Bharat Heavy Electricals Limited

Bhopal

Vocational Training Report 2011 on

TRACTION MOTORS(TXM)

Submitted By:
VIBHASH KUMAR DWIVEDI BHEL Token No. VT-207 National Institute of Technology, Patna Duration: 23-05-2011 to 12-06-2011 (3 weeks)

Acknowledgement
I am very much thankful to Bharat Heavy Electricals Limited (BHEL), Bhopal for providing me such a great opportunity of undergoing vocational training in Traction Motor (TXM) Engineering.

Further, I am also thankful to Traction Motor Engineering team for giving me valuable

knowledge of the department and helping me to understand the engineering processes.

Dated: DWIVEDI Place : Bhopal NIT, Patna

VIBHASH KUMAR

Signature and seal of Training Co-ordinator:

BHEL PROFILE
BHEL is the largest engineering and manufacturing enterprise in India in the energy related sector today. BHEL has built over the years, a robust domestic market

position by becoming the largest supplier of power plant equipment in India and by developing a strong market presence in select segments of the industries sector and the railways. BHEL caters to core sectors of the Indian economy, Power generation and Transmission, industry,

transportation, renewable energy, defense, etc. A wide network of BHELs 15 manufacturing divisions, 4 power sector regional centres, 15 regional offices, 8 service centres, 4 overseas offices, one subsidiary and a large number of project sites spread all over the India and abroad enables the company to promptly serve its customers and provide them with suitable products systems and services efficiently and at competitive prices. The company has foot prints in more than 70 countries around the world.

BHEL become the first public sector company in the country to win the coveted prize through its Haridwar unit under the CIIEXIM Bank Award for business excellence.

TRACTION MOTOR MANUFACTURING

1. Machine Shop: In this shop, machining at various parts of

magnetic frame is done. Initially the centering of machine is done, which becomes the reference for the further operations. The assembly of other items is done with the center marked here. Centering of the frame is done by applying register-cut in the frame. Initially frame is mounted on vertical boring machine at commutator end and a register-cut is applied at pole mounting pad. The center of PE/CE and center of

lug hole is taken as reference for all round machining of the frame and for final boring. The machining process of the frame is serially given below: Pinion end boring and facing on vertical boring machine. Commutator end boring and facing on vertical boring machine. Drilling Tapping All round machining on CNC Final boring of CE and PE. Welding of brush gear pad. Joint hole drilling. After the machining is completed, the frame is sent to assembly section.

2. Commutator and Core Area : The Commutator core

assembly and machining of brush holder is done here.

Brush Holder Finishing:

Finishing of brush holder involves several operations as follows:-

 Machining top and bottom surface are machined to make them parallel. Slotting coarse cutting of brush slot is done. Broaching final finishing of brush slot is done. Drilling holes in brush holder are drilled and tapped. Deburring all sharp edge are smoothened.

Commutator Building :
Sequences of Commutator assembly are as follows: Flattering of Commutator segment manually the Commutator surfaces are made parallel by milleting. Slitting milling operation is done to make slit in the riser of Commutator segment for housing the leads of armature winding. This step also enables the worker to easily recognize the placement of equalizer coil and armature coil while assembling the coils. Deburring all the sharp edges are cleaned and debarred. Commutator building alternate layers of Commutator segments and mica segment are arranged manually and then set. Static seasoning this involves the heating of commutator in oven in four cycle. Four cycle includes

three hot cycle and one cooling cycle. Each hot cycle includes continuous heating of Commutator at 150 degree C for eight hours and then tightening of screws in hot condition .After that the Commutator is allowed to cool down at room temperature and finally tightening is done in cold condition. Vee Turning a V-shape profile is made at both ends of Commutator so as to match the seating of steel hub at riser end and steel vee ring at another end. CNC machine is used for this. After the steel V-ring and hub are assembled on both sides of commutator and clamped. Mica V-ring and mica bush is inserted in between. Static seasoning Static balancing Dynamic balancing Commutator testing - Bar to Bar test - Flash test Pressuring of punching and shaft Dynamic balancing Alignment of Commutator w.r.t slot in armature is checked and starting point marked.

3. Winding Section:
The sequences of process followed in winding section are given below: Bar to bar test (500 V) and HV test (at 5.5 KV) to check the soundness of Commutator received from Commutator and core area. Equalizer winding (in case of lap winding) Bar to bar test to check the insulation between adjacent conductors of equalizer coil. Resiglass tape and glass mica application at CE and PE side respectively. Main winding nomex liner is used in straight portion and in over hang portion glass mica cloth is used. HV test at 5.5 KV Baking in oven for 6 hrs at 150 degree C. Temporary banding tinned steel sheet is used at 150 kgf pressure. HV test at 5KV. First turning riser facing and Commutator dia. Turning. Impulse test at 400V/turn. Tig welding.

 Baking in oven at 165` C for 6 hrs. Permanent banding resin treated glass tape is used at overhang position. Banking in oven 165`C for 6 hrs used for curing, also acts as pre heating of coil before VPI. HV test at 4.5KV and Impulse test (250V/turn) in hot condition. Vacuum pressure impregnation(VPI)-the cycle vary machine to machine, in general steps are follows: 1. Vacuum of 10-20mm Hg is created for 15min. 2. Resin is transferred to vessel. 3. Vacuum of 40mm Hg is created for 10min (to remove the air trapped in resin). 4. Insertion of nitrogen/Dry Air at 5bar for 30min. 5. Resin is transferred back to the storage tank. 6. Resin is again transferred to vessel. 7. Step 4 is repeated. Cleaning Curing of varnish in oven at 195`C for 10-15 hrs. maintained and ovality of Commutator is removed. Final turning-final finishing of Commutator. Mica under cutting. Second turning-inner bearing wiper distances are

 Cleaning and PTFE bush fitting. Final testing-HV Test(at 4.5KV) and impulse test(at 250V/turn). 4. Assembly Section: Assembly of Brush holder and complete machine takes place in this section. The machined magnet frame from machine shop and field coils mounted at poles from CIM are received and assembled here. Then after the pole mounting, the armature is vertically inserted in the frame with precisely maintaining the required air gap. Bearings are fitted. Pinion is mounted on shaft. Then assembled brush holders are fitted at appropriate positions. Earth return assembly and other cable connections are made. Then end shields are mounted, after the completion of assembly the machine is sent to testing area. 5. Testing area: All tests done in shop conform to IEC60349. Mainly two types of tests being performed for all machines: a) Type test: to be performed on first 1or 2 machines as per customers requirement for a new type of machine. Type test include some additional tests along with routine tests like vibration test and starting test.

b) Routine Test: to be perform on all machines. Main routine tests are: Machine winding cold resistance measurement. One hour temperature rise measurement. Characteristics test. Insulation resistance test both before and after HV test. High voltage test. Over speed test.

MANUFACTURING FACILITIES BHEL is well equipped to meet the requirements of design, development and manufacture of state-of-the art designs of the traction machines, with the facilities such as: Computer aided design and drafting systems. CNC notching line for stampings. Electroslag welding for stator magnet frames. Vacuum pressure impregnation plants for field coil and armatures.

 TIG welding equipment for armature coil to Commutator connection joints. Plant for high speed dynamic seasoning of Commutator. CNC machining center for magnet-undercutting and Commutator surface finishing equipment. Field coil forming equipment Automatic tapping machines for armature coils. Microprocessor controller induction hardening equipment for gears Gear teeth cutting, grinding and profile checking equipment CNC lathes and copy turning lathes Internal and external; grinding machines High frequency brazing equipment for traction generator Commutator riser Traction test plants with pulsating current testing facility Sophisticated quality control equipments, with 3-D measuring systems Advance test facilities for material and components.

BHELS PRODUCTS FOR TRANSPORTATION:

BHEL manufactures a wide range of rolling stocks for railway and other urban transportation applications. These include: AC locomotives AC/DC dual voltage locomotives Diesel electric main line locomotives Diesel Electric shunting locomotives Diesel Hydraulic shunting locomotives Battery powered road vehicles Diesel electric loco and DEMU of 350 HP with DC-DC drive Diesel Electric loco and DEMU of 700 and 1400 HP with DC-DC and AC-DC drive. Diesel electric loco 2400 HP with AC-DC drive. 25 KV AC freight loco of 4000 HP with AC-DC drive Dual voltage 5000 HP mixed traffic loco with thyristor control

 Dual voltage freight and passenger 5000HP electric loco.

TRACTION MOTORS:
Traction motors are the motors which are used for the propulsion of the vehicles and locomotives. These motors can either be AC or DC. DC traction motors can be series or compound excited with the axle suspension either on taper roller bearings or sleeve bearings. AC traction motors are squirrel cage induction motors with axle suspension on taper roller bearings.

DC TRACTION MOTORS:
MOTOR PRINCIPLE:
When a current carrying conductor is placed in a magnetic field, it experiences a force whose direction is given by Flemings Left hand rule.

CONSTRUCTION OF DC MOTOR:
A DC traction motor consists of the following essential parts:1. Stator 3. Field Coils 5. Armature windings 2. Pole Shoes 4. Armature Core 6. Commutator

7. Brushes and Bearings These parts of a DC traction motor can be grouped as follows: 1. Magnetic field system which includes Stator, pole shoes and Field coils. 2. Armature which includes armature core and windings. 3. Commutator and brush gear which includes Commutator brushes and bearings.

MAGNETIC FIELD SYSTEM: The Stator is the fixed part of the motor. It provides mechanical support for the poles and acts as a protecting cover of the machine. It also carries magnetic flux produced by them. The outer frame is called the yoke. Pole shoes are made up of thin laminations annealed steal riveted together. The thickness of laminations varies from 1mm to0.25mm. They support the exciting coils. The field coils consist of copper wire. When current is passed through it the flux is produced in Pole shoes.

It also increases the cross sectional area of the magnetic circuit and increases its reluctance. The field coils are connected in

series with one another such that when the current flows through the coils, alternate north and south poles are produced in the direction of rotation. ARMATURE: Armature is the rotating part of DC motor. The armature core houses the windings. It is a cylindrical drum shaped and is built up of laminations of silicon steel of approx 0.5mm thickness. The laminations are keyed to shaft. It has slots for windings. Usually, the laminations are perforated for air ducts required for cooling purpose. These ventilating channels permit axial flow of air to flow through them and thus helps in cooling of the motor. The purpose of using laminations is to reduce the eddy current losses. The armature winding consists of conductors made of copper coils insulated from each other. The conductors are placed in slots of the core. The different types of windings used are: Lap winding and Wave winding. In Lap winding, the ends of each armature coil are connected to adjacent segments on the Commutator so that the total number of parallel paths is equal to the total number of poles. In wave winding, the ends of each armature coil are connected to Commutator segments some distance apart, so that only two parallel paths are

provided between the positive and negative brushes. Lap winding is used for low voltage high current machine and wave winding is used for high voltage low power machine. COMMUTATOR AND BRUSHGEAR: Commutator is a cylindrical structure built up of wedge shaped segments of hard drawn copper bars or segments insulated from each other by 0.8 mm thick mica sheets. The conductors from the armature winding are connected at riser of the Commutator. To prevent Commutator from flying out under the action of centrifugal forces, these segments have V-grooves which are insulated by conical magnetite rings and Commutator hub is fixed at the ends. Currents are fed to the armature windings by means of carbon brushes mounted on the Commutator. Brushes are housed in a metal box called brush holder attached to the stator. Brushes are generally made up of carbon and are pressed to touch the Commutator by small spring. Current from the external circuit are passed to the armature winding through the Commutator by means of carbon brushes. Other than these parts a DC traction motor consists of Interpoles and equalizer windings.

Interpoles: These are small poles fixed to the yoke and spaced between the main poles. They are wound with comparatively few heavy gauge copper turns and are connected in series with the armature so that they carry full armature current. Interpoles neutralizes the cross magnetizing effect of the armature reaction. With Interpoles sparkles commutation is obtained up to 20-30% overload with fixed brush position. Equalizer windings: Due to slight variations in air gap length or in the magnetic properties of steel, there is slight imbalance in e.m.f in various parallel paths in Lap windings which results in the greater current in the conductor under stronger poles and thus the current distribution at crushes becomes unequal which in turn results in overload of some brushes and hence results in poor commutation. To overcome this problem, equalizer windings are used at the armature back. These windings helps to avoid unequal distribution of current at brushes and thereby helps to get sparkles commutation. These windings are not used in wave windings because there is no imbalance in the emf of the two parallel paths.

TYPES OF DC MOTORS AND THEIR CHARACTRISTICS:

There are three types of DC motors:

1. Series wound or Series motorsA series motor is one in which field coils are connected in series with the armature. In a series motor, the flux is produced by the armature current flowing in the field winding. Hence the series motor is variable flux machine. The speed is inversely proportional to the armature current. When the load is small the speed will be very large. The torque-current characteristics of a DC motor is initially parabolic and finally becomes linear when the load current becomes large. 2. Shunt wound or Shunt motorA shunt motor is one in which field coils are connected in parallel to the armature. In shunt motor, the drop in speed from no load to Full load is very small and hence run at almost constant speed. This motor has low starting torque. These motors are not used for traction purposes. 3. Compound motor: Compound motors have both series shunt field windings. So, its characteristics are intermediate between series and shunt motors. A compound motor has a high starting torque together with a safe no load speed.

AC TRACTION MOTORS:
Ac traction motors are essentially squirrel cage induction motors with axle suspension on taper roller bearings. A three phase induction motor essentially consists of two parts: 1. Stator 2. Rotor The stator is built of high grade alloy steel lamination to reduce eddy current losses. The laminations are slotted on the inner periphery and are insulated from each other. The insulated stator conductors are placed in these slots. The phase winding may be either star or delta connected. The rotor is also build of the thin laminations of the same material as the stator. The laminated cylindrical core is mounted directly on the shaft. These laminations are slotted on the outer periphery to receive the rotor conductors. A cage rotor consists of a cylindrical laminated core with slots nearly parallel to the shaft axis, or skewed. Each slots contains an uninsulated bar conductor of aluminium or copper. At each

end of the rotor, the rotor bar conductors are short circuited by heavy end rings of the same material. The conductors at the end rings form a cage like structure which was once commonly used for keeping squirrels, hence it is named as squirrel cage induction motor. The skewing of cage rotor conductor offer the following advantages: 1. More uniform torque is produced and the noise is reduced during operation. 2. The locking tendency of the rotor is reduced. During locking, the rotor and stator teeth attract each other due to magnetic action.

ADVANTAGES OF THE CAGE ROTOR: 1. Robust construction and cheaper. 2. The absence of brushes reduces the risk of sparking. 3. Lesser maintenance.

4. Higher efficiency and higher power factor.

APPLICATION OF DIFFERRENT MOTORS

TRACTION MOTOR TM4601AZ RATINGS 167KW,535V,340A,1260RPM APPLICATION FOR ELECTRIC MULTIPLE UNITs (25KV AC EMUs) 280KW,325V,1000A,430RPM FOR DIESEL ELECTRIC LOCOMOTIVES (WDM2C,WDG2,WDP2) 850KW,2180V,270A,1283RPM FOR 6000HP AC LOCOMOTIVES (WAG9,WAP7) 282KW,350V,925A,4947RPM FOR DIESEL ELECTRIC LOCO (WDM2C,WDG2,WDP2, WDM3D) 297KW, 1716V, FOR AC ELECTRIC 136A,1259RPM MULTIPLE UNIT (AC-DC EMU) 425KW,1520V,220A,600RPM FOR DIESEL ELECTRIC LOCO (WDG4) 207KW,535V,425A,1170RPM FOR DIESEL ELECTRIC MULTIPLE UNIT (1400HP DMU)

TM4907AZ

IM4801AZ/HT

TM50002BZ

DMKT53/42

IM450AZ

TM4303DY

CUSTOMERS OF TRACTION MOTORS MANUFACTURED BY BHEL:

Railways:
Indian Railways, Vietnam an Railways, Malaysian Railways, Srilankan Railways, Tanzanian railways, Underground Metro Other than railways Power corporations, Steel Plants, Port trusts, Kolkata Tram Car, Battery Powered road vehicles for various customers, Oil India Limited , Oil and Natural Gas Commission (ONGC) etc are the major customers of traction motors produced by BHEL. BHEL serves following sectors: Railways: 1. Diesel Electric Locomotives 2. Electric Locomotives 3. EMUs Urban Transportation: 1. ETB 3. BPRV 5. Mono Rail 2. Metro 4. Tram 6. Sky Bus

TRACTION MOTOR

STATOR OF AC TRACTION MOTOR

HOW MOTOR DRIVES AXLE

LAP WINDING

WAVE WINDING

COMMUTATOR

DIFFERENT PARTS OF A TRACTION MOTOR