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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.
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
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
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. Page 10 of 17 3.11 Technological map of current repairs of 6 kV PEN asynchronous electric motors.
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.
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.
3.14 Technological map for the current repair of the reserve exciter DAZ-18-10-6(U3), GSP-2000-1000.
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.
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:
Repair stages
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. 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.
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:
II. What is included in the restoration of appearance.
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:
4. Rotor maintenance:
5. Rotor balancing. 6. Replacement of bearings. 7. Repair of mechanical parts:
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.
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