VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangam, Machhe,Belagavi-590018

Internship Report on

“ASSEMBLY OF THREE PHASE AC INDUCTION MOTOR”

In Partial fulfilment of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

Submitted by

DEVARAJ.K.S 2RH17ME408

Under the Guidance of

Prof. M.D.Harlapur
Head of the department
Dept. of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

RURAL ENGINEERING COLLEGE

HULKOTI-582205
2019-2020
 R.T.E.Society’s
RURAL ENGINEERING COLLEGE
HULKOTI-582205

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the project work entitled,“Assembly of Three phase AC Induction Motor”
carried out by Mr.DEVARAJ.K.S(2RH17ME408), was bonafied student of Rural Engineering
College in partial fulfillment for the award of Bachelor of Engineering in Mechanical
Engineering of the Visvesvaraya Technological University, Belagavi during the year 2019-20.
It is also certified that all corrections/suggestions indicated for Internal Assessment have
been incorporated in the Report deposited in the department library. The Internship report has
been approved as it satisfies the academic requirements in respect of Internship Work prescribed
for the said Degree.

Signature of the Signature of the Signature of the HoD Signature of the

External Guide Guide Principal

Mr Surendra Dr.M.D.Harlapur V.M.Patil

Assistant Professor
HR of Kirloskar Electrical Dept. of Mechanical Dept. of Mechanical Engg REC,Hulkoti
Company Hubli Engg

External Viva

Name of the Examiners (Signature with date)

1.……….. ………………….. ……………………. ………………. ………………………..

2.……….. ………………….. ……………………. ………………. ………………………..

 ACKNOWLEDGEMENT
The euphoria in completing the seminar cannot be concluded without acknowledging
those who helped us. In this uncompromising world, it is comforting to kssnow that there are
people to guide through most difficult situations, providing valuable guidance and
encouragement.

The materialization of ideas and view of this project has been valuable contribution of
numerous friends and academicians in the form of selfless criticisms, well wishes and above
all words of inspiration. We deeply indebted to all of them.

We would like to take opportunity to thank our guide Prof. and

seminar coordinator Prof. Department of Mechanical Engineering, for
there immense guidance and support, without which the seminar would have been
unthinkable.

We extended our gratitude to V.M.Patil , Principal , REC Hulkoti , for his generous
support in all regards.

We greatly indepted to Dr.M.D.Harlapur , HoD Department of Mechanical, for his

unstinted support.

We extended our heartfelt thanks to all the faculty members, teaching and non-
teaching staff of Department of Mechanical Engineering, REC Hulkoti who have helped us
directly or indirectly.

i
 CONTENTS
Acknowledgement i

CHAPTER1 INTRODUCTION 1

Company Background 1

Company’s Objectives 3

Vision 3

Mission 3

Company infrastructure facility 3

Safety measures 4

Schedule of training undergone 4

Objective of the internship study 5

CHAPTER2 ASSEMBLY ON THREE PHASE 6

INDUCTION MOTOR

About the department 6

Production department 8

Three phase ac induction motor 12

theory

Types of machine 13

Maintenance of machine 14

Raw materials used 14

CHAPTER3 Conclusion 15

Reference 15
KIRLOSKAR ELECTRICAL COMPANY REC HULKOTI

CHAPTER 1
INTRODUCTION
Company background:
Kirloskar electric company(KEC) is the leading manufacturer of electrical
&electronics equipments in India. established in 1945, kirloskar electric produces more
than 70 products under 8 different product groups, catering to core sectors of the
economy like power generations, transmission and distribution, transportation and
renewable energy, sugar, steel, cement and allied industries.

About the founder:

Laxmanrao kirloskar, founder of the kirloskar industries was born on 20th
june,1869,in a small village, Gurlahosur in Belgaum district. He started his life as a
school teacher and later on, opened a cycle repair shop in Belgaum. But his ambition and
mission could not be satisfied by a small workshop at Belgaum.
Laxmanrao kashinath kirloskar(1869-1956) was an Indian businessman. He was
the founder of the kirloskar group, in 1888, he set up his first venture- a small bicycle
repair shop at Belgaum. Strongly believing that agricultural implements must fit the
milieu they are used in, he manufactured iron ploughs, the first kirloskar products.
Shantanurao kirloskar, the eldest son of the founder travelled to pune to initiate a new
aspect of the group’s activities- diesel engines.

History of kirloskar group:

Kirloskar group of companies is 70 years old company. The kirloskar name
stands for excellent engineering, quality and reliability. The business areas of companies
reflect its diversity, process control equipment and machine tools, rotating electrical
machines, etc.
KEC was established in the year 1946 at Bangalore. KEC had produced AC
motors in 1948 which was very first of kind in India.at present, KEC activity involved in
supplying electrical, industrial, and electronic equipments, systems, solutions, agricultural
utilities to the various industries.

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HISTORY OF KIRLOSKER ELECTRIC COMPANY:

1888- Engineering brother enterprise was established by Mr Laxman Rao and Mr
Kashinath kirlosker.
1901- India’s first mechanical fodder cutter machine made.
1904- First iron ploughs was invented.
1924- Export of ploughs to Britain begins.
1940- India’s first vertical diesel engine manufactured.
1942- First AC induction motor made in India.
1946- Kirlosker Electric &kirlosker oil engines established.
1949- India’s first 5HP AVI engine manufactured.
1953-India’s first transformer manufactured.
1958- First alternator in India was invented, kirlosker pneumatic company established.
1964- First electronic DC motor made in India.
1970- Mr.Ravi kirlosker appointed as managing director.
1973- First overseas established in Malaysia.
1984- JV Established for specialization in pumps.
1988- Completed 100 years.
1991- Established in Singapore.
1992- Kirlosker ferrous established.
1993- ISO 9001 certification.

KIRLOSKER UNITS IN INDIA:

UNIT1-BANGLORE-AC motors, AC generators, motorized gear units.
UNIT2-HUBLI-induction motors, AC generators.
UNIT3-PENYA-DC motors, generators, traction.
UNIT4-MYSORE-industrial electronic group thyristor devices, static investors, UPS
systems. Factory automation, group digital readouts, CNC systems, servo drives and
induction heaters.
UNIT5-BANGLORE-Transformers.
UNIT6-PUNE- Automotive electrical equipments, small range induction motors and
alternators upto 5HP.
UNIT7-TUMKUR- stampings, die-cast rotors/bodies and coils.
UNIT8-PUNE- cast resin, transformers and oil filled transformers.

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Company’s Objective:
vision:
We shall be amongst the first five pumps companies in the world by in the year
2015 become the preferred choice of customers as well as employees.

Mision:
We shall be known globally as a reliable, innovative and cost effective solution
provider in hydraulic machines and systems.

Company infrastructure facility:

Fig1.1. Entrance Fig1.2. Shop 1

Fig1.3. Shop 2

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Fig1.4 Shop 3 Fig1.5. Shop 4

Safety measures:
[1] Do not use any tools or equipment until instructed on their proper use.
[2] Use safety glasses whenever around chemicals that may splash or objects that can be
thrown.
[3] Most accidents occur when people rush their work.
[4] keep the industry clean and neat. Clutter and broken or dirty tools can create a safety
hazard.
[5] Be sure your hands are dry before working with electrical equipment.
[6] Do not let electrical cords dangle from workstations;dangling cords can cause tripping
or electrical shocks.
[7] Take noise cancellation measures.
[8] Do not exceed the input voltage range.
[9] Do not use the motor for load lowering operations.
[10] Conduct separate insulation resistance and dielectric strength tests for the motor and
driver.

Schedule of the training undergone:

Sl.no Week Discription

1 First week Introduction of company,shop1:welding
process,shrinking,tapping,drilling,balancing,shaft
fixing,single and double end key ways etc
2 Second week Shop2:Die casting of aluminium,types of
aluminium:EC grade,LM24.stator slots,

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3 Third week Shop3:coil winding assembly for different rotor

range.
4 Fourth week Shop4:testing of each part of machine,painting of
motors,rotor assembly for different size,fixing of
motor frame by using high temperature,fixing of
bearing.
Shop5: verticalmotors,horizontal motors for
higher ranges,automatic painting to the
machine,packaging,name plate details.
5 Submission of internship report

Objective of the internship study:

[1] To provide students the opportunity to test their interest in a particular career before
permanent commitments are made.
[2] To develop skills in the application of theory to practical work situations.
[3] To develop skills and techniques directly applicable to their careers.
[4] Internship will increase a students sense of responsibility and good work habits.
[5] To expose students to real work environment experience gain knowledgement in
writing report in technical works/projects.
[6] Internship students will have higher level of acedemic performance.
[7] Internship programs will increase student earning potential upon graduation.
[8] To build the strength,teamwork spirit and self confidence in student life.
[9] To enhance the ability to improve students creativity skills and sharing ideas.
[10] To build a good communication skill with group of workers and learn proper
behavior of corporate life in industrial sector.

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CHAPTER 2:
Title of the Area of Internship undergone
KIRLOSKAR ELECTRIC COMPANY PVT.LTD.GOKUL ROAD,HUBLI-580030

2. About the department:

Functional departments:
Kirloskar electric company hubli. consists of various departments.Department play
a vital role in the development of the company these department manage all operations of
the company. They are as follows:
 Human resource department.
 Engineering department.
 Production department.
 Maintenance department.
 Quality assurance department.
 Marketing department.
 Finance department.

HUMAN RESOURCE DEPARTMENT:

HRD functions is to satisfy the organizational needs, selecting right persons for
the right job and to manage people not only workers but also includes white collared
professionals. Thus, the main objective is to maintain cordial relationship, by providing
maximum welfare and thereby optimizing the personal contribution for the effective
functioning of the undertaking.

ENGINEERING DEPARTMENT:
Engineering departments plays a major role in giving shapes the product i.e.,
electric motors, generators, transformers, and controllers. It is mainly concerned with the
designing the product according to the needs and wants of customers. Highly technically
background employees will work together to ensure maximum satisfaction to the
customer. This department consists of 75 employees.

PRODUCTION DEPARTMENT:
Production department is the main department in any manufacturing unit as all
manufacturing activities are undertaken by this department. Production department in any
industry performs the functions of converting raw materialsinto finished goods requires a

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predetermined plan so that available resources of company are used to optimum level and
more wastage is reduced to the greater extent.
The department is divided into two shops:
[1]Feedershop(shop1andshop2)
[2] Assembly shop(shop3,shop4 and shop5)

MAINTENANCE DEPARTMENT:
Through integration with other modules(for ex: material management,
production, sales and distribution, personnel management and controlling) the data is
always kept current and processes that are necessary for plant maintenance and customer
service are automatically triggered in other areas(for ex: a purchase requisition for non-
stock materials in the materials management/purchasing area).

QUALITY ASSURANCE DEPARTMENT:

Quality is the fitness to end use. It is all pervasive.in this modern and competitive
world each and every company is training hard to introduce quality &detect-free
products. K.E.C is one such industry whose priority is not to be number one in quantity
but in quantity and reliability.

MARKETING DEPARTMENT:
The word “marketing” is derived from Latin word “MARCATUS” which means
MERCHANDISE where trade or place of business is conducted. The essence of
marketing is a transaction , which when one social unit strives to exchange something of
value with another social unit.

FINANCE DEPARTMENT:
The corporate finance department controls the financial activities of all 5 units of
kirloskar electric company(KEC).it is responsible for taking all the important financial
decision and also prepares the annual operating plans& the long range plans. The monthly
operating plans are divided into weekly& daily plans.

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Production departments:
Shop-1:
The manufacturing function are carried out in this shop.in this shop all the raw
materials are pooled up then given a shape, which is partially ready. The main function
like balancing, drilling, and rotor sub assembly is done here.
The following process involved:
[1] Bar cutting.
[2] Shrinking and pressing.
[3] Facing and centring
[4] Machining.
[5] Keyway milling.
[6] Drilling and tapping.
[7] Bearingand grinding.

Fig. 2.1 AC Induction motor Fig. 2.2 parts of Induction motor

[1] A balancing machine is a measuring tool used for balancing rotating machine parts
such as rotors for electric motors, fans, turbines, disc brakes, disc drives, propellers and
pumps.
[2] The machine usually consists of two rigid pedestals, with suspension and bearings on
top supporting a mounting platform.
[3] Drilling and tapping: drilling and tapping machines are used to drill or thread holes in
a surface. Drilling and tapping machines vary from the tiny bench machine used in the
finest jewellers operation to the huge, heavy-duty machines that bore large holes in steel
forgings at an astonishing rate. Vertical Drilling machine known as a drilling press.

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Shop-2:

Die casting of aluminium:

Here all the body shapes and name plates are done with aluminium which is
heated to 675-800 degree centigrade,it is in molten stage.

Fig. 2.3 Die casting

Die casting is a manufacturing process that can produce geometrically complex metal
parts through the use of reusable molts. called dies. The die casting process involves use
of furnace, metals, die casting machine,anddie.The metal typically non ferrous alloy such
as aluminium or zinc, is melted in the furnace and then injected into the dies in the die
casting machine.

Properties of aluminium alloys:

 Low density.
 Good corrosion resistance.
 High thermal and electrical conductivity.
 High dimensional stability.
 Relatively easy to cast.

Advantages of aluminium die casting:

 Excellent dimensional accuracy.

 Smooth cast surface.
 Reduces or eliminates secondary machining operations.

Disadvantages of aluminium die casting:

 High initial cost.

 Limited to high –fluidity metals.
 Casting must be smaller than 600mm.

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 Casting weight must be between 30grms to 10kg.

Shop-3:

Winding process of stator and rotor:

Scope:
This is applicable for all standard and non-standard motors frame size from 63to225.
Responsibility :
Operator/supervisor/foreman in charge(FIC)-winding.

Procedure for paper cutting:

 Receive the rolled insulating paper from stores.

 Cut insulation paper from the roll as per order.
 Paper cutting is to be done as per work order.
 Paper cutting is to be done after making.
 After cutting the paper, make a set and bind with the help of cotton tape and it for
next process.

Procedure for winding:

Fig. 2.4. Winding of Motor

1. Collect stacks as per lot numbers.

2. Keep stack on winding table.
3. Clean the stack using brush.
4. Collect coils, insulating paper, p130thermistors,and wedges.
5. Remove sharp edges of slot by filling.
6. Insert slot liners in slot.

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7. Insert the coil twisted end if the stack through as per elect span, use slot inner, slot top
and wedges.
8. Insert phase separation.
9. Insert the thermistor one per phase for frame 160to225,lead length500mm for frame
180,200and 225 frames standards.
10. End connections ref electrical specifications.
11. Binding of cover hangs with treeline tape or thread use sticker for identification.
Note:

Why windings are made up of copper?

1. The current distribution is more uniform with copper conductors due to the
higher conductivity.
2. Less cost.
3. Heat losses are less compare to aluminium.
4. Copper wire connections are easy.
5. Enamelled copper wire may last many years.

Shop-4:
This shop is known as INVOTECH CENTRE i.e. R&D division of the firm.in
this shop, the product development is the main function. This shop is closely related to
the engineering dept. and hence carries on its activities in accordance with theengineering
dept. the activities of this shop include tests for future department, vibrator testing
reliability etc.

Fig. 2.5 Types of Rotors Fig.2.6 Bearing

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Shop 5:

Fig 2.7 Starting and End connection Fig 2.8 Fixing of Rotor

Fig 2.9 Stator and Rotor parts

The function of this shop is assembling large frame size motors.In this section AC motors
the assembling of machine up to 450 is done. In this section AC motors the process
begins with the shafts being inserted into rotor through hydraulic press machine. This
shop is also has its own painting and dispatch section.

Three phase ac induction motor:

Working principle:
An electrical motor is such an electromechanical device which converts electrical
energy into a mechanical energy.in case of three phase AC operation, most widely used
motor is three phase induction motor as this type of motor does not require any starting
device or they are self-starting induction motors.

Construction:
The three phase induction motor is the most widely used electrical motor. Almost
80% of the mechanical power used by industries is provided by three phase induction
motors because of its simple and rugged construction ,low cost, good operating
characteristics, the absence ofCommutator and good speed regulation.in three phase

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induction motor, the power is transferred from stator to rotor winding through induction.
The induction motor is also called a synchronous motor.

Induction motor mainly contains two parts:

 Stator:
As its name indicates stator is a stationary part of induction motor. A stator
winding is placed in the stator of induction motor and the three phase supply is given to it.

 Rotor:
The rotor is a rotating part of induction motor. the rotor is connected to the
mechanical load through the shaft.

Advantages of three phase induction motor:

[1] Self-starting.
[2] Less armature reaction and brush sparking because of the absence of Commutators
and brushes that may causes sparks.
[3] Robust in construction.
[4] Economical.
[5] Easier to maintain.

Types of machines:
[1] Shaper machine.
[2] Drill press.
[3] Jig machines.
[4] Lathe machines.
[5] Alumimium chokes.
[6] Grinding machines.
[7] Welding machines.
[8] Milling machines.
[9] Planner.
[10] Drilling machines.

Maintenance of machines:
[1] Keep daily records of use and oversee operation.
[2] Maintain a schedule of planned maintenance.

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[3] Lubricate and clean frequently.

[4] Inspect and monitor components for wear and damage.
[5] Protect equipment during storage.
[6] Stay on top of large machinery operator training.
[7] Repair or replace broken or malfunctioning components.
[8] Remove all unnecessary materials.
[9] Take good care of accessories and parts of machines.
[10] Check allignment specification.

Raw materials:
[1] Welding wire.
[2] Casting-
 Aluminium.
 Iron.
 Steel.
 Stainless steel.
 Silver
 Copper.
 Magnesium.
[3] Plate metal.
[4] Bolts and nuts.
[5] Zinc.
[6] Tungsten.

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CHAPTER 3
CONCLUSION
During the 4 weeks, it was totally a new experience entering into the organization
and spent most of the time visiting various departments, interacting with people etc.in the
beginning of the training,I went to different production sites where the assembling of the
material is taking place.
There I understood as to how the production work is divided and how the
responsibility is allocated.after production site I the subsequent weeks I went to different
department like human resource management,quality,marketing,finance etc.i was able to
understand the importance of each department and their contributiontowards
achievements of the company objectives. I came to know the importance of managerial
knowledege such as planning,organizing,directing and controlling etc.
I also learnt the importance of time management that is key parameter for any
organization towards success path.it was really nice and great experience working in the
organization like KIRLOSKAR ELECTRIC CO LIMITED,which is of great repute in the
electrical industry.

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Reference:
[1] www.google.com
[2] www.kirloskar.in
[3] wikipedia
[4] AC motors wekepedia

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