This is a presentation of Sachin Motwani's (creator of this PPT) analysis during his internship in Indo Appliances, an India based company that boasts about high quality 'Made In India' Electrical Products.

1. Ceiling Fans and
Storage Water Heaters
Manufacturing
Sachin Motwani
42276802817
ECE - Sem V
(2017-2021)

2. About the Internship
Designation Test Engineer
Company K.K. Electro Appliances Pvt. Ltd.
Deals in Fan (Ceiling, Wall/Table, Pedestal, Ventilation, Exhaust),
Water Heater, Home Appliances, Air Cooler, Room Heater,
Water Pump
Duration 4 weeks
Date of Joining June 10, 2019
Date of Completion July 09, 2019
Timings 10 AM to 5 PM
Mentor Er. Kumar Gaurav
B.Tech (Mechanical)
http://www.indoappliances.com/

3. Ball
Bearings
Shaft Rotor Windings
Outer
Body
Blandes Condensor . Ceiling Fan
1. Ceiling Fans Manufacturing

4. Technology
➢ A brushless single-phase AC Induction motor attached to blades
➢ Capacitor used to kick start the AC motor
Ceiling Fans

5. Ball Bearings
➢ A type of rolling element
➢ Parts separated by a ring of small freely
rotating metal balls
➢ Purpose:
▪ To reduce rotational friction
▪ To support radial and axial load
➢ Press: Fitting inside the lids
1. Manual Press: Requires labor strength to fit the
bearings in the body. It can only be used for
fitting the top.
2. Hydro Pneumatic Press Special Purpose
Machine: Uses hydraulic pressure to force
the fitting.
Manual Press Hydro Pneumatic Press
Ceiling Fans

6. Shaft
➢ A vertical support for the fan suspension to the
ceiling
➢ Air Gauge Unit:
▪ uses air pressure to compare an unknown diameter
with the desired one.
Air Gauge Unit
Ceiling Fans

7. Rotor
Rotor
Die Cast
Turning using
Lathe
SPM Machine
Anti-Rust
Coating
Rotors
Slots (skewed
rotor bars)
Case
(Aluminum)
Compressed plates
(Iron)
Die Cast Cut
➢A circular ring that interacts with the magnetic field
of the windings to rotate the blades.
➢Materials: Iron plates & an aluminium case
Die Casting: metal casting into a mold cavity
Facing/Turning Operation: A lathe rotates a
workpiece (here, the rotor) about an axis of rotation
to perform turning (a.k.a. Facing)
Special Purpose Milling (SPM) Machine: uses a
rotating cutting tool on the stationary rotor to shape
its inner and outer diameter
Anti-Rust Coating: ‘green lacquer’ paint.
Ceiling Fans

8. The Lathe
Machine
Ceiling Fans

9. Windings
Revolution Secondary Windings Covering Secondary
Windings with Ribbon
Primary Windings Soldered wires for
connections Shaft Attached
Ceiling Fans
Primary Windings: Responsible for Starting the motor
Secondary Windings: Responsible for Running it

10. JLC Coil Winding Machine
Ceiling Fans

11. High Voltage Test Resistance Test on Ohmmeter
Ceiling Fans
Glowing bulb indicates a leakage Desired Resistance: 250 ohm

12. Assembling the Motor
Parts of a Ceiling Fan
A: Support
B: Top/Bottom
C: Ball Bearing
D: Stator
E: Armature
(Winded Rotor)
F: Cover
G: Capacitor
H: Connector.
Motion Rotor Motor
Ceiling Fans

13. Outer Body
Pneumatic Fastening Tool
Nuts used to attach top & bottom
Detailing using paint
Ceiling Fans

14. Electrical Connections & Condenser
Red: It electrically joins both inner and outer windings. This has to go in the positive slot of the
power plug. The purpose of this wire is to start the fan.
Yellow/Blue: It is connected only to the inner slot of the windings. It is connected to the
condenser from the other side.
Black: It is connected to the outer windings and are responsible for keeping the fan running.
In the switch side, the red one goes to the positive supply, black one and the condenser’s
unconnected wire to the negative. The common terminal between the condenser and the
yellow wire is grounded.
# The 90 degree phase lead in the capacitor provides the starting push to the motor
Ceiling Fans

15. Testing
High
Voltage
Breakdown
Test
Low
Voltage
Start Test
Power
Input Test
Testing RPM using Tachometer
Conveyor Belt used for hanging motors
Ceiling Fans
Accepted Power
Rating: 50W-
60W
Supply Voltage:
1.2kV
Supply Voltage:
60 V

16. Packaging
And the fan is ready for
sale.
Motor
Blades
Down Rod
Canopy
Shackle
Silica Gel Sachet
Ceiling Fans

17. 2. Storage Water Heaters
Tank
Geyser
Assembly Plate
Hydraulic
Pressure
Testing
Air Pressure
Testing
Glass Wool
Insulation
Body
Assembling
Thermostat &
Thermal Cut
out
Electrical
Connections
Supervisor
Testing
Packaging Electric Geyser

18. Outer Body
Storage Water Heaters
1. Measuring 2. Rolling 3. Spot Welding
4. Thread Cutting 5. Drilling 6. Painting

19. Tanks attached to supply pipes Tank filled with water Setting up Safety Valve
Simaultaneously, Nossal attached Outlet blocked & air pressure applied Presure air spray for quick drying
Air drying for checking leakage Quick empty using air pressure Removing Leftover water
Testing of Tank
1. High Pressure Test
Storage Water Heaters

20. Air pressure is set to 80 ATM
Cylinder forced inside the water
Unscrewing safety valve
Bubbles just start to pop up
Testing of Tank
2. Air Pressure Test
Storage Water Heaters

21. Glass Wool being wrapped around the tank
Density 𝟏𝟔𝒌𝒈/𝒎 𝟑
Thickness 25 mm
Bio-Soluble Yes
Fire Rating* Class ‘0’ Fire Rating
Fire Standards** BS 476 parts 4,5,6,7
Combustibility Incombustible
Storage Water Heaters
*Class 0 - protection for walls and similar material where limited combustibility is required in high-risk areas.
** For High Risk Fire-Prone appliances, it is very important to consider how its material will behave in fire and ensure the
elements of structure will not collapse but remain standing or hold back the fire for a prescribed time. The British
Standard BS 476 dictates the appropriate fire tests for these elements of structure/materials and grades the level of fire
resistance.

22. Assembling
Symbolic Circuit Diagram
Electrical Connections
Storage Water Heaters
Neutral: Heating Element and Green Indicator
Phase: Thermal cut out
Earth: Grounded
Red LED: Cut Out
Green: Thermostat

23. Thermostat & Thermal Cut Out
Thermal Cut Out (left) ;
Thermostat (right)
Thermostat is tested in oven Continuity Expected
Series Test of continuity Discontinuity Expected
Storage Water Heaters

24. Supervisor Testing
1. Load Test
◦ 250V must reduce to 230V
post load
2. Power Test
◦ Between 1800 W & 2100W
3. High Power Test (HVB) Test
◦ Phase & Neutral should be
discontinuous
◦ Ground continuous
Neutral
Load
The Switch
Ground
Load & Power Tester
Storage Water Heaters

25. Load & Power Test (Top) ; High
Voltage Breakdown Test (Bottom)
HVB Tester: Discontinuous
HVB Tester: Continuous
(Beeps)
Storage Water Heaters

26. Efficiency
Standing Loss (kWh/24hour/45°C )
“The energy consumption measurement of a filled
water heater, after steady state conditions have been
reached when connected to electrical supply and when
no water is drawn for 24 hours.”
Star rating is based on the standing losses.
The highest rating is given to that geyser which has the
lowest standing losses.
Star Rating Label for a 15L Geyser
Storage Water Heaters

27. Packaging
Conveyer Belt takes them to packaging section
After Packaging, the Storage
Water Heater is ready for sale.
Ready to be shipped
Storage Water Heaters

28. Conclusion
❑I learnt about the manufacturing of Ceiling Fans & Storage Water Heaters.
❑ Also, I learnt about the Science behind the two.
❑ I got an exposure of Industrial Standards & Workstyle.
❑Along with all this, I had a boost in my network by interacting with industrial experts.

29. Thank You