DEVELOPMENT OF SEMI-AUTOMATED RUST AND DRIED VARNISH CLEANER

MACHINE: SINGLE PHASE AND THREE PHASE MOTOR STATOR

A Design Project
Submitted to the faculty of the
Department of Industrial Technology
Cavite State University-Cavite College of Arts and Trades Campus
Rosario, Cavite

In partial fulfillment
of the requirements for the degree
Bachelor of Industrial Technology
with specialization in Electrical Technology

JOHN CEDRICK R. MONTON

JHON ERVIN L. PETURAL
CHRISTIAN N. VERDIDA
January 2024
DEVELOPMENT OF SEMI-AUTOMATED RUST AND DRIED VARNISH CLEANER
MACHINE: SINGLE PHASE AND THREE PHASE MOTOR STATOR

John Cedrick R. Monton

Jhon Etvin L. Petural
Christian N. Verdida

A design project manuscript submitted to the Faculty of the Department of Industrial

Technology of Cavite State University-Cavite College of Arts and Trades Campus,
Rosario, Cavite in partial fulfillment of the requirements for the degree of Bachelor of
Science in Industrial Technology major in Electrical Technology with Contribution No.
IT-ELEC-2025-02 Prepared under the supervision of our adviser Mr. Jurick P.
Paulino and our Technical critic Ms. Dennimar T. Hernandez.

INTRODUCTION

Rust formation and dried varnish accumulation in electric motor components

are significant challenges in industrial equipment maintenance. These issues are

particularly critical in the tooth and slot areas of the stator in single and three phase

motors but we also consider the other parts of the stator, where such buildup can

reduce motor efficiency, cause overheating, and lead to potential machine failure.

Traditional cleaning methods, that rely on physical labor and dangerous chemicals,

are not only time-consuming, but also create health concerns to workers and have a

bad impact on the environment. Additionally, manual approaches are insufficient for

removing contaminants such as dried varnish and rust from some locations that are

hard to reach, resulting in repeated maintenance issues and a shorter motor lifespan.

This research focuses on the creation of a semi-automated rust and dried

varnish cleaning equipment to address these issues. Designed specifically for the

entire motor stator, including stator tooth, slot, and so on, of single and three phase
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motors, the machine contains innovative cleaning mechanisms, ultrasonic cleaning

chemicals. The proposed prototype that aims to improve motor maintenance

operations for laboratory equipment, which will extend motor lifespan, improving

performance, and lowering operational expenses.

Electric motors operate a variety of equipment in industrial and educational

settings, therefore proper maintenance is critical for long-term operation. According

to Santos et al., (2021) , rust and varnish buildup in motor components can increase

energy consumption and cause premature motor failure. Putting robotics into

cleaning systems not only examines these maintenance difficulties, but it also

reduces labor intensity and human error compared to traditional approaches. This is

consistent with the demand for innovative and sustainable equipment maintenance

solutions in modern technical programs (Alvarez & Cruz, 2022).

This study provides a realistic solution to a major maintenance difficulty by

utilizing the effectiveness of ultrasonic cleaning chemicals. This prototype offers

significant benefits to the field of industrial maintenance and aligns with the

university's technical program aims of encouraging innovation and supporting

sustainability.

Objectives of the Study

The main objective of the study is to develop a Semi-Automated Rust and

Dried Varnish Cleaner Machine: Single and Three Phase Motor Stator for Electical

Technology.

Specifically, this study aims to:

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1. Design a semi-automated rust and dried varnish cleaner machine for stator in

single and three-phase motors;

2. Develop a PLC system that allows customization of cleaning cycle, motor

speed, and safety features based on the motor type;

3. Test the performance of the developed machine based on the following:

a. Visual inspection of the prototype

b. Cleaning efficiency using ultrasonic cleaning chemicals.

c. Measure compatibility of motor stator in the machine

d. Operational speed in cleaning and drying.

e. Safety testing;

4. Evaluate the efficiency of using a Semi-Automated Rust and Dried Varnish

Cleaner Machine: Single and Three Phase Motor Stator in the production

process based on the following:

a. Capability to clean such as dried varnish and rust of the stator;

b. Accurateness of the size of the motor stator in both single and three

phase motor;

c. Usability based on appropriateness, learnability, and operability of

the machine;

d. Flexibility of the control of the machine;

Significance of the Study

The study The work on the development of a semi-automated rust and

dried varnish cleaner machine has significance due to the addresses critical

challenges in electric motor maintenance, especially for single-phase and three-

phase motor stators. This project uses new technologies like ultrasonic cleaning

chemicals, and PLC to provide a safer, more efficient, and ecologically friendly

alternative to traditional approaches. This project offers an safer, more effective,

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and environmentally friendly option to old methods, helping to develop industrial

and educational processes.

Electrical Technology Instructors

The machine serves as a useful teaching tool, allowing instructors to

demonstrate real-world applications of cleaning technology and maintenance

processes. It improves the learning experience by integrating academic

knowledge with practical experience, preparing students for industrial use

standards.

Electrical Technology Students

The research assists students by allowing them to learn and practice

advanced maintenance skills in a controlled environment. This experience gives

them essential skills and information, increasing their competitiveness in the

labor market and preparing them for professional responsibilities.

Electrical Industry

Industries that use electric motors can benefit from the machine's ability

for better service procedures, reduce interruptions, and extend motor life. This

leads to lower costs and simpler operations, ultimately improving output.

Future Researchers

This work will serve as a valuable resource for future research to

improved cleaning treatments for electrical motors. It opens up opportunities to

research new technologies, chemicals, or solutions, improve machine operation,

and address wider uses in maintenance technology.

Scope and Limitation

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This study covers the Development of a Semi-Automated Rust and Dried

Varnish Cleaner Machine: Single and Three Phase Motor Stator for Electrical

Technology. Through this, the beneficiaries would be able to clean the one HP of

Three phase motor and AC motor for Single Phase Motor. The Semi-Automated

Rust and Dried Varnish Cleaner Machine, then, also improves efficiency and

quality of a motor in the electrical industry in the country. This project provides for

instructional purposes such as taking stator measurements, Cleaning agent, and

this innovation aligns with industry needs and supports advancements in

automated maintenance technology. Hence, other activities that are not

mentioned above are beyond the scope of the study.

Conceptual Framework

The conceptual framework used by the researchers to guide the study is

the input, process, and output model. The application of the model in this paper

is depicted in Figure 1 below.

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INPUT PROCESS

Knowledge Requirements: Planning

 Materials and Initial cost  Constructing the title
 Review of Related Literature  Budget Planning
 Hardware Requirements  Designing
Tools and Equipment:  Estimating the time frame
 Adjustable Wrench, Angle
Grinder, Screwdriver, Grinder, Fabricating
Computer, Pliers, Welding  Canvassing of materials
Machine, PPE, Vise Grip, and preparing tools and
Round Blade, Drill Press, Lathe equipment
Machine, Measuring Tools,  Lay-outing and assembly
Multimeter, Wire Stripper, of parts
Crimping Tools, Soldering Iron Testing
Skill Requirements:  Visual Inspection
 Electrical wiring  Repeatability Test
 Safety Testing
 Welding
 Dry Run
 Pneumatic Installation
 Measurement compatibility of
 Software Development for PLC the motor stator into the
 Prototype Development and machine
Assembly

FEEDBACK OUTPUT

Evaluation

 Recommendation Development of
 Reviews Semi-Automated Rust and
 Feedbacks from professors Dried Varnish Cleaner Machine:
(from Industrial Technology Single and Three Phase Motor
Department) Stator
 Feedbacks from students
(related from Electrical
Technology)

Figure 1. Conceptual framework of the development of Semi-Automated Rust and

Dried Varnish Cleaner Machine: Single and Three Phase Motor Stator

Input

In the conceptual framework of the study, the inputs are the related literature

and studies, materials namely, Bore Brush (Copper or Brass), Conveyor Belt Mesh,
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Universal Power Supply Unit, PLC, Relay Module Shield, Case & others,

Compressor, Filter & Fittings, Pneumatic Hose, Air compressor hose, Compressor

Air Pipe hose, Flow control Valve, 5/2 Way Solenoid Valves, Pneumatic Cylinder

Double Shaft, Galvanized Iron Pipe, Grinding disk, Sandpaper, Screw, Other

electronic control, Swivel Caster Wheels, Mild Steel Hinges, Omni Adapter, Power

cord cable equipment, and cost analysis. Preparations for these are made before the

construction of the project.

Process

The process includes the conceptualization of the project in which the

designing of the project is made, sourcing of materials needed, construction, and

testing.

Output

The expected output is a prototype of a functional Semi-Automated Rust and

Dried Varnish Cleaner Machine: Single and Three Phase Motor Stator.

Feedback

The feedback consists of recommendation, reviews and suggestions from

students and instructors after conducting evaluation of the project. The whole model

may repeat until the project results can be assessed as satisfactory.

Time and place of the study

This project study was conducted at Cavite State University -Cavite College

of Arts and Trades Campus from September 2024 to June 2025.

Definition of Terms

AC Motor: Electric motors that use alternating current to generate mechanical power

through rotational movement.

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Compressor: A device that increases the pressure of air by reducing its volume,

often used in pneumatic systems to power tools or machines.

Conveyor Belt: A mechanical device used for transporting materials or components,

typically in industrial applications. It is used here as part of the cleaning machine's

mechanism for moving parts.

Flow Control Valve: A valve used to regulate the speed or volume of air or liquid

passing through a system, essential for controlling cleaning pressure in pneumatic

cleaning applications.

Grinding Disk: A tool used for abrasive cleaning or smoothing surfaces, such as

removing heavy rust buildup from metal parts.

Hinges: Mechanical devices used to allow a machine or component to pivot or open,

such as for accessing the internal parts of the cleaning machine.

HP (Horsepower): A unit of power used to measure the motor's output, commonly

used to rate the power of electric motors.

Lathe Machine: A machine tool used to shape material by removing excess material

through cutting, often used for creating precise motor components.

Motor Stator: The stationary component of an electric motor or generator, consisting

of the iron core and windings, which interacts with the rotating part (rotor) to generate

mechanical energy.

Multimeter: An electronic measuring instrument used to measure voltage, current,

and resistance, vital for checking the performance and safety of the electrical

components of the cleaner.

Pneumatic: Referring to systems that use compressed air to transmit and control

power, often used in automation systems for their efficiency and speed.
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PLC (Programmable Logic Controller): A ruggedized computer used for

automation in industrial processes, enabling programmable control over machines

and systems.

Relay Module: An electrically operated switch used to control higher-power

components like motors, allowing the PLC to manage the cleaning cycle and safety

features.

Rust: A corrosion product that forms on metal surfaces, particularly iron and steel,

when exposed to moisture and oxygen. It negatively impacts the performance and

longevity of motor components.

Slot of Stator: Grooves along the stator's circumference that separate the stator

teeth. These slots house the winding coils.

Semi-Automated: A process that involves both human and machine interaction,

typically controlled by a central computer to automate specific tasks while still

requiring manual intervention at certain stages.

Single Phase Motor: A motor that operates on a single-phase power supply,

typically used in smaller or residential applications. It only requires two wires: one for

the live current and one for neutral.

Solenoid Valve: An electromechanical valve used to control the flow of air or liquid

in the pneumatic system, typically in the cleaning mechanism.

Soldering Iron: A tool used to melt solder, enabling the connection of electrical

components, crucial for assembling the PLC and electrical systems in the cleaning

machine.

Swivel Caster Wheels: Wheels that allow movement in all directions, used in the

machine design to enable easy positioning and mobility of the cleaning system.

Teeth of Stator: Projections that extend from the body of the stator, typically

designed to hold coils in place and create a magnetic field that interacts with the

rotor.
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Three Phase Motor: A motor that operates using a three-phase alternating current

(AC), which is more efficient for larger industrial motors compared to single-phase

motors.

Ultrasonic Cleaning Chemicals: A specialized cleaning solution used in ultrasonic

cleaning systems. These chemicals are designed to break down and remove

contaminants such as rust, dried varnish, and grease from surfaces.

Varnish: A coating material often applied to electric motor components to provide

insulation and protection. Over time, it can harden and accumulate, requiring

cleaning.

Welding: A process of joining materials, usually metals, by melting and fusing them

together, often with the addition of a filler material.

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REVIEW OF RELATED LITERATURE

This chapter presents a review of related literature and studies that are

relevant to the development of the current research. It focuses on previous research

that addresses motor cleaning methods, maintenance, and rust removal, which

directly relate to the objectives of this study. By analyzing existing literature, this

section will outline the gaps, current methodologies, and the potential contribution of

the present study in the field.

International Studies

A Review Of Cleaning Methods For Motor Windings

According to IM Culbert (2008), contamination of stator windings with

substances like oil, dust, and other materials commonly found in cement plants can

result in premature failure due to accelerated thermal aging and electrical tracking,

either between phases or to ground. Additionally, the accumulation of contaminants

reduces the cooling efficiency of the windings, leading to increased electrical

resistance losses, which ultimately decrease motor efficiency. This study explores

various cleaning techniques, such as steam cleaning, dry ice blasting, and solvent

scrubbing, for their effectiveness in removing debris from stator windings and cores.

However, the paper emphasizes that preventing contamination from occurring in the

first place remains the most effective approach to ensuring motor longevity and

performance.

In-Service Solvent Cleaning of Electric Motors

According to D. L. Stoddard and W. R. Wells (2017), a method is outlined for

cleaning dirt-contaminated electric motors in service, utilizing a stream of solvent

directed into the end bell opening of operating motors. The solvent vapors are safely
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vented outside, and the contaminated solvent, along with any debris, is collected in a

container with rags. This process effectively cleans the motors, reduces operating

temperatures, and extends motor lifespan, all while minimizing exposure to

hazardous solvent vapors for unprotected workers. Among the solvents tested,

methyl chloroform is found to be less damaging to motor insulation, with its fumes

being easier to manage than other solvents.

Review on Engineering Methods in Treatment of Chemical Rust

According to Nawfel Muhammed Baqer Muhsin (2020), this review focused

on rust formation in machines, explaining that rust, or iron oxide, is a reddish

compound resulting from the oxidation of iron when it comes into contact with water

and air. Over time, exposure to these elements causes iron to weaken and become

brittle as the bonds within the metal deteriorate. The term "rust" specifically refers to

the oxidation of iron and iron-containing alloys, while other metals undergo different

forms of corrosion that are not categorized as rust. All iron objects are susceptible to

rusting, but various methods exist to remove rust and prevent further damage. The

discussion also includes approaches to effectively eliminate rust from vehicles.

Local Studies

Maintenance of Electric Motors

According to Iskomunidad. (2019), electric motors are essential components

in industrial plants, and their failure, like that of other rotating machinery, can result in

significant operational challenges, including costly repairs, production halts, and

revenue losses. To mitigate these risks, maintenance engineers must be well-versed

in the principles of operation and preventive maintenance to ensure consistent and

efficient performance.
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A seminar addressing this topic aims to deepen participants' understanding of motor

operation, control, and maintenance. It also provides guidance on selecting

appropriate bearing types, implementing balancing techniques, and conducting tests,

troubleshooting, and repairs effectively to optimize motor reliability and functionality

Development of an Automated Cleaning System for Electric Motors

According to R. T. Perez and M. A. Dela Cruz (2021), this study presents the

development of an automated cleaning system designed to remove dust and grime

from electric motor components in local manufacturing facilities. The system uses a

combination of air blast and rotating brushes to clean motor parts, particularly the

stator, rotor, and windings. The research shows that automation in cleaning not only

reduces labor costs but also improves the consistency and effectiveness of motor

maintenance. The system has been successfully tested in several factories, leading

to improved motor performance and extended service life.

Application of Chemical Cleaning Agents in Motor Stator Maintenance

According to J. S. Bernardo (2019), the use of chemical cleaning agents for

the maintenance of motor stators is explored. The paper discusses various chemical

solutions, including solvents and detergents, that effectively remove rust and varnish

buildup from motor components. The study highlights the importance of selecting the

right chemical agents to avoid damaging sensitive parts and ensuring compliance

with environmental standards. It concludes that chemical cleaning, when used

appropriately, is a cost-effective solution for enhancing the performance and lifespan

of electric motors in the Philippines.

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Synthesis and Justification

The studies reviewed highlight various cleaning methods to improve electric

motor performance and longevity. For example, Culbert (2008) and Stoddard & Wells

examine how contaminants like dust and oil lead to motor failure and explore

cleaning techniques such as steam cleaning and dry ice blasting. These insights

align with the current research, which investigates the best cleaning practices for

motor components. Perez and Dela Cruz (2021) also discuss automation in cleaning

systems, which is relevant to the present study's goal of improving efficiency.

Additionally, Bernardo (2019) and Muhsin (2020) explore the use of chemical agents

for cleaning rust and varnish from motor parts.

These studies emphasize the need for effective motor cleaning to prevent

damage and enhance performance. The current research builds on this foundation,

aiming to combine automated systems and chemical cleaning for more efficient and

cost-effective maintenance. By addressing gaps in current methods, this study seeks

to make motor maintenance smarter, faster, and more reliable.

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METHODOLOGY

This section details the materials and processes used in the development of the

semi-automated rust and dried varnish cleaner machine for single and three-phase

motor stators.

Description of the Project

The Semi-Automated Rust And Dried Varnish Cleaner Machine: Single And

Three Phase Motor Stator was designed and developed to address the critical issue

of rust and varnish buildup in electric motor components, particularly in the tooth and

slot areas of the stator. This prototype aims to provide a more efficient, cost-effective,

and safer alternative to traditional manual cleaning methods.

The machine utilizes a cleaning process involving an ultrasonic solvent, into

which the motor stator is dipped. This solvent, combined with the machine's

automated process, effectively removes rust and varnish without the need for manual

scrubbing or harsh chemicals. It incorporates both single and three-phase motor

systems to drive its cleaning mechanism, making it adaptable to a variety of motor

sizes and power requirements. The semi-automated process minimizes manual labor

while enhancing cleaning accuracy, ensuring optimal results and reducing the risk of

damage to motor components.

The prototype is designed to be implemented at Cavite State University –

CCAT Campus, addressing the specific maintenance needs of electric motors used

in laboratory exercises. It is expected to enhance the lifespan and performance of the

motors, contributing to improved energy efficiency and reduced maintenance costs.

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Block Diagram

CLAMPING/ HOLDING BRUSHING

DIPPING PROCESS
PROCESS PROCESS

FINISH PRODUCT DRYING PROCESS

Design and Fabrication Procedures

Fabrication Procedures

Materials

This is a listing of all the materials needed for the study and a description of their use

in the design.

Table 1. List of materials and description

ITEMS DESCRIPTION

3 Phase Circuit Breaker

3 Phase Motor
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Blower

Bore Brush

Conveyor Belt

Door Handle

ESB

Fiber Glass

Fuse

Indicator Light

Magnetic Contactor w/ OL

Plug

DPneumatic Piston

Proximity Sensor

Push Button

Relay (8 pins)

Stainless Steel

Surface Brush

Timer

Toggle Switch

Ultrasonic Cleaning Solution

Wheel

Wire

Tools and Equipment

This is a listing of all the tools and equipment and their respective functions.

Table 2. List of tools and equipment

Tools Description
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Adjustable Wrench

Angle Grinder

Computer

Crimping Tools

Drill Press

Grinder

Lathe Machine

Machine

Measuring Tools

Multimeter

Pliers

PPE

Round Blade

Screwdriver

Soldering Iron

Vise Grip

Welding

Wire Stripper

Principle of Operation

Operating Procedure

1. Wear protective gloves.

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1.1. Manually place the stator inside the basktet mesh.

2. Put the basket mesh with the stator (single phase/ 3 phase) to the container full of

ultrasonic chemical.

3. Turn on the machine.

4. Select how many minutes that the machine will operate.

5. Collect the stator (single phase/ 3 phase) and put it in the respective location that

have indication that it’s for single phase or 3 phase, and secure it with the clamp

6. Push the button if it’s for single phase or 3 phase to start.

7. The machine will automatically cleaning the stator (single phase/ 3 phase).

8. Collect the stator at the end of machine

Maintenance Procedure

1. Drain the chemical from the container.

2. Wipe the container.

3. Collect the detachable brush and replace it with the new brush.

4. Check the program at the PLC.

Safety Control Measures

Cost of Materials

Testing and Evaluation

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Data Analysis