Internship-III

On
LARGE INDUSTRIAL MACHINE

Submitted in Partial fulfillment for the Award of the degree of

Bachelor of Technology
In
ELECTRICAL & ELECTRONICS ENGINEERING

Submitted to
ORIENTAL COLLEGE OF TECHNOLOGY, BHOPAL(M.P)

Submitted By:
AMAN DHURIYA 0126EX211001

Under the Guidance of

Mr. PRAKASH CHANDRA AHIRWAR
(Deputy Manager – Design)
CG Power & Industrial Solution Ltd.

ORIENTAL COLLEGE OF TECHNOLOGY,

BHOPAL

Department of Electrical &Electronics Engineering

App roved by AICTE New Delhi & Govt. of MP
Affi liated to Rajiv Gandhi Proudyogi ki Vishwavidhyalaya, Bhopal
Session July Dec 2024

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 ORIENTAL COLLEGE OF TECHNOLOGY, BHOPAL
Approved by AICTE, New Delhi & Govt. of M.P. Affiliated to Rajiv Gandhi ProudyogikiVishwavidyalaya, Bhopal
Oriental Campus, Raisen Road, Bhopal-462021 (MP) INDIA

----------------------------------------------------------------------------------------------------------------
Departmentof Electrical & Electronics Engineering

CANDIDATE’S DECLARATION

I hereby declare that the Internship -III report on“Large Industrial

Machines”which is being presented here for the partial fulfillment o f

the require ment of Degree of Bachelor of Technology has been carried

out at CG Power & Solutions Ltd. New Industrial Area, Mandideep,

Bhopal, M.P.-462046 The technical information provided in this

report is presented with due permission of the authorities from the

training organization.

Students Signatu re

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 ORIENTAL COLLEGE OF TECHNOLOGY, BHOPAL
Approved by AICTE, New Delhi & Govt. of M.P. Affiliated to Rajiv Gandhi ProudyogikiVishwavidyalaya, Bhopal
Oriental Campus, Raisen Road, Bhopal-462021 (MP) INDIA
----------------------------------------------------------------------------------------------------------------
Department of Electrical & Electronics Engineering

CERIFICATE OF INSTITUTE

This is to certify that Mr. / Ms. Aman Dhuriya of B.Tech. Electrical&Electronics

Engg.Department Enrollment No.0126EX211001 has completed Internship-III in

the month of October-2024 as partial fulfillment of the Bachelor of Technology in

Electrical & Electronics Engineering.

Mrs. Aruna Patel

Assistant Professor H.O.D
Faculty Coordinator

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 ACKNOWLEDGEMENT

It gives me immense pleasure to express my deepest sense of gratitude and sincere

thanks to our supervisor (Mr. Prakash Chandra Ahirwar, Deputy Manager -

Design), for their valuable guidance encouragement and help during the internship.

We express our gratefulness to Mrs. Aruna Patel, Faculty Coordinator, Electrical

& Electronics Engineering Department for cooperation, guidance and support.

AMAN DHURIYA

0126EX21100 1

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 TABLE OF CONTENTS

Front Page…………………………………………………………………………………….….. I

Candidates Declaration……………………………………………………………….…...……. lI

Certificate of Institute…………………………………………………………………………… III

Internship-I Certificate………………………………………………………………………….. IV

Acknowledgement………………………………………………………………………….……. V

CHAPTER 1 TYPES OF MACHINE MOTORS 1-2

CHAPTER 2 STAOR 3-5
2.1 Stator Manufacturing Process
2.2 Final Stage: Testing
CHAPTER 3 ROTOR 6-8
3.1 Rotor manufacturing process
3.2 Final Stage: Testing
CHAPTER 4 BALANCING 9

CHAPTER 5 HEAT EXCHANGER 10

CHAPTER 6 BEARING 11-13
CHAPTER 7 WELDING 14-16
7.1 resistance welding
7.2 laser welding
CHAPTER 8 LATHE MACHINE 17-18
8.1 precision machining
8.2 component manufacturing and material removal
8.3 customization and repair
8.4 material versatility
8.5 key learning
CHAPTER 9 CNC MACHINE 19-21
9.1 precision machining with automated control
9.2 Angle setting for coils
9.3 Automation effeciancy
9.4 Verasatility and adaptability
9.5 key learning
CHAPTER 10 TAPING ROBOT 22-24
10.1 Automated coil taping
10.2 key learning

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 1. Types of Machine Motors

1. CACA (Closed Air Circuit Air Cooled): Air circulates within a closed loop
to cool the motor.

2. CACW (Closed Air Circuit Water Cooled): Uses a water-cooled heat

exchanger to maintain motor temperature.

3. TETV (Totally Enclosed Tube Ventilated): Air circulates through external

tubes to cool the motor.

4. TEFC (Totally Enclosed Fan Cooled): The motor is sealed to prevent air
from entering, with an external fan for cooling.

5. SPDP (Screen Protected Drip Proof): Provides ventilation while protecting

the motor from moisture and debris.

6. Cage & Slip-ring (or Squirrel Cage and Wound Rotor Motors): Types of
rotors used in AC induction motors.

7. Horizontal and Vertical Motors: Refers to the mounting orientation of the

motor, impacting load handling and cooling.

8. 2 Pole to 18 Pole Motors: Refers to the number of magnetic poles, which

impacts speed and torque.

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 2.Stator
A stator is the stationary part of an electric motor or generator that works with the
rotor to produce motion or electricity. In motors, it consists of coils of wire
(windings) that, when energized, create a magnetic field. This magnetic field
interacts with the rotor's magnetic field, causing the rotor to spin. In generators, the
stator converts mechanical energy into electrical energy. It's a crucial component in
devices like electric motors, alternators, and various power generators.

2.1 Stator Manufacturing Process

Stage 1: Coil Winding

The process begins with bundles of copper wire, delivered in bobbins. These wires
are fed into a looping machine where they are shaped into coils. The precision in
winding is critical, as the consistency of the magnetic field depends on uniform coil
formation. Coil winding machinery ensures the exact number of turns, necessary for
achieving the desired electromagnetic characteristics.

Stage 2: Insulation and Taping

Before insertion into the stator core, the coils undergo insulation taping to prevent
short-circuiting and ensure the longevity of the motor. The coils are bent to specific
angles using CNC machines to fit perfectly into the stator slots. The taping, a critical
step for maintaining the motor's dielectric strength, is performed either manually or
with CNC machines, depending on precision requirements. There are two types of
insulation taping:

 Brown Taping: Generally used for higher mechanical strength and durability.

 White Taping: Employed for specific electrical insulation properties.

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Stage 3: Coil Insertion & Resin Treatment

Once the coils are insulated, they are inserted into the stator slots manually by skilled
operators. The placement of these coils directly affects the performance and
efficiency of the motor. Following this, the stator is processed in aspecialized
machine where hot, pressurized air is applied to remove moisture—a critical step to
avoid internal short circuits during motor operation. The stator is then immersed in
resin to enhance insulation, mechanical strength, and protection from environmental
factors.

Stage 4: Stator Balancing & Assembly

After resin treatment, the balancing of the stator is performed. In this stage,
metallic pieces are added or removed to ensure uniform weight distribution.
Imbalance in the stator can lead to vibrations, reducing the motor's efficiency and
lifespan. Following this, the stator is mounted into its housing or frame, a process
crucial for both the structural integrity and thermal management of the motor.

2.2 Final Stage: Testing

Before the motor is ready for operation, it undergoes rigorous testing. This includes:

 Fixed Voltage Testing: To ensure that the motor operates correctly under
standard conditions.

 Mixed Voltage Testing: To simulate varying operational scenarios and

verify the motor’s stability across a range of voltages.

At this point, the motor is thoroughly inspected to meet performance, safety, and
quality standards. With everything in place, the motor is ready for use, designed to
handle demanding industrial applications.

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 3.Rotor

A rotor is the rotating part of an electric motor or generator that interacts with the
stator's magnetic field to produce motion or electrical power. In motors, the rotor
spins as it is driven by the electromagnetic forces created between its magnetic field
and the stator. It typically consists of a core, which can be a squirrel cage (for
induction motors) or wound with coils (for wound rotor motors), and a shaft that
transfers the mechanical energy to perform work. The rotor plays a vital role in
converting electrical energy into mechanical energy or vice versa.
3.1 Rotor manufacturing process
involves several critical steps to ensure the rotor's mechanical strength, electrical
efficiency, and durability.

Stage 1: Core Lamination Stacking

 Laminations (thin sheets of electrical steel) are stamped out and stacked
together.

 These laminations reduce energy losses due to eddy currents.

 The stack is welded or bonded to form the rotor’s cylindrical core.

Stage 2: Shaft Insertion

 A steel shaft is inserted through the core’s center.

 Precise alignment ensures that the rotor will spin smoothly when the motor
operates.

Stage 3: Die-Casting (For Squirrel Cage Rotors)

 For squirrel cage rotors, aluminum or copper bars are cast into the rotor
slots.

 The die-casting process creates the characteristic "cage" structure of the rotor.

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Stage 3 (Alternative): Winding (For Wound Rotor Motors)

 In wound rotor motors, insulated copper wire is wound into the rotor slots.

 The windings are carefully placed to ensure uniform magnetic field

generation.

Stage 4: Insulation & Varnishing

 The rotor (especially for wound rotors) is coated with insulation material
such as varnish or resin.

 This prevents electrical shorts and adds protection against environmental

factors.

 The rotor is then cured in an oven.

Stage 5: Rotor Balancing

 To eliminate vibrations, the rotor undergoes balancing.

 Material may be added or removed to ensure even weight distribution during

rotation.

Stage 6: Assembly

 The rotor is assembled with end rings (in squirrel cage motors) or slip rings
(in wound rotor motors).

 Bearings are fitted to both ends of the rotor to facilitate smooth rotation.

Stage 7: Final Testing

 The rotor undergoes high-speed rotation and vibration tests to ensure

balance and smooth operation.

 Electrical tests are performed to verify the correct functionality of windings

or bars.

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 4.Balancing

In the transmission industry, balancing a rotor is essential to ensure smooth and

efficient operation of rotating equipment. The process typically occurs in stages:
Stage 1: Initial Inspection

 The rotor is inspected for physical damage or defects, such as bent shafts,
cracks, or material inconsistencies, which can cause imbalance.

Stage 2: Rough Balancing

 Major imbalances are corrected by adding or removing weight from the rotor.
This step reduces large imbalances before proceeding to more precise
adjustments.

Stage 3: Dynamic Balancing

 The rotor is mounted on a balancing machine, where it is spun to detect

imbalances. Vibrations are measured at various speeds, and weights are
adjusted to correct any detected imbalances. This ensures the rotor operates
smoothly under actual conditions.

Stage 4: Fine Balancing

 Precision weights are added or removed for high-speed or sensitive

applications. The goal is to minimize vibration and wear, ensuring quiet
operation and extending the rotor's lifespan.

Stage 5: Final Testing and Verification

 The rotor undergoes final testing, either in its actual working environment or
through simulation. The balance is verified against industry standards, and
any final adjustments are made before installation.

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 5.Heat Exchanger

The process of heat exchange via tube or fan in a motor, broken down into stages:
Stage 1: Heat Generation

 During motor operation, heat is generated due to electrical and mechanical

losses, such as friction and electrical resistance. This heat needs to be
dissipated to prevent motor overheating and maintain efficiency.

Stage 2: Heat Transfer Mechanism

 In the case of a tube-based heat exchanger, heat from the motor is transferred
through conduction to a cooling medium (air or fluid) inside the tubes.

 In a fan-based system, a fan forces air over the motor surface, increasing the
convective heat transfer rate and allowing the motor to cool down.

Stage 3: Cooling Medium Flow

 Tube Heat Exchanger: A cooling fluid (like water or oil) circulates through
the tubes, absorbing heat from the motor and carrying it away to be dissipated
elsewhere, often through radiators or cooling towers.

 Fan-Based Cooling: The fan continuously moves air over the motor's hot
surfaces, carrying away the heat. Some systems may use a forced-air system
where fans blow air into or over heat sinks.

Stage 4: Heat Dissipation

 In both methods, the heat is expelled into the surrounding environment. For
tube heat exchangers, the heated cooling medium is cooled down in an
external system, while in fan-based systems, the air heated by the motor
dissipates into the ambient atmosphere.

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 6.Bearing

Types of bearing used in this field, which are broken into stages:

Stage 1: Ball Bearings

 Description: These are the most common type of bearings, using rolling balls
between two metal rings (races) to reduce friction.

 Use in Motor Building: Ball bearings are typically used for small to medium-
sized motors where the loads are moderate. They provide smooth operation
and are ideal for high-speed applications.

 Benefits: Low friction, quiet operation, and long service life, making them
suitable for both radial and axial loads.

Stage 2: Roller Bearings

 Description: Roller bearings use cylindrical or tapered rollers instead of balls.

They can handle higher loads due to the increased contact area.

 Use in Motor Building: Often used in motors that carry heavy radial loads
but with lower speed requirements, such as in industrial or large electric
motors.

 Benefits: High load-carrying capacity, durable under heavy loads, and

suitable for radial loads.

Stage 3: Thrust Bearings

 Description: Designed specifically for axial (thrust) loads, these bearings use
rolling elements to reduce friction in applications where axial forces are
prominent.

 Use in Motor Building: Used in motors where the primary load is in the axial
direction, such as vertical motors or machines where the shaft is oriented
vertically.

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Stage 4: Sleeve Bearings (Journal Bearings)

 Description: These are simple cylindrical bearings made of a softer material

like bronze or plastic, where the shaft rotates within the sleeve.

 Use in Motor Building: Commonly used in high-speed, low-load

applications or when noise reduction is a key factor, such as in fans or blowers.

 Benefits: Quiet, cost-effective, and capable of supporting high-speed

rotations, but less efficient for heavy loads.

Stage 5: Needle Bearings

 Description: These are similar to roller bearings but use long, thin rollers.
They offer a large surface contact area while maintaining a low profile.

 Use in Motor Building: Applied in motors where space is limited, but the
bearing must support high radial loads, such as in compact, high-torque
motors.

 Benefits: High load capacity in a compact design, suitable for confined

spaces.

Stage 6: Magnetic Bearings

 Description: These use magnetic fields instead of physical contact to support

the rotor.

 Use in Motor Building: Typically used in high-speed, high-performance

applications like turbo-motors or specialized industrial motors.

 Benefits: No mechanical friction, allowing for extremely high speeds and

increased motor efficiency.

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 7.Welding

Welding is often used during the rotor stamping process to join laminations or
components of the rotor in a motor. Here are the common types of welding
techniques used
:
7.1. Resistance Welding (Spot Welding)

 Description: This is one of the most commonly used methods in rotor

assembly. It involves passing an electrical current through the metal
laminations, causing them to heat up and fuse at specific points.

 Application: Used to join the laminations together, ensuring structural

integrity while keeping the rotor stack compact and aligned.

 Advantages: Quick, reliable, and suitable for mass production. It produces

minimal distortion and ensures proper alignment.

7.2. Laser Welding

 Description: Laser beams are used to precisely melt and fuse materials
together. This method offers high precision and control, especially in tight
spaces.

 Application: Typically used for finer, more precise welding tasks on small
components of the rotor.

 Advantages: Produces minimal heat-affected zones, leading to less material

distortion. It’s ideal for high-precision work, with clean and narrow welds.

7.3. TIG Welding (Tungsten Inert Gas Welding)

 Description: In TIG welding, a tungsten electrode produces the arc, while a

filler material is manually fed into the weld pool. An inert gas (usually argon)
shields the weld from oxidation.

 Application: Used for precision tasks where stronger, higher-quality welds

are required on certain rotor components.

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.Advantages: TIG welding offers strong and high-quality welds, but it is slower and
requires skilled labour.

7.4. Electron Beam Welding (EBW)

 Description: This technique uses a focused beam of high-velocity electrons

to create the weld. The process is conducted in a vacuum, ensuring precision
and deep penetration with minimal distortion.

 Application: Ideal for joining thick rotor components or laminations

requiring strong, high-quality joints.

 Advantages: EBW provides high precision and penetration, with minimal

deformation. It is ideal for thick or difficult-to-weld materials.

7.5. Friction Welding

 Description: In friction welding, the components are joined by rotating them

relative to each other under pressure, generating heat due to friction and
creating a weld without melting the base materials.

 Application: Used in certain rotor assemblies for joining shafts or other

cylindrical components.

 Advantages: Creates strong, clean joints with minimal heat-affected zones.

No filler material is required.

These welding techniques are selected based on factors like the materials involved,
the precision required, and the type of motor rotor being assembled. Each method
ensures that the rotor is structurally sound and operates efficiently during motor use.

7.6. Electron Beam Welding (EBW)

 Description: This technique uses a focused beam of high-velocity electrons

to create the weld. The process is conducted in a vacuum, ensuring precision
and deep penetration with minimal distortion.

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  8.Lathe Machine

 Role of Lathe Machines in CG Power and Industrial Solutions
Transmission Ltd.

 During my internship at CG Power and Industrial Solutions Transmission
Ltd., I had the opportunity to observe and understand the vital role that lathe
machines play in the motor manufacturing industry. Below is a detailed
account of the role and significance of lathe machines in the production
processes:

8.1. Precision Machining

 Lathe machines are indispensable for achieving precision machining in the
production of motor components. Components such as motor shafts, gears,
and other rotating parts must be manufactured to exact specifications to ensure
the smooth functioning of motors. The lathe machine, through its ability to
rotate the workpiece at high speeds while a stationary cutting tool shapes the
material, allows for highly accurate machining, ensuring that tolerances are
met.
8.2. Component Manufacturing and Material Removal

 In motor production, not only are components such as rotor shafts, housings,
and bushings manufactured using lathe machines, but these machines are also
crucial for removing excess material from components like rotors. During my
time in the machine shop, I observed how the lathe is used to trim and smooth
excess material from the rotor to achieve the desired weight, balance, and
dimensions. This material removal process is vital for ensuring that the rotors
meet the specific performance requirements of the motor.

8.3. Customization and Repair
 Customization and repair are regular requirements in the motor industry.
During my time in the machine shop, I saw how lathes are used to modify
existing parts or repair components that require precise adjustments. This
flexibility is essential for the maintenance and servicing operations at CG
Power and Industrial Solutions, where some motors or transmission parts
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 8.4. Material Versatility

Lathes are versatile machines capable of machining a wide range of materials,

from metals like steel and copper to specialized alloys. This versatility is
critical in motor manufacturing, where different components may require
different materials depending on their function (e.g., structural integrity vs.
conductivity). CG Power and Industrial Solutions uses lathe machines to
shape parts made from a variety of materials, contributing to the diverse range
of products the company offers.

8.5. Key Learnings

Through my exposure to lathe machines at CG Power and Industrial Solutions

Transmission Ltd., I gained a deeper understanding of their significance in
modern manufacturing. Key takeaways from this experience include:
 The ability to produce high-precision parts is fundamental to ensuring the
reliability of motors and transmission systems.

 The material removal process, particularly for components like rotors, is

essential for ensuring balance and functionality.

9.CNC-Machine

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Role of CNC Machines in CG Power and Industrial Solutions
Transmission Ltd.

During my internship at CG Power and Industrial Solutions Transmission

Ltd., I gained insights into the various manufacturing processes, particularly
the use of CNC (Computer Numerical Control) machines. These machines
play a crucial role in achieving precision and consistency in the production of
motor components. Below is a detailed overview of how CNC machines
contribute to the manufacturing process:

9.1. Precision Machining with Automated Control

CNC machines are fundamental to producing motor components with high

precision and automation. These machines follow pre-programmed sequences
and automatically control tools to cut, shape, and refine materials. At CG
Power and Industrial Solutions, CNC machines are used to achieve the exact
dimensions, angles, and shapes necessary for components such as motor coils,
where precision is critical for proper motor function.

9.2. Angle Setting for Coils

One of the critical tasks performed by CNC machines is setting the precise
angle for motor coils. Coils must be aligned and shaped to specific angles to
ensure optimal performance and efficient electromagnetic operation in
motors. During my internship, I observed how CNC machines are used to
accurately bend and position the coils at the required angles, ensuring
uniformity across all components. This process is vital for maintaining motor
balance and functionality, as even minor deviations in the angle can affect the
performance of the motor.

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 9.3. Automation and Efficiency

CNC machines offer a high degree of automation, which enhances both

production speed and accuracy. Once the machine is programmed withthe
correct parameters, it can perform repetitive tasks with little human
intervention, significantly reducing the chance of human error. This
efficiency is particularly important at CG Power and Industrial Solutions,
where large volumes of components are manufactured, and consistency in
coil angle and dimensions is critical for the reliability of the final product

9.4. Versatility and Adaptability

CNC machines are also highly versatile, allowing for a wide range of
materials and components to be machined with precision. In the case of motor
manufacturing, they are used to process materials like copper (for the coils)
and various metals for other components. The adaptability of CNC machines
ensures that they can handle complex geometries, making them essential for
producing intricate parts like motor coils with precise angles and dimensions.

9.5. Key Learnings

My exposure to CNC machines at CG Power and Industrial Solutions

Transmission Ltd. provided me with valuable insights into the importance of
automated machining in modern manufacturing. Key takeaways from this
experience include:
 CNC machines ensure high-precision machining, especially in tasks like
setting the exact angle for motor coils, which is critical for motor performance.

 The automation provided by CNC technology increases production efficiency

and ensures consistency across large batches of components.

 CNC machines are highly versatile and adaptable, capable of working with a
variety of materials and producing complex geometries.

 The use of CNC technology minimizes the risk of human error and ensures
that components meet the required specifications for optimal motor operation.

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 10.Taping-Robot

Role of Taping Robots in CG Power and Industrial Solutions

Transmission Ltd.

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During my internship at CG Power and Industrial Solutions Transmission
Ltd., I had the opportunity to work with and observe various advanced
manufacturing processes, including the use of taping robots. These robots are
integral to automating and streamlining the motor production process. Below
is a detailed account of how taping robots contribute to the manufacturing
workflow:

10.1. Automated Coil Taping

Taping robots are primarily used in the motor manufacturing process to apply
insulating tapes around motor coils and wires. Insulating tape is critical to
ensuring that the coils are properly insulated to prevent electrical short circuits
and enhance the motor’s overall efficiency and durability. During my
internship, I observed how these robots are programmed to wrap the insulation
tape precisely around the coils, ensuring consistent coverage and reducing the
chances of human error.

10.2. Precision and Consistency

One of the key advantages of using taping robots is the high level of precision
and consistency they provide. The robots are designed to follow exact paths
and apply the correct tension while taping, ensuring that each coil is uniformly
insulated. This level of consistency is crucial in maintaining the quality of the
motor, as uneven or improperly applied tape can lead to malfunctions or
reduced motor efficiency. At CG Power and Industrial Solutions, this
automation helps maintain the high standards of quality expected in motor
production.

10.3. Increased Efficiency and Speed

Taping robots significantly improve the efficiency of the coil-taping process
by automating a task that would otherwise be time-consumingand
laborintensive. These robots can work continuously, applying tape to
multiple coils in a fraction of the time it would take to do manually. During
my time in the manufacturing division, I saw how this speed increased

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 10.4. Reduced Labor Costs and Human Error
The use of taping robots not only speeds up the production process but also
reduces the need for manual labor in coil taping. By automating this task, CG
Power and Industrial Solutions is able to minimize human errors, which are
more lkely when tasks are repetitive and physically demanding. Additionally,
the company can allocate human resources to more critical tasks that require
manual expertise, while routine operations like taping are handled efficiently
by robots.

10.5. Integration with Other Automation Systems

Taping robots at CG Power and Industrial Solutions are integrated into a larger
network of automated processes, allowing for seamless workflow between
different stages of production. For example, after coils are shaped and bent to
the required angles by CNC machines, the taping robots can immediately
insulate the coils, ensuring smooth transitions between production stages. This
integration reduces downtime and enhances the overall efficiency of the
manufacturing process.

10.6 Key Learnings

Through my exposure to taping robots at CG Power and Industrial Solutions
Transmission Ltd., I gained a better understanding of how automation
enhances manufacturing. Key takeaways from this experience include:
 Taping robots ensure precision and uniformity in coil insulation, which is
critical to preventing electrical faults and ensuring motor efficiency.

 Automating the taping process increases production speed, reduces human

error, and lowers labor costs.

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