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Ceiling fan works on principle of single phase induction motor using capacitor. Auxiliary winding is connected in parallel with the main winding. A 90-degree electrical phase difference between the two windings is obtained by connecting the capacitor and centrifugal switch. The effect is that the two winds act like a two-phase stator and produce the rotating field required to start the motor.
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Cost effective repairing of ceiling fan and energy efficient regulator
Ceiling fan works on principle of single phase induction motor using capacitor. Auxiliary winding is connected in parallel with the main winding. A 90-degree electrical phase difference between the two windings is obtained by connecting the capacitor and centrifugal switch. The effect is that the two winds act like a two-phase stator and produce the rotating field required to start the motor.
Ceiling fan works on principle of single phase induction motor using capacitor. Auxiliary winding is connected in parallel with the main winding. A 90-degree electrical phase difference between the two windings is obtained by connecting the capacitor and centrifugal switch. The effect is that the two winds act like a two-phase stator and produce the rotating field required to start the motor.
Report by : Group 10 Jibin Job Midhun Viswanath Muhammad Mijas Muhammad Zeeshan
CONTENTS
1)Introduction 1.1)working principle of ceiling fan 2)Construction 2.1)Capacitor 2.2)Bearing 2.3)Windings Starting winding Running winding 3)Types of faults(daigonosis and corrections) 3.1)capacitor faults 3.2)winding faults 3.3)bearing faults 4)Ceiling fan winding machine 4.1)Automatic ceiling fan winding machine 4.2)Manual ceiling fan winding machine 4.3)Procedure for winding 5)Cost estimation
1)INTRODUCTION 1.1)working principle of ceiling fan
The ceiling fan motor works on principle of single phase induction motor using capacitor. Working of capacitor start motor: The stator consists of the main winding and a starting winding (auxiliary). The starting winding is connected in parallel with the main winding and is placed physically at right angles to it. A 90-degree electrical phase difference between the two windings is obtained by connecting the auxiliary winding in series with a capacitor and centrifugal switch. When the motor is first energized, the centrifugal switch is closed. This places the capacitor in series with the auxiliary winding. The capacitor is of such value that the auxiliary circuit is effectively a resistive-capacitive circuit (referred to as capacitive reactance and expressed as X C ). In this circuit the current leads the line voltage by about 45 (because X C about equals R). The main winding has enough resistance-inductance (referred to as inductive reactance and expressed as X L ) to cause the current to lag the line voltage by about 45 (because X L about equals R). The currents in each winding are therefore 90 out of phase - so are the magnetic fields that are generated. The effect is that the two windings act like a two-phase stator and produce the rotating field required to start the motor. When nearly full speed is obtained, a centrifugal switch cuts out the starting winding. The motor then runs as a plain single-phase induction motor.
2)CONSTRUCTION 2.1)capacitor
In a ceiling fan there is an single phase induction motor. Single phase stator produces a non rotating, pulsating magnetic field.The single coil excited by a single phase current produces two counter rotating magnetic field phases, coinciding twice per revolution at 0 degrees and 180 degrees. When the phases rotate to 90 degree and -90 degree they cancel. At 45 deg and - 45 deg they are partially additive along the +x axis and cancel along the y axis. The sum of these two phases is a phasor stationary in space, but alternating polarity in time.
The two windings are wound with a geometric offset, effectively making a second set of poles phase shifted within the stator. The capacitor provides a phase shift to the current flowing in W1 and we therefore have a "two phase" motor while the switch is closed. When the motor is almost up to speed, the switch opens disconnecting W1 and the capacitor. The motor can be reversed by reversing the connections of either W1 or W2 (but not both). The fan capacitor produces a rotating magnetic field. This magnetic field makes the motor turn. If the capacitor is not working correctly, your motor will not function properly. If your motor is not working properly, you may hear a humming sound. The lower the capacitor rating you go the higher the chance the fan motor will not start (not enough capacitance). The higher the capacitor rating is, the motor will draw more amps when running. The motor could overheat and shut down on thermal overload.
2.2)Bearing
2.3)Windings The stator consists of the main winding and a starting winding (auxiliary). The starting winding is connected in parallel with the main winding and is placed physically at right angles to it. A 90-degree electrical phase difference between the two windings is obtained by connecting the auxiliary winding in series with a capacitor and centrifugal switch. When the motor is first energized, the centrifugal switch is closed. This places the capacitor in series with the auxiliary winding. The capacitor is of such value that the auxiliary circuit is effectively a resistive-capacitive circuit (referred to as capacitive reactance and expressed as X C ). In this circuit the current leads the line voltage by about 45 (because X C about equals R). The main winding has enough resistance-inductance (referred to as inductive reactance and expressed as X L ) to cause the current to lag the line voltage by about 45 (because X L about equals R). The currents in each winding are therefore 90 out of phase - so are the magnetic fields that are generated. The effect is that the two windings act like a two-phase stator and produce the rotating field required to start the motor. When nearly full speed is obtained, a centrifugal switch cuts out the starting winding. The motor then runs as a plain single-phase induction motor.
3)TYPES OF FAULTS
3.1)Capacitor faults: In order for an electric fan to work correctly, the ceiling fan capacitor must be fully functional. A ceiling fan capacitor has two important roles: to create a magnetic field when the fan is first turned on, and to change the direction of the fan, when the unit is switched into reverse. Not all fans have reverse direction, but this is a particularly useful feature during the cold weather season, to circulate warm air downward and lower overall heating costs. If the fan capacitor is not working correctly, then the fan may exhibit the following problems: The fan wont spin on its own. Notice whether a humming sound can be heard when the fan is switched on, or whether you need to help it along for it to start spinning. In this case, a ceiling fan would either not turn, or would spin extremely slowly (regardless of the speed setting selected). Use your senses: if you smell a burning odor, or you see a burned or melted black box, this could mean a problem with the ceiling fan capacitor. These are obvious signs of a bad ceiling fan capacitor. Often, the ceiling fan capacitor itself would appear to be bulging or malformed. Examine the ceiling fan capacitor for evidence of bulging, burns, or cracks? If the answer is yes, then one of the capacitors has blown. Capacitors tend to get really hot before shorting out, which results in the melting and scorching.. If you have a fan with multiple capacitors, a single ceiling fan capacitor may blow out, while the others may remain in good working order. 3.2)winding fault: winding fault mainly occurs due to voltage fluctuations in the supply.It can be detected by means of series bulb test.winding fault can be visually diagonised by burned out windings or broken winding.
3.3)Bearing fault: Bearing faults occurs due to wear and tear in the bearing.It will cause the rotor to come in contact with the stator and get locked.if there is bearing fault,then there will be a ahumming sound and also there are chances that the fan doesnt run at all.
4)CEILING FAN WINDING MACHINE There are two types of winding machines: Automatic ceiling fan winding machine. Manual ceiling fan winding machine.
4.1)Automatic ceiling fan winding machine
Acknowledged for its durability, high reliability, least maintenance and reduced break down time, Automatic Ceiling Fan Stator Winding Machine can accommodate and work with different type of stator. Manufactured using superior quality raw material and hi-tech machines, these are suitable for repair shop. Available in various specifications and custom designs, the range is offered at cost effective prices. Specifications: Wire Size: 0.1mm to 1.2 mm Stator Diameter: 35mm to 180mm Stator Thickness: 08mm to 36mm Max. Speed: 4500 rpm power: 220volt (50 hz) main motor Production Capacity: 85 stators/ hour
4.2)Manual ceiling fan winding machine
This machine is ideally suited for repair shops. Different type of stator can be accommodated. Hence making it highly reliable and maintenance free hence reducing break down time. Specifications: Stack Height : 2"- 6" approx Wire Diameter : 26 Swg to 38 Swg Winding Speed : 960/1440 RPM Winding Direction : Clock wise and Anti Clock wise.
4.3)Winding steps
First of all you would find the no of turns in the coil by counting one by one. Then you would make coils according to the no of turns. Insulate the stator holes with a paper to avoid the contact of coil with the stator. Now place the coils one by one on the stator The process of placing coils is done for both starting and running winding.
After the completion of placing coils you would give connection of coils in both windings. In last you would leave four wires, two of them are connected with each other which is known as common. The starting winding is now connected with capacitor and the running winding is directly connected with main supply. Then the capacitor is connected with main supply. After the connections the fan is closed and is connected with the main supply. If the fan is moving in anticlockwise direction, then its connections are reversed.
5)COST ESTIMATION
Cost of repairing 1 fan : Rs 100 Winding Copper : Rs. 50 (250g) Capacitor : Rs. 35 Milnex paper, sleeve, : Rs. 15 hook up wire, tie, varnish
Cost of repairing faulty fans in college : Rs 18,000
Number of faulty fans in college : 66 Cost of Materials : Rs. 6000 Cost of Machine : Rs. 12000
Current cost of repairing : Rs 23,000 Average cost per fan : Rs. 350
REFERENCE
Theory of Electrical Machines P.S. Bimbhra Electrical Technology B.L. Theraja WikiHow www.wikihow.com Red Beacon A manual on repairing ceiling fan Other electrical enthusiasts online forum