Detailed Project Report (DPR) on Induction Motors (Single and Three Phase) (Capacity: 100 Numbers per Day)

INDUCTION MOTORS (SINGLE AND THREE PHASE) 

[EIRI/EDPR/4652] J.C. 2869XL

INTRODUCTION

One of the most common electrical motor used in most applications is known as Induction motor. This motor is also called as asynchronous motor because it runs at a speed less than synchronous speed. Synchronous speed is the speed of rotation of the magnetic field in a rotary machine and it depends upon the frequency and number poles of the machine. An induction motor always runs at a speed less than synchronous speed because the rotating magnetic field which is produced in the stator will generate flux in the rotor which will make the rotor to rotate, but due to the lagging of flux current in the rotor with flux current in the stator, the rotor will never reach to its rotating magnetic field speed i.e. the synchronous speed. There are basically two types of induction motor that depend upon the input supply. They are:

1. Single phase induction motor and

2. Three phase induction motor

Single phase induction motor is not a self-starting motor and three phase induction motor is a self-starting motor. In general we need to give two supply i.e. double excitation to make a machine to rotate. For example if we consider a DC motor, we will give one supply to the stator and another to the rotor through brush arrangement.

Working Principle of Induction Motor

In induction motor we give only one supply, so it is really interesting to know that how it works. It is very simple, from the name itself we can understand that there is induction process occurred. Actually when we are giving the supply to the stator winding, flux will generate in the coil due to flow of current in the coil. Now the rotor winding is arranged in such a way that it becomes short circuited in the rotor itself. The flux from the stator will cut the coil in the rotor and since the rotor coils are short circuited, according to Faraday’s law of electromagnetic induction, current will start flowing in the coil of the rotor. When the current will flow, another flux will get generated in the rotor. Now there will be two fluxes, one is stator flux and another is rotor flux and the rotor flux will be lagging to the stator flux. Due to this, the rotor will feel a torque which will make the rotor to rotate in the direction of rotating magnetic flux. So the speed of the rotor will be depending upon the ac supply and the speed can be controlled by varying the input supply. This is the working principle of an induction motor of either type.

COST ESTIMATION

Plant Capacity            100 Nos/Day  

Land & Building (2000 sq.mt.)    Rs. 95.55 Lac    

Plant & Machinery                    Rs. 1.89 Cr 

Working Capital for 2 Months    Rs. 2.90 Cr 

Total Capital Investment          Rs. 6.06 Cr 

Rate of Return                          20%

Break Even Point                      67%

CONTENTS

INTRODUCTION

INDUCTION MOTOR

WORKING PRINCIPLE OF INDUCTION MOTOR

TYPES OF INDUCTION MOTOR

SINGLE PHASE INDUCTION MOTOR:

SINGLE PHASE INDUCTION MOTOR WAS CLASSIFIED INTO FOUR TYPES

THREE PHASE INDUCTION MOTOR:

THREE PHASE INDUCTION MOTOR WAS CLASSIFIED INTO TWO TYPES

THREE PHASE INDUCTION MOTOR

THREE PHASE INDUCTION MOTOR

STATOR:

ROTOR:

WORKING OF THREE PHASE INDUCTION MOTOR PRODUCTION OF ROTATING

MAGNETIC FIELD:

SECRETS BEHIND THE ROTATION:

THUS THE THREE PHASE INDUCTION MOTOR IS:

CONSTRUCTION OF THREE PHASE IM

THE OTHER PARTS, WHICH ARE REQUIRED TO COMPLETE THE INDUCTION MOTOR, ARE:

STATOR OF THREE PHASE INDUCTION MOTOR

THE STATOR OF THE THREE PHASE INDUCTION MOTOR CONSISTS OF THREE MAIN PARTS:

1. STATOR FRAME:

2. STATOR CORE:

3. STATOR WINDING OR FIELD WINDING:

TYPES OF THREE PHASE INDUCTION MOTOR

1. SQUIRREL CAGE THREE PHASE INDUCTION MOTOR:

ADVANTAGES OF SQUIRREL CAGE INDUCTION ROTOR

APPLICATIONS:

SLIP RING OR WOUND THREE PHASE INDUCTION MOTOR:

ADVANTAGES OF SLIP RING INDUCTION MOTOR

APPLICATION:

DIFFERENCE BETWEEN SLIP RING AND SQUIRREL CAGE INDUCTION MOTOR

EFFICIENCY OF THREE PHASE INDUCTION MOTOR

SINGLE PHASE INDUCTION MOTOR

THE SINGLE PHASE AC MOTORS ARE FURTHER CLASSIFIED AS:

CONSTRUCTION OF SINGLE PHASE INDUCTION MOTOR

STATOR:

ROTOR:

STATOR OF SINGLE PHASE INDUCTION MOTOR

ROTOR OF SINGLE PHASE INDUCTION MOTOR

WORKING PRINCIPLE OF SINGLE PHASE INDUCTION MOTOR

WHY SINGLE PHASE INDUCTION MOTOR IS NOT SELF STARTING?

HSN CODE

USES AND APPLICATION

FIELD OF APPLICATIONS

B.I.S./BRITISH STANDARD

GOVERNING INDIAN SPECIFICATION/STANDARD:

GOVERNING INTERNATIONAL STANDARDS:

BRITISH STANDARDS

DETAILS OF THE PRODUCT LICENSES TO OBTAINED:

COVERING RAW MATERIAL STANDARDS INDIAN/INTERNATIONAL STANDARDS:

MARKET SURVEY

IMPORT (RS LAKHS) OF A.C. SQUIRREL CAGE INDUCTION MOTORS 3 PHASE TYPE

TOP 10 IMPORT (RS LAKHS) SOURCES OF A.C. SQUIRREL CAGE INDUCTION MOTORS 3 PHASE TYPEDURING 2019-20

DATA ON EXPORTS FOR LAST THREE YEARS

EXPORT (RS LAKHS) OF A.C. SQUIRREL CAGE INDUCTION MOTORS 3 PHASE TYPE

TOP 10 EXPORTS (RS LAKHS) DESTINATION OF A.C. SQUIRREL CAGE INDUCTION MOTORS 3 PHASE TYPE DURING 2019-20

DEMAND IN THE DOMESTIC MARKET

DEMAND IN EXPORT MARKET

TOP 10 EXPORTERS OF ELECTRIC MOTORS; AC MOTORS, MULTI-PHASE, IN THE WORLD IN YEAR 2019 BY VALUE (USD MLN)

TOP 10 IMPORTERS OF ELECTRIC MOTORS; AC MOTORS, MULTI-PHASE, IN THE WORLD IN YEAR 2019 BY VALUE (USD MLN)

THE TECHNOLOGY EXISTING FOR THE MANUFACTURING OF THE PRODUCT & SUGGESTED MODERN TECHNOLOGY FOR IMPLEMENTATION IN THE MARKET:

THE IE EFFICIENCY CLASSES DEFINED AS:

IN MODERN DAY THE MAJOR CHALLENGE IN DESIGNING THE ROTATING MACHINE ARE:

ENERGY EFFICIENT MOTORS:

SQUIRREL CAGE ROTOR DESIGN AND TECHNOLOGY:

THE SQUIRREL CAGE ROTORS ARE MANUFACTURED BY TWO WAYS:

COPPER DIE CAST ROTOR (DCR) TECHNOLOGY:

BENEFITS OF DIE CAST ROTOR TECHNOLOGY:

DIE CAST COPPER ROTORS CAN PROVIDE ADVANTAGES IN THREE WAYS:

MAJOR COMPANIES

PROCESS FLOW CHART

FLOW PROCESS CHART OF THE MANUFACTURING:

THE STEPS INVOLVED IN THE MANUFACTURE OF ELECTRIC MOTOR ARE AS FOLLOWS:

(A) STATOR ASSEMBLY

(B) ROTOR ASSEMBLY

(C) MACHINING OF OTHER PARTS

(D) FINAL ASSEMBLY

(E) TESTING

(F) PAINTING AND PACKING

RAW MATERIAL REQUIRED

ADDRESSES OF MACHINERY AND EQUIPMENT SUPPLIER:

RAW MATERIAL SUPPLIER

COLD ROLLED NON GRADE ELECTRICAL STEEL SUPPLIER:

CAST IRON SUPPLIER:

ALUMINIUM INGOTS- ALLOYED SUPPLIER:

WINDING WIRE OF ENAMELLED COPPER SUPPLIER:

DETAILS OF TEST FACILITIES AVAILABLE IN INDIA LIST OF

RECOGNIZED LABORATORIES:

DETAILS OF THE MACHINERY SUPPLIERS:

ALUMINIUM TUBE

COPPER WIRE

SUPPLIERS OIF PLANT AND EQUIPMENTS

PIPE CUTTING MACHINE

CNC TURRET PUNCH PRESS AND CNC PRESS BREAK

CNC PRESS

PUNCHING PRESS

POWER PRESS

BENDING MACHINE

MECHANICAL PRESS

CNC PLASMA CUTTING MACHINE

CNC SHEET BENDING MACHINE

DRILLING MACHINE

POWER HACSAW

GRINDING MACHINE

ELECTRICAL PANEL

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

JIGS AND FIXTURE

LAB EQUIPMENTS SUPPLIERS

DG SET MANUFACTURER/SUPPLIER

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

PLANT LAYOUT

PLANT LOCATION

ORGANIATION CHART

IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)