The Design and Construction of Single-Phase Induction Motor

CHAPTER 1
INTRODUCTION

1.1 General Introduction

There are two basic reasons for the use of single-phase motors rather than 3-phase
motors. For reason of economy, most houses, offices and also rural areas are supplied with single phase
ac, as power requirements of individual load items are rather small. The economics of the motor and its
branch circuit. Fixed loads requiring not more than 0.5KW can generally be served most economically
with single phase power and a single-phase motor. Single phase motors are simple in construction,
reliable, easy to repair and comparatively cheaper in cost and therefore, find wide use in fans,
refrigerators, vacuum cleaners, washing machines, other kitchen equipment, tools, blowers, centrifugal
pumps, small farming appliances etc. Because of above reasons motors of comparatively small ratings
(mostly in fractional KW ratings) are manufactured in large number to operate on single phase ac at
standard frequencies. An indication of the number of such motors can be had from the fact that the sum
of total of all fractional kilowatt motors in use today far exceeds the total of integral kilowatt motors of
all types.
The standard industrial motor frame sizes as well as the current design trends of larger
lengths and smaller diameters which are not likely presented in literature are taken into account. At first,
to verify the proposed approach, a sample single phase induction motor design is obtained regarding
certain requirements, based mainly on the classic output coefficient concept. Then, numerous simulations
over a large number of candidate motor topologies are conducted. This series of investigations is
performed initially with respect to certain operational industrial criteria, the number of stator and rotor
slots, and the rotor cage material.
After the relevant results are presented and commented, a selection strategy of an
appropriate design is also proposed. Also, the effect of the running capacitor value is examined. It is seen
that the total design and selection procedure are verified very satisfactorily. Finally, useful conclusions
from a manufacturer's point of view are also extracted, dealing with important operational characteristics
of the motor, such as power factor, winding currents phase shift, total losses, starting/rated torque and
efficiency.

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1.2 Problem Statement

The objective of this project is to design and construct a single-phase induction motor. The motor
should be efficient, cost-effective, and suitable for common household or industrial applications. The
project aims to cover all aspects of motor design including theoretical calculations, material selection,
construction, and performance testing.

Single-phase induction motors are widely used in domestic and industrial applications due to their
simplicity, reliability, and relatively low cost. Understanding their design and construction is crucial
for electrical engineers and technicians. This project will focus on the detailed design parameters,
construction techniques, and testing methodologies required to build a functional single-phase
induction motor

Fig 1.1 Overview of LHP

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1.3 Objectives
The objective of this project is to design and construct a functional single-phase induction motor that

Meets specific performance criteria and is suitable for practical applications. The key objectives

include:

Performance Efficiency:

Design a motor that operates with high efficiency, minimizing energy losses and maximizing power

output.

Cost-Effectiveness:

Ensure that the motor is cost-effective by selecting affordable materials and optimizing the
manufacturing process.

Reliability and Durability:

Build a motor that is reliable and has a long operational lifespan with minimal maintenance
requirements.

Suitability for Applications:

Design the motor for common household and industrial applications, such as fans, pumps compressors,

and small machinery.

1.4 General Information of Industry

Establishment-1981
Plant Area- 15700 square meters
Manufacturing Area- 5200 square meters
Office area- 600 square meters
Average annual compounded Growth rate- 18%
Export (Direct and Indirect)- 25%
Installed capacity:-20,000 motors and Pumps per month
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 The Design and Construction of Single-Phase Induction Motor

Manpower:-500 (180 technical)

Certification- ISO 9001:2008
Standard product range:-6000+
Regular clients:-4000+

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1.5 Achievements

• Outstanding Productivity Performance Award by the State Government-for Maharashtra

• ISO 9001: 2008 by Bureau Veritas

• Rajiv Gandhi National Quality Award

• National Award for Quality Products By Government of India

1.6 Summary

Undergoing vocational training in esteemed good organization like Laxmi Hydraulics Ltd.
Solapur was very in distinguished period in my educational life. The manufacturing of stator,
rotor, pressing of rotor into the stator, etc. Also various test performed on motor such as Megger
test, high voltage test, resistance measurement test, locked rotor test, etc. and to obtain final
quality product is having immense potential & very skilled and experienced manpower. I
observed various process like coil making. Winding heat treatment on rotor pressing of rotor
into the stator, all motor assembly and various test performed on motors. It is a good company
with many versatile machines and various motors. Also learned how to maintain good
relationship between workers & supervisors, which results in increasing the productivity It was
excellent experience working here. The training has encouraged me and gives guidance how to
behave in industry and work as part of it.

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 The Design and Construction of Single-Phase Induction Motor

CHAPTER 2
LITERATURE REVIEW
2.1 General Introduction

Electric motors are extremely important in modern-day life. They are used in vacuum
cleaners, dishwashers, computer printers, fax machines, video cassette recorders, machine tools,
printing presses, automobiles, subway systems, sewage treatment plants, and water pumping
stations, to mention only a few applications. A review of literature for Electrical machines and power
electronics over the past 40 years shows a pattern of circuit invention, loss and reinvention, often
times repeated. This has ensued in a great waste of time and effort as well as perpetual legal
wrangling and the lossof useful ideas for long periods of time and there is a need to overcome the
shortcomings. This papergives an overview of the induction motor (IM) drives. It also examines
various control methodologies, using voltage and current control. The literature survey for
industrial controls and power electronics over last three decades shows design of Multi converters
in high power applications is often repeated. It, therefore, analyze the progress made in induction
machine drive research and development since its inception. Efforts are made to highlight the
current and future issues involved for the development of induction machine drive technology for
future applications. Important inventions from overseas and their impact are also discussed.
Authors strongly believe that this article shall be very much helpful to the researchers working in
the field IM drives for finding out the relevant references. An electric motor is an electrical machine
that converts electrical energy into mechanical energy. Most electric motors operate through the
interaction between the motor's magnetic field and electric current in a wire winding to generate
force in the form of torque applied on the motor's shaft. An electric generator is mechanically
identical to an electric motor, butoperates in reverse, converting mechanical energy into electrical
energy.

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2.1.1 Motor efficiency

Single-Phase Induction Motor (SPIM) is the main contributor to the electricity consumption in residential
and commercial sectors where three-phase power supply is not available. SPIM efficiencies range from as
low as 30% to as high as 65%, depending on the motor type and design. As seen in testing, when the load
on the motor goes from no load to full load, there are irregular operations that occur in the motor. This
could be due to some losses through the motor such as temperature. A three-phase motor has an
efficiency of about 74%, while a single-phase motor runs at 64%.

2.2 Summary

We know there are generally two types of motors, AC motor, and DC motor. AC motors are flexible for
speed control and demand low power during start. On the other hand, DC motors are widely used due to
its initial cost of low power units is less compared to AC and can be easily installed. Universal Motor is a
special type of motor that can run on a DC supply or a single-phase AC supply. Since it can run both on
AC and DC, it is called a universal motor. An electric motor is a device used to convert electricity into
mechanical energy—opposite to an electric generator. They operate using principles of electromagnetism,
which shows that a force is applied when an electric current is present in a magnetic field.

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CHAPTER 3
DESIGNING OF MOTOR

3.1 Single-phase Induction motor

• Single Phase Induction Motor Definition: A single-phase induction motor is an electrical motor
that converts single-phase electrical energy into mechanical energy using magnetic interactions.
• Construction: The construction features two main parts—stator and rotor—with the stator receiving
AC power and the rotor designed to rotate and drive mechanical loads.
• Working Principle: These motors use alternating magnetic fields produced in the stator to induce
current in the rotor, creating the torque necessary for rotation.
• Self-Starting Challenge: Unlike three-phase motors, single-phase induction motors are not self-
starting because the opposing magnetic forces at startup cancel out, producing no torque.
• Improving Start ability: To become self-starting, these motors employ techniques like split-phase
and capacitor methods to create an initial rotating magnetic field.

What is a Single Phase Induction Motor?

Single-phase power systems are more commonly used than three phase system in homes, businesses, and
to some extent in industry. This is because single-phase systems are more economical and sufficient for
the low power needs of most houses, shops, and offices.
Single-phase motors are simple to build, cost-effective, reliable, and easy to maintain. Thanks to these
benefits, they are used in appliances like vacuum cleaners, fans, and washing machines, as well as in
devices like centrifugal pumps and blowers.

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3.2 Construction of single-phase induction motor

The stator of an induction motor consists of poles carrying supply current to induce a magnetic
field that penetrates the rotor. To optimize the distribution of the magnetic field, windings are distributed
in slots around the stator, with the magnetic field having the same number of north and south poles.
Induction motors are most commonly run on single-phase or three-phase power, but two-phase motors
exist; in theory, induction motors can have any number of phases. Many single-phase motors having two
windings can be viewed as two-phase motors, since a capacitor is used to generate a second power phase
90° from the single-phase supply and feeds it to the second motor winding. Single-phase motors require
some mechanism to produce a rotating field on startup. Induction motors using a squirrel-cage
rotor winding may have the rotor bars skewed slightly to smooth out torque in each revolution.

Standardized NEMA & IEC motor frame sizes throughout the industry result in interchangeable
dimensions for shaft, foot mounting, general aspects as well as certain motor flange aspect. Since an
open, drip proof (ODP) motor design allows a free air exchange from outside to the inner stator windings,
this style of motor tends to be slightly more efficient because the windings are cooler. At a given power
rating, lower speed requires a larger frame.
The construction of a single-phase induction motor closely resembles that of a squirrel cage three-phase
induction motor. However, the single-phase motor’s stator features two windings, unlike the single three-
phase winding found in three phase induction motor.
Stator of Single Phase Induction Motor
The stator of the single-phase induction motor has laminated stamping to reduce eddy current losses on
its periphery. The slots are provided on its stamping to carry stator or main winding. Stampings are made
up of silicon steel to reduce the hysteresis losses. When we apply a single phase AC supply to the stator
winding, the magnetic field gets produced, and the motor rotates at speed slightly less than the

synchronous speed Ns. Synchronous speed Ns is given by

Where,
f = supply voltage frequency,
P = No. of poles of the motor.
The construction of the stator of the single-phase induction motor is similar to that of three phase
induction motor except there are two dissimilarities in the winding part of the single phase induction
motor.

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1. Firstly, the single-phase induction motors are mostly provided with concentric coils. We can
easily adjust the number of turns per coil can with the help of concentric coils. The mmf
distribution is almost sinusoidal.
2. In all types except for the shaded pole motor, an asynchronous motor includes two stator
windings: the main and the auxiliary winding. These windings are positioned at right angles to
each other in what is known as space quadrature.

Rotor of Single Phase Induction Motor

The construction of the rotor of the single-phase induction motor is similar to the squirrel cage three-
phase induction motor. The rotor is cylindrical and has slots all over its periphery. The slots are not made
parallel to each other but are a little bit skewed as the skewing prevents magnetic locking of stator and
rotor teeth and makes the working of induction motor more smooth and quieter (i.e. less noisy).
The squirrel cage rotor consists of aluminium, brass or copper bars. These aluminium or copper bars are
called rotor conductors and placed in the slots on the periphery of the rotor. The copper or aluminium
rings permanently short the rotor conductors called the end rings.

To provide mechanical strength, these rotor conductors are braced to the end ring and hence form a
complete closed circuit resembling a cage and hence got its name as squirrel cage induction motor. As
end rings permanently short the bars, the rotor electrical resistance is very small and it is not possible to
add external resistance as the bars get permanently shorted. The absence of slip ring and brushes make
the construction of single phase induction motor very simple and robust.

Fig no: squirrel cage rotor

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3.3 Working of single-phase induction motor

NOTE: We know that for the working of any electrical motor whether its AC or DC motor, we require
two fluxes as the interaction of these two fluxes produced the required torque.
When we apply a single phase AC supply to the stator winding of single phase induction motor, the
alternating current starts flowing through the stator or main winding. This alternating current produces an
alternating flux called main flux. This main flux also links with the rotor conductors and hence cut the
rotor conductors.
According to the Faraday’s law of electromagnetic induction, emf gets induced in the rotor. As the rotor
circuit is closed one so, the current starts flowing in the rotor. This current is called the rotor current. This
rotor current produces its flux called rotor flux. Since this flux is produced due to the induction principle
so, the motor working on this principle got its name as an induction motor. Now there are two fluxes one
is main flux, and another is called rotor flux. These two fluxes produce the desired torque which is
required by the motor to rotate.

Fig no single phase induction motor

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3.4 Motor Assembly

An induction motor or asynchronous motor is an AC electric motor in which the electric current in
the rotor that produces torque is obtained by electromagnetic induction from the magnetic field of
the stator winding.[1] An induction motor therefore needs no electrical connections to the rotor.[a] An
induction motor's rotor can be either wound type or squirrel-cage type.
Three-phase squirrel-cage induction motors are widely used as industrial drives because they are self-
starting, reliable, and economical. Single-phase induction motors are used extensively for smaller loads,
such as garbage disposals and stationary power tools. Although traditionally used for constant-speed
service, single- and three-phase induction motors are increasingly being installed in variable-speed
applications using variable-frequency drives (VFD). VFD offers energy savings opportunities for
induction motors in applications like fans, pumps, and compressors that have a variable load.

Fig no assembly of motor

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3.5 Painting of motor

Epoxy paint has better moisture resistance, mildew resistance, internal dryness and adhesion than alkyd
paint. It has high hardness and is widely used for surface coating of electrical and electronic equipment
parts in hot flashes.
POR-15 Engine Enamel high temperature engine paint is formulated to be the best self-leveling engine
paint available, with a richness and depth of color unsurpassed by any other paint of its type. Coat the
engine in a layer of engine enamel to paint it.

Work back and forth from one end of the block to the other to coat the surface of your engine. If you
removed the engine, work your way around the engine to paint the sides as well. The color should be
uniform and even without any drips.

Fig no painting of motor

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3.6 Name plate fitting

Much of the information you need to identify an electric motor is contained on the motor's nameplate.
The nameplate also provides some basic information about a motor’s operating characteristics. Proper
motor selection is extremely important for safe, efficient, and reliable motor operation.
A circulation pump motor is the heart of a swimming pool, and it is important to keep it beating properly
for the water to stay clean and healthy. When replacing a pump motor, there are several things a service
technician needs to understand. A replacement motor must be capable of carrying the same load as the
motor it is replacing, assuming that the original motor was sized correctly.

This is not a complicated concept, and if you replace like with like, there’s little need for further
understanding. However, real world situations aren’t always so clear and reviewing some basic concepts
and definitions should be helpful in selecting the correct replacement motor. If you suspect the failed
motor is not the right size, you should consult the OEM pump manufacturer for the proper motor
nameplate specifications. Much of the information you need to identify an electric motor is contained on
the motor's nameplate. The nameplate also provides some basic information about a motor's operating
characteristics. Proper motor selection is extremely important for safe, efficient, and reliable motor
operation. You must fully understand motor nameplate data in order to select the right motor for each
application. If an exact match between an old motor and its replacement is not possible, you must be able
to determine the most appropriate replacement.

fig no name plate

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3.7 Summary: -

Induction motors are electric motors that use alternating current (AC), propelled by a magnetic field that
rotates. They are made up of a rotor, a stator and coils that convert electrical energy into mechanical
energy using electromagnetic induction. The electromagnetic induction is the phenomenon in which the
electromotive force induces across the electrical conductor when it is placed in a rotating magnetic field.
When the three phase supply is given to the stator, the rotating magnetic field produced on it. The number
of slots should be so selected to give an integral number of slots per pole per phase. Generally for small
and medium size motors the number of slots per pole per phase lie between 3 to 5. The narrow range is 3
to 4.

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CHAPTER 4
HARDWARE DESCRIPTION

4.1 Motor frame

The stator frame consists of laminations of silicon steel, usually with a thickness of about 0.5 millimetre.
Lamination is necessary since a voltage is induced along the axial length of the steel as well as in the
stator conductors. The laminations are insulated from each other usually by a varnish layer. This breaks
up the conducting path in the steel and limits the losses (known as eddy current losses) in the steel.

The stator coils are normally made of copper; round conductors of many turns per coil are used for small
motors, and rectangular bars of fewer turns are employed for larger machines. The coils are electrically
insulated. It is common practice to bring only three leads out to a terminal block whether the winding is
connected in wye or in delta.

Fig no induction motor

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The magnetic part of the rotor is also made of steel laminations, mainly to facilitate stamping
conductor slots of the desired shape and size. In most induction motors, the rotor winding is of
the squirrel-cage type where solid conductors in the slots are shorted together at each end of the rotor iron
by conducting end rings. In such machines there is no need to insulate the conductors from the iron. For
motors up to about 300 kilowatts, the squirrel cage often consists of an aluminium casting incorporating
the conductors, the end rings, and a cooling fan. For larger motors, the squirrel cage is made of copper,
aluminium, or brass bars welded or brazed to end rings of a similar material. In any case, the rotor is very
rugged and is also economical to produce in contrast to rotors requiring electrically insulated windings.
The rotor slots need not be rectangular. The shape of the slots can be designed to provide a variety of
torque-speed characteristics.

Fig no frame of motor

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4.1.1 Pressing of stator in frame

The device has a stator frame (36) for holding and supporting the stator. A hydro cylinder is connected to
the stator frame and can be acted upon by a hydraulic fluid via a motor-driven hydraulic unit. The hydro
cylinder has a piston rod which lies against a rotor pressing against an end of the stator. Device for
pressing a rotor in or out of a stator of eccentric spiral pump, comprises hydro cylinder which is
connected to stator frame and which can be acted upon by hydraulic fluid via motor-driven hydraulic unit
Classifications
F04C2/1071 Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of
co-operating members similar to that of toothed gearing of internal-axis type with the outer member
having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and
outer member having a different number of threads and one of the two being made of elastic materials,
e.g. Moineau type.

Fig no pressing of stator frame

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• Four columns are made of high-strength alloy steel with hard chrome plated surface and good
abrasion resistance.
• Key hydraulic electrical parts come from famous brands of Germany, United Stated and Japan.
Quality is guaranteed.
• Extended guide design with good leading and high precision.
• The continuous circulating oil cooling system lowers the oil temperature during machine running.
• The moving bolster is equipped with an upper die stripping cylinder, which makes it convenient
for the upper die to unload material.
• PLC & HMI control system or common operating system are optional
• Using advanced hydraulic system allows few malfunctions. High reliability and small reversing
impact.

Fig no Stator core assembly

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4.1.2 Capacitor assembly for single-phase motor

A run capacitor is used in single-phase motors to maintain a running torque on an auxiliary coil
while the motor is loaded. These capacitors are considered continuous duty while the motor is
powered and will remain in the circuit while the start capacitor drops out.
To start a single-phase induction motor, a capacitor is connected in series with auxiliary or
starting winding used to generate a phase difference between the torques which are generated
by fluxes equal in magnitude but opposite in direction.

Fig no Single-phase capacitor start induction motor

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4.2 Stator Assembly

The stator is the stationary part of a rotary system,[1] found in electric generators, electric
motors, sirens, mud motors, or biological rotors (such as bacterial flagella or ATP synthase). Energy
flows through a stator to or from the rotating component of the system, the rotor. In an electric motor, the
stator provides a magnetic field that drives the rotating armature; in a generator, the stator converts the
rotating magnetic field to electric current. In fluid powered devices, the stator guides the flow of fluid to
or from the rotating part of the system.

Motor stators are made either from iron/steel or from a printed circuit board (PCB). Originally applied to
low-power applications, PCB stators can be lighter, smaller, and less noisy.

One design embeds thin copper traces in the PCB stator that serve as the windings. The traces are
interleaved with epoxy-glass laminates, that insulate each coil from its neighbours. An air core replaces
the traditional iron core, saving space and weight, and allowing a smaller air gap.

Hairpin windings may be used in the construction of electric motor stators. This technology, uses
windings with wires that individually, may have larger cross sections than those used in conventional
windings.

Fig no stator

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4.3 Rotor assembly

The rotor is a moving component of an electromagnetic system in the electric motor, electric generator,
or alternator. Its rotation is due to the interaction between the windings and magnetic fields which
produces a torque around the rotor's axis.
The rotor manufacturing process can be divided into 6 steps:
1. Design and Prototype
2. Lamination
3. Magnets or Conductor Bars Insertion
4. Machining and Laser Marking
5. Shaft Laser Cleaning and Press Fitting
6. Impregnation and Balancing

The rotor shaft is now the only part missing. The shaft ensures an efficient mechanical transfer
which brings power to the EV’s wheels. Manufactured separately, the shaft can be cleaned with a
laser to remove oil, dust, or any contaminants remaining from its manufacturing. It can also be
laser marked for traceability or tracking purposes. Now that the rotor is completely assembled, it is
impregnated in a resin bath to improve its mechanical strength and protect it from external
elements. To sustain speeds as high as 10,000 rpms, precise balancing is required to ensure smooth
running without vibration. Mass distribution is measured by placing the rotor on a horizontal or
vertical fixture equipped with measuring devices such as accelerometers, tachymeters, and scales.
These instruments monitor acceleration, rotation speed, and weight as the rotor spins. Adjustments
are made until the balance is met.

Fig no various motor rotor

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4.4 Casting of motor

The motor casting invention relates to a process for casting motor vehicle wheels from metal, such as
from an aluminum alloy, which wheels have a rim ring and a hub part connected by supporting radial
elements. According to the present process the casting mold is formed by a plurality of molded core parts
that are mainly ring- and/or disk-shaped and which are axially assembled while still attached to their
mold sections and are centered relative to each other by the relative adjustment of the mold sections. The
parting plane of the core parts runs perpendicularly to the wheel axis. This permits one-piece wheels to be
cast with great accuracy, which wheels have few, if any, visible mold seams.
Field of the Invention:
The present motor casting invention relates to a process for casting a motor vehicle wheel and other
motor parts from metal, especially from an aluminum alloy, said wheel having a rim ring and a hub part
connected thereto by supporting radial elements. Thus motor casting process is used to manufacturer
different kinds of metal parts of the vehicles which are also called metal casting or metal castings.

Fig no motor casting

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Advantages of motor casting:

Because of the special shape of the rim well, motor vehicle wheels cast from an aluminum alloy are
manufactured in such fashion that a bi- or multipartite radially-openable mold is used for forming the rim
well section. However, the precision that can be achieved in this manner as regards true-running, uniform
wall thickness, etc., make it necessary for the cast blank to be finished by a costly machining procedure.
All additional elements to be mounted, such as fan rings, trim coverings, especially trim coverings for
purposes of air guidance for example, have to be manufactured as separate elements and then mounted on
the cast wheel body, such as by bolting. Then, after machining and assembly of the additional parts,
additional finishing is required to balance the finished motor vehicle wheel. Feel free to contact us to buy
or for more information on motor casting, motor casting process, and motor castings.

Fig no cast iron motor

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4.5 Fan mounting

4.5.1 Fan cover mounting

Safety or identification of an idiot. One year at my place of work in a manufacturing plant, our team built
a test fixture consist of resistor load banks and a large fan. We mounted the fan onto the load banks for
maximum cooling, without the fan cover. Right after our initial run of the test fixture, in comes our new
Lean Manufacturing Expert sent from the HQ. He proceeded to ask bunch of questions concerning the
new contraption that he had found on the production floor. I was there to try to answer his questions until
the time when he demanded to know why is there not a cover for the fan blades that is turning at a high
rate of speed. The fan blades are physically blocked by array of bars and wiring harnesses. I explained
that this contraption also serves the purpose as an Idiot Finder, it will locate the personnel that lacks the
basic common sense to be safely standing on the production floor. The Expert proceed to peel back and
tried to wiggle his finger toward the rotating blade trying hardest to prove that the fixture is not safe to be
on the production floor while asking me what I mean by the fixture being an Idiot Finder. I looked
straight into his eyes, pointed to his finger and declared the Idiot Finder had proven to work when he got
his finger stuck in the wiring harness and becoming fractions of an inch away from the rotating blade. I
walked away leaving him still trying to figure out what I meant.

Fig no fan cover

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4.5.2 Fan assembly

Because no conductor has zero resistance, so current produces heat. That heat has to be
transferred to the environment, firstly by conduction through the adjacent wires and laminations until it
reaches the surface when it can be absorbed by air flowing over the laminations and windings. This air is
propelled by a fan usually at the non drive end of the motor. If the motor is TEFC (Totally Enclosed Fan
Cooled) the air is blown over fins on the outside of the motor if not, the air is blown through the motor,
through holes in the rotor and stator laminations.

Fig no fan assembly

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4.6 Winding test

Testing for winding faults requires performing a series of AC and DC measurements made between the
motor leads and the measured values are compared. If the measurements are balanced, the windings are
okay; if they are unbalanced, faults are indicated. The recommended measurements are: resistance. The
winding resistance of an electric motor plays a critical role in determining its performance characteristics.
For example, higher winding resistance results in lower power output, lower efficiency, and increased
heat losses.

Conversely, lower winding resistance can lead to excessive current draw, which can damage the motor
and associated equipment. Therefore, it is useful to measure and monitor the winding resistance of
electric motors to ensure optimal performance and prevent damage.

Winding resistance is typically determined by measuring the voltage and current in the motor. The
resistance is then calculated using Ohm's law, which states that resistance is equal to voltage divided by
current.

This measurement can be used to detect faults in the coil, such as short circuits or broken wires, and can
also be used to diagnose other issues in the motor, such as problems with the bearings or drive circuitry.

Fig no winding resistance test

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4.7 Routine test

NO LOAD TEST : The no load test on an induction motor is conducted to measure the rotational losses
of the motor and to determine some of its equivalent circuit parameters. In this test, a rated, balanced ac
voltage at a rated frequency is applied to the stator while it is running at no load. During this input power,
voltage, and phase current are measured at the no load.
BLOCKED ROTOR TEST: In this test, the rotor of the Induction Motor is blocked. A reduced voltage
is applied to the stator terminal so that the rated current flows through the stator winding. The input
power, voltage and current are measured.
The induction motor is one of the most important motors used in industrial applications. It is used to
convert electrical energy into mechanical energy. Its low cost and high performance in addition to its
reliability make them the most popular alternating current motors used in the industrial and commercial
fields.

Fig no routine test

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4.8 Summary

An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most
electric motors operate through the interaction between the motor's magnetic field and electric current in
a wire winding to generate force in the form of torque applied on the motor's shaft. This mechanical
energy can then be used to power everything from heavy, industrial machinery to everyday tools and
appliances such as hair dryers. Motor starters are one of the major inventions for motor control
applications. As the name suggests, a starter is an electrical device which controls the electrical power
for starting a motor. These electrical devices are also used for the purpose of stopping, reversing and
protecting electric motors. Motor starters are one of the major inventions for motor control applications.

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CHAPTER 5
METHODOLOGY
5.1 Flow of work

flow chart

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5.2 Types of motor

5.2.1 Types of motor classified by application

Types of Single-Phase Induction Motor

Single-phase induction motor is classified into four types of induction motors like Split Phase, Capacitor
Start, Capacitor Start & Capacitor Run, and Shaded Pole Induction Motor.

Fig no flow chart

The applications of single phase induction motor are; it is used in low-power applications and widely used
in domestic applications as well as industrial. And some of those are mentioned below:

• Pumps

• Compressors

• Small fans

• Mixers

• Toys

• High-speed vacuum cleaners

• Electric shavers

• Drilling machines

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5.3 Motors manufacturing photo gallery

Fig 5.1 Manufacturing of Motor

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5.4 Summary

Motor starters are one of the major inventions for motor control applications. As the name
suggests, a starter is an electrical device which controls the electrical power for starting a motor. These
electrical devices are also used for the purpose of stopping, reversing and protecting electric motors.

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 The Analysis of Design and Construction of Single-phase Induction Motor

CHAPTER 6
BUSINESS PLAN AND COMMERCIAL ASPECT

6.1 The LHP product portfolio

Table 6.1 Product Portfolio

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 The Analysis of Design and Construction of Single-phase Induction Motor

6.2 Testing procedure of the motor

Fig 6.1 Routine test block

6.3 Summary
An electric motor is a device used to convert electricity into mechanical energy—opposite to an
electric generator. They operate using principles of electromagnetism, which shows that a force is
applied when an electric current is present in a magnetic field.

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 The Analysis of Design and Construction of Single-phase Induction Motor

CHAPTER 7
CONCLUSION

7.1 Advantages

• Lightweight, Compact Unit

• Efficient Transmission

• This induction motor is smaller in size and lighter in weight.

• It is also cheaper in cost.

• These motors are highly efficient.

• These motor also requires less maintenance.

• 1-phase induction motors have a longer life.

7.2 Conclusion
Undergoing vocational training in esteemed good organization like Laxmi Hydraulics Ltd. Solapur
was very in distinguished period in my educational life. The manufacturing of stator, Rotor, pressing
of rotor into the stator, etc. Also various test performed on motor such as Megger test, high voltage
test, resistance measurement test, locked rotor test, etc. and to obtain final quality product is having
immense potential & very skilled and experienced manpower.
I observed various process like coil making. Winding heat treatment on rotor pressing of rotor into
the stator, all motor assembly and various test performed on motors
It is a good company with many versatile machines and various motors. Also learned how to maintain
good relationship between workers & supervisors, which results in increasing the productivity It was
excellent experience working here. The training has encouraged me and gives guidance how to behave
in industry and work as part of it.

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REFERENCES
1. Manuel Guerreiro, D. F. and Armando C. (2008). A Phasor Speed
Control of a Single or Two Phase Induction Motor, Proceeding of the
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[13]. Sarac V., Petkovska L., Cundev M. and
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