This unit involves the skills and knowledge required to prepare, place and connect coils and insulating in direct current (d.c.) motor armatures and poles.

It includes preparing to and rewinding d.c. machines by working safely, using tools, measuring and stator windings. It also includes applying technical and quality industry standards and completing workplace reports and winding records.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to rewind d.c. machine

1.1

Work health and safety (WHS)/occupational health and safety (OHS) requirements and workplace procedures for a given work area are identified and applied

1.2

Existing WHS/OHS risk control measures for work preparation are followed

1.3

Scope of work is determined from job specifications and regulatory requirements

1.4

Advice is sought from the work supervisor to ensure the work is coordinated effectively with others

1.5

Winding data is obtained from winding data records or directly from measurements of stator and recorded in accordance with workplace procedures

1.6

Materials required for the work are obtained in accordance with workplace procedures and job specification

1.7

Tools, equipment and testing devices needed to carry out work are obtained and checked for correct operation and safety

2

Rewind d.c. machine

2.1

Existing WHS/OHS risk control work measures are followed

2.2

Machines/equipment are checked and isolated in accordance with WHS/OHS requirements and workplace procedures

2.3

Induction machine is dismantled and parts tagged and stored to prevent loss or damage in accordance with workplace procedures and instructions

2.4

Winding is stripped from stator in accordance with workplace procedures

2.5

Armature and fields are wound and insulated in accordance with winding data, job specifications and workplace procedures

2.6

Machine is assembled and prepared for inspection and testing in accordance with workplace procedures

2.7

Unplanned situations are responded to in accordance with workplace procedures in a manner that minimises risk to personnel and equipment

2.8

Routine quality checks are conducted to ensure coils are correctly wound, with correct wire, number of turns and shape in accordance with workplace procedures and job specifications

2.9

Electrical coil work is completed in timeframe, environment and workplace conditions

3

Complete workplace reports

3.1

WHS/OHS work completion risk control measures are followed

3.2

Workplace report, forms/data sheets are completed accurately in accordance with workplace procedures

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions on at least two separate occasions and include:

applying relevant work health and safety (WHS)/occupational health and safety (OHS) requirements and workplace procedures and practices, including using risk control measures

applying sustainable energy principles and practices

completing workplace reports and documentation

dealing with unplanned events in accordance with workplace procedures in a manner that minimises risk to personnel and equipment

inspecting and testing of completed machine work

planning to rewind low voltage (LV) direct current (d.c.) machines

rewinding d.c. machines rated for LV, including:

adhering to quality workplace procedures

assembling machine and preparing for testing

completing workplace reports/forms accurately

dismantling machine and storing parts securely

following winding specifications

preparing stator for winding

selecting correct coils and insulation

winding and connecting armature and fields correctly

checking dimensions

using tools safely in accordance with workplace procedures.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions and include knowledge of:

commutation and interpoles, including:

conditions for sparkless commutation and methods used to reduce sparking

interpoles or commutating poles

principles of commutation and advantages of interpoles

resistance and electromagnetic field commutation

current industry practices and technologies

d.c. motor winding techniques

calculations and insulation specifications, including:

calculation of a half coil length and the amount of copper required

commutators and identification of insulation specifications

preparation of coils and equalisers

preparation of copper prior to insulating coils and equalisers on armatures

commutation and interpoles

critical details and measurements when stripping a stator of a d.c. machine, including:

lap winding with equalisers

types of windings

wave winding

winding layout

d.c. armature windings, including:

lap and wave windings, progressive and retrogressive windings

terms

preparation for rewinding, including:

checking the condition of a stripped core

core loss test

hot spots in armature core

testing commutator before use

removing of old winding

principles and construction, including:

construction of d.c. machine

d.c. machine types

types of armature windings, including parallel circuits

value of generated electromagnetic field

procedures and precautions required when inspecting, testing and/or re-using a commutator, including:

coil position and commutator segment relationship

commutator wear ring

removal of armature leads on tungsten inert gas (TIG) welded commutator

TIG welded and soft soldered commutators

selection of appropriate insulation, including:

B stage and VPI insulation

dielectric strength, temperature rating,

insulation properties, method of application and specific uses

insulations used on the slot portion and overhang

manufacturer recommendations

reason for selecting a particular insulation

simplex armature lap windings and wave windings, including:

characteristics and applications

commutator pitch

number and position of brushes

electrical power systems LV

identification of insulation specifications

relevant job safety assessments or risk mitigation processes

relevant manufacturer specifications

relevant safe working practices

relevant WHS/OHS legislated requirements

relevant workplace documentation

relevant workplace policies and procedures

simplex lap windings, including equalising connections for armature windings

simplex wave windings, including dummy coils, comparison of lap and wave windings, and armature winding calculations

sustainable energy principles and practices

testing techniques, including continuity, insulation testing, use of ‘growler’ and magnetic field testing.

Assessors must hold credentials specified within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must satisfy the Principles of Assessment and Rules of Evidence and all regulatory requirements included within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must occur in suitable workplace operational situations where it is appropriate to do so; where this is not appropriate, assessment must occur in suitable simulated workplace operational situations that replicate workplace conditions.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Resources for assessment must include access to:

a range of relevant exercises, case studies and/or other simulations

relevant and appropriate materials, tools, facilities, equipment and personal protective equipment (PPE) currently used in industry

resources that reflect current industry practices in relation to rewinding LV d.c. machines

applicable documentation, including workplace procedures, equipment specifications, regulations, relevant industry standards, codes of practice and operation manuals.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions may be found in the UEE Electrotechnology Training Package Companion Volume Implementation Guide.

Dismantling and winding armatures and field coils must include the following:

three different d.c. machines in an environment designed specifically for the purpose

Electrotechnology

Electrical