This document provides information about an industrial training completed at AG Electro Services Karad. It includes: - An introduction and overview of the company and various departments. - Descriptions of the purchase and store, production, quality, and engineering departments. - Details of the materials and processes used in coil winding, insulation, varnishing, assembly, and quality testing of an induction motor model. - Specifications for the PE1 motor model including number of turns, wire type, resistance values, weights and other parameters. - The step-by-step procedure for stator winding, connecting coils, installing leads, pressing, soldering, insulating, and testing the motor.

1. WELCOME
DEPARTMENT OF ELECTRICAL
ENGINEERING

2. A PRESENTATION ON
INDUASTRIAL TRANING
Submitted by
Miss:Jadhav Harshada Hanmant(2015016638)
Under the guidance of
Prof.Mr.Shivchandra Ravichandra Hindinamani
Traning guidance
Mr.Adarsh Shaha

3. COMPANY PROFILE
Company name :-
AG Electro Services Karad
Address:Plot No.6/2
Koyana Industrial estate
On Pune Bangaluru Highway
NH4 Malkapur Karad 415110
Mo.9822008646

4. Various Departments in the
company
Purchase and Store department
Production department
Quality Department
Engineering Department
Account Department

5. Purchase and Store Department
Section 1:
All model stack and die-cast material
Sub assembly material
Rework material
Non-moving stack
Reworkable material
Section2:
All model coil set
Bearing
hardware Material
Self-life items
All model seperator
Stack sample
Section 3:
Packing material
Lead wire
Lessing material
Paper and stack

6. Copper Wire:
For coil winding of copper is used.Copper is coated with another
insulating material so as to provide insulation to it.
Lead Wire:
It is said for connection purpose.
According to model length of lead wire changes.
Insulating Material:
Depending on class of insulation different material are used for insulation.
Insulation is done to avoid any connection of winding with other winding or with body of stack.
Insulating paper:It is inserted in slot and as a separator between two windings.

7. Insulating Thread:It is used to bind the outer winding.
Sleeves:
Insulating tape:
It is used to tight and provide insulations to stator winding

8. Coil Winding :
There are two methods-
1.Manual winding –
2. Auto winding machine –
Slot paper filling –
The coils are placed /Mounted in the slots of stator. According to the model of motor the
stator winding is done.

9. Stator Winding:
It is the outer most part of the three phase induction motor.the main function of stator
windings in an induction motor is when an AC voltage is applied to the stator windings a current
flows. The current through the windings produces a magnetic field in the stator. This induces a
voltage and current flow in the rotor circuits which also produces a magnetic field.

10. Inspection:-
Inspection is done under quality dept. There are three types of checking.
1.Visual checking :
2.Mechanical checking:
In mechanical checking ID, OD( Inner & Outer Diameter) of stack is checked. Also stack height
is checked.
3. Electrical checking :
Under this checking we check Resistance, Insulation Resistance(IR),
Surge, HV test, etc. this tests are carried out Here a surge machine is used to check all these parameters.

11. Varnishing
It is the process used to insulate the winding from contaminants to make the windings rigid and tight and to dissipate heat.
Here VPI (Vaccum Pressure Impregnation) method is implemented.
Process -
1.Pretraetment –
By using the air clean the winding, stator, roter winding should be free from dust, oil, grease.
2. Preheating –
To preheat at 120c for 2 hr.
3.Cooling –
To cool down to 0
4. Impregnation cycle –
•Vaccum creation not more than 10
•Vaccum holding time hold the winding at vaccum for 10 min.
•Allow resin to VIP chamber winding should be fully submerged in resin.
•Resign hold time – Hold the winding at resign for 30 min.
•Pressuring – To pressurize upto 2.9 kg/cm
•Pressuring holding time- Hold windings at pressure for 30min.
•Reducing pressure- To reduce the pressure to 0.7 kg/cm
•To return the resin to store tank.
•Draining- To drain the winding for 10 min.
•To reduce the air pressure to zero.
•Curing – Curing to be at 160

12. Assembly :
•Here stator and roter are attached with front and back cover.
•Broching : Make roter plain.
•Bearing pressing:Press Fit
Push Fit
•Air Gap between stator and roter 0.25mm to 0.45mm
•Locktite To remove air gap.

13. Quality Department
•Resistance Test –
As per our design the minimum and maximum range of the resistance is fixed. If there any Fault in the winding
connection the resistance is out of the range.
•HV Test-
High voltage is applied to stator. If any short circuit between body and winding and also between two windings then it
makes sound.
•Rotation Test-
Rotational direction of the rotor is tested. For these test V-A-W meter is used.

14. PE1 : Model of Induction Motor
• No. Of turns High speed = 151,81
Low speed = 155
• Copper wire (SWG)- Double coated, High Speed =30
Low Speed = 31
• Stock Height: 12.7 mm
• Double coated (DC)- 180
•Resistance –
High Speed= Min – 58.20 ohm
Max – 61.8 ohm
Low speed = Min-95.06 ohm
Max – 100.94 ohm
•Weight (Kg)-
High Speed = Min- 0.284 kg
Max- 0.302 kg
Low speed = Min-0.359 kg
Max- 0.381 kg
•No. of coil per group-8 (High Speed) 12 (Low Speed)
•No. of groups-3
•Pitch – 1-5, 1-4 (High Speed)
1-3 (Low speed)

15. •Stack is made up of electric steel – 50C 50 CRNGO Coil
•Laminations – 26
•ID – 117.3 mm
•OD – 189.3 mm
•Thickness – 0.5 mm
•Slot Paper – Pure Nomex paper = 10 mil*0.25 mm *26mm
•Outer – 10mil*0.25mm*15/16mm
Total outer – 48(High speed), 72 (Low speed)
•Separator – A=12(High speed)
B=18 (Low speed)
•Sleeve – 1mm, 3mm-UL Approved
Fiberglass sleeve - 220
- H class
•Breezing – Dislery water, Methenol Niddle - 18mm
•Lessing – Nylon 1sq.mm- Dust manufacturing
•Tepping- Fiberglass polyster
15mm width

16. Procedure
1. Slotting: Fill the slots of stack with slot paper.
2.Winding: Place the coils in the slots as shown in the fig.
3.Outer: After each coil is placed in the slots it is covered with outer paper.It simply provides
insulation between two coils.
4.Seperator: After one layer of winding separator is used.It provides insulation between two layers of
winding.
5.Sleeves: Before making connections sleeves are inserted.
6.Connections: All ends are connected in serious and starting ends are connected to end wire.Starting
ends are separately taken out.
7.Lead wire: It is used for connection purpose.
8.Pressing: Here the stator is pressed so that winding comes in uniform shape.
9.Breezing: The connection terminals are breezed means simply it is soldered.
10.Resistance cheking
11.Lessing: For make the windings tights lessing is done.
12.Tepping:It is done on both top and bottom end of stator.
13.Testing.

17. We understand the actual process of production of motor.Whatever we studied in our theory subjects that
concepts are actually cleared while doing this training.The technical concepts are visualized here.The overall
information about the motor is understood here by visualization,analyzing.Our therotical aspects are practically.
Conclusion