S.D.M.E.

Society’s
S.D.M. College of Engineering and Technology
Dhavalagiri, Dharwad-580002, Karnataka, India.
(Affiliated to VTU, Belagavi)

Internship Report
on
Kirloskar Electric Company Ltd
Submitted in Partial Fulfillment of the Requirement for the Award
of the Degree of

Bachelor of Engineering
in
Mechanical Engineering

Submittted by
Sourav M Patil
2SD21ME446

Under the Guidance of

Prof.Jayaram Bhat

Department of Mechanical Engineering

S.D.M. College of Engineering and Technology
Dharwad, Karnataka, India.

2023–2024
 S.D.M. College of Engineering and Technology,
Dharwad–580002

Department of Mechanical Engineering

CERTIFICATE

This is to certify that the Internship titled Operations and Manufacturing Process is a
bona fide work carried out by Sourav M Patil (2SD21ME446) submitted in partial fulfill-
ment of the requirements for the award of the degree of Bachelor of Engineering
in Mechanical Engineering of S.D.M. College of Engineering and Technology, Dhar-
wad, Karnataka. (An autonomous institution affiliated to Visvesvaraya Technological
University, Belgaum, Karnataka), during the year 2023–2024. It is certified that all cor-
rections/suggestions indicated for assessment have been incorporated in the report de-
posited in the department library. The seminar has been approved, as it satisfies the aca-
demic requirements in respect of Internship prescribed for the said degree.

Prof. Jayaram Bhat Dr. I. Sridhar

Internship Guide Head of Department

Name of Examiners Signature with Date

1)
2)

Department of Mechanical Engineering, SDMCET, Dharwad Page|ii

 DECLARATION
I hereby declare that the Internship titled " Operations and Manufacturing Process", has
been carried out under the guidance of Prof.Jayaram Bhat, Assistant Professor, Depart-
ment of Mechanical Engineering, S.D.M. College of Engineering and Technology, Dhar-
wad, in partial fulfillment of the degree of Bachelor of Engineering in Mechanical En-
gineering from Visvesvaraya Technological University, Belagavi, Karnataka during the
academic year 2023-2024.

I also declare that I have not submitted this Internship to any other university for the
award of any other degree.

Sourav M Patil
(2SD21ME446)

Place: Dharwad
Date: 30-10-2023

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 ACKNOWLEDGEMENT
It’s a queer to think of a clap without the striking of two human hands, similarly this
Internship owes a lot of credit to many people who have helped or influenced for this
Internship.
I would thank my guide Prof. Jayaram Bhat, (Co-guide if applicable) Mechanical En-
gineering Department, S.D.M. College of Engineering and Technology, for the constant
support, invaluable advice, guidance and permitting me to carry out this Internship.
I express my earnest profound gratefulness to Internship committee Dr. Anilkumar.
H. C, Dr. V. S. Kamate, Prof. S. G. Bindgi,and Prof. V. R. Shivannavar for helping me
throughout the Internship in every manner.
I wish to thank Dr. K. Gopinath, Principal and Dr. I. Sridhar, H.O.D Mechanical En-
gineering , S.D.M. College of Engineering and Technology Dharwad for permitting me
to carry out the Internship.

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 Abstract
.We consider it a privilege to express our sincere gratitude and respect to all those who
guided and inspired us throughout this project. We express our heartfelt thanks to our
guide Prof. Jayaram Bhat, for his valuable suggestions and guidance during the course of
this project. successful completion of this project owes to his coordination and stream-
lining of the project progress.

The main objective of this internship was to get an industrial exposure and to under-
stand actual manufacturing processes on a large scale. I got the information about the
company. I got much knowledge that how the manufacturing processes takes place and
finally, I am very thankful to the Kirloskar Electric Company Pvt. Ltd, Hubli, for giving
me an opportunity to carry out internship

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 Table of Contents

Table of Contents vi

List of Figures ix

List of Tables x

1 About the Company 1

1.1 Introduction to Company . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 History of company . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Important Dates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 CompanyProfile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Objectives Of Company . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 Mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.9 Awards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.10 Manufacturing Units Of Kirloskar Electric Company Limited . . . . . . 7
1.11 Establishment Of Units . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 DEPARTMENT OF KEC 8
2.1 Department and its types . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Different types of department . . . . . . . . . . . . . . . . . . . . . . 8
2.3 PRODUCTION DEPARTMENT . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 FINANCE DEPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . 9

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Kirloskar Electric Company Ltd

2.5 MARKETING DEPARTMENT . . . . . . . . . . . . . . . . . . . . . . 10

2.6 ENGINEERING DEPARTMENT . . . . . . . . . . . . . . . . . . . . . 10
2.7 MATERIAL MANAGEMENT DEPARTMENT . . . . . . . . . . . . . . . 10
2.8 QUALITY ASSURANCE DEPARTMENT . . . . . . . . . . . . . . . . . 11
2.9 STORES DEPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.10 COMPUTER DEPARTMENT . . . . . . . . . . . . . . . . . . . . . . 11

3 PRODUCTION SHOPS 12
3.1 STEPS INVOLVED IN PRODUCTION . . . . . . . . . . . . . . . . . . 12
3.2 SHOP I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 SHOP II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.1 Die Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 PRE-TREATMENT SHOP . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 SHOP III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.1 Assembly Shop . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 SHOP IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.1 Innovation and Research . . . . . . . . . . . . . . . . . . . . 14
3.7 SHOP V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 INDUCTION MOTOR 15
4.0.1 Construction of 3-phase induction motor . . . . . . . . . . . . 16
4.1 stator of 3 phase induction motor . . . . . . . . . . . . . . . . . . . . 16
4.2 Rotor of 3-phase induction motor . . . . . . . . . . . . . . . . . . . . 17
4.3 working principle of 3-phase induction motor . . . . . . . . . . . . . . 18

5 ASSEMBLY OF MOTOR 20
5.0.1 steps involved in assembly . . . . . . . . . . . . . . . . . . . . 20
5.0.2 Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 TESTING OF INDUCTION MOTOR . . . . . . . . . . . . . . . . . . . 21
5.1.1 Basic parameters . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.2 Details of main sets of tests performed of induction motor . . . . 22
5.1.3 Type test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.4 Routine test . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 INDUSTRIES SERVED AND CUSTOMERS 23

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Kirloskar Electric Company Ltd

7 CONCLUSION 25
7.1 Learning and outcomes . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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 List of Figures

1 Shri Laxmanrao Kashinath Kirloskar . . . . . . . . . . . . . . . . . . . . 2

2 Ravi L Kirloskar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Kirloskar Electric Company Ltd,Hubli . . . . . . . . . . . . . . . . . . . . 4
4 Bureau Veritas (India) Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Confirmative Europeenne . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 KEMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7 construction of induction motor . . . . . . . . . . . . . . . . . . . . . . 15

8 induction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10 rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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 List of Tables

1. Company Profile.........................4

2. Manufacturing Units.....................7

3. establishment of units......................7

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 Chapter 1
About the Company

1.1 Introduction to Company

• Kirloskar Electric Company Ltd. is one of the leading Indian electrical engineering com-
panies. Promoted by Kirloskar Brothers Ltd., Pune, the Company was incorporated in
Bangalore on 26th July, 1946 under the Mysore Companies Act XVIII of 1938, with tech-
nical and financial participation of well known British Company i.e. Brush Electrical En-
gineering Company Ltd., Loughborough, England, which is now a member of Hawker
Siddeley Group.

Kirloskar Electric was the catalyst for industrialization in India.

• Kirloskar Electric produces more than 70 products under eight product groups. We
cater to core economic sectors such as power generation, transmission distribution,
transportation, and renewable energy, to name a few.

• The Kirloskar Electric organization comprises nine manufacturing locations and 34 sales
offices spread across the country. We have a large network of spare parts dealers and ser-
vice centres. This enables us to provide premium products, exemplary systems services
at competitive rates to our clients.

• Kirloskar products are known for their high quality, durability, and reliability. This is
due to our emphasis on design, engineering, and manufacturing. We adhere to interna-
tional standards by acquiring adapting latest technologies along with in-house RD.

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Kirloskar Electric Company Ltd

1.2 History of company

Figure 1: Shri Laxmanrao Kashinath Kirloskar

Founder, Kirloskar Group of Companies

Lakshmanrao .K. Kirloskar was a successful industrialist. His chief merit lay in the trail
he blazed, for the principles in life he dependent upon where his vision and a spirit of
pioneering.

His message stands as a very practical guidance to all of us even today.

Ravi. L. Kirloskar

Figure 2: Ravi L Kirloskar

Founder, Kirloskar Electric Company Limited

Shri Ravi. L. Kirloskar was the youngest son of Laxmanrao and Radhabai Kirloskar. Hav-
ing a degree in electrical engineering from the Worcester Polytechnic Institute, U.S.A.,
he began his professional career at Kirloskar Brothers Ltd. In 1942, he designed and built
India’s first electric motor at Kirloskarvadi with his colleague N.K. Joshi. He went on to
head Kirloskar Electric, and guided the company to the highest levels of excellence.

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Kirloskar Electric Company Ltd

1.3 Important Dates

• 1888: Laxmanroa kashinath kirloskar established kirloskar brothers Ltd.(kbl) as an
engineering enterprise.

• 1940: Kirloskar Brothers manufactured indias first verticle diesel engine.

• 1942: Kirloskar brothers manufactures indias first AC Induction Motor.

• 1946: Kirloskar Electric Company LTD. established.

• 1949: 5 Hp petter type AV1 engine manufactured.

• 1953: Kirloskar electric produces indias first transformer.

• 1958: Kirloskar electric manufactures indias first alternator.

• 1964: Kirloskar electric creates indias first DC Motor.

• 1970:Mr.Ravi.L. Kirloskar appointed as managing director of kirloskar electric.

• 1973:First overseas operation opened in malaysia.

• 1976:Mr.Ravi.L.Kirloskar Elected Chairman Of Kirloskar Electric.

• 1984:Kirloskar Electric introduces the Thyristor Converter in India.

• 1988:Kirloskar Group celebrates 100 years in operations.

• 1991:Kirsons Trading Pte Ltd. (Kirloskar JV) Singapore, established.

• 1993:Kirloskar Electric receives ISO 9001certification.

• 2008:Kirloskar Electric acquires Lloyd Dynamowerke, a specialist German Motor

and Generator company.

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Kirloskar Electric Company Ltd

1.4 CompanyProfile
1. • It was established in the year 1969

2. • This unit is mainly concerned with production of AC Motor, DG Sets,

3. • AC Generators, Switch gears, transformers etc.

4. • Hubli turns out small and medium range AC Machines

Figure 3: Kirloskar Electric Company Ltd,Hubli

Name of the industry Kirloskar Electric Company Ltd.

Name of the business Sole ownership
Type of industry Large scale industry
Business type Exporter, manufacturing and supplier
Founder Vijay kirloskar
Headquarters Bangalore, India
Key people Vijay kirloskar CEO, Sanjeev S CFO
Address of industry Unit 2 post box no 112, Gokul Road, Hubli
Website of KEC www.kirloskarelectric.coom

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Kirloskar Electric Company Ltd

1.5 Certifications
Kirloskar Electric is the first electrical engineering company in India to be awarded ISO
9001 certification. We are also the first electrical equipment manufacturing company in
India to be awarded certification for providing the ’CE’ Mark for our products.
Kirloskar Electric is a pioneer in the export of electrical and electronic goods since the
last four decades. Kirloskar Electric is a status holder recognized by the Ministry of Com-
merce Industry, Government of India, as an export house.

The Export House Certificate

Kirloskar Electric Company Manufacturing units
at Bangalore, Hubli, Mysore Pune are certified by
BV for Quality Management systems to ISO9001
– 2015 Standards. We are also first in the elec-
trical Industry to obtain ISO9001 certification by
Figure 4: Bureau Veritas (India) Pvt
BV
Ltd

conformity to European standards meeting basic re-

quirements of Safety, Health, and Environment Protection
(SHEC). Kirloskar Electric is entitled to provide ’CE Mark-
ing’ for AC motors, AC generators, and DC machines. It al-
Figure 5: Confirmative
Europeenne lows the product unregistered legal access to the European
market.

’KEMA’ registered quality B.V. Netherlands have tested

our products with respect to low voltage directive, EMC
(Electromagnetic) directive and MD (Machinery) direc-
Figure 6: KEMA
tive.//[0.5cm]

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Kirloskar Electric Company Ltd

1.6 Objectives Of Company

• To provide products of highest quality and value.

• To achieve cost effectiveness in machine shops and production process.

• Provide excellent customer service and support.

• Grow the business and expand into new markets.

• To invest in the technology to achieve technological excellence and a competitive

edge.

• Commitment for continuous improvement in process, methods productivity and

quality

1.7 Vision
Kirloskar Electric vision is to become a world-class engineering enterprise, committed
to enhancing stakeholder value. As a globally renowned company, Kirloskar Electric pro-
vides elite products and strives to fulfil the expectations of industries and clients world-
wide.
The Power of Now is the energy of opportunities that comes to us disguised as challenges.
The Power of Now at Kirloskar Electric is the dynamic of making opportunities work as
by meeting clients’ tough specifications of cost competitiveness, quality, and reliability.

1.8 Mission
"The mission of Kirloskar Electronic Company Ltd, Hubli is to be a leading manufacturer
of high-quality motors for a variety of industries. The company aims to achieve this by
providing innovative products and services, meeting the highest standards of quality and
safety, and building strong relationships with its customers and partners.."

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Kirloskar Electric Company Ltd

1.9 Awards
National award for RD from the Department of Scientific
Industrial Research, Ministry of Science Technology, In-
dia

Best Innovative product for Digital drive by IEEMA at the Elecrama exhibition.

Kirloskar Electric Company is a status holder and has been awarded THE EXPORT HOUSE
CERTIFICATE recognized by Ministry of Commerce Industry, Government of India.

1.10 Manufacturing Units Of Kirloskar Electric Company

Limited
Location Products Manufactured
Govenhalli Ac motors,ac generators,dc machines,traction equipments
Hubli Ac motors,ac generators,engines
Tumkur Ac motors,press shop,component manufacturing division
Mysore Electronics,switchgear,transformers
Pune cast resign transformers oil filled transformers and dg sets

1.11 Establishment Of Units

Unit-1 Bangalore 1946
Unit-2 Hubli 1969
Unit-3 Peenya,Bangalore 1977
Unit-4 Mysore 1980
Unit-5 Bangalore 1984
Unit-6 Pune 1992
Unit-7 Tumkur 1995

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 Chapter 2
DEPARTMENT OF KEC

2.1 Department and its types

1. Department refers to specialized functional area within an organization or a divi-
sion, such as accoting, marketing planning etc. Generally every dopantomont has
its own manager and chain of command

2.2 Different types of department

• 1. Production department.

• 2. Finance department.

• 3. Marketing department.

• 4. Store department.

• 5. Quality assurance department.

• 6. Engineering department.

• 7. Personnel department.

• 8. Computer department.

• 9. Material management department.

• 10. System support department.

• 11. Central planning department.

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Kirloskar Electric Company Ltd

2.3 PRODUCTION DEPARTMENT

A production department is a group of functions within a business that is responsible
for the manufacturer of goods. This can include just a few specialized functions with all
other work outsourced, or a fully functioning department that converts raw materials,
assembles components into finished goods, and package them

The production department is responsible for the production activity carried out by its
unit. The whole running of units is depends upon the department helps in the produc-
tion, reaching the customers at right time. Slight difference in timing and quality upsets
the cycle.

2.3.1 objectives

• To follow up the production schedule as per the plan.

• To maintain close and key relationship with other department.

• To upgrade the technical efficiency of the production.

• The department is divided into shops:Feeder shop (shop 111) Assembly shop (shop
IIIV)

• Shop IV is used as research and development center. It is also called as "InvoTech

Center" and shop IV is painting section.

2.4 FINANCE DEPARTMENT

Finance department of any manufacturing organization could be a life that organization
which controls each and every activity of other departments, which are interrelated to
the finance department, and also it ensures the proper flow money to the departments
along with collection of money from the departments.

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Kirloskar Electric Company Ltd

2.5 MARKETING DEPARTMENT

Success of the product of a company totally depends on how its product is marketed and
position in the market. Marketing department hence plays a vital role for the success of
product in the market

KSL the subsidiary unit of KEC, is concerned only with production whereas KEC itself
is concerned with marketing only. KEC has good reputation in the market. Within the
efforts of marketing department, KEC has managed to promote its sales.

The marketing department is responsible for order acceptance that is it contacts poten-
tial customers and gets the orders. In addition to this, also gets orders from regular cus-
tomers.

2.6 ENGINEERING DEPARTMENT

The engineering department is responsible for the design and development activities us-
ing appropriate methods of control with adequate verification so that design meets the
specified requirement of the customers. The role of engineering department is to de-
sign and develop products and components taking into consideration the cost, producing
ability, usability and maintainability of the products.

2.7 MATERIAL MANAGEMENT DEPARTMENT

Material management department is one of the very important department of any indus-
try or manufacturing unit, raw material are necessary. But only acquiring o procuring of
raw material is not sufficient. The quality the delivery time and price factor are all to be
considered and this is not as simple as it seems. It involves lot of inspection negotiation.
Hence KSL has established a separate which takes care of all the above mentioned factors.

This department deals with planning and procurement of material, required for the pro-
cess of production.

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Kirloskar Electric Company Ltd

2.8 QUALITY ASSURANCE DEPARTMENT

1. The role of quality is to all functional division in achieving and maintaining level of
specified quality requirements economically.

2. Quality assurance department maintain quality as 150 9001-1994.

3. here is a separate quality labs which Prepares and maintain quality plans for new
requirements organize calibration functions fro external agencies.Arranges for re-
pair, rectification disposal of measuring instruments.

2.9 STORES DEPARTMENT

The role of stores department is to maintain accountability of the materials received and
stored and issued as per specified requirements

2.10 COMPUTER DEPARTMENT

The computer division is respomible for software development, maintenance of com-
puter hardware accessories using appropriate methods. To carry out all the computer de-
velopment modification activity. To plan, indent and maintain software/ tools required.
To evaluate and reduce manufacturing losses attributes to computer and system and ac-
cessories.

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 Chapter 3
PRODUCTION SHOPS

3.1 STEPS INVOLVED IN PRODUCTION

• Feeder shop (shop 1 and shop 2)

• Assembly shop (shop 3 and shop 5)

• RD department or InfoTech centre (shop 4)

3.2 SHOP I
1. Shop 1 main part is machinery of the rotor, manufacturing of the shaft and pro-
cessing of the shaft inside the rotor.

2. The shaft is manufactured based on the design provide by the engineers.

3. The CNC provides the accuracy of size in the manufacturing. Turning, facing is
done, then later milling is done on the manual/CNC.

4. Once shaft is done, the rotor is kept in the oven to heat up to 450 degree Celsius for
45 minutes.

5. The heated rotor has the increased diameter and hence the shaft is pressed inside
and left for cooling.

6. Once the rotor is cooled the shaft with the shell completely become the rotor.

7. Once pressing of the shaft is done, the entire stator is now machined to remove the
excess of casting.

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Kirloskar Electric Company Ltd

8. After the machinery is done, the rotor is tested for the balancing.

9. Balancing has to be done because, during the casting the material may be excess in
some side and less on other side, hence to avoid the vibration during the rotation.

10. The rotor is kept on the rotating platform and the digital reading shows the amount
of weights must be added at the particular angle in order balance the rotor.

11. Another main function is rotor assembly. Rotor is moving part of AC motors and
alternators. Steps are as below,

• Shrinking

• Turning

• Face step drilling

• Balancing

• winding

3.3 SHOP II

3.3.1 Die Casting

In this casting of 63mm-450mm rotors are prepared.Aluminium bars are melted in fur-
nace at temperature of 675-775 degree Celsius. Stampings of required core lengths are
pressed in themachine at a suitable squeeze angle using suitable holders, it is then placed
into a die cast machine.Melted aluminium is poured using ladle Hydraulic pressure is ap-
plied at one end which enables the molten metal to flow into the cavity and required shape
of the rotor is obtained.

3.4 PRE-TREATMENT SHOP

It is also known painting shop. Here the components used in the motors are pre-treated
and pointed. A unique innovation technology called UNIBAKES, installed in 1992 is used
for drying the components to be used in export motors.

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Kirloskar Electric Company Ltd

3.5 SHOP III

3.5.1 Assembly Shop

This is assembly shop, where the products will get ready up to 90 percent here. Only final
finishing would be left at this stage. The frame sizes of 63-180 motors are assembled here.
The assembling and foxing of covers, screws and nuts are done manually, the shift is fixed
through hydraulic pressing machine. The products come to connection wing where elec-
trical connections are given and then later on electrical parts are checked. The product is
given first coat of painting. This is done correct handling mistakes and small scratches.

3.6 SHOP IV

3.6.1 Innovation and Research

Research and Development (RD) and Innovation are the process of developing and com-
mercializing new ideas, implementing new processes or changing the way your business
makes money. It can also be viewed as the activities required keeping your business com-
petitive and sustainable for the long term.

Before the production in all the shops the design and development of the motor is de-
signed and checked here. They follow the IS 1231 which is meant for the production of the
Induction motor.

3.7 SHOP V
This shop is also as assembly shop. Ion this shop there are two sections, one deal with
AC motors and another one deals with AC generators. In the section of AC motors, the
assembling of machine up to 180-400 frames are done here. In this section of AC mo-
tors, the process begins with the shaft being inserted into rotor through hydraulic press
machine. This also has own painting and dispatch section.

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 Chapter 4
INDUCTION MOTOR

Figure 7: construction of induction motor

An induction motor or asynchronous motor is an AC electric motor in which the elec-

tric current in the rotor needed to produce torque is obtained by electromagnetic induc-
tion from the magnetic field of the Stator winding. An induction motor can therefore be
made without electrical connections to the rotor.

A 3-phase induction motor consists of a stator and a rotor. The stator carries a 3-phase
stator winding while the rotor carries a short-circuited winding called rotor winding. The
stator winding is supplied from a 3-phase supply. The rotor winding drives its voltage and
power from the stator winding through electromagnetic induction and hence the name

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Kirloskar Electric Company Ltd

4.0.1 Construction of 3-phase induction motor

Figure 8: induction motor

A three-phase induction motor contains a stator (the stationary part) and a rotor (which
rotates). Each contains electrical windings that carry current and thus creates a magnetic
field. The interaction of the magnetic fields creates the torque that rotates the rotor and
the load.

Fig shows the exploded view of a three-phase induction motor: 1. Fan cover,2 Cooling
fan, 3. End bell, 4. Lifting eye, 5. Nameplate, 6. Stator coils, 7. Bearing seal, 8. Ball
bearing, 9. Squirrel-cage rotor, 10. Cast-iron frame, 11. Wiring box (Courtesy: Baldor
Electric Company)

4.1 stator of 3 phase induction motor

Figure 9: stator

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• Figure 9 shows a close-up View of the stator of an induction machine. The stator core
is built of laminated, electrical-grade steel, and the coils are mounted in slots distributed
around the circumference of the stator. The stator winding of the three-phase induction
motor is very similar to the armature winding of a three-phase synchronous machine.
The core and coil assembly is shown in Figure 9 is placed in a frame, as shown in Figure 7

• The frame (item 10), in this case, is cast iron and has cooling fins and mounting feet cast
as part of the frame. The National Electrical Manufacturers’ Association (NEMA) defines
standard frame sizes so that motors will be interchangeable from one manufacturer to
another. One coil of wire occupies two slots in the stator (one slot for each side of the coil).
Only the portion of the coil in the slots contributes to the magnetic field. The coil sides are
connected together by the end turns, which are shown in the front of the picture. In fact,
the winding for a phase of the motor is typically composed of several coils of different
sizes that occupy a number of slots around the stator. There will be a set of windings for
each of the three phases times the number of pole pairs in the machine. So a two-pole
motor would have three-phase coils. While a four-pole motor would have six phase coils.
Copper wire is used in the stator coils. The size of the wire is a function of the motor’s
expected full-load current, insulation type, and rated operating temperature.

4.2 Rotor of 3-phase induction motor

Figure 10: rotor

Two types of rotors are used in induction machines: wound and squirrel cage. The

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Kirloskar Electric Company Ltd

wound rotor has a winding that is virtually a mirror image of the stator winding. Con-
nections to it are made via slip rings on the shaft. The wound-rotor machine is used for
special purposes, usually involving speed control.

The squirrel-cage induction motor is by far the most common type of induction motor.The
rotor is built of a stack of steel laminations, such as the one shown in figure 10. The lam-
inations are aligned and heat-shrunk onto the shaft, and then the molten aluminium is
forced into the slots to form the squirrel-cage winding. It is essential that no air pockets
be allowed to form as the squirrel cage is cast; otherwise, the resistance of the bar would
increase, causing excessive heating. The bars are shorted together at the ends by shorting
rings, which are formed at the same time as bars. The rotor winding thus appears like a
squirrel or hamster cage.

Figure 10 is a picture of a small, aluminium squirrel-cage rotor, from which the rotor
steel was selectively etched away to show the aluminium bars. One of the shorting rings
is visible at the left end of the squirrel cage. Larger rotors usually have fins cast onto them
to provide additional cooling surface

4.3 working principle of 3-phase induction motor

A three phase induction motor has a stator and a rotor. The stator carries a 3-phase
winding called as stator winding while the rotor carries a short circuited winding called
as rotor winding. The stator winding is fed from 3-phase supply and the rotor winding
derives its voltage and power from the stator winding through electromagnetic induc-

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tion. Therefore, the working principle of a 3-phase induction motor is fundamentally

based on electromagnetic induction.

Consider a portion of a three phase induction motor (see the figure). Therefore, the work-
ing of a three phase induction motor can be explained as follows –

When the stator winding is connected to a balanced three phase supply, a rotating mag-
netic field (RMF) is setup which rotates around the stator at synchronous speed (Ns).
Where,NS=120fP

The RMF passes through air gap and cuts the rotor conductors, which are stationary at
start. Due to relative motion between RMF and the stationary rotor, an EMF is induced
in the rotor conductors. Since the rotor circuit is short-circuited, a current starts flowing
in the rotor conductors.

Now, the current carrying rotor conductors are in a magnetic field created by the stator.
As a result of this, mechanical force acts on the rotor conductors. The sum of mechanical
forces on all the rotor conductors produces a torque which tries to move the rotor in the
same direction as the RMF.

Hence, the induction motor starts to rotate. From, the above discussion, it can be seen
that the three phase induction motor is self-starting motor.

The three induction motor accelerates till the speed reached to a speed just below the
synchronous speed.

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 Chapter 5
ASSEMBLY OF MOTOR

5.0.1 steps involved in assembly

• Collect the bodies which are brought and kept on pallets near pressing machine as
per the work order.

• Place the non-driving end pressing ring on the pressing machine bed as per the
core

• Start dimensions chart for stator pressing put the wound stator on the NDE press-
ing ring as per the chart such that lead wires are on the top side of the wound stator.

• Place the body on the wound stator such that terminals pad of the body is on the
top to draw the terminal lead and press the body for aluminium place the body on
ring

• Place the Depressing ring on the body

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Kirloskar Electric Company Ltd

• Press the body slowly as to apply the pressure of 50-60kg/sq.cm taking care to avoid
damages to the lead wires and overhang of the wound stator during the pressing
operation,

7. Stop the body pressing after the wound stator being pressed half way of the body.
Pass the lead wires through the terminal lead hole.

8. For 180 frames, pressing is done with a DE ring, keeping the body on the ta-
ble and the winding on the top body. Write a lot No, as per the work order with
market/paste the sticker with lot number on the body. Body ready for further pro-
cessing

5.0.2 Assembly Parts

• Frame

• Die Cast Rotor

• Shaft(key shaft)

• Cover(skirt)

• Balanced Rotor

• Fan

• Flange

• Inner bearing cover

• Fan insert

• Circlip

• Ball bearing

5.1 TESTING OF INDUCTION MOTOR

It is necessary that the health of large motors which consumes maximum power should
be taken care off. Tests are required to check the condition of the induction motor. Now
a days cost of techniques tests are available which gives the complete health card of in-
duction motors. By monitoring some parameters like voltage, current. Temperature and

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vibration problem could be diagnosed and by correcting these faults the overall efficiency
of the motors can be improved this will reduce the energy consumption and operational
costs.

5.1.1 Basic parameters

• Voltage-voltage is measured at the motor terminals and at the time of test it should
be approximately balanced. Machine performance can be calculated by using aver-
age of the phase voltage.

• Current-As the line current in all the phases motor can be calculated by a single
watt meter as they are connected in two-watt meter method.

• Power-Power input to three phase motor can be calculated by a single watt meter
as they are connected in two-watt meter method.

• Resistance - It is necessary to check the ground resistance of the motor body and
terminals of the machine.

5.1.2 Details of main sets of tests performed of induction motor

• Type test.

• Routine test.

5.1.3 Type test

The no load test on the induction motor is conducted to measure the rotational losses of
the motor and to determine some of its equivalent circuit parameters. In this test a rated
balanced AC voltage at a rated frequency is applied to the stator while it is running at no
load.

5.1.4 Routine test

This test is one of important test in the motor. Routine testing is done to measure the
winding insulation resistance of the armature field poles, probes, space heater, and bear-
ing.

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 Chapter 6
INDUSTRIES SERVED AND
CUSTOMERS

Kirloskar Electric Company supplies various types of custom-built products to different

applications including:

1. Sugar

• Cane Leveller

• Chopper

• Sugar Centrifuge

• Fibrizer

• Mills

• Cane Unloader

2. Steel

• Melting Shop

• Blast Furnace

• Cold Rolling Mill

• Rerolling Mill

• Hot Strip Mill

• Coke OEM

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Kirloskar Electric Company Ltd

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 Chapter 7
CONCLUSION

7.1 Learning and outcomes

Ability to analyse a given engineering problem, identify an appropriate problem-solving

methodology, implement the methodology and propose a meaningful solution.

This training helps to bridge the gap between the theoretical knowledge into practical.
item Ability to apply prior acquired knowledge in problem solving.

Ability to identify sources of hazards and identify appropriate health and safery mea-
sures.

Ability to work in a team.

Ability to take initiatives.

Ability to effectively communicate solution to a problem.

Ability to adopt a factual approach to decision making

Ability to take engineering action.

7.2 Conclusion

Habballi is one of the electrical industrial units which have got very productivity and very
good brand name an electrical industry. Market, the human resource policy and es of the
company of formulated at their best.

The company is having very skilled human resources so the companies can implement
new and d policies and strategies of human resources management, so as to scope up
which it is per and remaining the no. I electrical manufacturer in India

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Kirloskar Electric Company Ltd

The 4 weeks in plant training in KEC has given detail knowledge of the management of
an Origination and clear pictures of work flow of an origination KEC is electronic com-
pany in which, basic raw material is used for the production of motors

This duty gives information of how really big origination works by facing so many hurs
dles. As successfully overcoming the problems.

The culture in KEC is very cordial and the atmosphere of the workforce is also very good
which Contributed to study a lot.

7.3 References
• https://kirloskarelectric.com

• https://www.google.com/searchq-location-of-kirloskar-electric-company

• https://www.google.com/searchq-induction-motortbm

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