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Technological map for disassembling an asynchronous electric motor. Maintenance and overhaul of asynchronous motor

Introduction

Main part

1. Design and principle of operation of an asynchronous motor with a squirrel-cage rotor

2. Possible malfunctions of an asynchronous motor with a squirrel cage rotor and ways to eliminate them

3.Tool used

4. Technological map for repair and maintenance of an asynchronous motor with a squirrel-cage rotor

Economy

Labor protection and ecology

Conclusion

Bibliography

Introduction

Maintenance of electrical installations of industrial enterprises is carried out by hundreds of thousands of electricians, on whose qualifications reliable and trouble-free operation electrical installations. Proper organization of an electrician's work and competent management of electrical installations becomes a very complex and responsible matter, since any operating error can lead to significant material damage, failure of expensive equipment, large product losses, and irrational use of electricity.

Relevance chosen topic: against the backdrop of industrial development, the role of reliable and powerful electrical machines with high efficiency is increasingly increasing.

For my work, I chose the topic “Technology for repair and maintenance of an asynchronous motor with a squirrel-cage rotor,” since such a motor is one of the most common types of electric motors.

Goal of the work: study and describe the device, principle of operation, technology for repair and maintenance of an asynchronous motor with a squirrel-cage rotor.

Tasks:

· analyze literature and technical documentation on the selected topic;

· study and describe the device, principle of operation, possible malfunctions of an asynchronous motor with a squirrel-cage rotor;

· draw up a technological map for repair and maintenance of an asynchronous motor;

· make economic calculations of repair work;

· analyze the environmental situation at the site of industrial practice.

1. Main part

.1 Design and principle of operation of an asynchronous motor with a squirrel-cage rotor

An asynchronous machine is an alternating current electric machine, the rotor speed of which is not equal (in motor mode less) than the rotation speed magnetic field, created by the stator winding current. They are mainly used as electric motors and are the main converters of electrical energy into mechanical energy.

An induction motor consists of two main parts separated by an air gap: a stationary stator and a rotating rotor. Each of these parts has a core and a winding. In this case, the stator winding is connected to the network and is, as it were, primary, and the rotor winding is secondary, since energy enters it from the stator winding due to the magnetic connection between these windings. According to their design, asynchronous motors are divided into two types: motors with a squirrel-cage rotor and motors with a wound rotor. Let's consider the design of a three-phase asynchronous motor with a squirrel-cage rotor. Engines of this type are most widely used

Fig.1. Squirrel-cage induction motor

1-shaft; 2-outer bearing cover; 3-roller bearing; 4-inner bearing cover; 5-bearing shield; 6-terminal box; 7-stator winding; 8-rotor winding; 9-stator core; 10-core rotor; 11-electric motor housing; 12-fan casing; 13-fan; 14-ball bearing; 15-bolt grounding; 16-hole engine mount bolt

In the stator bore there is a rotating part of the engine, the rotor, consisting of a shaft and a core with a short-circuited winding. This winding, called a “squirrel wheel,” is a series of metal, aluminum or copper rods located in the grooves of the rotor core, closed on both sides by short-circuiting rings. The rotor core also has a laminated design, but the rotor sheets are not coated with insulating varnish, but have a thin oxide film on their surface. This is sufficient insulation that limits eddy currents, since their magnitude is small due to the low frequency of magnetization reversal of the rotor core. For example, with a network frequency of 50 Hz and a nominal slip of 6%, the magnetization reversal frequency of the rotor core is 3 Hz. Short-circuiting the rotor winding in most motors is accomplished by pouring molten aluminum alloy into the assembled rotor core. In this case, short-circuiting rings and ventilation blades are cast simultaneously with the winding rods. The rotor shaft rotates in rolling bearings located in bearing shields.

The ends of the phase windings are brought out to the terminal box terminals. Typically, asynchronous motors are designed to be connected to a three-phase network at two different voltages that differ by a factor of two. For example, the motor is designed to be connected to a network with a voltage of 380/660 V. If the network has a linear voltage of 660 V, then the stator winding should be connected with a star, and if 380 V, then with a triangle. In both cases, the voltage on the winding of each phase will be 380V. The terminals of the phase windings are placed on the panel in such a way that it is convenient to connect the phase windings using jumpers, without crossing the latter. Some small motors have only three terminals in the terminal box. In this case, the motor can be connected to the network at one voltage (the stator winding of such a motor is connected with a star or triangle inside the motor).

1.2 Possible malfunctions of an asynchronous motor with a squirrel cage rotor

An external malfunction can be:

insufficient engine ventilation;

violation of the device’s contact with the network;

device overload;

mismatch of the incoming voltage with the operating requirements of the engine.

The following can be considered internal failures of an asynchronous motor:

bearing faults;

broken rotor shaft;

weakening of the grip of the brushes;

stator mounting malfunctions;

the appearance of grooves on the commutator or slip rings;

short circuits between turns of windings;

insulation penetrating the body;

winding desoldering;

wrong polarity.

Malfunction

Manifestation

Causes

Does not develop the rated rotation speed and hums

One-way rotor attraction

a) wear of bearings b) misalignment of bearing shields c) bending of the shaft.

The current in all three phases is different and even at idle it exceeds the rated one

Poor speed and hums

1. The windings are connected incorrectly and one of the phases is “upside down” 2. The rotor winding rod is torn

The rotor does not rotate or rotates slowly

The engine is humming

The stator winding phase is broken

The whole car vibrates

The whole car vibrates

1. The centering of the coupling halves or the alignment of the shafts is disturbed 2. The rotor, pulley and coupling halves are unbalanced

Vibration disappears after disconnecting from the network, the current in the stator phases becomes unequal

One of the sections of the stator winding heats up quickly

Short circuit in the stator winding

Overheats at rated overloads

Heats up, malfunctions

1. Turn short circuit in the stator winding 2. Contamination of the windings or ventilation ducts

Low resistance

Low resistance


Electric motor installation:

The electric motor, delivered to the installation site from the manufacturer or from the warehouse where it was stored before installation, or from the workshop after inspection, is installed on a prepared base.

Depending on the conditions, the following are used as bases for electric motors: cast iron or steel plates, welded metal frames, brackets, slides, etc. Plates, frames or slides are aligned along the axes and in the horizontal plane and fixed on concrete foundations, floors, etc. . etc. using foundation bolts that are embedded in prepared holes. These holes are usually left when concreting foundations, placing wooden plugs in the appropriate places in advance.

Holes of small depth can also be punched in ready-made concrete foundations using electric and pneumatic hammers equipped with high-performance tools with carbide tips. The holes in the plate or frame for mounting the motor are usually made at the manufacturer, who supplies the overall plate or frame for the motor and the mechanism it drives.

If there are no holes for the electric motor, mark the base and drill holes at the installation site. To perform these works, the installation and installation dimensions of the installed electric motor are determined (see figure), namely: the distance between the vertical axis of the motor and the end of the shaft L6+L7 or the end of the mounted coupling half, the distance between the ends of the coupling halves on the shafts of the electric motor and the mechanism driven by it, the distance between the holes in the paws along the axis of the electric motor C2+C2, the distance between the holes in the paws in the perpendicular direction C+C.

In addition, the shaft height (axis height) on the mechanism and the height of the electric motor axis h must be measured. As a result of these last two measurements, the thickness of the paw pads is preliminarily determined.

For ease of centering of the electric motor, the thickness of the pads should be within the range of 2 - 5 mm. Electric motors are lifted onto foundations using cranes, hoists, winches and other mechanisms. Lifting electric motors weighing up to 80 kg in the absence of mechanisms can be done manually using decks and other devices. The electric motor installed on the base is pre-centered with a rough adjustment along the axes and in the horizontal plane. The final alignment is made when the shafts are mated.

1.3 Tool used

In the process of servicing and repairing an asynchronous motor with a squirrel-cage rotor, the following tool is used:

Alignment ruler

Staples and strings

Rulers for pulleys of different widths.

Wrenches 6 - 32 mm - 1 set.

Files - 1 set.

Set of heads - 1 set.

Metal brush - 1 pc.

Fitter knife - 1 pc.

Screwdriver set - 1 set.

Bench screwdriver - 1 pc.

Dies 4 - 16 mm - 1 set.

Taps 4 - 16 mm - 1 set.

Set of drills 3 - 16 mm - 1 set.

Mount - 1 pc.

Pliers - 1 pc.

Chisel - 1 pc.

Drill - 1 pc.

Core - 1 pc.

Flat brush - 2 pcs.

Hammer - 1 pc.

Shovel - 1 pc.

Brush-sweep - 1 pc.

1.4 Technological map for repair and maintenance of an asynchronous motor with a squirrel-cage rotor

Title and content of work

Equipment and accessories

Technical requirements

External inspection of an electrical machine, including control, protection, ventilation and cooling systems.


Compliance with technical data sheets for operation and electrical diagrams.

Visual check of the condition of the grounding conductor; checking the condition of the ground loop.

Hammer, shovel

Lack of anti-corrosion coating, loose fastenings, and mechanical damage are not allowed.

Check for the absence of extraneous noise.


Extraneous noise is not allowed.

Cleaning accessible parts from dirt and dust.

White spirit, rags, metal brush, broom brush.


Inspection of the elements connecting the engine to the driven mechanism.


Cracks at the seams, ruptures, distortions, and loosening of threaded connections are not allowed.

Checking the connection and reliability of the seal of the supplied cables, the technical condition and tightness of the input boxes and sealed input couplings; checking the condition of seals, surfaces and parts providing explosion protection;

explosion-proof of cable and wire entries.

Set of plumbing probes No. 1 Set of tools, set of screwdrivers, set of heads.

The roughness of the working surface Rd is no more than 1.25 microns.

Checking the fastening of the electric drive to the frame (valve).

Set of tools. Set of heads.

Loosening of the fastening is not allowed.


Inspection of the condition of starting and control equipment (ballasts).

Blowing the stator and rotor with compressed air.


Compressor.

Checking the insulation resistance of the windings; dry if necessary.

Megger voltage 500V.

The insulation resistance should not be less than 0.5 MOhm.

Checking the mating of parts that ensure tightness.

Set of plumbing probes No. 1. Set of tools, set of screwdrivers. Set of heads, sealant.

The clearance sizes are indicated in the operating manual.

Checking the presence of lubricant in the electric motor bearings (if there is a grease nipple, replenish).


Grease CIATIM - 221, syringe for pressing in grease.


Set of tools. Screwdriver Set.

Brush, paint (plate).

Inspection, cleaning and tightening of contact connections.

Set of tools. Sanding cloth according to GOST 5009-82.

Distortions, presence of oxide, loosening of contact connections are not allowed.

Grease CIATIM - 221, syringe for pressing in grease.


Inspection of circuit breaker components.

Set of tools. Screwdriver Set.

Checking the presence of cable markings, inscriptions and symbols on the casing, restoring if necessary.


Lack of markings and inscriptions are not allowed.

Security measures

The electric motor must be de-energized, the AV switched off, grounding installed, and posters posted. Apply portable grounding to the input ends of the electric motor cable. Fence the work area. Work using PPE. Work with verified devices and tested power tools and accessories.

An electrician for the repair of electrical equipment with an electrical safety group of at least three. Electrician for repair of electrical equipment with the third electrical safety group.

2. Economy

Types of jobs

Rotor damage

Stator damage

Shaft damage


Troubleshooting

Dismantling

Spare parts

Performance diagnostics

Total:


Conclusion: repairing asynchronous motor parts is more economical than replacing them.

3. Labor protection and ecology of converter production at EVRAZ NTMK

I completed my practical training in the converter shop of EVRAZ NTMK and had the opportunity to analyze the environmental situation and labor safety conditions at the plant in general and the converter shop in particular. squirrel cage asynchronous motor

The EVRAZ NTMK converter shop celebrated its 50th anniversary in the fall of 2013. This is one of the most modern steelmaking plants in Russia. Over the past few years, a full-scale reconstruction has been carried out here. Today the workshop includes a converter department with four 160-ton converters; an out-of-furnace steel processing section, which includes four ladle-furnace units and two circulation vacuum degassers; department for continuous casting of steel from four continuous casters. A cast iron desulfurization unit is in operation, which allows the production of steel with minimal sulfur content.

Reducing the negative impact of production on the environment and the population of Nizhny Tagil is the goal of the entire environmental policy of the Nizhny Tagil Iron and Steel Works. In recent years, the plant has invested significant funds in the technical reconstruction of the enterprise, which, along with modernization, necessarily solved the environmental problems of the city.

By 2007, the following were built and put into operation: an ONRS complex in the converter shop consisting of continuous casting machines No. 1, 2, 3, 4, ladle furnaces No. 1, 2, 3, a vacuum degasser;

As Sergei Permyakov, head of NTMK’s environmental protection department, noted, only thanks to the technical re-equipment of converter No. 4, it was possible to reduce emissions into the atmosphere by almost 500 tons per year. Dust emissions decreased by 30 tons as a result of major repairs of dust and gas collection units in the blast furnace and converter shops. Major repairs were also carried out on the dirty water supply cycle of the blast furnace, rolling and converter industries.

The implementation of these measures made it possible to reduce the content of petroleum products in water bodies by 14 tons, zinc by 977 kg, fluorine by 8,309 kg, and iron by 466 kg. Together with ecologists from Nizhny Tagil, this technology was used at the Nizhny Tagil reservoir.

In June 2010, an external recertification audit of the environmental management system was successfully carried out at OJSC NTMK. Based on the audit results, the certificate of compliance with the requirements of the international standard ISO 14001 was extended.

The implementation of environmental measures over the past five years has made it possible to reduce annual emissions of pollutants into the atmosphere by 32 thousand tons.

Conclusion

In the course of this work, I analyzed the literature and technical documentation on the chosen topic, studied and described the device, principle of operation, possible malfunctions of an asynchronous motor with a squirrel-cage rotor, compiled a repair and maintenance flow chart, made an economic calculation of repair work, described the environmental situation on the site undergoing industrial practice. Thus, the set goals of the task can be considered completed.

The knowledge and skills acquired during this work, acquired during production practice, will be useful in my future professional activities.

Bibliography

1. Lobzin S.A. Electric cars. - M.: IC "Academy", 2012.

Moskalenko V.V. Electrician's Handbook: Handbook. - M.: ProfObrIzdat, 2002.

Moskalenko V.V. Electric drive. - M.: IC "Academy", 2000.

Nesterenko V.M. Technology electrical installation work. - M.: IC "Academy", 2004.

Sibikin Yu.D., Sibikin M.Yu. Maintenance and repair of electrical equipment and networks of industrial enterprises. - M.: IRPO; Ed. Center "Academy", 2000.

Sibikin Yu.D., Sibikin M.Yu. Electrical installation technology. - M.: IC "Academy", 2000.

Sibikin Yu.D. Electrical safety during the operation of electrical installations of industrial enterprises. - M.: Publishing house. Center "Academy", 2007.

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3.11 Technological map of current repairs of 6 kV PEN asynchronous electric motors.

Name of operations

NTD (drawings, etc.)

Control operations

Note

Criteria

3.11.1 Disassembling the electric motor.

Remove the stator terminal cover, disconnect the power cable and resistance thermometer wires, disconnect the grounding

OVK.412.106 TO

Clean terminal surface, integrity of insulators and stud threads, tight fit of lugs on cables

hot-smooth sandpaper 12x13, gasoline, soldering iron

Oxidation of terminal surfaces, cracking of insulators, stripping of threads on studs, failure of fastening of lugs on cables

Sand the surface of the leads, wash with gasoline, replace the insulators if necessary, solder the tips

Disconnect and remove the diffusers from the ED.

OVK.412.106 TO

Take off air filter, blow and dry

OVK.412.106 TO

Device for purging, gasoline B-70, g/k 10x12

3.11.2 Stator inspection.

Check the fastening (from the outside) of the stator ventilation struts

OVK.412.106 TO

OK by tapping with a hammer

Uniform, hollow sound and no rattling

Hammer 0.2 kg

Loose fastening

Weld defective spacers

Clean from dust, dirt, oil and inspect the frontal parts of the stator winding

OVK.412.106 TO

No contamination, tight winding of bands and seating of spacers

Loosening bands and spacers

Rebandage the frontal parts of the winding, install spacers

3.11.3 Electric motor assembly.

Install diffusers on the ED.

OVK.412.106 TO

Install the air filter.

OVK.412.106 TO

Connect the power cable, resistance thermometer wires, connect the grounding, close the stator terminal cover,

OVK.412.106 TO

Clean the surface of the leads, rinse with gasoline, replace the insulators if necessary, solder the tips

After assembly, carry out a control measurement of the motor insulation resistance and absorption coefficient with a 2500V megger. The insulation resistance must be at least 40 MOhm, the absorption coefficient must be at least the value specified in clause 1.3.2.

3.12 Technological map of current repairs of 6 kV CN asynchronous electric motors.

Name of operations

NTD (drawings, etc.)

Control operations

Devices, tools, equipment

Possible defects, malfunctions

Note

Criteria

3.12.1 Disassembling the electric motor.

Remove the stator terminal cover, disconnect the power cable and resistance thermometer wires, disconnect the grounding

Clean terminal surface, integrity of insulators and stud threads, tight fit of lugs on cables

hot-pressure, sandpaper, gasoline, soldering iron

Oxidation of terminal surfaces, cracking of insulators, stripping of threads on studs, failure of fastening of lugs on cables

Sand the surface of the leads, wash with gasoline, replace the insulators if necessary, solder the tips

Measure the air gap between the stator and rotor

Set of test leads

Make a decision to transfer the engine to the KR to install the required air gap.

3.12.2 Stator inspection.

Clean from dirt and blow off with compressed air ventilation ducts, borings, winding end parts, stator housing

Blower, lint-free cloth

No contamination, tight winding of bands and seating of spacers

Bandage needle, bandage tape

Rebandage the frontal parts of the winding, install spacers

3.12.3 Electric motor assembly.

Measure the air gap between the stator and rotor

Compliance of clearances with requirements (Table 4.1).

Set of test leads

The air gap does not meet the required values

Make a decision to transfer the engine to the KR to install the required air gap.

Connect the power cable, resistance thermometer wires, connect the grounding, close the stator terminal cover,

Clean terminal surface, integrity of insulators and stud threads, tight fit of lugs on cables

hot-pressure, sandpaper, gasoline, soldering iron

Oxidation of terminal surfaces, cracking of insulators, stripping of threads on studs, failure of fastening of lugs on cables

Clean the surface of the leads, rinse with gasoline, replace the insulators if necessary, solder the tips

After assembly, carry out a control measurement of the motor insulation resistance and absorption coefficient with a 2500V megger. The insulation resistance must be at least 40 MOhm, the absorption coefficient must be at least the value specified in clause 1.3.2. When assembling, check the condition of the oil indicators, for which:

a) clean the oil indicators from external contaminants;

b) unscrew the stilling bolt from the oil level indicator, clean the internal cavity of the stilling chamber of the oil level indicator and the stilling bolt from dirt; install a new gasket for the head of the damping bolt and screw the bolt back in. It is allowed, if necessary, to lubricate the sealing gasket of the head of the stilling bolt with a thin layer of oil-resistant sealant KLT-75;

c) check that there is no plaque on the internal surfaces of the glass that would impede visual control of the oil level, or mechanical damage in the form of cracks and chips; clean the “breathing” hole in the top cover oil indicator;

d) blow through the oil indicators with compressed air with a pressure of no more than 2 kg/cm 2 to check the patency of the oil indicator with control of the air pressure coming out through the “breathing” hole;

If traces of oil leakage through the oil level seals, deposits on the inner surface of the glass that make it difficult to visually control the oil level, foreign particles (residues of sealant, etc.) or other defects are detected, the oil level indicator is completely disassembled and defects are eliminated, followed by reassembly. In this case, the stilling bolt is screwed into place last, after the sealant sealing the glass has hardened. After assembly, the oil indicator is installed on the oil pan with the inspection hole of the low indicator housing in the direction opposite to the electric motor housing, after which the oil indicator is re-checked according to paragraph d).

When installing the floorplates of the upper part of the body and connecting jumpers between the floorplates, use sealant (paint) in the threaded connection of the jumpers as a countermeasure.

3.13 Technological map of current repairs of 6 kV (NR) asynchronous electric motors.

Name of operations

NTD (drawings, etc.)

Control operations

Devices, tools, equipment

Possible defects, malfunctions

Note

Criteria

3.13.1 Disassembling the electric motor.

Remove the stator terminal cover, disconnect the power cable, grounding

IAEG.528122.002 TO

Clean terminal surface, integrity of insulators and stud threads, tight fit of lugs on cables

Oxidation of terminal surfaces, cracking of insulators, stripping of threads on studs, failure of fastening of lugs on cables

Sand the surface of the leads, wash with gasoline, replace the insulators if necessary, solder the tips

Remove the cooler shroud and fan

IAEG.528122.002 TO

hot-smoked 14x17, center punch, 3kg sledgehammer, mounting crowbar

Remove the outer bearing caps (flanges)

IAEG.528122.002 TO

3.13.2 Stator inspection.

Clean from dust, dirt, oil and inspect the frontal parts of the stator winding

IAEG.528122.002 TO

No contamination, tight winding of bands and seating of spacers

Bandage needle, bandage tape

Loosening bands and spacers

Rebandage the frontal parts of the winding, install spacers

3.13.3 Inspection of bearings.

Remove old grease

IAEG.528122.002 TO

Bath for washing parts, B-70 gasoline

Inspect the bearing

IAEG.528122.002 TO

No visible defects

Gouges, spalling, wear marks, dull tracks on rolling surfaces, deformation of balls or rollers

Replace bearing

If replacement is necessary, issue a Defect Report

3.13.4 Inspection of the cooler.

Clean the cooler tubes from dirt and blow them with dry air.

IAEG.528122.002 TO

Blower, lint-free cloth, cleaning rod

3.13.5 Electric motor assembly.

Install both shields on the electric motor

IAEG.528122.002 TO

Beam crane, stands, hot-rolled dynamometer 17x19, punch, sledgehammer 3 kg.

Install the outer bearing caps

IAEG.528122.002 TO

Install the cooler fan and shroud.

IAEG.528122.002 TO

Connect the power cable, grounding. Close the cover of the stator terminal box,

IAEG.528122.002 TO

Clean surface of the leads, integrity of the insulators and stud threads, tight fit of the lugs on the cables

hot-smooth 14x17, sandpaper, gasoline, soldering iron

Oxidation of terminal surfaces, cracking of insulators, stripping of threads on studs, failure of fastening of lugs on cables

Clean the surface of the leads, wash with gasoline, replace the insulators if necessary, solder the tips

3.14 Technological map for the current repair of the reserve exciter DAZ-18-10-6(U3), GSP-2000-1000.

Name of operations

NTD (drawings, etc.)

Control operations

Devices, tools, equipment

Possible defects, malfunctions

Note

Criteria

3.14.1 Disassembling the exciter.

Remove cable covers and disconnect power cables

Clean surface

hot-smoked 17x19, glass paper

Oxidation of terminals

Sand the surfaces of the terminals, wash with gasoline

Disconnect the bearing temperature sensor cables

6BS. 345.030.036

Clean surface

hot-smoked 17x19, glass paper

Oxidation of terminals

Sand the surfaces of the terminals, wash with gasoline

Disconnect the cables from the generator control panel

1BS. 217.038.039

Clean surface

hot-smoked 17x19, glass paper

Oxidation of terminals

Sand the surfaces of the terminals, wash with gasoline

3.14.2 Inspection of the generator stator.

Inspect the stator output

Clean surface of the tips, no tears or cracks in the insulation

Glass paper, fiberglass, electrical tape

Oxidation of tips, damage to insulation

Grinding, tinning of tips, insulation of leads

Tighten threaded connections

VK, test tightening

Tightly tightening threaded connections

Set of wrenches

Loosening threaded connections

Tighten loose screw connections

3.14.3 Exciter assembly.

Connect the cables to the generator control panel

1BS. 217.038.039

Clean surface

hot-smoked set, glass paper

Oxidation of terminals

Connect the bearing temperature sensor cables

6BS. 345.030.036

Clean surface

hot-smoked set, glass paper

Oxidation of terminals

Clean the surfaces of the terminals, rinse with gasoline

Install cable covers and connect power cables

Clean surface

hot-smoked set, glass paper

Oxidation of terminals

Clean the surfaces of the terminals, rinse with gasoline

When replacing a bearing, it must be pressed off the shaft using a screw puller. The new bearing is washed from preservative lubricant in B-70 gasoline. Heat the bearing in an oil bath or with an inductor to a temperature of 90°C and press it onto the shaft. Recommendations for installing bearings are given in Appendix 20. The fit on the shaft is tight. Then the bearing is filled with grease (LITOL-24, SVEM, CIATIM-201). After assembly, carry out a control measurement of the motor insulation resistance and absorption coefficient with a 2500V megger. The insulation resistance must be at least 40 MOhm, the absorption coefficient must be at least the value specified in clause 1.3.2.

I offer an example technological map current repair of 0.4 kV asynchronous electric motors with a power of 0.5 - 1.5 kW.

Security measures.

The electric motor must be de-energized, the AV switched off, grounding installed, and posters posted. Apply portable grounding to the input ends of the electric motor cable. Fence the work area. Work using PPE. Work with verified devices and tested power tools and accessories.

Brigade composition.

Electrician for repair of electrical equipment with at least 3 gr. on electrical safety. Electrician repairing electrical equipment with 3 gr. on electrical safety.

Tool.

Wrenches 6 – 32 mm – 1 set.

Files – 1 set.

Set of heads – 1 set.

Metal brush – 1 pc.

Fitter knife – 1 pc.

Screwdriver set – 1 set.

Bench screwdriver – 1 pc.

Dies 4 – 16 mm – 1 set.

Taps 4 – 16 mm – 1 set.

Set of drills 3 – 16 mm – 1 set.

Mount – 1 pc.

Pliers – 1 pc.

Chisel – 1 pc.

Drill – 1 pc.

Core – 1 pc.

Flat brush – 2 pcs.

Hammer – 1 pc.

Shovel – 1 pc.

Brush-sweep – 1 pc.

Devices, instruments, mechanisms, protective equipment.

Microohmmeter – 1 pc.

Megger 500 V - 1 pc.

Micrometric level – 1 pc.

Soldering tool – 1 pc.

Set of probes – 1 set.

Vernier calipers – 1 pc.

Safety helmets - individually.

Voltage indicator (380V).

First aid kit – 1 pc.

Mittens – 2 pairs.

Safety glasses – 2 pcs.

Materials and spare parts.

Solder POS – 0.02 kg

Copper-phosphorus solder – 0.02 kg

Alcohol – 0.05 kg

Sealant – oil-resistant gasket – 50 ml

Glass tape – 0.150 kg

Electrical insulating varnish – 0.4 kg

Sandpaper – 0.5 m

Wiping materials – 0.5 kg

PVC tape – 0.05 kg

Rosin – 0.005 kg

Keeper tape – 0.5 m

Grease CIATIM – 221 – 0.3 kg

White spirit – 0.3 l

Sequence of operations.

No.Title and content of workEquipment and accessoriesTechnical requirements
1 External inspection of an electrical machine, including systems
control, protection, ventilation and cooling.
Compliance with technical data sheets for operation and electrical diagrams.
2 Visual check of the condition of the grounding conductor;
checking the condition of the ground loop.
Hammer, shovelLack of anti-corrosion coating, loose fastenings, and mechanical damage are not allowed.
3 Check for the absence of extraneous noise. Extraneous noise is not allowed.
4 Cleaning accessible parts from dirt and dust.White spirit, rags, metal brush, broom brush.
5 Inspection of the elements connecting the engine to the driven mechanism. Cracks at the seams, ruptures, distortions, and loosening of threaded connections are not allowed.
6 Checking the connection and reliability of the seal of the supplied
cables, technical condition and tightness of inlet boxes and
sealed input couplings;
checking the condition of seals, surfaces and parts providing explosion protection;
explosion-proof of cable and wire entries.
Set of plumbing probes No. 1 Set of tools, set of screwdrivers, set of heads.The roughness of the working surface Rd is no more than 1.25 microns.
7 Checking the fastening of the electric drive to the frame (valve).Set of tools. Set of heads.Loosening of the fastening is not allowed.
8 Inspection of the condition of starting and control equipment (ballasts).
9 Blowing the stator and rotor with compressed air.Compressor.
10 Checking the insulation resistance of the windings;
dry if necessary.
Megger voltage 500V.The insulation resistance should not be less than 0.5 MOhm.
11 Checking the mating of parts that ensure tightness.Set of plumbing probes No. 1. Set of tools, set of screwdrivers. Set of heads, sealant.The clearance sizes are indicated in the operating manual.
12 Checking the presence of lubricant in the electric motor bearings (if there is a grease nipple, replenish).Grease CIATIM – 221, syringe for pressing in grease.
13 Inspection, cleaning and tightening of contact connections.Set of tools. Sanding cloth according to GOST 5009-82.Distortions, presence of oxide, loosening of contact connections are not allowed.
14 Inspection of circuit breaker components.Set of tools. Screwdriver Set.
15 Checking the presence of cable markings, inscriptions and symbols on the casing, restoring if necessary.Brush, paint (plate).Lack of markings and inscriptions are not allowed.

Additionally, it is possible to indicate in the table labor intensity, labor costs, and other necessary information applicable to your conditions.

This type of repair is used for engines in operation. Major repairs are carried out to restore the functionality and complete restoration of the service life of an electrical machine with the restoration or replacement of all worn or damaged components and the replacement of windings. Repairing a machine may not be practical if there is significant damage to mechanical components that cannot be repaired by our company.

A typical overhaul scope includes:

  • maintenance operations;

  • checking the air gap between the stator and the rotor (if the machine design allows this);
  • checking the axial run of the rotor and the gaps between the shaft journal and the plain bearing liner (if necessary, the liner is refilled);
  • complete disassembly of the machine and washing of all mechanical components and parts, purging and cleaning of the commutator, slip rings, brush mechanism and intact insulating parts, defect detection of components and parts;
  • repair of the housing, bearing shields, magnetic circuits (welding of cracks, restoration of threaded holes, restoration of seats in the housing and shields, removal of short circuits between individual sheets of stator and rotor cores, elimination of fluffing of sheets, restoration of pressing, repair of burnt-out areas with the installation of prostheses);
  • shaft repair (correction of end holes, elimination of deflection, restoration of mounting holes and keyways);
  • removal of old windings, production and installation of new windings from round wire, repair or production of new windings from rectangular wire and their installation, assembly and soldering (welding) of electrical circuits, impregnation and drying of windings, application of coating enamels to the frontal parts;
  • assembly and finishing of the machine, carrying out acceptance tests.

Repair stages

  • Reception and determination of electric motor faults:
  • mechanical and electrical faults;
  • reasons for failure;
  • determining the type and feasibility of repairs;
  • determining the cost of work;
  • conclusion of a contract for the work performed.

Depending on the weight and dimensions, as well as the nature of the engine repair, they are either repaired on site or sent to our facility. Mutual obligations of the customer and our company are regulated in technical conditions repairs.

  • In what form are electric motors accepted for repair?
  • Acceptance for repairs is carried out according to an act, which, in addition to passport data and the expected scope of repairs, indicates technical requirements requirements that the equipment must satisfy after repair: power, voltage, energy indicators, etc. Only complete electric motors that have all the main components and parts, including old windings, are accepted for repair. All connecting and installation parts must be removed by the customer. As a rule, we do not repair machines with broken housings and bearing shields, as well as with significant (more than 25%) damage to magnetic circuits, although there are exceptions.

    • Preparation for installation:
    • dismantling the old winding.
    • determination of winding data and comparison with reference data.
    • optimization of winding data.
    • repair of active stator and armature iron.
    • Winding manufacturing:
    • production of groove insulation
    • production of phase sections with electromechanical control
    • laying of phase sections.
    • performing switching work
    • bandaging and shaping of frontal parts
    • Preliminary tests. Impregnation and drying of the winding:
    • checking the condition of the turn insulation
    • checking the condition of interphase and body insulation
    • measuring the insulation resistance of an electric motor.
    • impregnation of the winding and drying of the electric motor in an electric furnace
    • winding resistance measurement.
    • The electric motor assembly itself:
    • restoration of seats.
    • bearing replacement.
    • welding of cracks.
    • restoration of fastening connections.
    • painting.

    • Final tests:

    • determination of parameters Ix.x.(A)
    • definition n x.x. (rpm)
    • bearing control
    • control t x.x. oS.

    Things to remember:

    During a major overhaul, rolling bearings that have exhausted their service life are replaced (regardless of their condition). The decision to use bearings that have not exhausted their service life is made after they have been defective. It should be remembered that the damage from a possible bearing failure and the associated engine failure (stoppage) is significantly greater than the cost of the bearing itself.

    Windings made of round wire and low-voltage windings made of rectangular wire are, as a rule, not reused during repairs, since it is almost impossible to remove such a wire without damage. After extraction, they are transferred to smelting. High-voltage windings made of rectangular wire can be reused after replacing the turn and body insulation at the request of the customer.

    QUALITY GUARANTEES:

    For electric motors in assembled and complete condition for after repair operation The electric motor is guaranteed for 12 months from the date of receipt of the electric motor for repair, subject to compliance in its further operation

    “RULES FOR THE OPERATION OF ELECTRICAL EQUIPMENT AND POWER INSTALLATIONS FOR CONSUMERS”.

    I. What is included in the electric motor test:

    • Resistance measurements.
    • Calculation of absorption coefficient.
    • Measurement of ohmic resistance by phase.
    • Checking the electric motor at idle speed.
    • Current matching idle move and frequencies. rotation to the passport values.
    • Calculation of transformation ratio.
    • Checking bearings for heating.
    • Checking for vibration of the electric motor.
    • Check for broken rotor conductors.
    • High voltage tests (as required by the customer).

    II. What is included in the restoration of appearance.

    • Removing old paint.
    • Straightening the body and attached parts.
    • Puttying potholes and dents.
    • Cleaning the shaft from corrosion.
    • Preservation or painting of the shaft.
    • Painting the electric motor.
    • Installation of a nameplate (required!!!).
    • The output ends of the windings are marked in accordance with the standard, and a new shield is installed on the machine body indicating our company (who carried out the repair), the date of release from repair and the technical data of the electric motor in accordance with the standards.

    III. What is included in current repairs:

    This type of repair is used for machines in operation or in reserve. Maintenance carried out at the installation site of the electric motor with its stopping and shutdown by your electrical maintenance personnel. If current repairs require special, complex devices and significant time, then they are carried out by the personnel of an electrical repair or specialized enterprise.

    1. Disassembly/assembly.

    2. Defect of the electric motor.

    During defect detection, we conduct a visual inspection of the components and parts of the machine, carry out the necessary measurements and tests, and determine the integrity individual parts and assembly units, the condition of working surfaces to determine the scope of necessary repairs. If the assembly unit is not damaged, it is not disassembled. Disassembly must be carried out using a special tool so as not to damage parts and assembly units.

    3. Current repair of the stator:

    • Washing electric motor parts:
    • Washing the motor winding coils.
    • Drying the motor stator.
    • Replacement and restoration of output ends.
    • Restoring the connection diagram of the winding coils.
    • Checking the resistance of housing and phase-to-phase insulation.
    • Varnish impregnation.
    • Coloring.
    • Replacement of insulators.

    4. Rotor maintenance:

    • Washing the rotor winding coils.
    • Drying the electric motor rotor.
    • Replacing bandages.
    • Re-wedging with the production of new wedges.
    • Restoring the connection diagram of the rotor winding coils.
    • Grooving/replacing slip rings.
    • Checking the resistance of housing and phase-to-phase insulation.
    • Checking the rotor for breaks.
    • Checking for interturn short circuits.
    • Varnish impregnation.
    • Coloring.

    5. Rotor balancing.

    6. Replacement of bearings.

    7. Repair of mechanical parts:

    • Repair/replacement of brush apparatus.
    • Restoration of bearing seats on shields.
    • Restoration of bearing seats on the shaft.
    • Manufacturing/replacement of new shields and bearing caps.

    CALCULATION OF THE COST OF THE FULL SET OF WORKS ON REPAIR OF ELECTRIC MOTORS IS CALCULATED ON CONTRACTUAL TERMS.

    We always carry out repairs so that after the repair the required level of operational reliability is ensured, and the technical performance of your equipment complies with standards and norms.

    Security measures.

    Before starting work, you should inspect the place of work to be done and put it in order; if it is cluttered with unnecessary items that interfere with work, it is necessary to put it in order and remove all unnecessary things. The electric motor must be de-energized, grounded, and posters posted. Apply portable grounding to the input ends of the electric motor cable. Fence the work area. Work using personal protective equipment. Work with verified instruments, mechanisms and proven power tools and accessories. All operations during a major overhaul to repair components and parts of an electric motor are carried out in specialized workshops using specialized equipment.

    Removal of the fence must be possible only with the use of a tool. When carrying out work in an area protected by a removable fence, it must be completely dismantled.

    Sliding or removable guards that allow access for adjustment or installation of controls or sensors on an operating pump must not be obstructed, but must prevent unauthorized access to a potentially hazardous area. Sliding guards attached to the pump must be fixed and in the open position.

    The ED must reflect the requirement to prohibit the removal of fences at work pump unit. To diagnose and assess the condition of a particular unit during operation, inspection windows must be provided in the fences, covered with meshes, perforations, and gratings.

    Brigade composition.

    Electrician for repair of electrical equipment with at least 3 gr. on electrical safety. Electrician repairing electrical equipment with 3 gr. on electrical safety.

    Tool.

    Files.

    Metal brush.

    Fitter's knife.

    Wrenches 6 - 32 mm.

    Screwdriver Set.

    Set of heads.

    Bench screwdriver.

    The brush is flat.

    Mount.

    Pliers.

    Scrub brush.

    Wood block

    Set of drills

    Hacksaw blade

    Electric arc welding (OMM5 electrode)

    Manual guillotine shears

    Manual disc shears

    Devices, instruments, mechanisms, protective equipment.

    Megger 500 V

    Micrometric level

    Set of probes

    Microohmmeter

    Calipers

    Safety helmets

    Voltage indicator (380V).

    Gloves

    Latex gloves

    Protective glasses

    Portable ground electrode

    Welding machine

    Washing machine for washing components and parts of electrical machines or bath

    KHIOT-6 brand paste

    Respirator

    Machine for cutting the frontal parts of windings SO-3M

    Lathe

    Gas plasma spraying installation

    Device for straightening shaft curvature

    Dynamic rotor balancing machine

    Soldering iron

    Winding machine

    Break-in mechanism

    Materials and spare parts.

    Sealant

    Glass tape

    Sandpaper

    Wiping materials

    Keeper tape

    White Spirit

    Spare bearing kit

    Spare ground

    Spare fan

    Synthetic detergent preparation ML-51

    KHIOT-6 brand paste

    Set of stoppers

    Set of studs

    Adhesive varnish

    Mica gaskets

    Textolite wedges

    Concentrated nitric acid

    Putty

    Chemical resistant enamel

    Napkins

    10% soda ash solution

    Fiberglass

    Asbestos cardboard

    Cast iron electrode grade B

    Table 4.

    Sequence of operations.

    Title and content of work

    Equipment and accessories

    Technical requirements

    Dismantle and remove the electric motor.

    Set of heads, bench screwdriver, welding machine(if the engine is welded).

    Conduct pre-repair tests. If the electric motor passes them safely, then carry out acceptance tests. If it passes them too, then send them back into operation. If the electric motor does not pass these tests, send it to an electrical repair shop for major repairs.

    Megger.

    Compliance with technical data sheets for operation and electrical diagrams. The shaft should rotate easily by hand, the insulation resistance should be at least 0.5 MOhm.

    Complete disassembly of the electric motor.

    Wrenches, a set of screwdrivers, a set of heads, a bench screwdriver, a hammer, a puller, a wooden block, kerosene, a burner, asbestos cardboard, tags, a machine for cutting the frontal parts of windings SO-3M, hooks

    Disassembly must be done carefully.

    Cleaning the surface, washing parts and components.

    White spirit, rags, metal brush, scouring brush, water, synthetic detergent ML-51, washing machine for washing components and parts of electrical machines or bath, KHIOT-6 brand paste, rubber gloves, respirator.

    The presence of contamination is not allowed; when diluting the detergent, workers must wear a respirator, safety glasses, rubber gloves, and have their hands lubricated up to the elbows with KHIOT-6 paste.

    Defects of all parts and assemblies of the electrical machine.

    Probe 0.2 mm thick, megohmmeter, caliper

    Parts and assemblies that do not need repair are sent to the assembly shop. Assemblies and parts that need repair are sent to the appropriate workshops for subsequent repairs. Parts and assemblies that cannot be repaired are replaced with new ones, which in turn are sent to the assembly shop.

    Core repair.

    Set of stoppers, drill, set of drills, hacksaw blade, electric arc welding (OMM5 electrode with a diameter of 2 mm), set of pins, file, adhesive varnish, textolite wedges, hammer, mica spacers, BT-99 varnish, concentrated nitric acid, putty, chemically resistant enamel, napkins, 10% soda ash solution, water, alcohol, fiberglass, EL-4 glue.

    Repair of housing and bearing shields.

    Velvet file, oven, cast iron electrode grade B, flux, drill, set of drills, solution of 6F sealant and water, acetone, wire brush, hammer, welding, dies.

    Shaft repair.

    Files, metal brush, lathe, E42 electrode, electric arc welding (OMM5 electrode), drill, set of drills, acetone, gas plasma spraying installation, cutter, device for straightening the curvature of the shaft.

    Repair of short-circuited rotor windings.

    Torch, gasoline, welding, solder, hammer, drill, set of drills, machine for dynamic rotor balancing.

    Manufacturing and installation of windings.

    Soldering iron, hand guillotine shears, hand disk shears, winding machine, hammer.

    Repair of rotor core winding and pole winding.

    Installer's knife, torch, water, soldering iron, solder, metal brush, electrical cardboard, press, rolling mechanism.

    Impregnation of stator and rotor windings.

    Varnish brand ML-92.

    Electric motor assembly, dynamic rotor balancing.

    Wrenches, a set of screwdrivers, a set of sockets, a bench screwdriver, a hammer, a wooden block, a universal balancing machine.

    Assembly must be done carefully.

    Checking the technical condition of bearings and the presence of lubrication. If necessary, lubricate and replace them.

    Grease, syringe for pressing in grease, set of spare bearings.

    Bearings must be well lubricated and in good technical condition.

    Blowing the stator and rotor with compressed air.

    Blowing the stator and rotor with compressed air.

    Checking the technical condition of the fan. Replace it if there is mechanical damage.

    Screwdriver Set,

    set of heads,

    bench screwdriver, spare fan.

    The fan must be of the correct shape, not have chips, cracks, or touch the casing.

    Acceptance tests, running-in of the electric motor.

    Megger, set of probes.

    The test results must correspond to the values ​​​​in the engine passport.

    Checking the fastenings after installing the engine in its original place.

    Wrenches, screwdriver set,

    set of heads,

    bench screwdriver.

    All bolts and nuts must be well tightened (but not overtightened) and have no thread breaks. The presence of worn or deformed rubber bushings is not allowed; the pulley, coupling half or sprocket must be tightly seated on the shaft and have no axial movements.

    Inspect the elements connecting the motor to the driven mechanism after installing the electric motor in its original place.

    Cracks at the seams, ruptures, distortions, and loosening of threaded connections are not allowed.

    Checking the serviceability of grounding. If necessary, clean the surfaces from rust, tighten the fasteners, and replace the faulty grounding with a new one.

    Wrenches, screwdriver set,

    set of heads,

    bench screwdriver, spare grounding.

    Lack of anti-corrosion coating, loosening of fastenings, mechanical damage are not allowed.

    Checking the connection and reliability of the seal of the supplied cables, the technical condition and tightness of the input boxes and sealed input couplings;

    Set of plumbing probes No. 1, set of screwdrivers, set of heads.

    The roughness of the working surface Rd is no more than 1.25 microns. The insulating coating of the output ends of the electric motor windings and wires supplying power must be intact.

    Checking the contact connections in the terminal box.

    Set of screwdrivers, set of sockets, pliers.

    The clamp board (if present) should not be chipped, cracked or charred. The insulation at the junctions of the wires must be free of damage and defects.

    Inspection, cleaning and tightening of contact connections.

    Sanding cloth, screwdrivers, set of sockets, wrenches.

    Distortions, presence of oxide, loosening of contact connections are not allowed.

    Checking the mating of parts that ensure tightness.

    Set of plumbing probes No. 1, set of screwdrivers, set of heads, sealant.

    The clearance sizes are indicated in the operating manual.

    Checking circuit breaker components.

    A set of screwdrivers, a set of sockets, a set of wrenches, a mechanic's screwdriver.

    Checking the presence of cable markings, inscriptions and symbols on the casing.

    Brush, paint, sign.

    Lack of markings and inscriptions are not allowed.

     


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