It is found out that the main lines connecting the main, delta and wye contactor were swap and
such configuration indeed provided such outcome. Then it is agreed to reconfigure the electrical control
system to which is suitable to again be tested to the motor. Following the reconfiguration process, comes
the big boy motor testing, and this time the motor operates at much smoother phase and with such result
the long process of restructuring and different testing was much worthwhile. The transition phase between
wye and delta starter has become evident in providing smooth operation of big motors.

The results obtained on this project were made through dedication and sure will in finishing the
said project. It was also made clear through history that through such valiant students supervised by a
talented and skillful instructor made the project feasible and successful and has broken the unoperational
years of the shear cutting machine.

16
VI. Conclusion and Recommendation

In conclusion, building a delta-wye starter in a shear cutting machine can be an effective way to
ensure that the machine starts and operates smoothly while reducing the risk of damage to the machine
or injury to personnel. A delta-wye starter provides a method for reducing the inrush current that occurs
when a motor starts up, which can cause damage to the motor and other components in the machine. By
using a delta-wye starter, the motor is started with reduced voltage, which limits the inrush current and
protects the motor. The delta-wye starter is designed to operate in two modes: delta and wye. The delta
mode is used during startup to provide full voltage to the motor, while the wye mode is used during normal
operation to provide reduced voltage to the motor. By using a combination of these modes, the delta-wye
starter can reduce the inrush current during startup and improve the efficiency of the machine during
normal operation.

When building a delta-wye starter for a shear cutting machine, it is essential to understand the
electrical requirements of the machine and select the appropriate components for the starter. Choosing
high-quality components, such as contactors, relays, and resistors, can help to ensure that the starter
operates reliably and reduces the risk of failure. It is also crucial to follow safety guidelines and procedures
during the installation and operation of the delta-wye starter to minimize the risk of injury or damage to
the machine. One significant advantage of using a delta-wye starter in a shear cutting machine is the
potential cost savings it can offer. By reducing the inrush current and protecting the motor, the machine
is less likely to experience downtime due to motor failure, which can result in costly repairs and lost
productivity. Additionally, the reduced starting current can lead to lower energy costs, as the machine will
draw less power during startup.

It is highly recommended to future students to first, understand the requirements of the machine.
It is important to have a good understanding of the shear cutting machine's electrical requirements and
operational needs. This will help in designing and implementing an effective delta-wye starter that meets
the specific needs of the machine. Next is to choose the right components. When building a delta-wye
starter, it is crucial to choose the right components, including contactors, relays, and transformers.
Selecting high-quality components will ensure that the starter operates reliably and reduces the risk of
failure. Followed by abiding to safety guidelines. Safety should always be a top priority when working on
electrical equipment. Ensure that all safety guidelines and procedures are followed during the installation
and operation of the delta-wye starter. Lastly, test and troubleshoot your wirings. After building and
installing the delta-wye starter, it is important to test it thoroughly to ensure that it is working as expected.
Any issues should be identified and resolved promptly to avoid any potential damage to the machine or
safety risks.

Overall, the use of a delta-wye starter in a shear cutting machine can be an effective way to
improve its performance, increase its lifespan, and reduce operating costs. With proper planning, design,
and installation, a delta-wye starter can be an excellent investment for any machine operator looking to
improve their machine's efficiency and reliability.

17
VII. References

Torque curve - HomoFaciens. (n.d.). Retrieved February 25, 2023, from homofaciens.de website:
https://homofaciens.de/technics-electric-motors-torque-curve_en.htm

Three-phase Y and Delta Configurations | Polyphase AC Circuits | Electronics Textbook. (2016).

Retrieved from Allaboutcircuits.com website:
https://www.allaboutcircuits.com/textbook/alternating-current/chpt-10/three-phase-y-delta-
configurations/

Δ-Y and Y-Δ Conversions | DC Network Analysis | Electronics Textbook. (n.d.). Retrieved from
www.allaboutcircuits.com website: https://www.allaboutcircuits.com/textbook/direct-
current/chpt-10/delta-y-and-y-conversions/

What Is Wye And Delta? | Chapter 1 - Voltage, Current, Energy, and Power | Power Electronics
Textbook. (n.d.). Retrieved from eepower.com website: https://eepower.com/power-electronics-
textbook/vol-i-electrical-power-systems-design/chapter-1-introduction-power/what-is-wye-and-
delta/#

Mizan, E. (2019, September 8). Induction Motor | Why Does The Rotor Rotate | Working Principle.
Retrieved February 25, 2023, from ICEEET website: https://www.iceeet.com/why-does-the-
rotor-rotate/

Workbook, A. E. (2021, June 27). What is a 3 Phase Induction Motor? Diagram, Working & Types.
Retrieved from ElectricalWorkbook website: https://electricalworkbook.com/three-phase-
induction-motor/

Shearing Machines (sheet metal) Selection Guide: Types, Features, Applications | Engineering360.
(n.d.). Retrieved from www.globalspec.com website:
https://www.globalspec.com/learnmore/manufacturing_process_equipment/machine_tools/she
ars

Delta VS Wye Explained | Greentech Renewables. (2011, May 18). Retrieved February 25, 2023, from
www.greentechrenewables.com website:
https://www.greentechrenewables.com/question/delta-vs-wye-explained

Cutting | TRUMPF. (n.d.). Retrieved February 25, 2023, from www.trumpf.com website:
https://www.trumpf.com/en_INT/solutions/applications/process-cutting-shears-slitting-shears-
and-nibblers/

Guillotine Metal Shear Accuracy - SHENCHONG. (n.d.). Retrieved February 25, 2023, from
www.shenchong.com website: https://www.shenchong.com/guillotine-metal-shear.html

Yam, I. J. (n.d.). Using Star-Delta Motor Control (With Circuit Diagrams). Retrieved from TurboFuture
website: https://turbofuture.com/industrial/How-to-learn-Star-Delta-Motor-Control-A-Basic-
Guide-to-Learning-Star-Delta-Motor-Controller

Shearing Machine: Definition, Types, Working, Application & Operation [Complete Guide]. (2021,
November 10). Retrieved from Engineering Learn website:
https://engineeringlearn.com/shearing-machine-definition-types-working-application-operation-
complete-guide/

Zapata, J. (2020, May 6). Three Phase Induction Motor: Types, Working, and Applications. Retrieved
from ELECTRICAL TECHNOLOGY website:
https://www.electricaltechnology.org/2020/05/three-phase-induction-motor.html

18
 Rating Slip
Groups 5, 6, 8
SHEAR CUTTING MACHINE REHABILITATION

Rating 0 – 10 (10 as highest; 0 as lowest)

SURNAME RATING
Albios, Hannie Mae 7
Arguilles, Joshua 8
Avila, Josephine Jan 7
Cabarubias, Jasper
De La Cruz, Von Diosequim 9
Gonzales, Christine Grace
Gubalane, Victorino III 8
Jandumon, Ian Cesar 8
Jubay, Jayclien 8
Matuguina, Miko 8
Mayaman, Charles Vincent 6
Muñez, Jhuniel 7
Pole, Johann Christian 8
Roxas, Luis Manuel 9
Triste, Queen 6