Cost effective repairing unit

to monitor efficient working of

Electric fans in college

Under the Guidance of Asst. Prof. Ms. Shilpi
















Report by : Group 10
Jibin Job
Midhun Viswanath
Muhammad Mijas
Muhammad Zeeshan


CONTENTS

1)Introduction
1.1)working principle of ceiling fan
2)Construction
2.1)Capacitor
2.2)Bearing
2.3)Windings
Starting winding
Running winding
3)Types of faults(daigonosis and corrections)
3.1)capacitor faults
3.2)winding faults
3.3)bearing faults
4)Ceiling fan winding machine
4.1)Automatic ceiling fan winding machine
4.2)Manual ceiling fan winding machine
4.3)Procedure for winding
5)Cost estimation


1)INTRODUCTION
1.1)working principle of ceiling fan


The ceiling fan motor works on principle of single phase induction
motor using capacitor.
Working of capacitor start motor: The stator consists of the main
winding and a starting winding (auxiliary). The starting winding is
connected in parallel with the main winding and is placed physically
at right angles to it. A 90-degree electrical phase difference between
the two windings is obtained by connecting the auxiliary winding in
series with a capacitor and centrifugal switch. When the motor is first
energized, the centrifugal switch is closed. This places the capacitor
in series with the auxiliary winding. The capacitor is of such value that
the auxiliary circuit is effectively a resistive-capacitive circuit (referred
to as capacitive reactance and expressed as X
C
). In this circuit the
current leads the line voltage by about 45 (because X
C
about equals
R). The main winding has enough resistance-inductance (referred to
as inductive reactance and expressed as X
L
) to cause the current to
lag the line voltage by about 45 (because X
L
about equals R). The
currents in each winding are therefore 90 out of phase - so are the
magnetic fields that are generated. The effect is that the two
windings act like a two-phase stator and produce the rotating field
required to start the motor. When nearly full speed is obtained, a
centrifugal switch cuts out the starting winding. The motor then runs
as a plain single-phase induction motor.



2)CONSTRUCTION
2.1)capacitor

In a ceiling fan there is an single phase induction motor.
Single phase stator produces a non rotating, pulsating magnetic
field.The single coil excited by a single phase current produces
two counter rotating magnetic field phases, coinciding twice per
revolution at 0 degrees and 180 degrees. When the phases
rotate to 90 degree and -90 degree they cancel. At 45 deg and -
45 deg they are partially additive along the +x axis and cancel
along the y axis. The sum of these two phases is a phasor
stationary in space, but alternating polarity in time.

The two windings are wound with a geometric offset, effectively
making a second set of poles phase shifted within the stator.
The capacitor provides a phase shift to the current flowing in
W1 and we therefore have a "two phase" motor while the switch
is closed. When the motor is almost up to speed, the switch
opens disconnecting W1 and the capacitor. The motor can be
reversed by reversing the connections of either W1 or W2 (but
not both).
The fan capacitor produces a rotating magnetic field. This magnetic
field makes the motor turn. If the capacitor is not working correctly,
your motor will not function properly. If your motor is not working
properly, you may hear a humming sound.
The lower the capacitor rating you go the higher the chance the fan
motor will not start (not enough capacitance).
The higher the capacitor rating is, the motor will draw more amps
when running. The motor could overheat and shut down on thermal
overload.

2.2)Bearing






2.3)Windings
The stator consists of the main winding and a starting winding
(auxiliary). The starting winding is connected in parallel with the main
winding and is placed physically at right angles to it. A
90-degree electrical phase difference between the two windings is
obtained by connecting the auxiliary winding in series with a
capacitor and centrifugal switch. When the motor is first energized,
the centrifugal switch is closed. This places the capacitor in series
with the auxiliary winding. The capacitor is of such value that the
auxiliary circuit is effectively a resistive-capacitive circuit (referred to
as capacitive reactance and expressed as X
C
). In this circuit the
current leads the line voltage by about 45 (because X
C
about equals
R). The main winding has enough resistance-inductance (referred to
as inductive reactance and expressed as X
L
) to cause the current to
lag the line voltage by about 45 (because X
L
about equals R). The
currents in each winding are therefore 90 out of phase - so are the
magnetic fields that are generated. The effect is that the two
windings act like a two-phase stator and produce the rotating field
required to start the motor. When nearly full speed is obtained, a
centrifugal switch cuts out the starting winding. The motor then runs
as a plain single-phase induction motor.



3)TYPES OF FAULTS

3.1)Capacitor faults:
In order for an electric fan to work correctly, the ceiling
fan capacitor must be fully functional. A ceiling fan
capacitor has two important roles: to create a magnetic
field when the fan is first turned on, and to change the
direction of the fan, when the unit is switched into reverse.
Not all fans have reverse direction, but this is a particularly
useful feature during the cold weather season, to
circulate warm air downward and lower overall heating
costs.
If the fan capacitor is not working correctly, then the fan
may exhibit the following problems:
The fan wont spin on its own. Notice whether a humming
sound can be heard when the fan is switched on, or
whether you need to help it along for it to start spinning.
In this case, a ceiling fan would either not turn, or would
spin extremely slowly (regardless of the speed setting
selected).
Use your senses: if you smell a burning odor, or you see a
burned or melted black box, this could mean a problem
with the ceiling fan capacitor.
These are obvious signs of a bad ceiling fan capacitor.
Often, the ceiling fan capacitor itself would appear to be
bulging or malformed. Examine the ceiling fan capacitor
for evidence of bulging, burns, or cracks? If the answer is
yes, then one of the capacitors has blown. Capacitors
tend to get really hot before shorting out, which results in
the melting and scorching.. If you have a fan with multiple
capacitors, a single ceiling fan capacitor may blow out,
while the others may remain in good working order.
3.2)winding fault:
winding fault mainly occurs due to voltage fluctuations in
the supply.It can be detected by means of series bulb
test.winding fault can be visually diagonised by burned
out windings or broken winding.

3.3)Bearing fault:
Bearing faults occurs due to wear and tear in the
bearing.It will cause the rotor to come in contact with the
stator and get locked.if there is bearing fault,then there
will be a ahumming sound and also there are chances
that the fan doesnt run at all.















4)CEILING FAN WINDING MACHINE
There are two types of winding machines:
Automatic ceiling fan winding machine.
Manual ceiling fan winding machine.



4.1)Automatic ceiling fan winding machine

Acknowledged for its durability, high reliability, least maintenance
and reduced break down time, Automatic Ceiling Fan Stator Winding
Machine can accommodate and work with different type of stator.
Manufactured using superior quality raw material and hi-tech
machines, these are suitable for repair shop. Available in various
specifications and custom designs, the range is offered at cost
effective prices.
Specifications:
Wire Size: 0.1mm to 1.2 mm
Stator Diameter: 35mm to 180mm
Stator Thickness: 08mm to 36mm
Max. Speed: 4500 rpm
power: 220volt (50 hz) main motor
Production Capacity: 85 stators/ hour






4.2)Manual ceiling fan winding machine


This machine is ideally suited for repair shops. Different type of
stator can be accommodated. Hence making it highly reliable and
maintenance free hence reducing break down time.
Specifications:
Stack Height : 2"- 6" approx
Wire Diameter : 26 Swg to 38 Swg
Winding Speed : 960/1440 RPM
Winding Direction : Clock wise and Anti Clock wise.












4.3)Winding steps

First of all you would find the no of turns in the coil by counting
one by one.
Then you would make coils according to the no of turns.
Insulate the stator holes with a paper to avoid the contact of coil
with the stator.
Now place the coils one by one on the stator
The process of placing coils is done for both starting and
running winding.




After the completion of placing coils you would give connection
of coils in both windings.
In last you would leave four wires, two of them are connected
with each other which is known as common.
The starting winding is now connected with capacitor and the
running winding is directly connected with main supply.
Then the capacitor is connected with main supply.
After the connections the fan is closed and is connected with the
main supply.
If the fan is moving in anticlockwise direction, then its
connections are reversed.












5)COST ESTIMATION


Cost of repairing 1 fan : Rs 100
Winding Copper : Rs. 50 (250g)
Capacitor : Rs. 35
Milnex paper, sleeve, : Rs. 15
hook up wire, tie, varnish

Cost of repairing faulty fans in college : Rs 18,000

Number of faulty fans in college : 66
Cost of Materials : Rs. 6000
Cost of Machine : Rs. 12000

Current cost of repairing : Rs 23,000
Average cost per fan : Rs. 350













REFERENCE

Theory of Electrical Machines P.S. Bimbhra
Electrical Technology B.L. Theraja
WikiHow www.wikihow.com
Red Beacon A manual on repairing ceiling fan
Other electrical enthusiasts online forum