process improvement of colouring

8/12/2019 Process Improvement of Colouring

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CONTENTS

SL NO.

PAGE NO.

1. Introduction06

2. Organization profile

07-173. OPI!A" #I$%E.

1&

'. (PE) O# OPI!A" #I$E%1*

+,"I-+OE #I$E%1*

)ING"E-+OE #I$E%20

)PE!IA" P,%P,)E #I$E%21

. !O"O%) O# NA,%A" #I$E%) / !O"O,%ING +A!INE22-27

PA(-O##23

PA(-O## EN)ION23

IONIAION $A%23

IN !O"O,%ING / , !,%ING ,NI23-2


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ANI-,) $"O4E%2

, "A+P 4I #IG,%E26

!AP)AN

27

AE-,P27

6. %O,$"E )OOING2&-32

7. I+P%OE+EN O# !O"O,%ING32-3&

&. !ON!",)ION33

*. %E#E%AN!)3'

INTRODUCTIONIn coloring process, usually the first step of cable production,

ultraiolet curing in! is applied on a natural fiber so the fiber can be

identified in production, construction and use" It is generally

accepted that coloring process #ill increase the attenuation and

influence the $icro bend resistance of the fiber, because cured in!

layer #ith the thic!ness of %&'u$ is applied around the fiber surface,#hich #ill li$it the bending(" )hen the colored fiber applied #ith high

$odulus in! is bent, lateral stress is induced and electro$agnetic

#ae #ill not be totally reflected in bending area, part of #hich is

reealed fro$ fiber core to coating, and lead to attenuation increase

or step in attenuation cure" *o#eer, it is not applicable to +"'-


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fibers" In the follo#ing section, coloring process. influence on bend

perfor$ance of +"'- fibers #ill be discussed, and the test results

+"'- fibers #ith i$proed bend perfor$ance is specifically

deeloped to facilitate the installation and $aintenance of net#or!s,

#hich brings data transfer technology to the indiidual end&user and

is en/oying an accelerating deploy$ent #orld&oer" 0nd its capability

to #ithstand bends #ith e1ceptional lo# radius #ithout increase in

attenuation is highly appreciated in applications" 2y $odifying

refractie inde1 profile, +"'- fibers hae achieed bend perfor$ance

i$proe$ent3 ho#eer, #ith the deelop$ent and application of

+"'- fiber cables, 4uestion has been raised for #hether the cable

production process #ill influence the bend perfor$ance of +"'-

fibers"

OR+0NI50TION 6RO7ILE

)terlite i5 a leading gloal proider of Optical #ier58 eleco99unication

!ale5 and Po:er ran59i55ion !onductor5. ;e !o9pan< i5 India=5 onlin In5ulated !opper eleco9 !ale5

)olid In5ulated !opper eleco9 !ale5

Aerial )elf-)upporting !opper eleco9 !ale5

P!+ -)creened !opper eleco9

5) STRUCTURED DATA CABLES

Sterlite Cat 5e LAN Cables

Sterlite Cat 6 LAN Cables

All of )terlite5 Product5 are 9anufactured at I)O *001J200& certified

facilitie5 )terlite5 Optical #ier facilitie5 are al5o certified for t;e I)O

1'001J200' Eniron9ent +anage9ent )


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1

Custo$ersJ o reduced t;e 5crap and proiding 9ore and 9ore

enefit to t;e plant

E?ceeding cu5to9er e?pectation5 in L! perfor9ance

#la:le55 ne: product launc;e5 D9eeting all agreed progra9

9ile5tone5

!reating alue t;roug; differentiated product offering5

ShareholdersJ o create enc;9ar> alue < deliering

e5pite t;e turulent gloal econo9ic 5ituation t;roug; t;e ;a5 een con5idered a5 one of t;e op 3 outperfor9ing

5toc>5 of India in 200*.$ot; our core u5ine55 5eg9ent5 of po:er

tran59i55ion conductor5 / optical fier5 ;ae 5;o:n 5ignificant

olu9e gro:t; t;i5


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1

4or>-life alance.

SuppliersJ

o fo5ter long ter9 partner5;ip5 e a difference in co99unit;oli.

3. eleco99unication cale D!opper cale in adra.

'. Po:er tran59i55ion cale in %a>;oli.


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1

ere8 +< raining place ;ad eing in %a>;oli adra/ Nagar ;aeliD)" for eleco99unication cale5.

6RODUCT R0N+E O7 STERLITE TEC*NOLO+IES LTD 7OR

O6TIC 7I2ER C02LE

FIBER OPTIC CABLES

)terlite=5 #ier Optic !ale plant5 produce t;e co9plete range of

erre5trial #ier Optic !ale5 in 5tandard and cu5to9ized de5ign58 :it;fier count5 up to &6'.

M)terlite uct-"ite )erie5

M

)terlite Ar9or-"ite )erie5

M)terlite Aerial-"ite )erie5

M)terlite %ion-"ite )erie5

M)terlite Pre9i5e !ale )erie5

6L0NT LOC0TION>

)terlite tec;nologie5 li9ited

)ure< no 6&B1 %a>;oli illage8 +ad;uan da9 %oad

)ila55a-3*6230

,nion erritor< of adra Nagar / aeli8 India

6ROCESS 7LO) C*0RT


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1

OPI!A" #I$%E

Optical fier i5 a fle?ile8 tran5parent fier 9ade of a pure gla55 D5ilica not

9uc; :ider t;en a ;u9an ;air. It function5 a5 a :aeguide or lig;t pipeQ8


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1

to tran59it lig;t et:een t;e t:o end5 of t;e fier. ;e field of applied

5cience and engineering concerned :it; t;e de5ign and application5 of

optical fier i5 >no:n a5 fier optic5.

Optical fier5 are :idel< u5ed in fier optic5 co99unication8 :;ic; per9it5

tran59i55ion oer longer di5tance5 and at ;ig;er and:idt;5 t;an ot;er

for95 of co99unication. #ier5 are u5ed in5tead of 9etal :ire5 ecau5e

5ignal5 trael along t;e9 :it; le55 lo55 and are al5o i99une to

electro9agnetic interference .#ier5 are al5o u5ed for illu9ination8 and are

:rapped in undle5 5o t;e< can e u5ed to carr< i9age58 t;u5 allo:ing

ie:ing in tig;t 5pace5. )peciall< de5igned fier5 are u5ed for a ariet< of

ot;er application58 including 5en5or and fier la5er5.

Optical fier t


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1

1-MULTI-MODES FIBER

;e propagation of lig;t t;roug; a 9ulti 9ode5 fier.

#ier :it; large core dia9eter Dgreater t;an 10 9icro9eter5 9a< e

anal


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1

;e5tructureofat


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1

P;otonic cr


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1

PA(-O##-

;e auto-traer5ing pa relea5e nut.


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2

;e fier i5 t;en guided t;roug; a la5er optic 5canner :;ic; control5 t;e

traer5ing 9otor8 oer a 5;oc> a5oring dancer8 a ten5ion 9ea5uring

;ead and a pigtail guiding.

PA(-O## EN)ION-

;e pa5 co9ing fro9

inaccurate8 irregularl< :ound or eccentric pa e@uall< in

ot; direction5. 4;en c;anging t;e ten5ion it can ea5il< e 5tetted < a

read adFu5ting of t;e po5ition of t;e dancer. !o9pare t;e adFu5t9ent :it;

t;e di5pla< of t;e actual po5ition.

IONIAION $A%-

Ionization ar i5 fitted :it; an ionizing ar near t;e inlet 5ide of t;e coloring

and coating 5 5uppl< unit i5 proided :it; ea5< to c;ange in> tan>5 ;older5

:;ere t;e in> tan>5 ;anged up to feed t;e coloring Din> applicator ;ead5.


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2

;e in> tan> i5 pre55ured. )o t;e ;eated applicator ;ead can e 5upported

:it; in>.

;e in> feed tuing fi?ed on t;e top of eac; tan> at a connecting piece

:;ic; fit5 into t;e appropriate receptacle of t;e in> applicator ;ead.

4;en t;e production line i5 not running 8t;e in> tan> can e re9oed :i5e and t;en pre55ing

do:n Dt;e in> tan> :ill not e 5et under pre55ure. 4;ile t;e production line

i5 5topped.

"eel detector detect5 t;e 9ini9u9 leel of t;e in> tan>.

IN APP"I!AO% EA-

;e in> applicator ;ead5 are fi?ed nearl< t;e inlet of t;e u -irradiator5.

Eac; of t;e9 con5i5t5 of an in> connector coupling8 a 5elf-centering inlet

die Du5uall< a dia of 0.2699 and a 5elf-centering outlet die Du5uall< a dia

of 0.26399.

;e applicator ;ead i5 fi?ed on t;e 5upport < 9ean5 of t;e ;eated cla9p

leer deice :;ic; ;old it fir9l< and at t;e e?act centre po5ition relatie to

t;e fire. )o t;e in> applicator ;ead can e ea5il< re9oed and in5talled.

IN APP"I!AO% EA EAING-


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#or t;e reducing t;e in> i5co5it< t;e in> applicator ;ead :ill e ;eated8

nor9all< et:een 30-6S!. ;e range can e 9odified et:een 20-70 S!.

IN APP"I!AO% EA P%EEAE%-

#or pre;eating t;e in> applicator ;ead5 t;ere i5 pre;eating place on t;e in>

coating unit :;ic; i5 con5tantl< pre;eated to t;e adFu5ted te9perature. )o

t;e in> applicator ;ead i5 :ar9 :;en t;e ;ead :ill e u5ed.

ANI ,) $"O4E%-

;e in> applicator ;ead t;e fier pa55e5 t;roug; du5t re9oing air lo:ernozzle :it; indiiduall< adFu5tale air flo:.

;i5 preent5 fro9 du5t particle5 to conglo9erate and to affect t;e ea5ing period.

;e lo:er :ill lo: onl< :;en t;e fier i5 running for econo9izing

co9pre55ed air.

;e adFu5t of flo: of done < uring t;e t;rottle ale.

Anti du5t lo:er a cla9p leer deice :it; ruer cap8 :;ic; ;old t;e fier

< pre55ing it again5t a 5upport.

, "A+P-


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2

;e , Hla9p i5 9ounted in line :it; t;e fier. ;e fier pa55 i5 protected

< a @uartz tue :;ic; i5 flooded :it; nitrogen and :;ic; can ea5il< e

re9oed for cleaning.

;e u -la9p ;a5 to e cooled < a 5trong air 5trea9 :;ic; i5 5upplied 5.

;e fier i5 introduced t;roug; t;e , la9p < 9ean5 of an air 5trea9

:;ic; i5 opened < a ale at t;e inlet 5ide of t;e la9p5. a>e care to u5e

oil-free air Dno nitrogen for introduction ecau5e of an eentual ri5> of

getting ro:n re9nant depo5it5 in> t;e @uartz tue5 :;ic; could affect t;e

irradiation efficienc5 relea5e5 a corre5ponding alert 5ignal on t;e alert proce55ing9odule of t;e 9ain control cainet and di5pla


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2

;e cap5tan i5 t;e 5peed deter9ining part of t;e fier line. A ce-up ten5ion :it;in t;e :;ole 5peed range up to ;ig; degree of

accuracno:n t;at t;e target reel 9u5t e :ound not onl< to a ;ig; degree

of geo9etric preci5ion :;ic; en5ure t;e troule free furt;er proce55ing of

t;e reel and al5o a reliale 9ea5ure of t;e fier attenuation on t;e fini5;ed

reel. Actual alue5 :ill e di5plae-up a?le < 9ean5 of a @uic> relea5e nut and a

preci5ion center adapter fitting to t;e 5;ape of t;e reel central ore8 e?actl t;e Pae-up dancer ten5ion8 5;oulde et:een 30-0 cN. Ad;ere to t;e Proce55 );eet.!;ec> it :it; ;ree-pulle< ten5ion 9eter in ca5e all t;e earing5 of pullee-up :inding < rotating t;e9 and feeling

t;eir 9otion < placing if t;e O-ring of t;e ie i5 not flat and

not :orn-out.

!lean t;e ie. %eplace tO-ring.

Align9ent

Align9ent of t;e line to e c;ec>ed. !lo5e t;e iri58 iffier i5 in t;e centre it i5 o> ot;er:i5e re-align. Al5oc;ec> t;e align9ent at t;e die-5tand :it; align9ent

tool. #ier 5;ould e in centre.

%ealign t;e "ine :it; t;e of t;e ie align9ent too

)ee> elp fro9 +aintena

P,Para9eter

!;ec> t;e P,T1000 i5 et:een 1700-2100. If it i5elo: 1600 it 9ig;t cau5e oer-curing of t;e fier

re5ulting in A.Ad;ere to t;e Proce55 );

2ENDCUR9E

$earing5

!;ec> t;e pulle< 9otion i5 free :it;out friction8 e5p.t;e raer5e pulle< near t;e a>e-up. !o9pare t;e

rotation of pulle if t;e O-ring of t;e ie i5 not flat and

not :orn-out.

!lean t;e ie and fi? iproperled. !lo5e t;e iri58 iffier i5 in t;e centre it i5 o> ot;er:i5e re-align. Al5oc;ec> t;e align9ent at t;e die-5tand :it; align9ent

tool. #ier 5;ould e in centre. In t;i5 ca5e it i5 li>el< to

e acco9panied < !olorlo55.

%ealign t;e "ine :it; t;e of t;e ie align9ent too

)ee> elp fro9 +aintena

Pulle t;e grooe of t;e pulle< :it; toot;pic>8 if t

in ti55ue paper :et :itacetone. If grooe ;a5 9notc;e58 replace t;e pulleatlea5t file it :it; 5andpato te9poraril< 59oot;en

grooe.

en5ionPara9eter

!;ec> t;e Pae-up dancer ten5ion8 5;oulde et:een 30-0 cN. Ad;ere to t;e Proce55 );eet.!;ec> it :it; ;ree-pulle< ten5ion 9eter in ca5e t;e traer5e alue 5etting8 Pitc; 5;ould e '&0-00 9icron.

Ad;ere to t;e Proce55 );

)en5orc;ec> :;et;er t;e 5en5or i5 not dirt if t;e fier after fini5;ing i5 loop free 59oot;l t;e traer5epara9eter5 and ten5io

para9eter. Ad;ere to t;


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2

I=6RO9E=ENT O7 COLOURIN+

?&I=6RO9E T*E OEE @O9ER 0LL EAUI6=ENT O7

E77IENC: B


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2

2-INK SAVING

BEFORE

,5e5 of 0.26 9icron outlet die.

!oating dia & 9icron.

Aerage in> lo55e5 11& >g B9ont;.

60 g9 in> 5crap5 in eac; ottle.

,5e 100>9B1>g in>.


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2

07TER

,5e5 of 263 9icron outlet die.

!oating dia 3- 9icron.

Aerage in> gain 200 >gB 9ont;.

Onl< g9 in>5 5crap in eac; ottle.

,5e 0.06>gB>9 in> in5tead of 0.07&>gB>9.

%e5ulted in %+ 5aing of 11.3lac5 in 6 9ont;5.


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2

0CTI9ITIES

rac>ing all e9pt< ottle5.

Giing t;e 5ignature eer< e9pt< ottle.

)a: t;e in> ottle5 proper e9pt< or not.

oing t;e die cleaning after 20f>9.


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3

+ea5ure :;ic; 9ac;ine 9ore 5crap t;e in> / :;ing

action on t;i5 9ac;ine.

ail< coat dia 9ea5ure9ent and 9Bc :i5e anal


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3

No proper infra5tructure and location for e9pt< 5pool5

irect du9ping to 5crap in re5ulting in dent and da9age.

&0 reFection in rec


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3

100 o> 5pool di5patc; to of.

)e9i o> 5pool 9oe to coloring.

%eFected 5pool 9oe to 5crap.

)top du9ping in a5; tra


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3

RESULTS&

!o5t co9pari5on :it; 5crap alueB5pool for O#!-%5 3.6 la>;5 oer

5crap.

Oer all profitailit< to t;e entire u5ine55 O# of-%5 3*.6 la>;5.

Total saving OF


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3

Conclusion

In order to increa5e t;e perfor9ance of t;e cale8 to reduce t;e

co5t5 of t;e final product and to en;ance t;e production range of

t;e e@uip9ent8 ne: tec;nologie5 and deice5 ;ae een

inented to reduce optical lo558 increa5e production 5peed58

reduce t;e 5et-up and do:n ti9e5 of t;e line8 reduce product

5crap8 and allo: 9ore production fle?iilit


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%E#E%AN!E

1. . $. O5tro:5> of optical fier5 and cale58 1*&&.

3. a>anori O>o5;i8 Optical fier58 1*&2.

'. %oert G... )epal8 #ier Optic58 1*&'.

. Optical fier co99unication HGerd ei5er

6. andoo> of applied 9at;e9atic5 for engineer5 / 5cienti5t5-

D+

7. :::.5terlitetec;nologie5.co9

&. +ede> /)corner G+$ +anual ;and oo>

*. $ate58 %egi5 C D2001. Optical Switching and NetworkingHandbook. Ne: (or>J +cGra:-ill"

process improvement of colouring

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