Detailed Project Report on bldc motor for ev

BLDC MOTOR FOR EV

[CODE NO.4311]  

In simple words we can say a device that produces rotational force is a motor. The very basic principal of functioning of an electrical motor lies on the fact that force is experienced in the direction perpendicular to magnetic field and the current, when field and current are made to interact with each other.

In any electric motor, operation is dependent upon simple electromagnetism. A current carrying conductor generates a magnetic field, when this is then placed in an external magnetic field; it will encounter a force proportional to the current in the conductor and to the strength of the external magnetic field.It is a device which converts electrical energy to mechanical energy. It works on the fact that a current carrying conductor placed in a magnetic field experiences a force which causes it to rotate with respect to its original position.

Classification or Types of Motor

The primary classification of motor or types of motor can be tabulated as shown below:

 DC Motor

DC power systems are not very common in the contemporary engineering practice. However, DC motors have been used in industrial applications for years Coupled with a DC drive, DC motors provide very precise control DC motors can be used with conveyors, elevators, extruders, marine applications, material handling, paper, plastics, rubber, steel, and textile applications, automobile, aircraft, and portable electronics, in speed control applications

A DC motor is an electric motor that runs on direct current power.

Practical DC Motor consists of field windings to provide the magnetic flux and armature which acts as the conductor.

Brushless DC Motors Work

The input of DC motor is current/voltage and its output is torque. Understanding the operation of DC motor is very simple from a basic diagram is shown in below. DC motor basically consist two main parts. The rotating part is called the rotor and the stationary part is also called the stator. The rotor rotates with respect to the stator.

The rotor consists of windings, the windings being electrically associated with the commutator. The geometry of the brushes, commutator contacts and rotor windings are such that when power is applied, the polarities of the energized winding and the stator magnets are misaligned and the rotor will turn until it is very nearly straightened with the stator’s field magnets.

As the rotor reaches alignment, the brushes move to the next commutator contacts and energize the next winding. The rotation reverses the direction of current through the rotor winding, prompting a flip of the rotor’s magnetic field, driving it to keep rotating.

Working of DC Motor

Working principle of DC Motor mainly depends upon Fleming Left Hand rule. In a basic DC motor, an armature is placed in between magnetic poles. If the armature winding is supplied by an external DC source, current starts flowing through the armature conductors. As the conductors are carrying current inside a magnetic field, they will experience a force which tends to rotate the armature. Suppose armature conductors under N poles of the field magnet, are carrying current downwards (crosses) and those under S poles are carrying current upwards (dots). By applying Fleming’s Left hand Rule, the direction of force F, experienced by the conductor under N poles and the force experienced by the conductors under S-poles can be determined. It is found that at any instant the forces experienced by the conductors are in such a direction that they tend to rotate the armature.

Again, due this rotation the conductors under N-poles come under S-pole and the conductors under S-poles come under N-pole. While the conductors go form N-poles to S-pole and S-poles to N-pole, the direction of current through them, is reversed by means of commutator. Due to this reversal of current, all the conductors come under N-poles carry current in downward direction and all the conductors come under S-poles carry current in upward direction as shown in the figure. Hence, every conductor comes under N-pole experiences force in same direction and same is true for the conductors come under S-poles. This phenomenon helps to develop continuous and unidirectional torque.

Advantages of DC motors: 

1. It is easy to control their speed in a wide range; their torque-speed characteristic has, historically, been easier to tailor than that of all AC motor categories. This is why most traction and servo motors have been DC machines. For example, motors for driving rail vehicles were, until recently, exclusively DC machines. 

2. Their reduced overall dimensions permit a considerable space saving which let the manufacturer of the machines or of plants not to be conditioned by the exaggerated dimensions of circular motors. 

Disadvantages of DC motors 

1. Since they need brushes to connect the rotor winding. Brush wear occurs, and it increases dramatically in low-pressure environment. So they cannot be used in artificial hearts. If used on aircraft, the brushes would need replacement after one hour of operation. 

2. Sparks from the brushes may cause explosion if the environment contains explosive materials. 

3. RF noise from the brushes may interfere with nearby TV sets, or electronic devices, Etc.

4. DC motors are also expensive relative to AC motors. 

Thus all application of DC motors have employed a mechanical switch or commutator to turn the terminal current, which is constant or DC, into alternating current in the armature of the machine. Therefore, DC machines are also called commutating machines.  

COST ESTIMATION

Plant Capacity                                             150 Nos./Day

Land & Building ( 5000 sq.mt.)                  Rs. 6.79 Cr

Plant & Machinery                                       Rs. 7.93 Cr

Working Capital for 2 Months             Rs. 101.45 Cr

Total Capital Investment                           Rs. 113.60 Cr

Rate of Return                                             17%

Break Even Point                                        52%

• INTRODUCTION
• CLASSIFICATION OR TYPES OF MOTOR
• DC MOTOR
• BRUSHLESS DC MOTORS WORK
• WORKING OF DC MOTOR
• ADVANTAGES OF DC MOTORS:
• DISADVANTAGES OF DC MOTORS
• TYPES OF DC MOTORS:
• TYPES OF DC MOTORS
• THE DC MOTORS ARE DIVIDED MAINLY TO:
• BRUSHLESS D.C MOTOR
• WORKING PRINCIPLE AND OPERATION OF BLDC MOTOR
• CONSTRUCTION OF BLDC MOTOR
• ROTOR
• HALL SENSORS
• TYPES OF BRUSHLESS DC MOTORS
• INNER ROTOR DESIGN
• OUTER ROTOR DESIGN
• ADVANTAGES OF BRUSHLESS DC MOTOR
• DISADVANTAGES OF BRUSHLESS DC MOTORS
• DISADVANTAGES OF BLDC MOTOR
• USES AND APPLICATIONS OF BLDC MOTORS
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS OFBRUSHLESS D.C MOTOR
• FABRICATION PROCESS OF STATOR
• 1. STAMPING
• 2. STACKING
• 3. SLOT INSULATION
• 4. WINDING
• 5. PREPPING
• FABRICATION PROCESS OF ROTOR
• ROTOR MAGNET
• 1. SHAFT MACHINING
• 2. HUB MACHINING
• 3. HUB MAGANET GLUING
• 4. BEARING PRESSING
• FABRICATION OF HOUSING AND END BELL MANUFACTURING
• ELECTRONICS MANUFACTURING:
• ASSEMBLING OF BLDC MOTOR
• TESTING OF BLDC MOTOR
• CLASSIFICATION OF TEST
• 1. TYPE TESTS
• 2. ROTINE TESTS
• 3. PERFORMANCE TEST
• (A) NO LOAD TEST
• (B) OPEN CIRCUIT VOLTAGE RATIO 'REST FOR WOUND
• (C) ROTOR (SLIP RING) MOTORS
• (D) LOCKED ROTOR TEST
• (E) FULL LOAD TEST
• (8) MARKING
• MARKET POSITION
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• 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. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• PLANT LAYOUT
• SUPPLIERS OF BLDC MOTOR
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF CRNGO SILICON STEEL
• SUPPLIERS OF INSULATION KRAFT PAPER
• SUPPLIERS OF COPPER WINDING WIRE
• SUPPLIERS OF PERMANENT MAGNET
• SUPPLIERS OF MOTOR SHAFT
• SUPPLIERS OF D.C MOTOR PARTS
• SUPPLIERS OF BLDC HALL SENSOR CONTROLLER
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF MOTOR MAKING MACHINES
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF ELECTRICAL MEASURING AND TESTING EQUIPMENT
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SHOT BLASTING MACHINE

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)