bhel project report {prm}

Press Shop Division Is A Feeder Division, Equipped With Latest & Sophisticated CNC Machines Other Than Conventional Presses Which Are Used For Manufacturing Laminations For Electrical Machines, Hydro Generators And Traction Motors.

SECTIONS IN PRMSECTIONS IN PRM

1. Material Planning

2. Tooling

3. Technology & Facility Planning

4. Production Planning & Control

5. CNC Area

6. Heavy Blanking

7. Detail Sections

8. Blanking

9. Notching

10.Varnishing

PRODUCT GROUP PRODUCT RANGE

IMM 150 KW TO 2 MW

LEM 300 KW TO 17.5 MW

TRACTION MOTORS D.C. :45 KW TO 630 KW

A.C. :200 KW TO 1150KW

TRACTION AUXILIARIES

2 KW TO 2.5 MW

HYDRO 2 MW TO 200 MW

•Press Shop Is Responsible For

Manufacture And Supply Of

Laminations (Punching) For :

PRODUCT PROFILE

• Stator and Rotor laminations for Large , Medium and small Electrical Machines. ( IMM / LEM)

• Stator , Rotor Rim and Pole laminations for Hydro Generators. (PLM)

• Armature , Main Pole and Cum pole laminations for traction Motors. (TXM)

• Stator , Rim , Pole laminations for Traction Alternators. ( TAM)

Multi Slot Rotor Laminations

Circular Stator Laminations

Segmental Stator Laminations

PRODUCTS FOR LARGE ELECTRIC PRODUCTS FOR LARGE ELECTRIC MACHINESMACHINES

Rotor Spacer Plate Assembly

Rotor lamination

Stator Punching Stator and Rotor lamination

Stator Punching Stack

PRODUCTS FOR INDUSTRIAL PRODUCTS FOR INDUSTRIAL MACHINESMACHINES

STATOR SPACER PLATE ASSEMBLY

ROTOR RIM AND POLE ASSEMBLY

STATOR LAMINATION

PRODUCTS FOR HYDRO PRODUCTS FOR HYDRO GENERATORSGENERATORS

POLE LAMINATION

RIM LAMINATIONRIM LAMINATION

OD exceeds 3.5 m and may reach up

to 18.0 m .Core is split into segments .

Maximum width of available magnetic

sheet steel is about 1.0 m. Single core

might be heavy and bulky for

handling.

To facilitate handling into the factory.

Smooth transport by rail or road.

Reasons for Segments laminations

for Stator Core :

6 FRA STATOR AND ROTOR LAMINATIONS

TM 4601 ARMATURE LAMINATION

6 FXA ARMATURE LAMIANTION

COMPOLE LAMINATION

MAIN POLE LAMIANTION

PRODUCTS FOR TRACTION MOTORSPRODUCTS FOR TRACTION MOTORS

MAIN POLE LAMINATION

PRODUCTS FOR TRACTION PRODUCTS FOR TRACTION ALTERNATORSALTERNATORS

EXCITER STATOR

EXCITER ROTOR

MAJOR FACILITIES :

- 250 Ton CNC Blanking Line Press

- 8 Ton / 16 Ton 6 Station CNC Auto Notch Press

- 16 Ton CNC Segmental Notching Press.

- 8 Ton 8 Station CNC Auto Notch Press.

- 32 Ton CNC Segmental Notching

- 12.5 Ton Notching Press.

- Blanking Presses ( 40 T 1600 T)

- Conventional Notching Presses ( 6 Ton to 12 Ton)

- Vertical Spindle Surface Grinding Machine

- Varnishing Plant

- De-burring Machine / Belt Burr Grinder .

- Projection welding Machines

- Spot Welding Machines

VARNISHING : TO INCREASE THE INSULATION THICKNESS

TOTAL VARNISH THICKNESS REQD. : 5 TO 9 MICRONS PER SIDE .

• PRE HEAT ZONE : 300 ± 100 ºC

• COOLING

• VARNISHING

• HEATING : 450 ± 50 ºC

• COOLING

MATERIAL USED IN PRESS SHOP MATERIAL USED IN PRESS SHOP FOR MANUFACTURING OF FOR MANUFACTURING OF

STAMPINGSSTAMPINGS

1. CRNGO SILICON STEEL , CR Sheet

2. COATED MATERIAL (6 1.5 MICRON STABOLITE 40 VARNISH)

3. Major Supplier - RSP Raurkela , TKES NASIK, ALLOVERGY – Germany,

4. MATERIAL Thickness -

- 0.35MM TO 0.75MM ( STATOR & ROTOR )

- 1 to 2.25 mm ( Pole Punchings)

- 1.6 To 4.5 mm ( Rim Laminations )

TYPE OF PRESS TOOLS TYPE OF PRESS TOOLS ::

SINGLE NOTCH TOOLS : Produce single notch in a

stroke and used when the required quantities are less .

e.g Notching , Venting , Trimming etc.

COMPOUND TOOLS :Two or more than two cutting

operations are completed in a stroke, used for mass

production

COMBINATIONS TOOLS : Cutting & non cutting

operations like bending, forming are performed in a

stroke

PROGRESSIVE TOOLS : It performs a series of

fundamental sheet metal operations at two or more

stations during each stroke .

Quantity of laminations

Design / Profile of laminations

Cutting Load (of available Presses)

Machine Delivery time

SELECTION OF PRESS SELECTION OF PRESS TOOLSTOOLS

MANUFACTURING OF IMM & LEM LAMINATIONS

PRECAUTION TAKEN DURING SPOT WELDING :

STATOR SPACER PLATE FOR HYDRO GENERATORS

1) CHECK FOR PARALLEL SURFACE OF SPACERS

2) SET MACHINE FOR CORRECT CURRENT SETTING AS PER MACHINE PARAMETERS

3) CHECK THE ASSEMBLY THROUGH DROP TEST ( FROM ONE METER HEIGHT )