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OBSERVATIONS AT AGM, GERMANY

H-RANGE

AREVA T & D INDIA LTD.


LTI VADODARA

Core cutting & Lamination coil storage procedure


OBJECT:
This procedure describes the core cutting procedure.
SCOPE:
This sequential steps describes the H range Transformers core cutting procedure.

1. Slitted coil come from outer source:


In AGM lamination coil is slitted from outside
source.
Supplier of slitted coil:Thyssen Krupp steel
Made in Germany
For N-range assembled core is made by outer
sourceLager from Italy
-

The coils are come to plant from supplier end by


Container.

The coils are shifted to coil storage area with the


use of forklift(Jungheinrich)
2.

Put all coil from container to factory by forklift.

Then store the coil in coil storage area as shown in


figure temporarily.

ALOK SHAH

Page 1 of 21

OBSERVATIONS AT AGM, GERMANY


H-RANGE

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3. Coil Upending Procedure: The coils are coming to plant in vertical condition &
CRGO coil storage in stand is in horizontal
condition so it must be necessary to reverse the
coil from vertical to horizontal condition.

One man lift the coil from slitted coil storage area by
the use of forklift & put it on to the coil upending
machine.

For that coil upending machine is used.

Capacity of machine 5T max.

There is motor in machine which down the coil from


vertical condition to horizontal condition.
The size of coil upending machine:-

- It is 1000 mm in length and 1000 mm width

- Maximum weight of coil is 3.5T in AGM.

Advantages:-

This procedure is very easy & less time consumes


procedure for coil upending.

Supplier name of machine:Superleraft,Helmut Schulenburg GmbH


6920 Sinsheim/st

ALOK SHAH

1m

1m

Page 2 of 21

OBSERVATIONS AT AGM, GERMANY


H-RANGE
-

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The CRGO coil is tight with steel strapping from the


supplier end.
So cutting steel strapping one cutter is used.
Cutting tool:- BESSEY D27A

After upending procedure shifting the coil to coil storage


stand.
4

Coil shifting procedure:-

For shifting coil two types of C-Hooks are used.


One small C-hook & one big C-HOOK.

810
mm

Small C-Hook :Small C-hook is used for lifting the coil from coil stand
(Only for lying on floor and lower tier of the stand)

1m

Lifting Capacity of small C-Hook :-4.5 T


Small C-hook Height is 810mm.
Big C-Hook:Big C-hook is used for lifting the coil from stand from floor
as well as from upending machine.
Big C-Hook lifting Capacity :- 5T

1m

Min. adjustable limit of big C-Hook

Min. adjustable limit of big C-Hook


Min. Adjustable
limit 1.86m
Supplier of C-Hook :
Siegert co.
Tel:-040/8503055
Crain for lifting:-10T,Demac
Consumables: Hand gloves,Helmet,Safety shoes
Imp :
At the time of coil shifting the operator must wear helmet for
protection.

ALOK SHAH

Max. Adjustable
limit 2..90m

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OBSERVATIONS AT AGM, GERMANY


H-RANGE

5.

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Coil storage area: The coils are storage in the coil stand.
- There are total 3 stand in which coils are stored.
-

.Out of three one stand lengths is 15m & other two


stand length is 12m.

There are three nos of rows for coil store in stand


for 1 stand.

Capacity of arm in which coil insert:- 4.5T

Capacity of one column of three arm:-13.5T

The length of arm for coil store is 1.40m.


l.40m

For identification of coils store in the coil stand they


mark identification:FR 01 13 01
FR-COIL STAND, 01-First stand, 13-In one row 13
number of coil, 01-Number of rows
Total coils store in the coil stands are 123 nos.

Coil stand manufacturer:Electrolux constructor

ALOK SHAH

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OBSERVATIONS AT AGM, GERMANY


H-RANGE

6.

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Core cutting procedure:

Core cutting machine is fully hydraulic so that so


many numbers of pressure gauges are fitting in
core cutting line.
Process: The operator shifts the coil from coil
stand to coil cutting area.

Before load the coil on D-coiler the operator must check


the following parameter:-

1)Thickness of CRGO
2)Grade of CRGO
3)Width of CRGO
4)Weight of coil
5)Any damage lamination is or not
6)Core loss value.
7)Flux density etc.

In D-coiler there are two former for CRGO coil load. When
Main coil is complete then former is automatically changed
180 degree by pressing button on core cutting machine
operating board & coil cutting is in progress.

In D-coiler part there is one hydraulic key. If coil ID is 510mm


then after push the key the coil ID is automatically expand &
cover in to its ID.

D-coiler there is number of slot.


Note:-So when load the coil one thing must remember
that the large portion of slot is come on upper side so it
is easy to enter the C-holder hook in to the D-coiler.
Slot dimension : 135 mm
C-hook width-60mm
-

ALOK SHAH

Page 5 of 21

OBSERVATIONS AT AGM, GERMANY


H-RANGE

In core cutting machine for forwarding D-coiler one forwardreverse switch is that. When ON the switch D-coiler is
automatically forwarding & lamination is coming out from coil.

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switch for
D-coiler
forwarding
-reversing

Before CRGO is going to cutting process cut the start portion


of CRGO from the D-coiler because of some damage portion
at starting of coil in transportation as well as in lifting.
For that cutter is used.

For cutting CRGO:- Make-Yein


BLS 1.6X,230V-350W,1.5A
1.6mm blade for cutting,4800/min
Made in Germany.

After cutting damage CRGO cut the both edge of CRGO for
easy going in core cutting plate for that cutter is used,
Cutter:- Holex cutter

Now insert the CRGO in core cutting plate for that up the arm
& the arm supporting plate remains also in direction with arm.
For that small operating panel is used.

ALOK SHAH

Page 6 of 21

OBSERVATIONS AT AGM, GERMANY


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Operating panel is used for up-down position of arm &


arm supporting plate.

In core cutting machine there are so many number of rollers &


locking pin so CRGO is pass very tightly & locking pin lock the
CRGO at both end so width of the CRGO remains same.

After passing from D-coiler the CRGO is pass in to the large


depth of pit. The coil is passing to big pit & like goes inside pit
& come upper side.
Reason:- It is a reason for CRGO go in to the depth
because when any minor or serious problem occur in
process then there is no directly load on to the D-coiler
because CRGO is go in to the big pit & up to that cutting
process is automatically stop.
And also down the arm & arm supporting plate with use of
panel.

Now CRGO passing towards cutter of machine.


When CRGO is pass trough angle cutting process then firstly
remain the angle 0 degree so some portion of CRGO is cut
from blade & going to the wastage material drum.

ALOK SHAH

Page 7 of 21

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After collecting the small portion of CRGO test is done.


Testing purpose:- For measuring core loss (W/kg) for that
portion of CRGO.For every new loaded coil is testing by this
method.
Testing equipment:DAC-IR-3

SOKEN

Iron loss measurement

Testing Procedure:In tester one round cylinder (Head) is that which is placed
on the cutting CRGO.That height is 70mm & dia 50mm.

There are total 8 reading is that in W/kg. And all the 8


readings are Wright in to the testing details form.

Core loss
measuring

Following is the sequence of testing:

After take reading of core loss Wright all the 8 readings in


to the testing format. Also enter all the reading in
computer with that coil for which take the reading.
In soken testing meter following parameter is that:-

Frequency
50Hz 60Hz
Flux density
1T 1.5T 1.7T

ALOK SHAH

Measure
ON
OFF
Core Type
G
S
t

Thickness

Power

Head

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OBSERVATIONS AT AGM, GERMANY


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Insert all the core loss testing detail in computer & average of
reading is check with new coil loaded sticker.

After testing of core loss measurement enter the programme


of suitable design.
.The programme is installing in George core cutting panel. It
is main panel.

Core cutting George machine is from Germany..


Core cutting machine:-CNC 800WT
There is a panel for operating the machine. Details of
panel is below:H.Georg, Maschinenfabrik, S910 Kreutzer
Panel details:- 440V,50HZ
Capacity:- 170KVA
Installing Date: 1992

Imp: It is must be note that core cutting Georg machine is


fully hydraulic.

ALOK SHAH

Page 9 of 21

OBSERVATIONS AT AGM, GERMANY


H-RANGE

AREVA T & D INDIA LTD.


LTI VADODARA

All the data of core cutting in suitable size are mention in


design. The data mention in design are following:1)Number of step
2)Number of zyklen
Zyklen means in one step of stacking core how many
number of spilitted lamination.
3)Width of CRGO for every step
4)Weight of CRGO per each step
5)No. of holes
6)Hole to Hole distance
7)Total weight of CRGO
8)Thickness of every step for HV&LV
9)flux density
10) Grade of CRGO etc.

Now enter all the above data in programme & push the start
button so cutting process is start.
n starting of core cutting one panel is that in which there are
different types of push button is that. Different types of push
button have different activity done which is mention below:-

1) For arm up & for arm down.


2) For CRGO locking plate up & down.
3) For width of the CRGO adjust.
4) For CRGO passing forward & CRGO passing reverse
on core passing plate.5) For 180 degree movement D-coiler.6) Emergency stop button.etc.
7) start button
8) Roller hole goes down & up- messrolle roller hole goes
down transportrolle roller hole goes up.
9)Stop button
This panel is operating only for starting purpose after
programme entering the entire function do by Main panel.

ALOK SHAH

Page 10 of 21

OBSERVATIONS AT AGM, GERMANY


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The starting panel is also connected to the Main panel.


Near start panel one computer is that in which add different
data for new coil load on to the D-coiler.
Following are the different data:1)width of coil
2)weight of coil
3)Flux density
4)Thickness of CRGO
5)Order number of job
6)Grade Of CRGO
8) Burrs level check.
The tolerance in burrs level:- 0.27+/- 0.001mm

There is one general tool board near panel for starting


process:1)Measure tape 3m (Garant)
2)Knife
3) Electrical tape rubber tape. It is used for sticking CRGO on
coil
4) Micrometer: - Make Promat, 0-25mm, 0.001min.
Micrometer is used to check burrs level of CRGO.
5)Vanier:- Make- Inox 0-15cm
Now CRGO is passing towards up to angle cutting.
There are 3 types of angle making in machine.
1)-45 degree
2) 0 degree
3) +45 degree.

In process firstly CRGO cut in +45 degree then


CRGO going back direction

Then CRGO is going hole making procedure.


Now there are two hole punching device is that. In which one
hole punch is fixed at centre & other hole punch is move
forward-reverse as per design hole marking. In hole punch
hole die is 16mm dia so all the CRGO have 16mm hole.

ALOK SHAH

Page 11 of 21

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After hole making then CRGO going towards then cut in -45
degree AND then go to stacking car.

Then CRGO is going to the stacking car via some slope


portion of CRGO passing plate. Then CRGO is going to the
stacking car under belt.

Stacking car:In AGM max. Length of CRGO cutting is 4.2m.


There are two stacking station. In first station there are two
car & in second station there are three car.
So total 5 cars in two stations.
Station A
6m

The length of the first station is 6m in which there are two cars
& the length of the second station is 4.5m in which there are
three cars.

Station B
4.5m

In stacking cars there is total 7nos locking arrangement at the


side edge of CRGO so when CRGO come in to the stacking
car the locking is automatically go inside & lock the CRGO
from both side.

ALOK SHAH

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H-RANGE

After collecting first cutting CRGO following points to be


measured.

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Measuring table

1) Thickness of Lamination.
2) As per drawing measure length of lamination.
3) Total number of holes.
4)Hole to hole distance
5) Width of cutting lamination.
6)By the use of guiding pin insert pin in to the hole &
make sure that hole is 16mm or not.
7)Right angle checking.
For measure total length of lamination put the lamination on
one table in which 5m length scale is that from the use of this
scale measure above reading.
Size of table:-1937mmwidthx5000mmlengthx350mm height.

Measurement of hole to hole distance

To measure right angle with corner of lamination.

To measure length of lamination.

To measure width of lamination.

To measure thickness of step.

ALOK SHAH

Page 13 of 21

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Consumables for measuring purpose:1)Hand gloves


Make:-Lebon GTD/PU/G/S T11 CE
2)Measure tape 5m (Garant)
Tools for Measuring purpose:1) Micrometer to check thickness of lamination.
Make:- Promat,0-25mm,0.001mm
2)Guiding pin 15mm diameter
3)Right angle
4) Vanier make:Inox 0 to 100cm for measure large thickness of step
Inox 0 to 54 cm
Mitutoyo made in Japan 0 to 15cm
Preisser 0 to 30 cm

Measuring
tool stand
500mm

Note:-The capacity of core cutting machine to cut max width


is 990mm.
After checking first lamination continue the programme as per
drawing.

After the completion of first step of cutting, measure the


thickness of the first step with the use of Vernier calliper.

250
mm

470mm

The waste material drum size is given below:1100mm length X 1100mm b X 500mm depth 2nos
1400mm length X 1200 mm b X 910mm depth
1000mm length X 1300mm b X 1070mm depth
Check point:After the completion of every step, check the thickness of
the step as per the drawing and damage material.
For every number of step change the following parameter as
per drawing:1)Width
2) Number of lamination sheets in one step.
3)Hole to Hole distance
4) Change the coil as per width given in drawing on D-coiler.

There are so many different length of wooden block which are


put below cutting lamination in stacking car for supporting
purpose.
Size:-100mm X 100mm & length is different for every step.

ALOK SHAH

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There is big steel cupboard to store all the wooden block in


different length.

For stacking car adjustment there is one small panel which is


also connected to the main panel. In this panel following
functions are do:-

Station-B

Station-A

1)To adjust stacking car height as per thickness of step


2)Forward-Reverse of stacking car
3)Emergency stop push button
4) Start button
5)Stop button
The above data is for both stacking station.

There is some Important Point For


stacking equipment:-

core cutting &

1)Performance :- 4-5 T per shift


2)Starting OEE Measurement in 2007
3)Cutting & stacking core sheets
The photo of above activity is mention in opposite side:

7) Lamination storage area:After completion of cutting process the laminations are in


stacking position so stacking cars are come outside & one by
one shifting the complete stacked lamination to lamination
storage area.

ALOK SHAH

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H-RANGE
For shifting stacked lamination following consumables are
used:-

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Lamination
storage area

Consumables:
1)hand gloves Lebon GTD/PU/G/S T11 CE
2)Helmet
3)Safety shoes
4)Lamination pallet Lifting cycling

All the lifting Plates are 3T capacity but in different length


because of different width.
1140mm,1200mm,730mm
For Lifting stacking lamination two numbers of lifting Plates
are used of same length so total weight is 6T.
Note:The operator can not operate Crain without Helmet &
hand gloves.

In lamination stack at the corner there is very sharp edges so


it is dangerous for injury.

For that one MS square piece is put vertically at the position


of sharp edge of lamination stack so it is not harmful for body.
It is used for protection of human body.

ALOK SHAH

Page 16 of 21

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Note:-Whenever show the lamination stack without cover


sharp edge then immediately cover the sharp edge.
Decease order
center
2

3
1
Increase order1
The core is cutting in first increase order (1) then decease
order(2) & then centre(3). So for every step coil is changed,
Programme is also changed, Process is also restart from
new coil loading to core cutting process & maintain in to the
stacking arrangement.

Example:If some design the total number of steps is 13.


And all the step have different type of weight, step thickness
for HV-LV, Added thickness as per step increasing, Width of
CRGO as per every step, number of lamination sheet in one
step..
Also in design the gross weight of HV-LV & also gross weight
of total step including centre.

Generally core cutting is starting from LV side first & then HV


side & then centre.Beacuase we starting the core filling from
LV side.
In LV side starting the programme from last

step i.e. 12 number (highest width of


steps).Because If we starting the programme
from last step(From 12th number) then at top
small width of CRGO is coming (i.e. 1st step)
So that In core filling from LV side it is easy to

ALOK SHAH

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filling because of small width.


In HV side starting the programme from first
step i.e. 1 number (small width of steps).
Because if we starting the programme from first
step(From 1st step) then at top large width of
CRGO is coming(12th number)
So that in core filling from HV side it is easy to
filling because of large width.
Then centre of the core is cutting.

In core cutting process the corners of lamination cut & also in


hole making some lamination is also wastage for that one
drum is put under running belt so in process whatever
lamination waste it is going in scrap.
After some days remove wastage lamination from that area.

8) Preventive maintenance:The core cutting machine is fully hydraulic so preventive


maintenance is necessary at every 2 months.
For that following parts must be check whether they are ok or
not.-

ALOK SHAH

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1) Rollers condition whether it is ok or not or some damage


found then immediately replace because it is dangerous for
core cutting.
2)Core cutting blade
If sharpness of the blade is damage then replace it.
3) Hole making punch or die to be checked whether it is free
from oil, dust, dirt, water etc.
For maintenance purpose one toolbox is used which is from
Georg. In this toolbox there are different type of tools are
there which can be used at the time of maintenance.
Following are the tools list:-

Tools:-

1)Battery- Garrity

2)Alenkey set- Promat


1.5mm,2mm,2.5mm,3mm,4mm,5mm,6mm,8mm,10mm

3)Plier- Knipex 20-160

4)cutter Knipex 70-160

5)Pipe wrench- Knipex

ALOK SHAH

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6)Spanners:24-27,30-32,17-19,10-13 Fix spanners


17-19,6-7 Ring spanner

7)Hammer-wiha
Made in Germany

9)Alenkey-Qualitat,Wiha
6mm diaX 200mm length
Vanadium-sp
Made in Germany

10)Signier spray
It is used to protect Hole punch from dust, dirt, oil, water etc.
It is in black colour.
Apply spray on the die of the hole punch for removing
impurities.

1 number

Hole die:

ALOK SHAH

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1 number is inserted in to the 2 number.

2 number

For wastage steel strap one drum is used.


980mm length X 1270mm b X 890mm depth for wastage steel
over new coil.

ALOK SHAH

Page 21 of 21