BHEL PROJECT REPORT {PRM}
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Transcript of 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 )