TRAINING REPORT PRESENTATION

ON
PRODUCTION AND QUALITY
CONTROL OF A.C. MOTORS

BY :-
RAHUL SINGH
RANA
 ABSTRACT
 This consists of a short description, an
outcome of summer training done by
me at Marathon Electric, Faridabad.
 Its About the production of A.C. motors
describing all the assembly and
passing line processes of motor
manufacturing plant.
 Along with an introduction to A.C.
motors focusing on induction motor
and its construction.

 INTRODUCTION
 ELECTRIC MOTOR: Device converting
electrical energy into mechanical

energy.
 PRINCIPLE OF OPERATION: Current
carrying conductor placed in a
magnetic field, experiences a
mechanical force whose direction is
given by Fleming’s Left-hand rule and
whose magnitude is given by:
 F = BIL Newton.
CLASSIFICATIO
N
 A.C. MOTORS
 Electric motor that is driven by an alternating current.
Consists of two basic parts, an outside stationary
stator having coils supplied with a.c. to produce a
rotating magnetic field, and an inside rotor attached
to the output shaft that is given a torque by the
rotating field.
TYPES:

 1. Synchronous motor: Rotates exactly at the supply

frequency or a sub multiple of the supply frequency.
Magnetic field on the rotor is either generated by
current delivered through slip rings or by a
permanent magnet.


 2. Induction motor: Turns slightly slower than the

supply frequency. Magnetic field on the rotor of this
motor is created by an induced current.
 HISTORY & FACTS
 In 1882, Serbian inventor Nicola Tesla identified the rotating
magnetic induction field principle and pioneered the use of this
rotating and inducting electromagnetic field force to generate
torque in rotating machines. He exploited this principle in the
design of a poly-phase induction motor in 1883. In 1885,
Galileo Ferraris independently researched the concept. In 1888,
Ferraris published his research in a paper to the Royal
Academy of Sciences in Turin.


 Introduction of Tesla's motor from 1888 onwards initiated what is

sometimes referred to as the Second Industrial Revolution,
making possible both the efficient generation and long
distance distribution of electrical energy using the alternating
current transmission system, also of Tesla's invention (1888).


 Tesla later obtained U.S. Patent 0,416,194, Electric Motor

(December 1889), which resembles the motor seen in many of
Tesla's photos. This classic alternating current electro-
magnetic motor was an induction motor.
 INDUCTION MOTORS
 Most AC motors & 90% of industrial motors are
induction motors, they are favored due to their
ruggedness and simplicity.


 Induction motors are the workhorses of industry and

motors up to about 500 kW (670 hp) in output are
produced in highly standardized frame sizes,
making them nearly completely interchangeable
between manufacturers (although European and
North American standard dimensions are
different). Very large induction motors are capable
of tens of megawatts of output, for pipeline
compressors, wind-tunnel drives, and overland
conveyor systems.


 Most large (> 1 hp or 1 kW) industrial motors are

poly-phase induction motors, i.e. the stator
 PRINCIPLE OF OPERATION
 Based on rotating magnetic induction field
principle, the rotating and inducting
electromagnetic field force generates torque
in rotating machines.


 Conversion of electrical power into mechanical

power takes place in the rotating part of the
motor. In Induction motors rotor receive
electric power by induction in exactly the
same way as the secondary of a 2-winding
transformer receives its power from the
primary. That is why such motors are known
as induction motors.
 CONSTRUCTION
An Induction motor consists of 2 main parts: 
1. A stator and 2. A rotor
Both are assembled together as one assembly,
rotor known as an armature, a stator containing
windings connected to a poly-phase energy
source as shown in Figure:


 (TESLA POLY-PHASE INDUCTION MOTOR)


 STATOR:
Made up of a number of stampings, which are slotted
to receive the windings. It is wound for a definite
number of poles, (the no. of poles P, produced in the
rotating field is P = 2n where n is the no. of stator
slots/pole/phase) the exact no. of poles being
determined by the requirements of speed. Greater the

no. of poles, lesser the speed and vice versa.
The stator is wound with pairs of coils corresponding
to the phases of electrical energy available. For e.g. 2-
phase induction motor stator has 2-pairs of coils, one
pair for each of the two phases of AC. The individual
coils of a pair are connected in series and correspond

to the opposite poles of an electromagnet.
Stator laminations are thin insulated rings with slots
punched from sheets of electrical grade steel. A stack





 (Figure: Stator frame showing slots for windings.)



Wound stator is called as a field (or stator field) in

terms of production, the plant where whole process
of insulation and insertion of winding and other
processes takes place is called as passing line.
PASSING LINE
 1. INSULATION
Insulation paper which is a good quality mica sheet is
inserted into the slots of the stator at slot insulator
machines.
Stator core is built from high-quality low-loss silicon
steel laminations and flash-enameled on both sides.
Insulation paper is inserted into the slots accordingly as
the stack height, slot width, shape and dimensions,
generally stack heights varies from 18mm to 500mm.
A wide range of insulating machines is available in the
market.
General check points for insulation are proper checking
for stack height, diameter and other mechanical
dimensions of stator core, besides insertion of slot
paper should be uniform and of equal height with no
shifting down from its original position.
(Figure : INSULATING MACHINE)
(Courtesy: Statomat Machines)
 2. WINDING
Coils are wound on an external fixture, and then
worked into the slots. Insulation wedged between the
coil periphery and the slot protects against abrasion.


 (Figure: Stator with (a) 2-φ and (b) 3-φ windings.)

 2. WINDING(Cont.)
In actual large motors, a pole winding, is divided into
identical coils inserted into many smaller slots than above.
This group is called a phase belt.


 (Figure: Winding structure.)



The distributed coils of the phase belt cancel some of the

odd harmonics, producing a more sinusoidal magnetic field
distribution across the pole.
 Types of winding
1. Wave Winding: Distributed or non-distributed coil


(also known as split phase and non-split phase

winding). The waves are formed directly during the
winding process which saves space and guarantees an
optimal winding result.

2. Loose-Tooth / Bobbin Winding
3. Concentric Winding







 (Figure: Winding machines)

 (Courtesy: Statomat Machines)
 3. INSERTION
Wound coils are inserted into the stator slots at insertion
machines along with the wedge paper for insulation of
coil periphery from stator laminations and adjoining
coils.


 4. FORMING


The best winding and insertion still doesn't make the

perfect stator, Forming process is another focal point in
the production process.
Processes carried at this stage are such as
expanding lamellas, to final forming of I.D., O.D.
and heights of the winding head, scratch wire
detection. After this lead or cables connection are
made to the field & winding and insulation tapes
are applied.
 5. LACING
Lacing or knotting is done at the machine for finally
tightening the all the loose wires of coil winding. The end
turns are laced with a "diamond" stitch pattern.


Then the final process is carried out on field where final

inspection is done for visually detecting and removing the
defects on account of following:
 Loose wires/wiring, Lacing or knotting problem.
 Wedge paper problem, shifted down wedge paper.
 Slot paper.
 Cables or connecting lead length and proper
application of insulation tape.
 Without marking.


This is the most critical and important stage of passing line

from point of view of quality control. At this stage the
responsibility lies wholly on operator as there is no
intervention of machinery and the defects have to be
detected visually and removed manually.
6. COMPUTERIZED WINDING TEST
Computerized winding tester is the most comprehensive
quality control method for in-plant testing process
industries. It is extremely effective as a diagnostic tool
to evaluate and detect any windings fault such as:
 turn – to – turn short circuits

 coil – to – coil short circuits

 phase – to – phase short circuits

 reverse coil connections

 open coils

 grounded coils

 defective insulation

Tests performed by the computerized winding tester:
 Resistance test: Performed on the Main and Auxiliary
windings. All the resistance measurements are
corrected to the ambient temperature (25° C) using
the temperature sensors. It checks wrong turn count,
poor connections, mislabelled leads, and incorrect

wire size.
 Insulation resistance test: IR or megohm test checks

the strength of the insulation.
 AC Hi-Pot test: Detects if there is a breakdown to
ground or between windings which would otherwise
go undetected using average current measurement
techniques. This measures the resistive portion of the

leakage current, rather than the total current.
 Surge test: The high voltage surge test checks for
insulation problems between turns, coils, and phases
of the winding. Surge tests can also detect other
faults which change the inductance of a winding such

as reversed coils.
 Rotation test: The rotation direction test determines


 (Manual Surge Comparison tester)

 

 (Computerized Winding test machine)

 (Courtesy: The Automation Engg. Inc. , Fort
Wayne, Indiana)

 7. VARNISHING
Wound stator i.e. the field goes for varnish plant where
penetrating coat of good insulating varnishes are
applied on windings to protect them from action of
vibration, heat, water, oil, dirt and acid fume.
Insulating varnish provides a solid film protective
covering.
VARNISH PLANT HAS 2 STATIONS
FINAL PRODUCT of PASSING LINE-
FIELD(wound stator)
 ROTOR:
 ROTOR TEST LINE
 ROTOR TEST:
Designed to evaluate the Electromagnetic properties of
squirrel cage rotors.


Test system consists of Mechanical and Display unit,

interconnected by cable. The test set operates on the
basis of inductive measurement, accepting a wide range of
rotors, from small type to pump rotors which have long
shaft.


 APPLICATIONS:
Broken or interrupted rotor bars.
Poor or missing connections to the rotor end rings.Rotor
bar resistance measurement.
A short circuit between two or more bars.
Error in the relative position between commutator & slots.
Non-uniformity between lamination of the commutator.
 After this, shaft-rotor assembly is
passed on to for I.D. (Internal
Diameter) Reaming and O.D. (Outer
diameter) Reaming, which is done

with help of Micrometer.
 Next step is that of lacquering and
painting the shaft-rotor assembly, this
is done manually by applying a good

quality resin based lacquer.
 Lacquer used for the purpose is
generally oil mixed shellac based
compound, which forms a thin and a
highly elastic insulation layer on the
Rotor Shaft Assembly
ASSEMBLY LINE
 1. Shell Field Pressing:
Shell is pressed on to the field, i.e. the
stator is inserted into the shell.
 2. Assembly of Motor:

Rotor-shaft Assembly is inserted into the

Stator-shell assembly, along with the
end shield casing.
 3. Running of Motor:

Motor is tested by running it on the

input supply voltage and current which
is a little higher than that specified by
customer requirements.
 4. Noise Testing:
Most important stage of assembly
line from point of view of Quality
control, basically it is a Inspection
Stage where all assembled motors

are tested for Noise limit.
Whole arrangement is enclosed
inside the sound proof glass walls,
with two operators employed on the
noise testing Machine.


Tests Performed:
 Noise:
Analyzes audible noise, generated by a motor, by doing a
frequency analysis and comparing it to an envelope
based on a median of setup motors. Six different ranges
available for noise - 1000 Hz, 2000 Hz, 3000Hz, 5000 Hz,

7000 Hz and 10,000.
 Vibration & Resonance:
Analyzes a combination of audible noise and vibration,
generated by a motor, by doing a frequency analysis and
comparing it to an envelope based on a median of setup
motors.
Resonant frequency is much larger than other frequencies
generated within the motor.
Resonance is measured in Rones. Four ranges available for

Resonance - 500 Hz, 1000 Hz, 2000 Hz and 3000 Hz.
 Ambient Cancellation Technique:
Cancellation testing technique identifies the ambient
noise, resonance and vibration levels on the factory floor
Noise Testing System
 Motor
#1
The Gray shaded area is the test envelope
The green waveform indicates the motor NOISE generated

2 data points
are outside
the test
envelope
The Gray shaded area is the test envelope
The green waveform indicates the motor RESONANCE generated

8 data points
are outside the
test envelope
Motor
#2
The Gray shaded area is the test envelope
The green waveform indicates the motor NOISE generated

114 data
points are
outside the
test envelope
The Gray shaded area is the test envelope
The green waveform indicates the motor RESONANCE generated

171 data points

are outside the
test envelope
 5. NLT (No Load Test):
Inspection stage of Production Control,
at this stage various tests are
performed on assembled motor.
Performed for Voltage, Current, Power,
Power Factor, Speed (RPM) & Direction.
Performed by unloading the shaft of
the motor as much as possible or
applying it as close to zero torque as
possible.
A regulated AC voltage is applied to
the motor leads and motor voltage,
current, wattage and direction are
 After this stage the assembled
motor is passed through firewall
test, from where it is passed on to
for final packaging, where name
plate is placed on the motor
casing, and it is packed after oiling
the shaft, so as to prevent it from
rusting in a palette of 175 motors
each.
 6. SCAT:
Inspection stage of quality control;
here six motors are randomly
selected from a palette of 175
motors and selected tests are
performed on motor which are same
as that done at NLT and Noise

testing.
Motors which do not pass this test are
sent back to concern point of
production line where the failure
 C

B
A - Clamp Bolt /Nut
A B – Name Plate
D C – Motor Casing (End Shield)
D – Motor Shaft
F
E – Conduit Adapter
F – Terminal

G G – Motor Lead

FINAL PRODUCT