Smt. Indira Gandhi College of Engineering Navi Mumbai.

Estd : 1993-94
(Approved by AICTE New Delhi & Govt. of Maharashtra,
Affiliate to University of Mumbai)

Report on Industrial Visit of DOL motors

T.E/ Electrical
By – Meet Bhatt (07)

Prof. Satish Nimbalkar

I/C Industrial Visit
Type of insulation
The insulation used by the DOL Groups for the manufacturing Motors is Class F and Class H types.

1) Class F Insulation:

Class F insulation consists of materials or combinations of materials such as mica, glass fibre, asbestos, etc.,
with suitable bonding, impregnating or coating substances, as well as other materials or combinations of
materials, not necessarily inorganic, which by experience or tests can be shown to be capable of operation at the
Class F temperature (materials possessing a degree of thermal stability allowing them to be operated at a
temperature 25 Centigrade degrees higher than Class B materials).

Maximum allowed temperature: (IEC60034-1 & NEMA MG1-12.43): 155C, 311F.

2) Class C Insulation:
Class C insulation consists of materials or combinations of materials such as mica, porcelain, glass, quartz with
or without an inorganic binder (beware a few older applications used asbestos). Other materials or combinations
of materials may be included in this class, if by experience or tests they can be shown to be capable of operation
at temperatures above the Class H limit. Specific materials or combinations of materials in this class will have a
temperature limit, which is dependent upon their physical, chemical and electrical properties.
Maximum allowed temperature: (IEC60034-1 only): >180C, 356F.

IR and PI Value
IR (Insulation Resistance) Value: IR is a measure of the insulation resistance of the motor windings. It is
typically measured in ohms and indicates the resistance to electrical leakage between the motor windings and
the motor's frame or casing. Higher IR values are desirable as they signify better insulation integrity. The
specific IR value can vary depending on the motor's design and application but is typically in the range of
several megohms (millions of ohms).

PI (Polarization Index): The PI is a ratio of the insulation resistance measured at two different time intervals. It's
used to assess the condition of the motor's insulation over time. The first measurement is taken after one minute,
and the second measurement is taken after ten minutes of applying a test voltage. The PI value is calculated by
dividing the insulation resistance at 10 minutes by the insulation resistance at 1 minute. A higher PI value
(typically greater than 2.0) suggests good insulation quality and indicates that the insulation can withstand
voltage stress.
These values are critical for maintaining the reliability and safety of electric motors, particularly in industrial
and commercial applications. Regular testing of IR and PI helps identify insulation issues before they lead to
motor failures.

Drop test
Drop test for an electric motor is typically performed to assess the motor's resilience and to check for any
damage or defects resulting from impacts or shocks during transportation, handling, or operation. Here's a
general outline of how a drop test for an electric motor can be conducted:

 Prepare the Motor: Ensure the electric motor is properly secured or mounted as it would be in its operational
configuration. Make sure all connections and attachments are secure.
 Select a Test Height: Determine the height from which you will drop the motor. The height can vary
depending on the motor's size and weight, as well as the testing standards or requirements applicable to your
specific case.
 Drop the Motor: Carefully release the motor from the chosen height, allowing it to free-fall and experience
an impact when it lands. It's important to control the orientation of the motor during the drop to simulate
realistic conditions.
 Inspect for Damage: After the drop, thoroughly inspect the motor for any visible damage or loose
components. This may include checking for cracks, dents, loose wires, or other signs of damage.
 Functional Testing: After the visual inspection, you should also perform functional tests to ensure the motor
still operates within its specified parameters. This may involve running the motor to check its performance
and efficiency.
 Record Results: Document the results of the drop test, noting any damage or changes in the motor's
performance. This information can be used to assess the motor's ability to withstand shocks and to
determine if any corrective actions are needed.

Please note that specific procedures and standards for drop testing may vary depending on the industry, the type
of motor, and the application. It's essential to follow any relevant guidelines and safety precautions to ensure a
thorough and accurate assessment of the motor's condition.

Surge test
Purpose: To detect partial discharge and insulation weaknesses.

Procedure: Apply a voltage surge (short-duration high voltage pulse) to the motor windings and analyze the
response. A surge test helps identify issues like turn-to-turn insulation faults.

Coil formation
Electric motors consist of coils of wire wound around a laminated iron core. These coils are an essential
component of the motor, as they generate the magnetic fields that interact with the rotor to produce mechanical
motion. Here's a brief overview of the coil formation in electric motors:

 Stator Coils: The stationary part of the motor is called the stator. Stator coils are typically wound around
laminated iron cores that form the stator's structure. These coils are often made of copper wire and are
insulated to prevent short-circuits. The number of stator coils and their arrangement depend on the motor's
design and type (e.g., single-phase or three-phase motor).

 Rotor Coils: In some motor designs, such as in induction motors, there are rotor coils as well. These are
located on the rotor, the rotating part of the motor. Rotor coils interact with the magnetic field generated by
the stator coils, inducing currents and creating the motor's torque.

 Coil Winding Process: Coils are formed by winding copper wire around the stator or rotor core. The
winding process involves multiple turns or windings of wire to create a coil. The number of turns and the
wire size are crucial factors in determining the motor's performance characteristics, such as speed and
torque. Proper winding tension and insulation are essential to ensure the coils are well-formed and free from
short-circuits.

 Coil Insulation: The wire used for coil winding is insulated to prevent electrical contact between individual
turns and to protect the coils from moisture, dust, and other contaminants. Insulation materials can include
 enamel, varnish, or other specialized coatings.

 Coil Connections: The ends of the coils are typically connected to the motor's terminal blocks or leads. The
connections between coils are often arranged in specific patterns to achieve the desired phase relationships
in the motor.

 Coil Arrangement: The arrangement of stator coils varies depending on the motor type. For example, three-
phase motors often have a star or delta connection of coils to create a rotating magnetic field. Single-phase
motors have different winding arrangements depending on the specific motor design.

Shaft assembly:
The shaft assembly in an electric motor is a critical component that connects the motor's rotor to the external
load or the driven equipment. It plays a key role in transmitting mechanical power from the motor to the load.
Here's an overview of the shaft assembly in an electric motor:

 Shaft Material: Motor shafts are typically made from high-strength materials, such as steel (often stainless
or carbon steel), alloy steel, or other materials with the necessary mechanical properties to withstand the
stresses and loads applied during operation.

 Shaft Design: Motor shafts are designed with specific dimensions, including length, diameter, and keyways,
to accommodate the requirements of the motor and the driven load. The design of the shaft may include
features like keyways, threads, flats, or other custom configurations to facilitate coupling with the motor
rotor and the driven equipment.

 Bearings and Bushings: The shaft is typically supported by bearings or bushings at both ends to reduce
friction and allow smooth rotation. Bearings are selected based on the motor's size, speed, and load
requirements.

 Rotor Connection: The rotor of the electric motor is attached to one end of the shaft. The connection method
can vary depending on the motor design and type. In some cases, the rotor is secured with a press fit or set
screw.

 Coupling: The other end of the shaft is often connected to the driven equipment using a coupling. Couplings
come in various types, such as flexible couplings, rigid couplings, or other specialized couplings, and are
chosen based on the application's requirements.

 Balancing: To minimize vibrations and ensure smooth operation, the shaft assembly may undergo dynamic
balancing, which involves removing material from the shaft to correct any imbalances.

 Alignment: Proper alignment of the shaft is crucial to prevent premature wear and mechanical issues. Shaft
alignment ensures that the motor and the driven equipment are in line and operate smoothly.
VPI (vacuum pressure impregnation)
VPI stands for Vacuum Pressure Impregnation, and it's a crucial process in the manufacturing of electric
motors, particularly for ensuring the insulation of the motor windings is reliable and robust. The VPI process
involves the impregnation of the motor's windings with insulating resin under vacuum and pressure to enhance
electrical insulation and protect the windings from environmental factors. Here's an overview of the VPI process
in motor manufacturing:

Preparation of Windings: Before VPI can begin, the motor's windings are wound onto the stator core. The
windings may consist of coils of insulated copper wire.

Vacuum Chamber: The windings and stator assembly are placed in a vacuum chamber or vessel specially
designed for the VPI process.

Evacuation: The vacuum chamber is sealed, and air is removed from the chamber to create a vacuum. This
process evacuates the air from within the motor and the gaps in the windings.

Resin Injection: After achieving a suitable vacuum, an insulating resin, typically epoxy-based, is introduced into
the chamber. The vacuum ensures that the resin can penetrate all spaces between and within the windings.

Pressure Application: Once the resin has filled the spaces between the windings, pressure is applied to the
chamber. This pressure forces the resin to permeate the insulation and fill any remaining voids or air pockets,
ensuring complete impregnation.

Curing: The chamber may be heated to accelerate the curing process of the epoxy resin. Curing hardens the
resin, effectively locking the windings in place and creating a solid, protective barrier around them.

Cooling and Venting: After the curing process is complete, the chamber is cooled, and any remaining resin not
absorbed is collected for reuse. The chamber is then vented to restore atmospheric pressure.

Final Inspection: The motor is inspected to ensure the VPI process was successful and that the windings are
well-insulated and sealed.

Dynamic balancing of rotor

Dynamic balancing of a rotor in an electric motor is a critical process that ensures the rotor rotates smoothly
without causing excessive vibration or mechanical stress on the motor and its bearings. Unbalanced rotors can
lead to reduced motor life, increased noise, and vibration, and in extreme cases, they can damage the motor or
its surrounding components.
Photo Of Visit: