The document summarizes Vishnu Vardhan's summer internship at Suzlon Generators' manufacturing plant in Pune, India. The internship provided hands-on experience in the manufacturing processes for wind turbine generators. Key processes included lamination of steel sheets for rotors and stators, core building, rotor winding, stator assembly, vacuum pressure impregnation for insulation, and final assembly. The internship gave valuable practical knowledge about renewable energy manufacturing that will help in Vishnu's career goal of working in the renewable energy field.
First of all, let me take this opportunity to introduce myself, Mohamad Fazlan from EFD induction Malaysia. I would like to take this opportunity also to share our company profile, sharing our technology as what we cater.
Impact of Bearing Vibration on yarn quality in Ring Frameiosrjce
IOSR Journal of Polymer and Textile Engineering (IOSR-JPTE) is ambitious to disseminate information and experience in education, practice and investigation between polimer, fibric and all the sciences involved in textile.
Trituradora de material mineral primario de carbónjoyalcrusher
Stationay trituradora de mandíbula es una buena opción como carbón trituradora de mandíbulas primaria de grueso y medio de trituración, lo que es más, la trituradora de mandíbula móvil es un buen equipo de trituración primaria, es ampliamente utilizado en la minería, materiales, carretera, vía férrea y las industrias hidráulicas, etc construcción . mandíbula móvil de trituración http://joyaltrituradora.com/product/Mobile-Crushing-Plant.html y cribado de plantas puede ser terminado en un tiempo para producir el tamaño y la capacidad requerida. Para la minería del carbón, la máquina trituradora móvil de carbón es una excelente elección. Puede eliminar los obstáculos de los lugares y circunstancias de trituración, y ofrecen la máxima eficiencia y plantas de los proyectos de bajo coste para el cliente.
Trituradora de mandíbula http://joyaltrituradora.com/product/Jaw-Crusher.html es la trituradora de mineral primario de carbón triturado. Está diseñado para aplastar de manera eficiente todo, incluso más dura piedra y materiales reciclados. Los Joyal trituradoras de piedra http://joyaltrituradora.com/product/Crushing.html están diseñadas para el servicio de larga duración con un mantenimiento mínimo para duro, resistente, material abrasivo y de alta capacidad de sobrecarga.
Primay carbón trituradora de mandíbula
Joyal tiene muchos tipos de trituradoras de mineral http://joyaltrituradora.com/index.html para la venta, como la trituradora de mandíbula, trituradora de cono, trituradora de impacto, trituradora de martillos, trituradora móvil, trituradora de impacto vertical del eje y así sucesivamente. Carbón Primay trituradora de mandíbula fabricado por Joyal es trituradoras de clase premium debido a su diseño, así como a los materiales que se utilizan para producirlas, a fin de garantizar la máxima funcionalidad y fiabilidad posible, sin ningún compromiso. Cada modelo se prueba prácticamente para el estrés, tensión, choque, la deformación, la carga térmica, la vibración y el ruido en una amplia gama de condiciones de carga. El resultado es una fiabilidad excepcional.
¿Por qué elegir la trituradora de mandíbula como primaty carbón equipos de trituración
PE trituradora de mandíbula es adecuado para la trituración primaria y secundaria y se puede procesar la resistencia a la compresión de materia prima menos de 320Mpa. Además, la trituradora de mandíbula para el carbón tiene el diseño de la cavidad derecha para la cavidad es el corazón y el propósito principal de la trituradora de mandíbulas. La abertura de alimentación adecuado que racionar profundidad asegura el bloqueo mínimo y se elimina la altura necesaria de la trituradora. Los perfiles de los dientes y el espesor de la trituradora de mandíbula se trabajan y se combinan con las aleaciones de acero al manganeso adecuadas para maximizar el rendimiento y minimizar los costos de operación. La capacidad de producción de 10-1300t / h con el máximo de alimentación es de 1250mm. PE
TeraSpin is a leading supplier of precision textile spinning machinery components for ring spinning and roving frames to OEMs and spinning mills around the world. With its unflinching focus on innovation and quality, TeraSpin has established itself as a renowned global brand.
For more information visit www.ategroup.com/teraspin
First of all, let me take this opportunity to introduce myself, Mohamad Fazlan from EFD induction Malaysia. I would like to take this opportunity also to share our company profile, sharing our technology as what we cater.
Impact of Bearing Vibration on yarn quality in Ring Frameiosrjce
IOSR Journal of Polymer and Textile Engineering (IOSR-JPTE) is ambitious to disseminate information and experience in education, practice and investigation between polimer, fibric and all the sciences involved in textile.
Trituradora de material mineral primario de carbónjoyalcrusher
Stationay trituradora de mandíbula es una buena opción como carbón trituradora de mandíbulas primaria de grueso y medio de trituración, lo que es más, la trituradora de mandíbula móvil es un buen equipo de trituración primaria, es ampliamente utilizado en la minería, materiales, carretera, vía férrea y las industrias hidráulicas, etc construcción . mandíbula móvil de trituración http://joyaltrituradora.com/product/Mobile-Crushing-Plant.html y cribado de plantas puede ser terminado en un tiempo para producir el tamaño y la capacidad requerida. Para la minería del carbón, la máquina trituradora móvil de carbón es una excelente elección. Puede eliminar los obstáculos de los lugares y circunstancias de trituración, y ofrecen la máxima eficiencia y plantas de los proyectos de bajo coste para el cliente.
Trituradora de mandíbula http://joyaltrituradora.com/product/Jaw-Crusher.html es la trituradora de mineral primario de carbón triturado. Está diseñado para aplastar de manera eficiente todo, incluso más dura piedra y materiales reciclados. Los Joyal trituradoras de piedra http://joyaltrituradora.com/product/Crushing.html están diseñadas para el servicio de larga duración con un mantenimiento mínimo para duro, resistente, material abrasivo y de alta capacidad de sobrecarga.
Primay carbón trituradora de mandíbula
Joyal tiene muchos tipos de trituradoras de mineral http://joyaltrituradora.com/index.html para la venta, como la trituradora de mandíbula, trituradora de cono, trituradora de impacto, trituradora de martillos, trituradora móvil, trituradora de impacto vertical del eje y así sucesivamente. Carbón Primay trituradora de mandíbula fabricado por Joyal es trituradoras de clase premium debido a su diseño, así como a los materiales que se utilizan para producirlas, a fin de garantizar la máxima funcionalidad y fiabilidad posible, sin ningún compromiso. Cada modelo se prueba prácticamente para el estrés, tensión, choque, la deformación, la carga térmica, la vibración y el ruido en una amplia gama de condiciones de carga. El resultado es una fiabilidad excepcional.
¿Por qué elegir la trituradora de mandíbula como primaty carbón equipos de trituración
PE trituradora de mandíbula es adecuado para la trituración primaria y secundaria y se puede procesar la resistencia a la compresión de materia prima menos de 320Mpa. Además, la trituradora de mandíbula para el carbón tiene el diseño de la cavidad derecha para la cavidad es el corazón y el propósito principal de la trituradora de mandíbulas. La abertura de alimentación adecuado que racionar profundidad asegura el bloqueo mínimo y se elimina la altura necesaria de la trituradora. Los perfiles de los dientes y el espesor de la trituradora de mandíbula se trabajan y se combinan con las aleaciones de acero al manganeso adecuadas para maximizar el rendimiento y minimizar los costos de operación. La capacidad de producción de 10-1300t / h con el máximo de alimentación es de 1250mm. PE
TeraSpin is a leading supplier of precision textile spinning machinery components for ring spinning and roving frames to OEMs and spinning mills around the world. With its unflinching focus on innovation and quality, TeraSpin has established itself as a renowned global brand.
For more information visit www.ategroup.com/teraspin
This is a Report presented by Sachin Motwani at his College against the successful accomplishment of Internship at a Ceiling Fans & Storage Water Heaters manufacturing Company: Indo Appliances.
Condition monitoring of rotating electrical machinesAnkit Basera
Condition monitoring of rotating electrical machines, Construction, Operation, Types, Specification Of Electrical Machines, Different Failure Modes Of Electrical Machines, Failure Modes And Root Causes In Rotating Electrical Machines
Failure Mode Analysis Of Torsion Shaft In Garrett-5 Engine Using Two Test PiecesIJERA Editor
This work deals with “Failure Analysis of Internal splines in Torsion Shaft” of “TPE 331-5-252D - GARRET ENGINE” which is used in Dornier aircraft. Garret Engine is a type of air breathing engine. It comes under the category of Turboprop engines of Gas turbine engine. As separate shafts are used for propeller and turbine, this aids them to rotate at different RPM. A torsion shaft is used to transmit the torque from main shaft to propeller shaft. Torsion shaft is used to give a deflection which is also used to measure the torque of the engine. This torsion shaft is internally connected with the main power transmission shaft and its other end is coupled to a coupler shaft with engagement of its internal splines to the external splines of coupler shaft. Further this coupler connects to the gearing system and transmits power to the propeller shaft. Due to Continues variable load over internal splines, it is subjected to high rate of wear and tear. This problem can be rectified by Failure Mode Analysis Method, in which heat treatment process of torsion shaft is being carried out. Two test pieces are heat treated separately at different temperatures of 5800C and 5400C at variable time durations. Tuffriding which is a Liquid nitriding process is done with this two test pieces and results are analyzed. The hardness of the material is increased to desired values and its life time is also increased which overcomes the problem.
Innovative concept of coiling machine integrated with rolling mill to replace...eSAT Journals
Abstract: Building Construction Involves Use Of Stirrups To Give Strength To Columns And Beams And Are Widely Used In Various Shapes In Steel Reinforcement. It Is Regular Practice To Make Stirrups On Construction Sites. Existing Engineering Standards Recommend Use Of Continuous Helical Coil For Better Strength Of Structure But It Is Having A Very Rudimentary Level Of Technology. Hence This Work Focuses On Developing A Coiling Machine As An Integrated System Of The Rolling Mill Where The Steel Bars Are Produced. The Integrated Coiling Machine Will Overcome Almost All Problems And Limitations Associated With Manual Stirrup Making And Even Of Semiautomatic And Full Automatic Stirrup Making Machines. This Paper Embarks On Integration Of Stirrup Making Activity With Rolling Mill So As To Take The Advantages Of Plastic Deformation Of Steel At Elevated Temperature, Imbibing The Metallurgical And Mechanical Properties And Eliminating Residual Stresses Compared To Todays Stirrup Making Practices. Key Words: - Stirrup, Rolling Mill, Helical Coil, Coil
This is a Report presented by Sachin Motwani at his College against the successful accomplishment of Internship at a Ceiling Fans & Storage Water Heaters manufacturing Company: Indo Appliances.
Condition monitoring of rotating electrical machinesAnkit Basera
Condition monitoring of rotating electrical machines, Construction, Operation, Types, Specification Of Electrical Machines, Different Failure Modes Of Electrical Machines, Failure Modes And Root Causes In Rotating Electrical Machines
Failure Mode Analysis Of Torsion Shaft In Garrett-5 Engine Using Two Test PiecesIJERA Editor
This work deals with “Failure Analysis of Internal splines in Torsion Shaft” of “TPE 331-5-252D - GARRET ENGINE” which is used in Dornier aircraft. Garret Engine is a type of air breathing engine. It comes under the category of Turboprop engines of Gas turbine engine. As separate shafts are used for propeller and turbine, this aids them to rotate at different RPM. A torsion shaft is used to transmit the torque from main shaft to propeller shaft. Torsion shaft is used to give a deflection which is also used to measure the torque of the engine. This torsion shaft is internally connected with the main power transmission shaft and its other end is coupled to a coupler shaft with engagement of its internal splines to the external splines of coupler shaft. Further this coupler connects to the gearing system and transmits power to the propeller shaft. Due to Continues variable load over internal splines, it is subjected to high rate of wear and tear. This problem can be rectified by Failure Mode Analysis Method, in which heat treatment process of torsion shaft is being carried out. Two test pieces are heat treated separately at different temperatures of 5800C and 5400C at variable time durations. Tuffriding which is a Liquid nitriding process is done with this two test pieces and results are analyzed. The hardness of the material is increased to desired values and its life time is also increased which overcomes the problem.
Innovative concept of coiling machine integrated with rolling mill to replace...eSAT Journals
Abstract: Building Construction Involves Use Of Stirrups To Give Strength To Columns And Beams And Are Widely Used In Various Shapes In Steel Reinforcement. It Is Regular Practice To Make Stirrups On Construction Sites. Existing Engineering Standards Recommend Use Of Continuous Helical Coil For Better Strength Of Structure But It Is Having A Very Rudimentary Level Of Technology. Hence This Work Focuses On Developing A Coiling Machine As An Integrated System Of The Rolling Mill Where The Steel Bars Are Produced. The Integrated Coiling Machine Will Overcome Almost All Problems And Limitations Associated With Manual Stirrup Making And Even Of Semiautomatic And Full Automatic Stirrup Making Machines. This Paper Embarks On Integration Of Stirrup Making Activity With Rolling Mill So As To Take The Advantages Of Plastic Deformation Of Steel At Elevated Temperature, Imbibing The Metallurgical And Mechanical Properties And Eliminating Residual Stresses Compared To Todays Stirrup Making Practices. Key Words: - Stirrup, Rolling Mill, Helical Coil, Coil
2. PURPOSE
Suzlon Generators proves to be the biggest manufacturer of Wind
Turbine Generators in India and is one of the leading Energy
firms in the present global scenario. The purpose behind this
internship program is to enhance the level of understanding
towards the industrial ways of functioning and have a hands on
experience with the manufacturing processes involved in the
making of the Generator components.
The internship program involved an extensive in-
plant training where the student was acquainted with various
operational techniques and processes which will prove to be
helpful in gaining practical knowledge for the student and help
the firm produce well versed engineers for the future of
renewable energy.
3. SUBDIVISIONS IN THE
PLANT
Lamination shop
Core building shop
Rotor winding shop
Stator building shop
VPI shop
Assembly shop
The generator models produced by the Suzlon Plant include 2.1 Mw, 1.5
Mw and 600 Kw generators which have their own specifications for the
sizes of stators and rotors. The raw material, i.e. grade 50C400 steel with
golden yellow coating of grade C3M is supplied by a nearby Thyssen Krupp
plant.
The Suzlon generator plant consists of the following six
manufacturing shops where the rotors and stators are manufactured from the
scratch.
4. The Lamination Shop
50C400 steel roll with a 4 micron silicon coating grade of C3M is
used for the basic lamina cutting.
A 250 ton press, operating between .5 mm and 2 mm is used, roll is
opened and bent flat automatically, monitored using lasers.
The flat plate is sent to the VLC programmed blanking machine
where discs of prescribed dimensions are punched out
automatically.
The discs are sent to the workers, who place them in punching
machines and projections are cut in the disc, allowing the scope of
formation of slots for the magnetic core (in stator) and copper bars
to be inserted (in rotor).
Two manually operated machines cut out rotor and stator sections
respectively.
5. Core Building Shop
An “I” profile, metal rod is cut and weld together with an uncoated rotor
lamina, using spot welding machine.
Coated rotor laminas are taken and stacked together, placing a “I” profile
welded uncoated lamina after a prescribed number of regular laminas.
The laminas are held together using metal compression plate and kept in an
oven for 6 hours, 180° C.
The shaft is inserted in the rotor while hot, such that, upon cooling, it firmly
clenches the material.
Stator laminas are similarly, joined and welded together with the help of
mandrill.
The VTL (Vertical Turning Lathe) machine performs turning operation on
the stator to remove the excess metals and any deformations.
Filing and cleaning of the stator is done.
6. Rotor Winding Shop
Copper flats (rectangular bars) are taken and taped with
insulating fabric coating.
The flats are inserted in the rotor slots.
Copper bars are manually turned into a semi spiral shape
and again insulated.
The Cu1655 and Cu1630 flats are joined together by
interfacing with a 40% Silver strip, by Induction Brazing
process.
7. Stator Shop
The wires are taken and manually molded into frames, by looping
process.
Coil taping takes place, coated with polyester tape for insulation.
Coils are stitched together, by process called ‘Stitching’.
Lead formation is done, where a reference is made for further
processes and makes the tip of the stator.
By the ‘Sleeving’ process, sleeves are mode on the stator modules.
Insulation is applied by using glass taping.
Soft core magnet bars are inserted in the stator slots, thus mounting
and wedging is accomplished.
A double mount of Poromate is utilized for insulation between two
coils.
8. VPI (Vacuum Pressure Impregnation)
Shop
VPI helps in reducing the vibrations and binding the
components together, reducing noise and mechanical wear.
The stator and rotor are put and rotated in separate chambers
at low RPMs.
A vacuum of 0.018 mBar is maintained there to avoid foreign
contaminants and air pockets.
Resin is sprayed at a high temperature and an even coating is
obtained while rotating the rotor/stator for about 12 hours.
Resin mixture 100:90:0.08 ratio of Resin, Hardener and
Accelerator; the resin used is EPR-162.
The component is set to dry. This process takes about 30
hours.
9. Assembly Shop
The Stator core insertion takes place at 140° C, for two hours.
Vertical leveling of the module is ensured.
Welding of the stator is done with the frame.
Rotor balancing is done by test run at low RPMs, weights are added
in the buffer slots, if required.
All the components are painted and well greased bearings are
inserted on both ends.
The rotor/stator assembly is placed in a protective case.
End shield assembly is done at both the ends.
Slip ring, brush gear assembly is inserted on the non driving end.
Slip ring housing is fitted for protection.
Air cooling assembly is set up at the top of the frame.
Speed encoder assembly is fitted on the shaft.
10. Conclusion
The Generators are shipped all across the country
with wind farms ranging from Tamil Nadu to
Maharashtra. Different wind speeds require
different dimensions and Suzlon leaves no stone
unturned in seeing that happen efficiently.
Firms like Suzlon, which promote
renewable energy technologies are a boon to nature
and are helping this world recover the tragedy
caused by fossil fuels.
11. My heartfelt thanks to the officials and the firm, which
gave me such an amazing opportunity to work and
understand the manufacturing processes involved in the
making of a Windmill generator. I aspire to work in the
field of renewables and this training would be a major
paving stone in my career.
Thanks and regards
Vishnu Vardhan
Student, B.E 2nd Year
VIT University
vishnu6895@gmail.com
A note of Thanks