CHAPTER 1.

INTRODUCTION TO CROMPTON GREAVES POWER &

INDUSTRIAL SOLUTION

CG Power and Industrial Solutions Limited is a global pioneering leader in the management
and application of electrical energy. CG Power and Industrial Solutions provides end-to-end
solutions that cover the entire value chain of engineering offerings to serve the electrical needs
of its customers. From generation, transmission, distribution and conversion, CG Power and
Industrial Solutions offerings include electrical products, systems and services for utilities,
power generation and industries. CG Power and Industrial Solutions amongst the worlds top
ten transformer manufacturers, the leader in motors business in India, a leading maker of ultra-
high voltage transformers.CG Power and Industrial Solutions has 16 manufacturing divisions
spread across India and 10 outside India. CG was established in 1937 in India.
C.G. have established the technology for manufacture of compact, reliable SLIM transformers
with high overload capacity in collaboration with Duponts Nomex thermal insulating
technology, rendering it a world leader in wind farm installations, where these transformers
have extensive utility. The range of Power Transformers offered is from 25 kVA to 600 MVA,
and 11 kV to 765 kV class, and Reactors from 10 MVA to 125 MVA, and 33 kV to 765 kV
class. These products are conforming to IEC, ANSI, IS, BS and other international standards.
CG has been aggressively investing in R&D, product certifications, product quality,
productivity enhancement and operational excellence. CG`s Global R&D center, located in
India, has been recognized for its innovation and received the prestigious "National Award for
the Best R&D Efforts"
CG is situated in Kanjurgmarg alongside the station, this location assists it to achieve the
manufacturing of transformer in a convenient way by outsourcing the component, increase its
manufacturing efficiency, dispatching the transformer through train. CG manufacturing
process begins with the creation of the materials from which the design is made which is out
sourced. These materials are then modified through manufacturing processes to become the
required part. The manufacturing process also include treating (such as heat treating or
coating), machining, or reshaping the material, checks for quality assurance during or after the
manufacturing, and planning the production process prior to manufacturing.

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 CHAPTER 2.

INTRODUCTION TO TRNASFORMER

Transformer is an electrical device that transfers electrical energy between two or more circuits
through electromagnetic induction. A varying current in the transformer's primary winding
creates a varying magnetic flux in the transformer core and a varying magnetic field impinging
on the secondary winding. This varying magnetic field at the secondary winding induces a
varying EMF or voltage in the secondary winding due to electromagnetic induction. The
primary and secondary windings are wrapped around a core of infinitely high magnetic
permeability so that all of the magnetic flux passes through both the primary and secondary
windings.

According to Faraday's law, since the same magnetic flux passes through both the primary and
secondary windings in an ideal transformer, a voltage is induced in each winding. The primary
EMF is sometimes termed counter EMF. This is in accordance with Lenz's law, which states
that induction of EMF always opposes development of any such change in magnetic field. The
transformer winding voltage ratio is thus shown to be directly proportional to the winding turns
ratio. Transformer production process is as follows-

FIG NO. 1

TRANSFORMER
PRODUCTION PROCESS

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 CHAPTER 3.

CTC BOBBIN FIXTURE

5.1 OVERVIEW
This project is based on Transformer coil conductors Shaft, Sleeve & Stand.
Following equipment were analyzed using Ansys software to detect failure, assuming
loading capacity 5 ton (49033 N).
o Shaft, its wear & tear problem was resolved,
o Sleeve, its taper angle was modified to avoid slipping of bobbin,
o Stand (supporting structure), its structure was optimized.
The main issue was the misalignment between the stands which caused depletion of
shaft material & the bearing to wear out.

FIG NO. 2 EXISTING FIXTURE

5.2 INTRODUCTION

Transformer consist of coils for transferring power through magnetic field without a
metallic connection between the coils. Coils are winded using Continuously Transposed
Conductor (or CTC) which is for power transformer windings. It consists of a group of
enameled rectangular wires, usually with PVF enamel, which are stranded to create a
rectangular rope. This conductor is used for manufacturing low losses windings for electric
machines. This winding process is done on special purpose machine, which consist of a

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 long mandrel, which is rotated between the two centers of machines. The conductor is then
wound by rotating this mandrel as per design.

The conductor comes rotated about spool for winding purpose. To support the spool fixture
is used. Fixture is a work-holding or support device used in the manufacturing industry.
Fixture is used to securely locate (position in a specific location or orientation) and support
the spool, ensuring that all parts produced using the fixture will maintain conformity and
interchangeability. Using a fixture improves the economy of production by allowing
smooth operation and quick transition from part to part, reducing the requirement for skilled
labor by simplifying how workpieces are mounted. CTC Bobbin fixture consist of shaft,
sleeve, bearing, stand.

5.3 PROBLEM STATEMENT

The process of loading of Bobbin on fixture should be optimized for time efficiency
and following-
Wear and tear of Shaft at contact with the bearing.
Wear and tear of resting spool Sleeves & slipping of bobbin which rest on the sleeves.
Misalignment between stands, its weight reduction for convenient usage & reduction

in size to acquire less floor area.

FIG NO. 3 SHAFT WEAR AND TEAR FIG NO. 4 SLEEVE WEAR

5.4 METHODOLOGY
For proposing fixture, the existing fixture was studied its cons and pros were noted. Current
fixture was modeled and analysis were done to get results which were practical. With the
help of all the result the proposed fixture was designed of 5-ton capacity, after modelling
in solid works analysis were carried in Ansys to check if the suitability of fixture.

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 FIG NO. 5 MANUFACTURING STEPS

5.5 MATERIAL DATA OF BOBBIN FIXTURE

Fixture>Constants
Density 7850 kg m^-3

Fixture >Compressive, Tensile Yield Strength

Compressive, Tensile Yield Strength Pa
2.5e+008

Fixture >Tensile Ultimate Strength

Tensile Ultimate Strength Pa
4.6e+008

Fixture >Isotropic Elasticity

Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
2.e+011 0.3 1.6667e+011 7.6923e+010

5.6 SHAFT DESIGN

Shaft model is made to check its loading capacity.
Dimension of shaft used in fixture are as follows-
I. Shaft diameter was assumed 75mm taking reference the existing shaft.

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 II. Coupler sleeve is of 55mm so slot of 60mm is given to the end of the shaft & a
through hole is given for shaft engagement.
III. Diameter 12mm hole, 8mm deep is given at pitch of 50mm x 30 NOS for
locating & aligning the sleeve and dog guide with the bobbin.

FIG NO. 6 SHAFT DESIGN

5.7 SHAFT ANALYSIS
Material- Structural Steel & Force applied- (12500N + 12500N) 25000N & gravity on
model, as shaft is symmetric so only half load is applied.
Shaft was subjected to 3 supports.
Mesh element size- 0.005m.
Nodes- 128726, Elements- 58919.
Total deformation-0.00380 m, Equivalent stress-1.790e9 Pa.

FIG NO. 7 SHAFT ANALYSIS

5.8 SLEEVE DESIGN
Sleeve design was made to check the loading capacity, resolving the slipping of bobbin
& wear and tear of the sleeves.
Existing sleeve length was 45mm & the taper angle was 4.
In the proposed model, the taper angle was made 5. Expandable mandrel, Internal
grippers, Spring plunger, Taper lock were considered as reference for taper angle.

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 The length of the sleeve was increased to 55mm which avoided the slipping of bobbin
and a range of 90 to 80 Bobbin diameter could be mounted on it.

FIG NO. 8 SLEEVE DESIGN

5.9 SLEEVE ANALYSIS
Material- structural steel & Force applied 2500N & gravity on model as the total
weight would be divided between the two sleeves.
Mesh element size- 0.002m.
Nodes-161299, Elements- 94137.
Deformation-0.000542m, Equivalent stress- 3.23e8 Pa.

FIG NO. 9 SLEEVE ANALYSIS

5.10 STAND DESIGN

Stand should be simple in structure & capacity should be 5 ton, it should be of minimum
cost, minimum weight or maximum performance or a combination of these. Resolving
wear and tear of shaft at contact with the bearing which is caused due to misalignment.

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 Dimension constraint- Length between stand (SPOOL WIDTH) 1370 mm, Minimum
height of stand (SPOOL DIAM.) 1050 mm. Standard ISMC 150x75x5.12 is used.
3 channels are used in between the plates for meeting the height requirement & it also
increase structure strength, Hooks are provided on both side for lifting purpose.
Stopper is added to make it stable.

FIG NO. 10 STAND

5.11 STAND ANALYSIS
Material- Structural Steel & Force applied- 6250N & gravity on model, as stand is
symmetric so only quarter model and load is applied.
Mesh element size- 0.005m.
Nodes- 340646, Elements- 67610.
Total deformation-0.00040 m, Equivalent stress-3.78e8 Pa.

FIG NO. 11 STAND ANALYSIS

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5.12 CONCLUSION
CTC Bobbin fixture was optimized and designed to sustain 5-ton capacity, its
parts were analyzed for any failure.
Shaft was suitable according to analysis so no modification was done.
Sleeve taper angle was rectified and its overall length was increased as to cover a
long range of diameter.
Stand was designed in simple structure and light weight for more convenient use.
Following are the benefits over the existing stand.
CURRENT SPOOL PROPOSED SPOOL
STAND STAND
STRUCTURE ISMC 200x75x6.8 ISMC 150x75x5.
ALIGNMENT MISALIGNMENT CAN NO MISALIGNMENT.
BETWEEN STAND OCCUR.
CONVNIENCE LESS CONVINIENT AS MORE CONVINIENT
FOR OPERATION WEIGHT IS MORE. AS WEIGHT IS LESS.
WEIGHT (KG) 103.14 43.51
OVERALL WIDTH 1370 595
(MM)
OVERALL 2400 1875
LENGTH (MM)
EXTRA FEATURE - STOPPER

FIG NO. 12 EXISTING FIXTURE FIG NO. 13 PROPOSED FIXTURE

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 CHAPTER NO 4

INTER-BAY COIL TROLLEY

4.1 PROJECT OVERVIEW

Transformer require core for generating its magnetic field this core is made up of laminate.
Laminate comes in coil form which are needed to go through different process to achieve
core sheets, this process is done in different Bays for this purpose Interbay trolley is
utilized. Currently this process is achieved by forklift which requires at least 2 workers. For
cost & time saving Interbay trolley is proposed.

4.2 INTRODUCTION

Inter bay trolley propels electrically by current taken by means of a trolley from a
conducting wire strung overhead or running beneath a slot between the tracks. It transports
heavy material in between the Bays of the factory. Trolley are used which reduces the time
required to transport the material and a single person can handle it. This trolley saves the
time as well as the person needed for shifting.

FIG NO. 14 INTER BAY TROLLEY

4.3 PROBLEM STATEMENT

Transformer require a peculiar coil to produce a varying magnetic field. For achieving
the coil, the parent coil is transported from storage Bay 11 with the help of forklift and
then it goes to Bay 10 through De-coiler, Slitter Machine, Trimming Cutter & Re-coiler.
The inefficient shifting of coil done by workers using forklift take on an average 5
minutes for shifting one coil, resulting in minimum 25min wasted for 5 coils per day &
at least two workers are required while shifting, If the forklift is used for other purpose
shifting coil is post ponded. Efficiency of shifting needs to be increased

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4.4 METHODOLOGY
For proposing an inter bay trolley reference of the existing Interbay trolley model was
made and its weight was calculated which was 580kg
In house production of the trolley was decided and the wheels, sprocket, chain required
would be out sourced as it wont be able to build or even for outsourcing the production
cost would reduce as design and drawing of all components would be provided.
For manufacturing hardware from scrap or non-utilized equipment were going to be
used. Structure was found that could be used for the base structure of the Trolley &
plate used as rib could be made from the scrap sheets.
In house production cost are as follows.

SR NO. ITEM WEIGHT COST

1 FABRICATION 580 58000
2 2 HP MOTOR - 10000
3 SHAFT 45 3600
4 WHEEL 12000
5 DUPLEX SPROCKET AND CHAIN 10000
TOTAL 93,600.

FIG NO. 15 TROLLEY DESIGN FIG NO. 16 NON-UTILIZED

STRUCTURE

4.5 CALCULATION FOR 2 STAGE SPUR GEAR SPEED REDUCTION

I. Data
25 full depth involute teeth.
1425rpm, 10KW, 45C8.

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 SUT= 700N/MM2, BHN=340.
Grade 6- 8.00 + 0.63.
CS =1.5, FOS=1.5.
II. SOLUTION-
I. Estimate of module based on beam strength.
i=Angular velocity of the first driving gear = 1425 = 8.90
Angular velocity of last driven. 160
i = = 2.98
2.98 speed reduction at each stage.
For a 20, minimum no of teeth is 18,
Zp=18,
zg=izp
=53.64 = 54.
z1= z3 = 18.

z2 = z4 = 54.

The speed of shaft are as follows,

nA= 1425rpm.

z1 18
nB= nA x (z2) = 1425 x (54) = 475rpm.

z3 18
nC= nB x (z4) = 1425 x (54) = 158.3rpm.

speed of output shaft is 158.3 rpm.

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cv= (3+v) = 3/8.

1/3
60X10^6 (KW) x cs x fos
m=( )X( b SUT )
z3 x n3 x cv x ( )x ( )
m 3

1/3
60X10^6 (10) x 1.5 x 1.5
m=( )X( 3 700 )
18 x 475 x 10 x ( )x 10x( ) 0.308
8 3

= 5.71= 6mm.

II. Gear dimension

m = 6mm.

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 d3 = m x z3 = 6 x (18) = 108mm.

d4 = m x z4 = 6 x (54) = 324mm.

b=10 x m = 60mm.

60X106 60X106 10
Mt = ( ) = ( 2 x x 475 ) = 201037.9 Nmm.
2xxn

Pt= 2Mt/dp = 2 x 201037.9 /144 = 2792.

III. Factor of safety using Buckinghams,

Sb= m x b x b x Y = 6 x 60 x 700/3 x 0.308 = 25872N.

x d3 x nb x 108 x 475
V= ( )=( ) = 2.68 m/s.
60 x 10^3 60 x 10^3

21x v x (Ceb+Pt)
Pd= (21 x v+(Ceb+Pt))

21x 2.68 x (11400 x 27.95 x 10^3 x 60 + 2792)

Pd= (21 x 2.68+(11400 x 27.95 x 10^3 x 60 + 2792))

= 6035N.

Peff= (Cs x Pt x Pd) = 1.5 x 2792 + 6035

=10222N.

FOS = Sb/Peff = 25872/10222 = 2.53

IV. Pitting failure

Q= 2zg/zg + zp = 2 x 54/54 + 18 = 1.5
340 2
Sw= b x q x Dp x k = 60 x 1.5 x 108 x 0.16 x ( 100 )

= 17978 N
FOS= SW/Peff = 17978/10222 = 1.75
The design is satisfactory and the factor of safety is adequate against failure.
V. Gear diameter
Module = 6mm
Face width = 60mm
Addendum = 6mm
Dedendum = 1.25m = 7.5mm
Gear 1 & 3

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 Pitch circle diameter = 108mm
Addendum circle diameter = 120mm
Dedendum circle diameter =93mm
No. of teeth = 18
Gear 2 & 4
Pitch circle diameter = 308mm
Addendum circle diameter = 320mm
Dedendum circle diameter = 293mm
No. of teeth = 54

4.6 CONCLUSION
Inter bay trolley would result in time saving for shifting of the coil as single person
could shift the coil using overhead crane and the trolley.
The trolley would save time of the workers as well as the need of forklift.
From production point of view, it would result in cost saving and consumption of
the non-utilized material in company or if the trolley is outsourced the cost for
designing would be saved.

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 CHAPTER 5

CORE BUILDING FIXTURE

5.1 OVERVIEW
Core in transformers is often stated as being to increase and concentrate the magnetic flux
that links the primary and secondary coils. In this project transformer core building fixture
capacity of 150 ton & 5 limbs or cores is proposed which would help to build transformer
of higher efficiency, power factor & transformation ratio

5.2 INTRODUCTION
In an electrical power transformer, there are primary, secondary and may be tertiary
windings. The performance of a transformer mainly depends upon the flux linkages
between these windings. For efficient flux linking between these windings, one low
reluctance magnetic path common to all windings should be provided in the transformer.
This low reluctance magnetic path in transformer is known as core of transformer.
The construction of a simple two-winding transformer consists of each winding being
wound on a separate limb or core of the soft iron form which provides the necessary
magnetic circuit. This magnetic circuit, know more commonly as the transformer core is
designed to provide a path for the magnetic field to flow around, which is necessary for
induction of the voltage between the two windings.

FIG NO. 17 TRANSFORMER CORE

CONSTRUCTION

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5.3 PROBLEM STATEMENT
The current fixture capacity is of 100-ton & 3 limbs or cores building feature. Due to
advance in years the fixture is sagged which results in unevenness in the core as well as the
erosion of the parts has occurred. The fixture limbs adjustment is laborious. Hence a new
fixture of 150-ton capacity & 5 limbs or core building feature is required to build core
efficiently.

FIG NO. 18 FIXTURE CONDITION

5.4 METHODOLGY
Designing and modelling of proposed core building fixture is made considering the fixture
used in Crompton greaves & Donum deu. Existing fixture in both the company was
modeled which gave the idea of plate, nut, bolt, ribs size used. Weld sizes in fixture. Fine
Finishing needed to the surface to get higher accuracy & stress relieving of the fixture.

5.5 FIXTURE DESIGN

FIG NO. 19 PROPOSED FIXTURE

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 FIG NO.20 CORE LIFTING FIXTURE DRAWING

Core building fixture is being designed considering a number of options. When designing we
cannot apply rigid rules to get the best design for the machine at the lowest possible cost. Fixed
line of steps for designing the machine or machine elements cannot come out with the best
product. When the new product is to be developed the problems keep on arising at design stage,
and these can be solved only by having flexible approach and considering various ways.

Writing statement of what exactly is the problem for which the machine design has to be done.
This statement should be very clear and as detailed as possible. This statement is sort of the list
of the aims that are to be achieved from machine design. After having a firm understanding we
should research for other option or substitute which could be used. As modification are needed
in fixture a lot of exploration, testing and development alternatives is needed. Also, the
material, design is checked if it is well qualified for the job.

Fixtures are essential elements of production processes as they are required in most of the
automated manufacturing, inspection, and assembly operations. Fixtures must correctly locate
a workpiece in a given orientation with respect to a cutting tool or measuring device, or with
respect to another component, as for instance in assembly or welding. Such location must be
invariant in the sense that the devices must clamp and secure the workpiece in that location for

17
the particular processing operation. Fixtures are normally designed for a definite operation to
process a specific workpiece and are designed and manufactured individually.

FIG NO.21 LIFTING HOOK

FIG NO.22 ROCKER ARM

5.6 CONCLUSION
The proposed core building fixture was made taking references of the existing fixture.
Proposed fixture is effective than existing fixture as its lifting capacity is 150 tons, its
overall weigh 29 ton & 5 limbs feature was added. Existing fixture wear and tear and its
lifting problem were noted, it was optimized in proposed fixture to increase its efficiency.
Proposed fixture would have fine finishing surface which would result in better stacking
quality. Jack are added to fixture which would make the stacking of laminate more
adjustable and avoid the obstruction of core cover by fixture.

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CHAPTER 6

FIXTURES

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 REFERENCES

1. http://www.avanthagroup.com/companies-crompton-greaves.asp
2. https://en.wikipedia.org/

3. https://www.electrical4u.com/what-is-transformer-definition-working-principle-of-
transformer/
4. http://www.electronics-tutorials.ws/transformer/transformer-construction.html
5. Machine Design VB Bhandari.

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