ABSTRACT

This report presents the knowledge and experience acquired during my eight weeks of
industrial practical training undertaken at poly machinery company limited.

My training was focused on assembly of different machines like maize sheller, sand mixer
and other agricultural and construction machine as well as maintenance of these machines.

During my training I acquired knowledge in different sector of mechanical engineering such

as cutting using a grinder, welding and assembly of different machines.

This report has deeply explained about winding and maintenance of an electrical motor as
well as how it functions.

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 DECLARATIONS
I hereby declare that this report has been prepared by me to fulfil the curricular requirement
of Higher diploma of mechanical engineering offered by National Institute of Transport under
department of Transport Engineering Technology.

Student Name: JAPHET PAUL.

Registered number: NIT/BMEL/2021/1404.

Signature…………………………………………………………

Date………………………………………………………………

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 CERTIFICATION
This certify that she has read and hereby recommend for acceptance the industrial practical
training report in the fulfilment of the requirement for the bachelor degree in mechanical
engineering at National Institute Of transport.

Supervisors Name: GERWALDA MOSHI

Signature…………………………………….

Date……………………………………………

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 ACKNOWLEDGEMENT
I would like to express my sincere gratitude to the following individuals and organizations for
their valuable contribution in preparing this technical report

Great tanks to my almighty god who provided me with strength, health and reinforce my
undertaking capability to undertake this project

Secondly, I would like to thank my parents who provided me with money for food and
transport fee, they also supported me with good advice

Thirdly I thank my industrial supervisor madam GERWALDA and my technician at poly

machinery company limited Mr. MAMBO who guided me in doing different tasks and helped
me with solution to numerous question

I am also grateful to poly machinery company limited for having materials and equipment
that where necessary during my training

Final thanks to fellow students and friends who gave some advice in preparing tis technical
report.

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 LIST OF ABBRAVIATION
AC alternating current

DC direct current

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 TABLE OF CONTENTS
ABSTRACT................................................................................................................................i
DECLARATIONS.....................................................................................................................ii
CERTIFICATION....................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................iv
LIST OF ABBRAVIATION......................................................................................................v
CHAPTER ONE.......................................................................................................................1
1.0 INTRODUCTION................................................................................................................1
1.1 HISTORICAL BACKGROUND.........................................................................................1
1.2 ORGANIZATION FUNCTION..........................................................................................1
1.3 ORGANIZATION CHART.................................................................................................2
1.4 ORGANIZATION MISSION, VISION AND OBJECTIVES............................................3
1.4.1 VISION.........................................................................................................................3
1.4.2 MISSION......................................................................................................................3
1.4.3 OBJECTIVES...............................................................................................................3
CHAPTER TWO.....................................................................................................................4
2.0 ELECTRIC MOTOR...........................................................................................................4
2.1 WINDING OF THREE PHASE AC INDUCTION MOTOR.............................................5
2.1.1 SINGLE LAYER WINDING.......................................................................................6
2.1.2 DOUBLE LAYER WINDING.....................................................................................8
2.1.3 STEPS FOR REWINDING..........................................................................................9
2.2 OBJECTIVE OF MOTOR REWINDING...........................................................................9
2.3 PROBLEM FORMULATION...........................................................................................10
2.4 ANALYSIS........................................................................................................................10
CHAPTER THREE...............................................................................................................11
3.0 CONCLUSION AND RECOMANDITION......................................................................11
3.1. CONCLUSION.................................................................................................................11
3.2. RECOMANDITION.........................................................................................................11
REFERENCES.......................................................................................................................12

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 LIST OF FIGURES
Figure 1: Organization structure...............................................................................................2
Figure 2:Parts of an electric motor............................................................................................4
Figure 3: Single layer winding..................................................................................................7
Figure 4: Double Layer Winding..............................................................................................8
Figure 5: Design flow chart for motor rewinding...................................................................10

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 CHAPTER ONE

1.0 INTRODUCTION
P0LY MACHINERY deals with agricultural and construction machines production and
maintenance of those machines. During earlier times POLY MACHINERY CO., LTD was
implementing its first corporate plans contributing much to its capacity strength, confidence,
building of its customers, and public at large. It has identified and collected information on
useful technology, facilitate technology transfer and adaptation provided technical back up
support to development of enterprises. The organization has tried to develop its knowledge
base so as to enable it to provide enterprises well informed provisional services.

1.1 HISTORICAL BACKGROUND

The mandate of POLY MACHINERY was started on AUGUST of 2011 to perform the
following function, firstly to enhance technology development transfer and promote technical
services, also to improve training and level of technology that are specialized in construction
and agricultural activities.

P0LY MACHINERY deals with agricultural and construction machines production and
maintenance of those machines. During earlier times POLY MACHINERY CO., LTD was
implementing its first corporate plans contributing much to its capacity strength, confidence,
building of its customers, and public at large.

It has identified and collected information on useful technology, facilitate technology transfer
and adaptation provided technical back up support to development of enterprises. The
organization has tried to develop its knowledge base so as to enable it to provide enterprises
well informed provisional services.

1.2 ORGANIZATION FUNCTION

i. services to promote the development of an agricultural industries in Tanzania
ii. To provide high quality services and support to customer
iii. To carry out market research in good manufactured by the company in Tanzania and
East Africa as whole.
iv. To provide necessary for his /her machine when repairmen are needed
v. To open the poly machinery branches in order to ensure easy availability of services.

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1.3 ORGANIZATION CHART

Figure 1: Organization structure

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1.4 ORGANIZATION MISSION, VISION AND OBJECTIVES

1.4.1 VISION

To create promote and sustain innovative entrepreneur base by providing SMEs with
capacity, development services to enhance their contribution in industrial development

1.4.2 MISSION

A leading institution in promotion of small manufacturing industries for sustainable

industrialization

1.4.3 OBJECTIVES

i. To enhance technology development

ii. To improve training, consultancy and extension services

iii. To improve and expand financial advisory

iv. To enhance capacity building of the organization

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 CHAPTER TWO

2.0 ELECTRIC MOTOR

A motor is defined as a device or machine that convert electrical energy into rotational
mechanical energy. It converts electrical energy into kinetic energy through
electromagnetism. Most motors operate through the interaction between magnetic field of a
motor and the electric current in the wire winding to generate force in form of torque applied
on the on the motor’s shaft.

Electric motor can be powered by direct current (DC) sources such as batteries or by
alternating current (ac) such as power grid, invertors or electrical generator. Electric motors
may be classified according to different consideration s such as power source type,
application, construction and type of motion output. They can be brushed or brushless, single
phase, two phase, or three phase, axial or radial flux and may also be air cooled liquid cooled
motor.

Parts of an electric motor

A basic electric motor consists of two main parts which are rotor and stator

A rotor is a rotating part of the motor and holds the shaft of the motor. Its rotation is due to
interaction between the winding and magnetic fields which produces torque around the axis
of the rotor. It does the main work of the motor and rotates inside the stationary part of the
motors

Stator is a stationary part of a motor, it consists of laminated core and coils of insulated wire
known as winding, when an alternating current is applied to a stator it creates a rotating
magnetic field.in different configurations stator may act as field magnets that interacts with
the rotor to create motions or as armature that works with moving field coils in the rotor.
They are generally permanent magnets or electromagnets that maintain field alignment.

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 Figure 2:Parts of an electric motor

2.1 WINDING OF THREE PHASE AC INDUCTION MOTOR

Windings are wires that are placed within coils generally enclosed around a coated flexible
magnetic core to change magnetic poles while strengthened with the current. Electric
machines are available in two fundamental magnet field pole configurations namely salient
pole and non-salient pole

In the salient pole configuration machine, the magnetic field pole can be generated or
produced with a winding wound approximately under the pole face. In non-salient pole
configuration, the winding can be dispersed within slots of pole face. A shaded pole motor
includes a winding which is placed around the pole part that holds up a magnetic phase.
Some kind of motors include conductors with thicker metal like sheets of metal otherwise
bars generally copper

The slots on stator core of three phase motor winding carries stator winding. Stator winding is
the motor winding in three phase that that is connected in star or delta form based on the type
of starting method used

The motor like a squired cage can be frequently on track by the star to delta stator and thus
the stator of the motor can be connected in delta. The slip ring three phase induction motor is
in progress by including resistances, thus the three phase induction motor stator winding can
be associated in star otherwise delta form. Whenever the stator winding is energized by three
phase ac supply then it generates a rotating magnetic field

Electric motor rewinding involves three main steps first removal or stripping of old windings,
secondly, inserting and properly connecting the new windings and insulating the complete
winding

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The process begins by gathering winding data since most motors have significant differences
in their winding even if they have the same horse power, speed and voltage. These data
include the number of slots, wire size, number of coils, number of turns per critical
dimension, bracing and insulating parameters. After all the information have been gathered
the existing motor winding are stripped out of the motor core, then what follows is the actual
making of the coils. Key parameters of this process include layering, wire tension and
keeping count number of turns in the coil. Once the coils are made, they are inserted in stator
slots and then connected. When inserting coils the process varies whether you are working on
a random wound winding or a form wound winding but it is the same basic process of
inserting coils and insulating into the core of the motor. Then the coils must be connected
together to form the complete winding. Blocking and bracing is an important point to note in
this process and if the winding is not properly braced, the mechanical movement can cause
winding failure

Multiple tests are run during the entire winding process to ensure the integrity and quality of
the coil windings. These tests re performed in accordance to IEEE and EASA standards.
After the rewinding process is complete the insulation process follows

Behind providing electrical insulation the varnish used also keeps the coils from moving,
bonds the multiple coils together and protects the windings from contamination. One of the
two approach can be used for applying the insulation to the newly wound coil. The more
traditional varnish dip and bake or the technologically advanced vacuum pressure
impregnation process for larger or higher voltage electric motors. In doing all processes
associated with motor rewinding, the operator must be very carefully to avoid all kind of
error that may arise during the process.

Based on arrangement there are basically two types of stator winding in three phase induction
motor these are

I. Single layer winding

II. Double layer winding

2.1.1 SINGLE LAYER WINDING

In this type of winding arrangement one coil side of coil occupies the whole of slot. They are
not used for machines having commutators and allow the use of semi closed and closed type
of slots

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In single layer winding the coils are arranged in groups, each group has its overhang closing
the overhang of adjacent groups, this is possible only by having individual coil groups of
different shape and size, this means that single layer winding requires a variety of sets of
coils with each shape differing in both size and shape from other sets

In this arrangement coil occupies slot completely without any other coil lying on top of it and
the number of coils equals half the number of slots. Concentric or chain winding type are
common and short pitched coils cannot be used in this winding. The laying of concentrated
winding depends on the number of slots per pole per phase and coil span

Useful parameters

Z= number of stator slots

2p= number of poles

Q= number of slots per pole per phase

M= number of phases

Y= coil span

Concentric winding

in this winding the first of the q coils which is the smallest is thrown to q th slot having coil
span y=(τ-q+1) and the second coil which is larger than the first coil will be thrown from
second slot to its coil span, y=(τ-q+2). And if q=3 the third coil which is the largest coil will
be thrown from first slot having its coil span y=(τ-q+3)

for instance, when z=24 and 2p=4 the single layer winding diagram will be as shown in the
figure. in this case

24 24
q= =2 and τ = =6
4∗3 4

The inner coil from second slot having coil span y= (6-2+1) =5 to the 7 th slot. The outer coil
which is larger than the inner coil is thrown from first slot having coil span y = (6-2+2) =6 to
the 8th slot.

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The other coils are arranged in the same manner. There are 12 coils and two coil groups per
each phase. The winding diagram is similar to unsulfurated concentric winding with two
plane overhangs.

Figure 3: Single layer winding

2.1.2 DOUBLE LAYER WINDING

In double layer winding two coil sides are placed on single slot. The double layer winding is
the most used class of windings, though both wave and lap types are possible and because of
inherent problems of wave windings, it is now an accepted practice to use lap winding for
double layer AC winding

in double layer winding all coil are of the same shape and size, each coil has its own coil side
in top half of one slot and the other coil side on the bottom half of the other slot. The problem
of overhang does not exist in double layer winding as in case of single layer. Each coil is
occupied by the side of two coils and allowed to form two-layer stator

unlike concentric winding double layer winding consist of identical coils all of the same
shape and pitch and a coil pitch may be full or fractional but majority stator winding use
fractional because the amount of copper used in the overhang is reduced and hence savings of
copper also the magnitude of certain harmonics in Emf is reduced

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 Figure 4: Double Layer Winding

2.1.3 STEPS FOR REWINDING

i. Disassemble the motor: parts of the motor such as the rotor and the stator are
separated from each other and each part is inspected for the damage. Disassembling of
a motor helps prevent damages and ensure that the original winding and connections
are followed
ii. Removal of old winding: the old or damaged windings are carefully removed from the
stator and then several areas of the motor are cleaned including left over resin, vanish
and insulation. The sharp knife or wire cutter are typically used to cut the winding
wires starting from terminals and work around. The process must be done very careful
to any damage in the stator lamination also insulating material such as varnish or tape
must be removed from the coil. Once cut the winding are pulled out from the slots and
the stator slots and surfaces are cleaned
iii. Design and prepare the winding: under this section the motor winding data are
gathered, this may involve heating the VPI stator winding of a motor in the burnout
oven to burn away varnish. This section also includes deciding what methods will be
used for winding process, either double layer or single layer winding depending on
the availability of material and type of a motor

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 iv. Inserting new winding: new winding is inserted in coils taking care to avoid nicks or
cuts on the coil insulation and defines the connection for the group of coils
v. Test the motor: test the motor to ensure it is working properly

2.2 OBJECTIVE OF MOTOR REWINDING

The following are the of motor rewinding

i. To ensure the motor continue to perform efficiently and prolongs is service life by
replacing worm or damaged winding s
ii. To restore or enhance the motors operational performances including torque and
speed characteristics
iii. To reduce over heat risky by using better insulation material and technique
iv. To improve the reliability and lifespan of the motor through high quality rewinding
practices
v. To reduce or minimize operational noise caused by poorly or damaged wound stator
coils
vi. To facilitate testing and diagnostic to identify underlying issue and ensure proper
functionality cost repair

2.3 PROBLEM FORMULATION

There can be a wide variety of issues behind motor failure that may necessitate rewinding.
These issues include

i. Insulation failure and grounded shorted coil: Insulation failure can take several
different forms including winding that have shorted turn to turn, phase to phase, coil
to coil or grounding at the edge of the slot. These particular issues can usually be
traced back to contamination, abrasion, voltage surges, overall age of the machine or
vibration.
ii. Thermal deterioration: this is another common source of motor insulation failure,
basically it is caused when the insulation overheats due to poor connection n the
motor terminal, a locked rotor resulting in high current in the stator excessive load
demand that exceed the ratings of the motor or excessive reversal and starts.

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2.4 ANALYSIS
When compared to motor replacement, motor rewinding is less efficient, higher chances to
wear and tear and the lifespan is low. However, motor rewinding may be cost effective
compared to motor replacement.

2.5 DESIGN

Figure 5: Design flow chart for motor rewinding

CHAPTER THREE

3.0 CONCLUSION AND RECOMANDITION

3.1. CONCLUSION.
This industrial practical training report discusses briefly explanation of stator rewinding of
three phase induction motor by stating general steps which are to be followed for the safety
rewinding process it also explains some basic parts of a motor and types of rewinding process
such as double layer and single layer winding. the rewinding process is essential for
improving the functionality of a motor and it may be used instead of motor replacement
which in turn reduces the cost. The operator must be very careful so that unnecessary
damages do not occur during the rewinding process

3.2. RECOMANDITION
I thoroughly enjoyed doing my industrial practical training at poly machinery company
limited, and I gained much knowledge during the whole period of training. Poly machinery is

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a honest institution with skilled trainers who helped me and other students to learn and
understand different matters associated with train industry.

REFERENCES
Bimhhra, p.s (2000) “electrical machinery theory performance and applications” Khanna
publishers

Theraja b.l. & theraja A.K. (1996) “a text book of electrical technology” Khanna publishers

Industrial practical training diary

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