PRODUCT ENGINEERING DEPARTMENT

Energy - WEG INDUSTRIES (INDIA) PVT. LTD.

 Safe & Hazardous
Area

DESIGN &
SELECTION
OF MOTOR

Performance Consultant
Parameters Specification
Design Engineering
 Objective
Team of Electrical & Mechanical Design Engineers charged with
the responsibility of
- absorbing WEG Electrical Machine design technology
- adapting it to suit locally available materials
- modify it to suit local customer aspirations
- indigenize to make machines more economic & competitive
- innovate to reflect state of the art.
 Staff
 Mechanical Engineers : 42(including 1 Brazilian)
 Electrical Engineers : 10(including 1 Brazilian)

Design Engineering 2
Design Technology
Synchronous & Asynchronous Machines

ELECTROMAGNETIC
DESIGN

THERMAL AND NOISE

ANALYSIS

MECHANICAL
DESIGN

Design Engineering 3
Design Technology
Mechanical Design

MECHANICAL
DESIGN

MECHANICAL MACHINE
MECHANICAL PARTS
BASIC DESIGN DESIGN ANALYSIS DRAFTING
- SHAFT BEARING SELECTION; -2D AND 3D CAD Software
- BEARING TEMPERATURE & LIFE
-MACHINE PARTS STRUCTURAL
ANALYSIS; -SOLID WORKS
CALCULATIONS
-DESIGN GUIDELINES - AutoCAD
-SHAFT STRESS CALCULATION;
-ROTOR CRITICAL SPEED CALC.;
-FLUID FLOW ANALYSIS
-COOLING /VENTILATION
CALCULATION;
-BASE LOADS CALCULATION
- TORSIONAL ANALYSIS

Design Engineering 4
 Design Technology
Thermal Evaluation
TEMPERATURE RISE
Stator winding
Rotor winding
TEMPERATURE Air flow inside machine
Air pressure
Fan efficiency
Losses (friction & ducts)

SIMULATION OF TEMPERATURE RISE

IN IRON AND WINDING BY SASVPI

Design Engineering 5
Design Technology
Noise Calculation
GENERAL NOISE PREDICTION

- Natural frequencies

- Spatial harmonics of flux density

- Origin of flux density harmonics

Design Engineering 6
Design Technology
Mechanical Basic Design
BEARING CALCULATION INPUT DATA
Sleeve Bearings:
- Effective lubricant film temperature;
- Frictional power loss;
- Lubricant film stiffness coefficients;
- Lubricant film damping coefficients;
- Hydrodynamic required flow rate.

Anti-Friction Bearings:
- L10h bearing life;
- Re-lubrication interval;
- Re-lubrication grease quantity. OUTPUT DATA

Design Engineering 7
Design Technology
Mechanical Basic Design
ROTOR CRITICAL SPEED CALCULATION INPUT DATA

ROTOR DYNAMICS ANALYSIS

-Rotor natural frequencies;
-Campbell diagram;
-Rotor unbalance response.

OUTPUT DATA

Design Engineering 8
Design Technology
Mechanical Basic Design
SHAFT STRESS CALCULATION ANALYTICAL
CALCULATION
-ANALYTICAL CALCULATION USING SPECIFIC
PROCEDURES
CALCULATION PROCEDURES; FINITE ELEMENTS
-FINITE ELEMENTS SIMULATIONS. SIMULATIONS
-Fatigue analysis;

-Static analysis;

-Loads:
- Start up;
- Rated speed.

Design Engineering 9
Design Technology
Mechanical Basic Design
FLUID FLOW ANALYSIS
Simulation tool is applied in order to acquire qualitative and quantitative
results like pressure drop, flow rate, etc.

Design Engineering 10
Design Technology
Mechanical Basic Design
COOLING CALCULATION -ANALYTICAL CFHEX INPUT AND OUTPUT DATA
-CFHEX Software
AIR-AIR HEAT EXCHANGER SOFTWARE
-Fan calculation software

FAN CALCULATION INPUT AND OUTPUT DATA

Design Engineering 11
Design Technology
Mechanical Basic Design
COOLING CALCULATION – FIELD ANALYSIS
Finite element simulations

Design Engineering 12
Design Technology
Mechanical Design
STRUCTURAL ANALYSIS OF MACHINE PARTS
- ANALYTICAL CALCULATION USING SPECIFIC
CALCULATION PROCEDURES;
- FINITE ELEMENT SIMULATIONS.

-Rotor:
- Rotor core;
- Rotor teeth;
- Rotor overhang banding;
- Dove tail;
- Pole shoe;
- Short circuit ring;
- Rotor spider;
- Rotor rim;
- Fan;
- Flywheel;
Stator:
- Stator Frame;
- End shields
- Foundation;

Design Engineering 13
 Design Technology
Motor Design
OPTIMIZATION TOOL
Capabilities

- Multi-objective optimization

-Coupling of existing analysis and

calculation tools

-Input data according to design standards

Choice of best solution
-Standard design constraints may be considered (parallel chart)

-Test experimental data can be considered

-Multi-decision criteria making

Design Engineering 14
Design Technology
Machine Parts Detailing
2D AND 3D CAD SOFTWARE

Design Engineering 15
NOISE & VIBRATION
 Standards IEC 60034-9, NEMA MG1 Part 9.
SOUND CHECKING POINTS

These standards define noise limits for electric rotating machines related
to:
 Speed
 Output power
 Degree of protection of the enclosure and method of cooling

Vibration limits for electric rotating machines are established with these
machines running at no load. Such limits are given in two ways:
 By the maximum allowable sound level in dB (A)
 By the average allowable sound pressure level
NOISE & VIBRATION
SOUND CHECKING POINTS
NOISE & VIBRATION
NOISE LEVEL
NOISE & VIBRATION
VIBRATION : HORIZONTAL MOTOR
NOISE & VIBRATION
VIBRATION : VERTICAL MOTOR
4.2.3 – Elastic support condition for electrical machine tests

The free condition can be obtained by suspending the machine by a

spring or by placing it on an elastic base
NOISE & VIBRATION

IEC 60034-14 NEMA MG1-7 IEEE 841

% of the base vibration

It do not stablishes
relating to the corresponding 25% 25%
this requirement
bearing point

Out of range: Out of range: Out of range:

 10% around frpm  10% around frpm  25% around frpm

Out of range: Out of range: Out of range:

fn
 5% around  5% around  25% around
(natural frequencies)
(2 x frpm) (2 x frpm) (2 x frpm)

Out of range: Out of range: Out of range:

 5% around  5% around  25% around
(2 x fline) (2 x fline) (2 x fline)
NOISE & VIBRATION
Shaft key (ISO 8821)
The keyway should be filled with half-key:
- Key with half height and length identical to the normal key used during
operation
- key with normal height, but with a half length.
Balancing
The balancing process aims at to improve the mass distribution of a body
so it runs with minimum unbalanced centrifugal forces.
The balance qualities are defined in the standard ISO 1940-1 and are
indicated in terms of eccentricity of the rotor mass center relating to the
rotation center and the angular speed of the rotor. The specification of
the balance quality is function of the required vibration grade.
NOISE & VIBRATION
Vibration limits r.m.s. according to IEC 60034-14
Shaft
56  H  132 132 < H  280 H > 280
height
Vibration
grade Displ. Velocity Accel Displ. Velocity Accel. Displ. Velocity Accel.
Mounting
mm mm/s m/s2 mm mm/s m/s2 mm mm/s m/s2

Free
25 1,6 2,5 35 2,2 3,5 45 2,8 4,4
suspension
A
Rigid
21 1,3 2,0 29 1,8 2,8 37 2,3 3,6
mounting

Free
11 0,7 1,1 18 1,1 1,7 29 1,8 2,8
suspension
B
Rigid
-- --- -- 14 0,9 1,4 24 1,5 2,4
mounting

Grade A applies to machines without special vibration requirements.

Grade B applies to machines with special vibration requirements. The rigid mounted is not allowed for
machines with shaft heights lower than 132.
BEARING & LUBRICATION
ROLLER BEARING
BEARING & LUBRICATION
STANDARD GREASE IN WEG EQUIPMENTS
WEG Motors are usually supplied with :
-Polyrex EM 103 (Exxon Mobil) – up to Frame 450
-30º a 170ºC
Base: Polyureya
Oil: Mineral
-Staburags N12MF (Klüber) – Frame 500 and above
-20ºC a 140ºC
Base: Sodium Complex and MoS2
Oil: Mineral
BEARING & LUBRICATION
SLEEVE BEARING
BEARING & LUBRICATION
SLEEVE BEARING
 BEARING & LUBRICATION
SLEEVE BEARING

• Sleeve bearings, oil lubricated;

• Useful life of 100.000 hours, less
vibration, lower operation
temperature.
• Thermal protection detector type
PT100.
BEARING & LUBRICATION
SLEEVE BEARING

• Bipartite bearings makes

easier and faster the
maintenance.
Thermal Protection Set point :
• 100ºC Alarm
• 120ºC Trip
BEARING & LUBRICATION
LUBRICATING SELF-LUBRICATED BEARINGS
The period of oil exchange in the auto-lubricated bearings
depends on the temperature of bearing work and must be in
agreement the above table:

Smaller than 75ºC = 20.000 hours

Between 75 e 80ºC = 16.000 hours

Between 80 e 85ºC = 12.000 hours

Between 85 e 90ºC = 8.000 hours

Between 90 e 95ºC = 6.000 hours

Between 95 e 100ºC = 4.000 hours

 Design Engineering Interdepartmental Support
CONTINUOUS SUPPORT TO ALL DEPARTMENTS TO ENSURE A QUALITY PRODUCT
1. MARKETING DEPARTMENT
• ASSESS ALL CUSTOMER ENQUIRIES
• GIVE TECHNICAL OFFERS
• CLARIFY ALL CUSTOMER QUERIES
• SUPPORT MARKETING DURING
TECHNICAL DISCUSSIONS
• ASSESS COMPETITOR INFORMATION
2. PURCHASE DEPARTMENT
• ALTERNATE MATERIAL ASSESSMENT
• VENDOR ASSESSMENT
• CLARIFY VENDOR QUERIES
• APPROVE VENDOR
TECH.SPECS/DRAWINGS
3. INDUSTRIAL ENGINEERING
• DRAWING CLARIFICATIONS
• FEEDBACK IMPLEMENTATION
• FIXTURE & PROCESS SUPPORT
4. MANUFACTURING ENGINEERING
• MANUFACTURE PROCESS &
DRAWING QUERY SUPPORT
• DEVIATION ASSESSMENT
Product Engineering
• FEEDBACK ON ALTERNATE
FABRICATION/MACHINING
PROCESSES
• MACHINE ASSEMBLY SUPPORT &
FEEDBACK IMPLEMENTATION
• DEVIATION RESOLUTION
5. QUALITY ASSURANCE
• TEST RESULT REVIEW
• DEVIATION ASSESSMENT
• ALTERNATE TEST ASSESSMENT
• WHETTING QA PLANS
6. ERECTION, COMMISSIONING & SERVICING
• SUPPORT TO CUSTOMER DURING THE
ERECTION & COMMISSIONING
• ANALYSING MACHINE PROBLEMS ON
SITE
• TROUBLESHOOTING ASSISTANCE TO
SERVICING TEAM
32
Medium & High Voltage Motors

Wound Rotor or Slip Ring

 Applicable on motor from “M” line only
 Ventilation system is mixed (axial e radial)
 The insulation system is similar to the stator
 Commonly used to drive loads with high inertia, where the starting time is
quite high, or when it's required high starting torque with low starting
current.
 The slip rings are usually made ​of copper, but offered in stainless steel
too.
Slip Ring Arrangements

Degree of protection offered: IP24, IP55 & IP56

- Internal Slip ring arrangement : IP55 & IP56

- External slip ring arrangement : IP24 (IP55 & IP56 upon request)
35
Presentation title 36
Slip Ring Arrangements
External Slip ring cooling circuit arrangements IP24:
Slip Ring Arrangements
External Slip ring cooling circuit arrangements IP24:
Slip Ring Arrangements
Internal Slip ring cooling circuit arrangements IP55/IP56:
Slip Ring Arrangements
Internal Slip ring cooling circuit arrangements IP55/IP56:
Automatic / manual brush lifting system

The slip ring motors are supplied with brush lifting system, which provides the
following benefits in motor performance over the years:

 Avoids the constant and premature

wear of the brushes and slip rings;
 Reduces the quantity of stops for
maintenance and replacement of the
brushes;
 Prevents the accumulation of dust
inside the brushes compartment,
maintaining a high insulation level of
the rotor;
 Increases the brushes and slip rings
lifetime, and the motor lifetime itself.
Raisable Brush Slip ring

Video

42
Components

43
Cross Sectional View
Salient Features Of WEG Slip ring Design

Copper connection plates to avoid

Bending and stress in cables – smaller
Diameter sliprings.

Cable guide and locking plates to support

The cables and avoid stress during operation
- larger diameter sliprings.
Salient Features Of WEG Slip ring Design

Insulation of the complete

terminal assembly with
heat shrinkable tubing

Use of IMETEX expanding ring for

axial locking and runout correction.
Salient Features Of WEG Slip ring Design
Proper spacing of cables internal to the shaft to achieve better heat dissipation
Medium & High Voltage Motors

Applications

Customer: MAN TURBO AG (GERMANY)

14,000 kW, 10,000 V, 6 poles, frame 1000 (MAL)
Application: Compressor

Customer: BOC LIMITED (ÍNDIA)

6.800 kW, 11.000 V, 4 poles, frame 710 (MAW)
Application: Centrifugal Compressor
 THANK YOU
WEG INDUSTRIES (INDIA) PVT. LTD
EXP-2
MOORANAPALLI
SIPCOT – II
HOSUR
TAMIL NADU

Product Engineering 49