experience at [STANDARD ELETRICAL AND ENGINEERING] workshop the was start at [27/06/2024] to [07/08/2024] and covering various electrical aspect of motor rewinding, repair and maintenance
Objective 1. It will help to explain process of electrical motor rewinding 2. For practical experience of diagnosing motor fault and improve the hand experience and knowledge of it 3. Read about motors and its specific use ,what kind of motor exist and what they are made up of 4. In order to achieve this objective the following technical skills is used specialized tools and equipment for motor rewinding is used MY EXPERIENCE During my internship at [Motor Repair Workshop], I had the chance to fully involve myself in this field of motor repair and maintenance. Most of myresponsibilities during the internship is to diagnosing motor malfunctions, performing repairs as well as carrying out preventive maintenance on different typesof motors and equipment. Among other things, I learnt how to troubleshoot electrical issues and mechanical problems,use diagnostic tools and other safety protocols in a workshop.
These include skills like motor tear-down, rewinding and re-
assembling which were acquired during the period. Furthermore, it enhanced my ability in interpreting technical diagrams, conducting performance tests and accurately repair procedures. Moreover through interacting with colleagues as wellas customers during the period I was able to develop stronger communication skills that are essential for conveying complex technical information and achieving customer satisfaction.
Some examples of what I did for the organization included being
an active participant in team projects aimed at improving the efficiency of operations within the workshop as well as customer service. For example specific assignmentswere accomplished effectively within stipulated time frames while on top of these improvements also some practical insights taken from this program helped me generate ideas for process enhancement.
ACTIVITIES DONE THERE
1. Motor disassembly 2. Fault diagnosis 3. Rewinding process 4. Testing and reassembling 5. Maintenance and safety etc MOTOR DISASSEMBLY
Each step in the process of disassembling an electric motor
should be performed carefully to remove risk of injury and to maintain the structural durability of the motor. It is recommended to start by removing any power supply source from the motor unit and putting on relevant protection measures like gloves and eyewear. Total dismantling of the device may be necessary, which would require the user to remove all outer casings and enclosures to reach the inner parts of the device. Locate wires and remove them from the particular circuit or device under test noting their positions for future connection. Be sure to bring with you the right tools and materials such as screwdrivers and wrenches to correctly remove bolts and fasteners that hold the motor components tightly. Now unscrew the stator having the windings apart from the rotor fixed on bearings while ensuring that no dust or sand particle go in the components. Examine each component for worn or damaged insulation, or any other signs of wear on bearings. It is used to take photograph of the disassembly process where applicable, with the purpose of noting the state of various parts and help to easy reassembly all it . Wash related components if required to remove dust and different things for perfect working. For any problems that may have been realized , this includes situations like changing of worn out components like bearings or greasing bearings. Last but not the least, disassemble the motor in the same direction and replace the motor in the reverse order leaving no single wire connection loose or wrong connection. It is important to check the functionality of the motor after any repairs or adjustments have been made to ensure the continuity of service operation. Inspection or reassembly, this is used keep approach on motor working properly and is reliable. FAULT DIAGNOSE
To assist in diagnosing common motor faults, including insulation
failures, bearing issues, and winding problems, it is important to understand the causes, and diagnostic methods for each type of fault In diagnosing motor faults it is helpful to look at the causes and diagnostics tests for each kind of fault, which include; insulation faults, bearing faults, and winding faults: • INSULATION FAILURE
Insulation Failures:- are defined by the high leakage currents and low insulation resistances and tripping of the circuit breakers that one might not expect to trip. It is usually possible to relate such failures often to issues such as moisture content, age degeneration, chemical pollution, high temperatures, and mechanical damaging. Some of the diagnosis tests adopted for insulation failure include, megger test • BEARING ISSUES
Bearing Issues:- are usually accompanied by such signs that can be
commented including the noise level, the vibration level, and temperature and any sign of misalignment. The common causes of bearing failure include inadequate lubrication, intrusion of abrasive materials such as dust, misalignment of the shafts and loads beyond the allowable limit, and & improper installation. An example of detective and preventive action of bearing problems entails using Vibration analysis and Thermal Imaging in analyzing and deciding the level of impact of the problem . • WINDING PROBLEMS
Winding Problems:-- may include low motor efficiency, the current sharing may not be smooth, there may be excessive heating and in extreme cases, the insulation layer in the winding can be seen to be burnt out. They are as a result of overloading, electric shocks, mish arbitrary and poor design of their circuits, and maybe because they were manufactured with bad workmanship. Some other winding problems of diagnosing include the application of resistances measurement, server surge testing, and thermography analysis that will show the short circuit, open circuit, and insulation faults.
It is thus only possible if one is knowledgeable and utilizes these
diagnostic tools to determine the normal and para motor operations and has the ability to adjust several motor defects that recurrent in nature. MOTOR REWINDING
Rewinding is among the procedures that have to be tightly controlled
at every stage to guarantee the correct functionality of an electric motor and its durability. First of all, it is necessary to shut down the power and proceed with the disassembly of the motor to reach the stator. The old windings are then carefully taken out to avoid any impact to the stator core which is exposed for possible further damage or signs of wear. Freshly bought copper wire that has been properly gauged and insulated to a fine thread is unwound and rewound in the new designed pattern. These freshly wound coils are properly placed in their respective slots in the stator and are made very secure. The strands finish is soldered on the correct terminal and insulated properly to avoid electrical connections. After this, electrical tests are conducted whereby the windings are thoroughly checked for correct installation and insulation. Once confirmed, The motor is reassembled in a way that makes sure all the parts are well locked in places as needed. Last of all, acceptance tests are carried out to ensure that the motor functions substaintially operates as it was designed under the operational testing. It is imperative to point out this method to be holistic for revival and sustenance of electric motors across the application fields. TESTING AND REASSEMBLY
A motor test is a procedure of examining the state of specific motor
and its capability to perform certain tasks. This mostly includes electrical tests like continuity tests, insulation resistance tests and voltage drop tests across the windings. Mechanical tests put the component right and checks on its rotation and the state of the bearing. It is through functional tests that one is sure that the motor is operating within the loading status. They may also conduct temperature and vibration test to put it to severance for some time. It is worthy to realize that the goal of motor testing is to confirm that the motor is ready for use and in good healthy state for the intended role The process of rewinding a motor is quite delicate and it plays a significant role in the performance or the expected life of the motor. For instance, starting with the components’ inspection, there can be some damages or excessive wear resulted from the accident. In this case spare parts are bought to a particular standard, as displayed by the manufacturing companies. Ultimately, every part or reassembly from bearings down to seals is arranged, to create the most perfect of alignment with incredible of friction’s effects. Joining is done with a lot of care with regard to the torque levels and how much stress the joining point can take. To arrive at the final assembly, pre-tests are carried out to check on the sense of the structure and the power’s preparedness to work. If there is any change required, it is done at the time of replacement of parts and records are properly maintained so that next time it is not required to give it for grinding. When it is done, this systematic approach ensures that the motor is on as it should be and there is no worry of it posing any danger MAINTANCE AND SAFETY Maintaining a motor is the key to ensuring its long-term operation. Routine checks are aimed at detecting any mechanical wear or damage occurring within fans, motors and/or drives, as well as in other system components. Importantly, any such can be identified early (hopefully), which provides opportunity for planning corrective action immediately. Bearings and other moving parts should be properly lubricated in accordance with manufacturers' recommendations to ensure that overheating related to friction does not occur. Motors should also be regularly cleaned of accumulated dirt and dust that can impede air flow over the unit's external surface, reducing its cooling efficiency. All electrical connections leading to the motor have to be inspected during routine checks as well. If any damaged or corroded connections are detected they ought to be replaced right away so as not to risk future malfunctioning of the equipment due to excessive electrical resistance. The operating temperature of motors should also be closely monitored for signs of overheating – a source of serious motor failures that we face repeatedly in our inspections (refer here). Shafts and coupling associated directly with motors require periodic adjustment too. Misalignment increases energy consumption along with aligned bearings vibrations. For best results motors ought also always remain dry since excess moisture will causes corrosion & rusting lower their lifespan even more than temperatures higher then ambient (though it is also recommended noting that high humidity alone rarely triggers accelerated degradation).
In pursuit of maintaining perfect condition all records connected with
each service and inspection carried must invested on regular basis along access providing power professional insulation carried should become part operator highest quality systems management process. OUTCOME OF THE INTERSHIP ✓ SKILLS AQUIRED FROM THIS 1. Proficiency in using tools for diagnostic for motor fault identification 2. Knowledge of different motor winding techniques 3. Ability to work with precision tools and machinery 4. Enhance understanding the component and there function 5. Improving problem solving skills and attention in detail
✓ Conclusion of it The internship at [STANDARD ELETRICAL AND ENGINEERING] Electrical Motor Rewinding Workshop provided a valuable learning experience. It enhanced my technical knowledge and practical skills in the field of electrical motor rewinding. The hands-on experience and mentorship from skilled professionals have prepared me well for a future career in electrical engineering.
