Professional Documents
Culture Documents
HUBBALLI
INTERNSHIP Report on
Submitted by
Shravanabelagola-573 135
2017-18
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CERTIFICATE
ii
AKNOWLEDGEMENT
We sincerely thank all the respondents whose spared their valuable time and have
provided all the information required to us.
Lastly we are grateful to our parents and friends for their co-operation and invariable
support.
iii
DECLARATION
We Mr. Pranit Rajesh Patil and Mr. Abhishek Ashok Thorat, students of
Bahubali College of Engineering, Shravanabelagola, studying in 8th semester BE in
Mechanical engineering. Thank our institution for giving us this opportunity.
We had been for internship at Kirloskar Electric Company Pvt. Ltd. Hubballi.
We further declare that this project report is the result of our own efforts and has not
been submitted earlier to any other college for any other degree.
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CONTENTS
1 CERTIFICATE ii
2 AKNOWLEDGEMENT iii
3 DECLARATION iv
4 INTRODUCTION 1-3
Founders 1-3
5 HISTORY 4-8
6 COMPANIES 9
10 AC MOTORS 15-22
Quality assurance 25
12 LEARNING OUTCOMES 36
13 REFERENCE 37
INTRODUCTION
DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 5
KIRLOSKAR ELECTRIC COMPANY PVT. LTD. HUBBALLI
FOUNDERS:
Was a successful industrialist, but his chief merit lay in the trail he blazed, for the
principle in life he depended upon were his vision and a spirit of pioneering.
"My faith is in the human intellect. It gives us our means to create wealth by directing
our talents towards productive work. And therefore, freedom for individual ability is the only
way a society can prosper. After all, you can’t distribute wealth unless you first create it. And
you can’t create it unless you know how."
His Childhood
Born on June 20, 1869 in the small town of Gurlhosur in Dharwar district, he was the
fifth and youngest child of a retired land surveyor by name Kashinath Vasudeo Kirloskar
whose income was twelve rupees a month.
At the age of three he lost his mother and his father had to look after him and was
sent to Belgaum, Karnataka to study. His hobby was drawing and toy making.
When he was still in fourth standard, at the age of sixteen, he quit school to go to
Bombay. He enrolled himself in the Sir J.J.School of Art and Crafts and gave up painting and
confined himself to drawing in black and white.
While he was still a student in the third year school at the Art School, he joined as a
drawing teacher in Victoria Jubilee Technical School at a very nominal monthly salary. At the
Technical School he acquired a working knowledge of handling lathes, drills and presses.
His Wish
Even though India was backward compared to the western countries in the industrial
revolution, Laxmanrao instinctively felt that they are precursors of a newer industrial era.
Railways was limited to selected parts of the country and only other means of
mechanical transportation was pedal cycle and what surprise it caused among the people! In
those days, Laxmanrao mastered the art of riding it and also learnt how to take it apart and
put it together again. He corresponded with a british firm of manufacturers and obtained the
agency for selling cycles.
He returned to Belgaum, and there along with his wife and brother he opened the
cycle shop. This was the beginning of the firm, Kirloskar Brothers.
Since the plague started in Belgaum, Kirloskar Brothers had to evacuate to an open
place Thalakwadi (now known as Tilakwadi) in suburb of Belgaum.
Laxmanrao noticed that animals ate the dry leaves, but the stalks they left alone for
they were thick and difficult to masticate. So he made a chaff cutter that cut the sheaves
including the stalks into small pieces this saved a lot of fodder. But the farmers were not
interested in buying it and the chaff cutting machine was a failure
Ravindra L. Kirloskar:
He was the youngest son of Laxmanrao and
Radhabhai Kirloskar, who later headed KEC
operations.
"Quality must go beyond standard tests and procedures. It must be equated with self
respect and personal pride."
His Industrialisation
In 1948, Ravi Kirloskar and N.W.Gurjar started the Indian Electrical Association to
promote the growth of the industry and to represent it's interests.
He was closely associated with the Indian Standards Association and, the first draft
for ISI Standard 325 for electric motors was drawn up by him. His policy was tied up with
the Government's Five Year Plans, especially in the context of electrical industry.
He persuaded the Karnataka Electricity Board to try out mini-hydel power plant as a
revolutionary concept in India for the first time.
Ravi Kirloskar founded the Indian Association for Quality and Reliability in 1972.
By the time he retired as Chairman in 1979, the Association had seven branches and over
2000 members.
His Vision
"We cannot continue as slaves of foriegn know-how indefinitely, we must
intensify our R & D efforts," he would repeatedly say.
He was a very observant man and he was able to use the past to analyse and interpret
the future. He had talent for absorbing information easily and had a very good grasp of
fundamentals.
Long before small scale industries became popular, he encouraged his workers to
branch out on their own and also provided technical guidance, financial assistance and
assured them a market for their products.
HISTORY
India’s first iron plough from the Kirloskar Group, not only became an instrument of
wealth for the entire society but also kick started an industrial revolution in India. Today
building on its core engineering strength, the group’s scope of operations spans across a
gamut of industrial equipment ranging from pumps & valves, eco-friendly diesel engines &
silent generating sets, air & gas compressors, air-conditioning and refrigeration equipment, a
wide range of anti-corrosion coatings and castings for automotive sector.
GLOBAL PRESENCE:
INDIA
World’s largest irrigation scheme brought Green Revolution in over 4,600 towns
and villages in drought-prone Saurashtra.
Rugged and dependable power packs, 100% reliable back-up power for radar
grids, HVAC solutions for fighter aircrafts and propulsion power for naval ships meets
country’s defence needs.
Millions of energy efficient Kirloskar engines and pumpsets save energy worth
billions.
Diesel engines power over 80 different applications. Gensets form the backbone
of satellite, cellular and telecommunications.
Gas compression solutions for natural gas filling stations ensure environment
free transportation.
Critical castings that house one among four tractor engines in India.
AFRICA
A large number of Kirloskar pumps have transformed a million lives across the length
and breadth of Africa by providing water for agricultural irrigation and other necessities.
With their unique AAA (Adaptable, Appropriate and Affordable) technology, Kirloskar is
committed to bringing about a Green Revolution in Africa.
In Senegal, over 2,300 Kirloskar diesel engine-driven pumps and over 20 drip
irrigation systems across the Senegal river have increased the annual rice production from
less than 100,000 tonnes to 460,000 tonnes by increasing the irrigated land from 24,500
hectares to 85,000 hectares. Senegal is well supported by Kirloskar to achieve self-
sufficiency in food by 2013.
EGYPT
For the past thirty years, over 100,000 Kirloskar pumpsets have been working along
the river Nile, for greening the desert lands in Egypt. A total of 40 pumping stations
incorporating Kirloskar pumps have been able to reclaim over 150,000 acres of desert land
for agriculture, making the brand name ‘Kirloskar’ synonymous with pumps in Egypt.
MIDDLE EAST
Reliable and energy efficient compressors help preserve seafood, also bringing
prosperity to fishermen in the Middle East.
LAO PDR
Kirloskar pumps have changed the economy of Lao PDR from an importer of food
grains to becoming a self-sufficient nation. About 7,500 pumps worth over US$3.1 million
have increased the land under irrigation from 15,000 hectares in 1996 to over 140,000
hectares, increasing the rice production from 20,000 tonnes / annum to over 500,000 tonnes /
annum.
COMPANIES
GREEN INITIATIVES
KBL’S office is India’s 2nd greenest building.
KIRLOSKAR PRODUCTS:
Green Solutions
Trading and After Sales Services of Kirloskar Products in Middle East & Africa
2. Hubli
3. Tumkur
4. Mysore
5. Pune.
AC MOTORS
Kirloskar Electric was the first company in India to manufacture AC motors way
back in 1948. Since then it has developed millions of motors for domestic and international
market.
Alternating Current (AC) is what power companies transmit through the electric
wires. AC travels in both directions and is used so that transformers may raise and lower the
voltage. Electric generators produce low voltage electricity and transformers are used to raise
the voltage for long distance transmission.
INTRODUCTION
1. Enclosure
Enclosure
The enclosure consists of a frame (or yoke) and two end brackets (or bearing housings).
A motor's enclosure not only holds the motor's components together, it also protects
the internal components from moisture and containments. The degree of protection depends
on the enclosure type. In addition, the type of enclosure affects the motor's cooling.
2. Stator
Stator
A. Stator Core
The stator is the stationary part of the motor's electromagnetic circuit. The stator is
electrical circuit that performs as electromagnet. The stator core is made up of many thin
metal sheets, called laminations. Laminations are used to reduce energy losses that would
result if a solid core were used.
B. Stator (Windings)
Stator laminations are stacked together forming a hollow cylinder. Coils of insulated
wire are inserted into slots of the stator core.
When the assembled motor is in operation, the stator windings are connected directly to the
power source. Each grouping of coils, together with the steel core it surrounds, becomes an
electromagnet when current is applied. Electromagnetism is the basic principle behind motor
operation.
3. Rotor
Rotor
The rotor is the rotating part of the motor's electromagnetic circuit. Magnetic field
from the stator induces an opposing magnetic field onto the rotor causing the rotor to “push”
away from the stator field.
There are a lot of rotor types like Squirrel cage rotor and wound rotor, they will be
explained later.
1. Bearings:
Bearings, mounted on the shaft, support the rotor and allow it to turn. Not all bearings are
suitable for every application; a universal, all-purpose bearing does not exist. The choice of
bearing arrangement is based on the following qualities:
Bearings Types:
There are many types of bearings on the market, each with different characteristics
and different uses, these types are as follows:
Deep groove ball bearings are the most common type of bearing, and can handle both
radial and thrust loads. Due to their low-frictional torque, they are suitable for high speeds.
In a ball bearing, the load is transmitted from the outer race to the ball and from the
ball to the inner race.
Since the ball is a sphere, it only contacts the inner and outer race at a very small
point, which helps it to spin very smoothly. This also means that there is not very much
contact area holding the load, so if the bearing is overloaded, the balls can deform, ruining
the bearing.
These roller bearings are used in applications where they must hold heavy radial
loads. In the roller bearing, the roller is a cylinder, so the contact between the inner and outer
race is not a point but a line. This spreads the load out over a larger area, allowing the
bearing to handle much greater radial loads than a ball bearing.
However, this type of bearing is not designed to handle much thrust loading.
Angular Contact ball bearings have raceways in the inner and outer rings which are
displaced with respect to each other in the direction of the bearing axis. This means that they
are suitable for the accommodation of combined loads such as simultaneously acting radial
and axial loads in vertical machines.
In Spherical Roller thrust bearings, the load is transmitted from one raceway to the
other at an angle to the bearing axis. They are suitable for the accommodation of high axial
loads in addition to simultaneously acting small radial loads. Spherical roller thrust bearings
are also self-aligning.
E. Sleeve Bearings
Sleeve bearings have no moving parts, they rely on a thin film of oil to reduce
friction and allow the motor shaft to turn freely. This film of oil is critical to the life of a
sleeve bearing.
When properly lubricated, there is actually no physical contact between the bearing
and the shaft. If for some reason the oil film breaks down, metal-to-metal contact between
the shaft and the bearing will cause the bearing to wear very quickly and soon fail.
Sleeve bearings are often chosen because of their relatively quiet operation and lower
cost compared to ball bearings.
5. Conduit Box
Conduit Box
Point of connection of electrical power to the motor’s stator windings.
6. Eye Bolt
Eye Bolt
Used to lift heavy motors with a hoist or crane to prevent motor damage.
Magnetic Poles:
Poles in a motor are always an even number and come in sets of two (north and
south). In an AC motor, the number of poles work in conjunction with frequency to
determine the synchronous speed.
Objectives:
Shop 1:
The manufacturing functions are carried out in this shop. In this shop all the raw
materials are pooled up then given a shape, which is semi ready. Various steps are carried out
here to give final shape of various parts of the products like shaft, base milling, machining
i.e. boring, drilling, tapping, covers are also done here.
To avoid the run out 360 degree balancing is done. Here additional balancing type is
adopted.
Pressure testing is carried out to know if any leakage, blowholes. If they are present
it’s rejected.
Shop 2:
In this shop only die casting is done. i.e. shape of body and name plates are given in
their final shape. Here all three body shape and name plates are done with aluminum, which
is heated upto 750 to 800 degree centigrade. This molten aluminum itself takes the given
shape after cooling. Machine used is H660.
Pre-treatment shop:
It is also known as painting shop. Here the components used in the motors are
pretreated and painted. A unique innovation technology called UNIBAKES, installed in 1992
used for drying the components to be used in export motors.
Shop 3:
This is assembly shop, where the products will get ready upto 9% here. Only final
finishing stages will be left at this stage. The frame size 63-180 motors are assembled here.
The assembling i.e. fixing covers, screws and nuts are done manually. The shaft is fixed
through hydraulic pressing machine. The product comes to connection wing where electrical
connections are given and then later on electrical parts are checked. The product is given first
coat of painting.
Shop 4:
This shop is known as INVOTECH CENTER i.e. R&D division of the firm in this
shop, the product development is the main function. This shop is closely related to the
engineering department and hence carries on its activities in accordance with the engineering
department. The activities of this shop include tests for future department, vibrators testing
reliability etc.
Shop 5:
This shop is for assembly. In this shop there are two sections. One deal with AC
motors and other one with AC generator. In this section of AC motors, the assembling of
machine upto 200-450 frames is done here. In this section of AC motors, the process begins
with the shaft being inserted into rotor through hydraulic press machine. This also has own
painting and dispatch section.
Functions:
1. Preparation of drawing jigs, fixtures, dies, tooling storage devices and gauges.
Quality assurance:
The role of quality is so functional division in achieving and maintaining level of
specified quality requirements economically.
Functions:
3. Ensuring that calibrated instruments are used for measurements and coordinating
with calibration.
Primo
KEC designs, manufacture and supply close type cage primo motors to
suit the exact requirements of the application resulting in satisfactory
performance and operation.
Special
Crane Duty Wound Rotor
Kirloskar Electric’s AC cage/wound rotor crane duty motors are
specially designed for crane applications. The mechanical features are
particularly made for tough tasks involving weirs and sluices, lifts and
auxiliary motors in rolling mills, etc.
Wind Generators
Kirloskar Electric's specially designed Wind Generators are light
weight generators suitable for mounting at approximately 30 meter
height. Advanced engineering techniques and materials used for
manufacturing these generators conform to various international
standards and meet the customer's requirement.
High Voltage
Spectrum X F - IC 411
Kirloskar Electric’s Spectrum X F is a series of three phase large AC
induction Motors.
AC Motors
High Voltage Motors: Megapack Closed Type Cage
Duty S1 (continuous)
INDUSTRY APPLICATIONS
CEMENT
CHEMICAL
FERT & CHEM
MINING
PAPER
POWER
STEEL
SUGAR
Duty S1 (continuous)
INDUSTRY APPLICATIONS
CEMENT
CHEMICAL
FERT & CHEM
MINING
PAPER
POWER
STEEL
SUGAR
Duty S1 (continuous)
Duty S1 (continuous)
Duty S1 (continuous)
Duty S1 (continuous)
Duty S1 (continuous)
Duty S1(continuous)
LEARNING OUTCOMES:
1. Ability to analyse a given engineering problem, identify an appropriate problem
solving methodology, implement the methodology and propose a meaningful
solution.
2. This training helps to bridge the gap between the theoretical knowledge into
practical.
3. Ability to apply prior acquired knowledge in problem solving.
4. Ability to identify sources of hazards and identify appropriate health and safety
measures.
5. Ability to work in a team.
6. Ability to take initiatives.
7. Ability to effectively communicate solution to a problem.
8. Ability to adopt a factual approach to decision making.
9. Ability to take engineering action.
REFERENCE
1. www.google.com
2. www.kirloskar.in
3. Wikipedia
4. AC Motors Wikipedia