ssk training report
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idea about ssk kapur thala.Swarna subrub khoslaTRANSCRIPT
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TABLE OF CONTENTS
Sr.No. Name. Page no.
1 Acknowledgement 1
2 Preface 2
3 Introduction 3
4 Company’s Profile 4
5 Advertisement Policy 12
5.1 Sales Promotion Stretegy 12
6 Production Infrastructure 13
6.1 Electrical Wiring Accessories. 14
6.2 Industrial Plugs And Sockets: 14
6.3 Pma–Ag Switzerland:A Safe And Universal
Electrical Wiring Protection System15
6.4 Wohner Technology 16
6.5 Environmental Management Systems (Ac): 17
6.6 Electrical Panels: 18
6.7 Enclosure Systems: 19
6.8 Mcb Distribution Boards 20
6.9 Switchgear 21
7 Main Departments 21
7.1 Sheet Metal Shop 22
7.1.a C.R.C.A (Cold Rolled Carbon Annealed) Sheet 22
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7.1.1 Machines Used 23
7.1.1.a Punching Machine 24
7.1.a.2 Features 25
7.1.1.b Bending Machine 26
7.1.1.b.2 Features 27
7.1.1.c Welding Machine 28
7.1.1.c2 Features 29
7.1.1.d Shearing Machine 29
7.2 Press Shop 31
7.3 Paint Shop 32
7.3.1 Appratus Set Up 32
7.3.2 Paint Process 34
7.3.3 Test After Paint 37
7.4 Electroplating Shop 37
7.4.1 Steps For Electroplating 37
7.4.2 Types Of Electroplating 38
7.4.3 Inspection 40
7.4.4 Treatment Methods 40
7.4.5 Storage And Safety 41
8 Switch Gear Divison 41
8.1 Product Manufactured 41
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8.1.a Rewirable Switch Fuse 41
8.1.b On Load Changeover Switch 42
8.1.c Double Break Fuse Switch 43
8.1.d Switch Disconnector Fuse 43
8.2 Distribution Boards 44
8.2.1 Features:- 44
8.2.2 Classification Of The Circuit Breaker 44
9 Testing List 49
10 Moulding Shop 59
10.1 Machine Used 59
10.2 Injection Molding Machines 59
10.3 Grainer Machine 64
11 Testing Labs 65
12 Technical Performance Of Switches 70
13 Panel Shop 72
13.1 Panel Types 72
13.2 Lt Power Panel For Ac Coach 73
13.3 Panel Parts 74
13.4 Panel Discription 75
14 Ac System(Cool Pack) 80
15 Product Range Of Ssk 81
16 Observation 100
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17 Conclusion 101
18 Appendix(Table & Fig) 102
1. ACKNOWLEDGEMENTWe cannot achieve anything worthwhile in the field of technical education until or unless the
theoretical education acquired in the classroom is effectively wedded to its practical approach
that is taking place in the modern industries and research institute. Although an engineer can
only be successful through sheer hard work, but the contribution of his teachers and all those
who have been helpful cannot be overlooked.
Today as a student, I am in high spirit and stepping forward into the challenging future. Any
technical course is incomplete without some type of training. The course of B.Tech. of P.T.U.
JALANDHAR also requires six months of technical training.
I am thankful to “ESS ESS KAY CO. PVT.LTD. KAPURTHALA” for helping me to
complete my industrial training.
I would also like to express my gratitude towards my training manager, Mr. RAJESH
KHANNA and Mr. DILBAG SINGH for rendering invaluable help and guidance during my
training.
I am also very thankful to Mr. GAGAN BHARDWAJ, in providing all the facilities towards
the successful completion of my project.
My thanks are also to all staff members of the division who helped directly or indirectly in
completing my training.
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Last but not least I thank all the individuals who supported and criticized me in this period of
training semester.
SAVYASACHI
2. PREFACE
SWITCHGEAR is a common term used to mention all the protection and control
devices that makes the electrical installation safe and easy to use. All the protection
equipment such as circuit breakers and fuses to pilot devices such as push buttons are
included in term switchgear.
ESS ESS KAY CO. PVT.LTD. KAPURTHALA manufactures a variety of protection and
control switchgear. Equipped with the latest technology in the state of the art plane, the
company has established itself in the field of the switchgear as a pioneer since its beginning.
The company manufactures MCB, MCCB, FUSE SWITCHES, RCCB, LOAD
CHANGE OVER, CUBICAL FUSE UNIT, DISTRIBUTION BOARDS, CONTROL
PANELS, AIR CONDITIONER(cool pack) and various other products.
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During the six months industrial training at SSK ELECTRICALS CO. PVT.
LTD., the departments and all the products of the company were analyzed as a part of the six
months training schedule.
3. INTRODUCTION TO COMPANY--A BIRDS EYE VIEW
Ess Ess Kay Engg. Co. was established for manufacture of electrical wiring accessories in
1935 at Lahore (now in Pakistan) under the leadership of a visionary and a dynamic
entrepreneur. A pioneering effort for indigenous development of tumbler switches was
undertaken for the first time in India amidst stiff competition from imported goods, non-
existence of skilled labour and raw materials and political turmoil culminating into partition
of the country. In 1947 The Company therefore had to shift from Lahore and re-establish
itself afresh and with a renewed vigor at Kapurthala, Punjab. In the infant stage itself, the
product was awarded IS certification.
During the last 75 years the company has always kept itself abreast of latest technological
developments, growing steadfastly and scaling new heights. At present, the organization is a
conglomeration of six units spread over an area of 45000 square yards. The manufacturing
range consists of a broad band of switches, wires, switchgear, electrical panels, bus bar
systems, enclosures, cable protection systems, environmental management system,
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microprocessor control units, connectors, Industrial plugs and sockets, with an annual
turnover of over 100 crores.
Our marketing centers are dotted all over the country to ensure efficient and reliable after
sales service to our esteemed customers. We have, of late entered into foreign collaboration
with four companies of proven record, defying International boundaries and opening up
avenues in the international market. Expansion and diversification being our ongoing process,
new ranges of Zen and Heritage switches have been added to the product range.
4. COMPANY’S PROFILE
1. Name ESS ESS KAY ENGG. Co. Ltd.
2. Status Private Limited Company
3. Date of Incorporation 1935 at Lahore (Pakistan)
4. Total Factory Area 45000 Sq. Yards.
5. Contact Factory Area, P.O. Box –8,
Kapurthala – 144601
Punjab
Phone – 01822-232587, 232956
Fax no.- 01822-232668.
Web page:-www.ssk.co.in,
e-mail: [email protected]
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6. Facilities (a) Modern Tool Room.
(b) Lab with latest equipments.
(c) R & D cell.
7. Quality Certification Most of SSK products carry
Bureau of Indian Standard
Certification Mark and ISO
9002 in process.
8. Products Profile
(a) Household Electrical Accessories (Switches)
(b) MCB Distribution Boards
(c) Switchgears
(d) Electrical Power Control and Distribution Panels
(e) Switchboard Cabinets for LHB Coaches
(f) Roof Mounted AC Package Units
(g) Enclosures
(h) Cable Protection System – PMA
(i) “Wohner” Bus Bar System
(j) “Pallazoli” Connectors and Industrial Plugs
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9. Vision
Fig: -
1
To
develop a strong Client base with an equally effective Support structure which acts as a
catalyst for effective deployment of futuristically complete and credible information
solutions. They strive to achieve this by focusing individually on each project and build a
healthy relationship with their Customers.
10. Quality
Quality is a comprehensive & fundamental rule or belief, for leading & operating an
organization. And this helps in continually improving performance over the long term.
11. Objectives of company
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I. SSK Engineering Company plays emphases on forming a long lasting relationship with its
customers by offers optimum requirement and upgrade the quality of its human resource
system machinery and equipment.
II. The company has highly motivated work force of about 800 people and this is due to
conviction that their employees are most valuable assets. It has got various schemes like
SSK ENGINEERING COMPANY financing scheme, scholarships scheme for children of
employees etc.
III. Company has provided to its customer the safety of life from electrical hazards, security
and growth for its employees, satisfactory return to investor and useful contribution
towards development of community and society.
IV. The company has a distinction of having the most beautiful and cleanest factory in
Kapurthala region
12. Customer Satisfaction and Trust
Schmittlein said - "An organization that is perceived as doing a relatively good job, or
of being relatively forthcoming in one area of trust, is seen as doing well elsewhere, too .The
value of that trust element has not been going down over time." We too believe that Customer
Satisfaction and Trust will always be our Key for success!!!
13. Human Resource
The success of “SSK Engineering Company” Depends upon the people
working there. They are the foundation of this company. They are pillar holding the position
of this concern. The SSK ENGINEERING COMPANY is proud to have people like these.
The company’s list of human resource is as follows.
Table 1
Type No
Qualified M.B.A. Engineer 140
Diploma holders 70
Sales staff 65
Workmen 450
Resident 35
Other 150
The company has not lost a single man-day during its 44 years of existence. To take care of the workers of company has also introduced a SSK ENGINEERING COMPANY f-financing
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scheme governed and managed totally by the workforce for their over benefit. The company is also laying a great emphasis on training and development of its employees as it leads to establish a motivated and harmonious work environment.
14. Environment of the concern The company has the distinction of having the mesmerizing infrastructure.
The environment of “SSK Engineering Company” is fully workable, each and every person in the concern is filled with the spirit of doing their work in a different and specialized way. As a responsible corporate citizen, the company has built a beautiful round about at Kapurthala , which is being maintained by it. It has also been the pioneer in installing hundreds of tree guard to aid the greening of Kapurthala.
15. Expansion plans
The company is professionally managed. It is continuously improving its product range and has plans to achieve over Rs. 100 crores turnover within next 6 years. With the economy of the country starting to emerge from recession and power industry being thrown open to private sector, the company is poised to perform better in coming years. It has very ambitious expansions plan in various stages of implementation. The director are confident that in years to come, the company’s performance and operating result will go up.
16. Industrial relations
The personnel policies and managerial philosophy of this group are people oriented. Human resources are fully encouraged to obtain maximum career development growth within the organization. The quality of the product working conditions and natural consideration and understanding between the management and the workers has resulted in extremely cordial industrial relations.
The company has peaceful industrial relations from very inception since 1958. It is said that not even a single moment has been ever wasted nor there has been any instance of Industrial Relation breakdown throughout its history. The top management believes in running the organization with efficiency, devotion and high ethics of business.
17. AlliancesTo keep SSK ENGINEERING COMPANY excellent and technologically pioneer the
company has gone in for technical tie up with reported manufacturing units. Following are its
alliances: -
1. Kasuga Electrical work Japan:- The company s into alliance for the manufacturing
of Molded case circuits.
2. Lawson fuse Ltd. U.K.:- The alliance is for manufacturing of high breaking capacity
fuses.
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3. PC Electric Co. Australia:- The alliance is for the manufacturing of insulated plugs
and sockets.
4. Havells New Delhi :- The alliance is for the manually sharing and development of
market. Havells have invested in “SSK Engineering Company” and have 60 % profit
sharing alliance.
18. Collaborationsa. PMA AG, Switzerland–Cable Protection System
b. Wohner Gmbh, Germany – Bus Bar system.
c. Pallazoli, Italy – Connectors & Industrial Plugs.
d. Aircotech, Switzerland – AC Package Units.
19. Our ClientsDomestic Clients Overseas Clients
Rail coach factory (RCF)
Larsen & Toubro
Indian Oil Corporation Ltd. (IOCL)
Tata
B.H.E.L.
Escorts
Jaypee Group
Jindal Stainless Steel, among others
Hidustan ltd, jalandahr
Eaton Electric Limited, UK
Syrian Electricity Board, Syria
Electricity Board Bangladesh
Electricity Authority of Cyprus
Cylon Electricity Board, Sri Lanka
Electricity Distribution Directorate,
Bahrain
Jordan Electric Power Supply Co.,
Jordan
20.1 Housing / Commercial Projects:1. DLF 24. Cotton City, Coimbatore
2. UNITECH 25. South Indian Shelters, Chennai
3. ESSEL Tower, Gurgaon 26. Shreenath Tower, Rajkot
4. Raheja Builders 27. Alaap, Rajkot
5. NIHO 28. NRI City , Jaipur
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6. ELDECO 29. Royal En Sign , Jaipur
7. Parsvnath 30. Sand Dune, Jaipur
8. HEWO 31. Paradise Group, Jaipur
9. AWHO 32. Suncity, Delhi
10. Ansals 33. Unique builders Jaipur,
11. Akashganga, Jaipur, 34. Index One, Jaipur
12. Brahma Majestic. Pune 35. Brahma Builders, Pune
13. Nike Nore & Associates, Pune 36. Parmar Builder, Pune
14. Sanghvi Builder / OM Builders, Pune 37. Goyal Ganga, Pune
15. Esha Realators, Pune 38. Kolte Patil Builders, Pune
16. Pharande Developers, Pune 39. Rohitin Mehta Associates, Pune
17. Beharay Rathi Builders, Pune 40. K.D Builders, Pune
18. Landscape Construction, Pajim Goa 41. Kamat Construction, Panjim Goa
19. Models Construction, Panjim Goa 42. Richmont Builders, Goa
20. Omaxe-Green City Faridabad 43. Krishna Residency, Mumbai
21. Safal Twins, Mumbai 44. Aggarwal Residency, Mumbai
22. Royal Chambers, Mumbai 45. Ramoji Film City, Hyderabad
23. Ansal City, Jodhpur, 46. Rajtilak, Surat and many more
……………..
20.2 Hospitals1. Escorts, Amritsar 5. Sir Ganga Ram Hospital, Delhi
2. Apollo, Delhi 6. Batra Hospital, Delhi
3. DMC, Ludhiana 7. Fortis, Mohali
4. Vintage Hospital, Panjim Goa and many more …………..
20.3 Government / Public Sector / Private Sector / Others1. Parliament House 16. Rail Coach Factory, Kapurthala
2. THDC 17. NTPC
3. PSEB 18. MPEB
4. Chattisgarh Electricity Board 19. LIC
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5. United Bank of India 20. ICICI Bank
6. UTI Bank 21. BHEL
7. PWD, Punjab,UP,Haryana,Rajasthan,Assam 22. IOCL
8. AECL 23. HCL
9. ITI Rai Bareilly 24. GNVF Ltd.
10. HAL 25. BEL
11. CPWD 26. NFL
12. Kalpataru Power Transmission Ltd. 27. Biocon , Bangalore
13. National Institute of Oceanography, Goa 28. Krishi Bhawan, Panjim Goa
14. Office of GSIDC, Panjim Goa 29. Ordnance Factory, Khamaria M.P
15. Airport Authority of India 30. SBI and many more ……………..
20.4 Religious InstitutionsSwaminarayan Temple, Baroda, Surat, Bharuch, Ahmedabad
Golden Temple, Amritsar
Radhaswami Dera Baba Jaimal Singh, Beas and many more….
We have long list satisfied customers in India as well as abroad. The following are
very big customers for Woehner products. Their annual purchase of Woehner material is
more than 2.5 million duetsch marks each.
1. CARRIER, France
2. SIEMENS, Germany
3. ALLEN BRADLEY
4. SCHNEIDER, France
5. KLOCKNER – MOLLER
6. ABB
7. GE-Power Control
We feel that using our Bus Bar System, troubles in the panels are reduced to the
minimum and making the end product overall more sophisticated & reliable.
We manufacture only LT panels.
1. PDB - Power Distribution Boards
2. CDB – Control Distribution Boards
3. Feeder Panels
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4. Motor Panels – Star Delta / D.O.L Panel
5. Energy LT Panels
We do not manufacture AMF Panel with Synchronisation or HT Panels.
We do not manufacture Motor Panels with PLC derive system.
21. Research, Development and Quality Maintenance.SSK being the market leader hence the secret of “SSK Engineering Company”
success is quality maintenance. Company has become successful because of their research
and development department. The company has been beaten the clock in achieving their
objective. It happened because of their research and development department, which is highly
equipped and maintained. The company has growing pains also but yet company able to carry
away those pains and reached the new heights of excellence. Research and development
department plays a key role in analyzing and finding solutions to various problems.
Regarding the quality and in development new designs. The company uses CAD/CAM
machines for entire design and development. It has fuel in house facilities of short circuit
testing up to 10 KA and various other equipment’s for Electrical and mechanical tests.
In this research and development after every four hours of manufacturing, the manufactured
products are checked also before transferring to other divisions for assembling etc. The
quality is checked. Workers of the “SSK Engineering Company” also give their suggestions
to improve quality.All the goods manufactured at “SSK Engineering Company” are ISI
marked. Also the company has achieved ISO 9001 from BVQI (Bureau verities Quality
International). The emphasis on quality and constant technology up gradation has helped the
“SSK Engineering Company” in creating a unique position for its products not only in the
domestic but also in international market. Every year the company is spending more and on
its research and development.
5. ADVERTISEMENT POLICY OF SSK ENGINEERING COMPANY
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The general trend of “SSK Engineering Company” is to spend 1 % of sales target as
advertising expenditure and on sales promotion techniques. The advertising expenditure will
be given according to the target of the dealer and the rest 0.5 %is expand on manufacturing of
complimentary gifts Calendars, Key chain, tolls kits, diaries, table clothes, slips pads etc.
Some time dealers wants to make these gifts on their on their own, for that company provides
0.5 % of expenditure to them.
“SSK Engineering Company” is trying to improve their sales in all over India. Company is
using techniques of SWOT Analysis. A separate policy for replacement of good has been
circulated. All defective goods to be sent to company’ deposit in copulation after approval of
the concerned territory sales persons. The returned goods should be accompanied by dealer’s
challan dearly mentioning the reason for return the products or issue a credit not after
inspection and verification as per policy.
5.1 Sales Promotion Strategy
Full range of products:
In order to cater to the demand of the demand of the market the business house has
introduced a wide variety of products in full range.
Timely supply:
Timely supply of goods is an important factor of company’s strategy which leads to
increased sales.
Competitive price:
In the present competitive scenario only that products seems to survive which offers
high quality goods at reasonable price.
Qualitative approach:
Today’s customer is a quality conscious and demand high quality goods. The quality
policy of the concern is ISO certified which speak highly of its World Class Quality.
Effective Training of latest Technology
From time to time employees are exposed to latest prevailing technology and
practices so that they remain competent to the market environment.
Effective marketing practice:
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Advertisement is the most popular techniques of sales promotion. Launching of new
product and creating a success story majority depends upon effective marketing advertising
campaign.
Close Contacts:
Personal contacts in and outside the industry has helped SSK ENGINEERING
COMPANY make rapid strides in the electrical good market.
Stress on after sales service
Goods after sales service are the plus points of any concern. To keep the customers
satisfied long after the product has been sold is useful for the concern in the long run.
Stress on Publicity:
It has always been SSK ENGINEERING COMPANY’s key policy to publicize its
products from the awareness of the consumers.
Flexible structure:
Flexible structure has helped SSK ENGINEERING COMPANY to upkeep its
products according to changing requirement and market conditions.
6. PRODUCTION INFRASTRUCTURE/ANALYSIS:
Production Standards:
Quality management systems, being hallmark of our activities, quality standards are being
followed in all production activities. Precision type machines are being used to ensure
quality. The important machines in use are - Deckel Maho machining center, CNC wire cut
machine, CNC grinder, Profile Projector with digital readout facility, CNC Punch Press and
CNC Brake Press.
Moulding section consists of L&T make Demag; machines and Injection moulding
machines are being utilized.
Electroplating facilities exist for gold plating, Silver plating, Nickel plating and
tinning processes for different components which are being used for complete range of
products
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Testing Labs with the testing facilities have been equipped to ensure adherence to IS
standards. Painting section consists of seven-tank arrangement for phosphating and
pessivating process before powder coating of various components. Paints of superior quality
are being used to provide anti rust characteristics to our products.
Design and development activities:
To aid and assist production activities, we have full-fledged design and development division.
CAD facilities exist through Visicam software computers and a plotter.
6.1 Electrical Wiring Accessories.
Switches and sockets conforming to IS 3854 – 1997, IS 1293 – 1998 respectively are
being manufactured with a broad band of variants. The products with arc extinguishing and
anti track electrical characteristics have wider applications in house electrical appliances,
commercial and industrial establishments. Providing earthing pins and shutters over live pins
has ensured safety of the users. The modular design and aesthetically manufactured switches
are being extensively used in prestigious buildings like hotels, conference rooms and
government establishments. Other products include Rewireable Switch Fuse Combination
Units, Double Break Fuse Switch Combination Units, Changeover Switches, Porcelain Fuse
Units, MCB Distribution Boards, Plug Socket Distribution Boards, Industrial Plugs &
Sockets, Distribution Fuse Boards etc..
Our products are free from electric shocks and fire hazards and have applications in damp
and explosive atmosphere. The switches available in matching colors are aesthetically
superior and are removable and washable with convenience. They are economical because
color changes in switches are possible without any change of the base.
6.2 Industrial Plugs and Sockets:
“Pallazoli” industrial interlocked socket outlets, plugs and connectors are being used
in potentially explosive atmosphere such as in pharmaceutical and chemical industries, car
parkings, plastic industry, sugar mills, petrol and oil stations and similar installations prone to
fire hazards.
The products have been created for the first time without screws for assembly of components
and cable clamping. The outlets can be wired with convenience and are available with fuse
monitoring system. These are available for a voltage range of 400 – 500 V and a current
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rating from 10A to 125A with a protection category IP67. The products are available in 2
Pole, 3 Pole and 4 Pole versions.
Wall mounting interlock socket outlets are available in ULSSE - Ex series, TAIS – Ex series
and ALUPRE – Ex series whereas plugs are available in CEE – Ex series, ATEX. The special
features are:
1. Interlock system is a positive protection against electric shocks and opening arcs.
2. Explosions are prevented as the plugs and sockets are non sparking.
3. The products comply with international standards – CEI EN 6039, CEI EN 60917, CEI
EN 60742.
4. The components are robust and have high resistance to heat fire and chemical agents.
5. Socket outlets are pre wired and therefore save wiring time.
6. The sockets have ergonomic control with provision of fuses and MCB’s.
7. Matching accessories like support plates aluminum alloy flanges and cable glands are
readily available to suit different applications.
6.3. PMA–AG Switzerland:
A Safe and universal electrical wiring protection system.
PMA Leaders in the design and production of nylon cable protection system have over 6500
tested and proven products for cable protection system. The products have world wide access
to traction applications, heavy plant and vehicle construction aviation, fiber optics, solar
energy, metro rail systems, robotics and machine building industries. PMA conduits system
can be tailor made to meet specific industrial requirements. Products have halogen free self-
extinguishing properties and meet international quality and safety standards. The products
have proven record during the last 30 years and have certification from the following. IEC
61386 / EN 50086, UL recognition, CSA, NF, SNCF, DB.
PMA conduit pipes have a large range of accessories like bends, clips, sealing rings, clamps,
swivel connectors, adopters, terminals, protection sleeves, universal safety clips, oval clips,
hexagon nuts and lock nuts. The conduits along with accessories can be assembled at site
with convenience. The conduits find wide applications in hazardous damp and high
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temperature environments. Fire retardancy make their applications safer in public
installations such as railway coaches, theatres, conference halls, shops aviation and power
control panels.
Technical features PMA products:
1. The components are made from polyamide and nickel plated Aluminum and offers
excellent screening characteristics as per European EMC regulations. These provide high
shielding effectiveness and low transfer impedance.
2. The components withstand hostile temperature conditions between –75 C to 450 C and
thus have given satisfactory performance all over the world.
3. These are safe and easy to install for various industrial applications.
4. Accessories like clips, bends reduces adopters swivel connectors, tube clamps,
connectors, safety and sensing systems all add to provide IP 67 protection as per
international standards. The system has excellent fire retardancy, neat and cleans layout
and shielding properties.
6.4. Wohner Technology:
Wohner a trend setter in Bus Bar system technology is continuously improving its systems.
Convenient terminals which require no drilling are available for connecting conductors with
cross sections from 1.5 to 120 Sq. mm. Bus Bar connecting terminals allow bus bar systems
to be connected length wise. Other advantages are ease of rapid circuit change over, easy
installation, supply of customers need based system. With universal terminals or terminal
plates, cables up to 300 Sq. mm can be connected without drilling holes. The range includes:
1. Universal Bus Bar support
2. Standard copper Bus Bar
3. End Cover
4. Compartment section
5. Bottom trough
6. Trough edge section
7. Connection terminal
8. Connection accessories
9. Triple Bus Bar sections
10. Bus Bar adapter.
11. Plug in connector panel mounting components
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12. Comb type Bus Bar
13. Barrier support
14. Barrier
15. Spacer
16. Cover frame
Applications:
1. Low voltage power distribution panels
2. Power control and motor control centers
3. Overhead Bus Bar trunking.
4. LT Bus Bar ducts.
5. Customized Bus Bar systems.
Special Features:
o Compact in design.
o Versatile technology for wide range applications
o Patented technology – Trend setter for new NH Bus mounting fuse switch disconnector.
o Composite Bus Bar system and LAN Bus technology and control of components through
PC.
o Absence of drilling holes – reliability and efficiency of Bus Bar system.
o Adopters – ensure easy and quick mounting of connectors, MCCB’s and other
components.
o Snap on push fit arrangement.
o Absence of hardware ensures no chance of heating and flash over.
o Absence of use of crimping sockets reduces installation cost in a compact area.
o Wiring layout is neat and clean and ensures total flexibility for upgradation and expansion
without major changes in design.
o Universal adoption for all types of equipments without hassels.
o Conforms to IEC – 947
6.5 Environmental Management Systems (AC):
We have joined hands with Aircotech of Switzerland for development of roof mounted AC
package units for Indian Railways, military shelters and for industrial and commercial
installations. Our units have striking features - compact size, easy to install, cost effective per
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TR, rugged and antirust stain less frames. Equipped with air cooled condensers, requirement
and availability of water as a cooling medium is totally eliminated. Being compact and fully
wired, the units can be installed within an hour and find convenient location on roof tops,
thus eliminating the need for space which can be gainfully utilized for commercial purposes.
Our units are energy efficient economical and cheaper in operational costs as the capacity of
the system can be controlled as per the cooling load requirements during journey.
Our production activities get technical support from our collaborators who have expertise for
equipments for traction applications and military shelters. The micro processor control of
units provides diagnostic facilities through interface with laptop apart from automatic fine
control of temperature, humidity, fresh air quality etc. Our units meet requirements of
international quality standards such as UIC 553 OR, UIC 553 – I, EN 50155, EN 55011, EN
50141 besides applicability of relevant Indian Standards. They have been specially designed
to work satisfactorily under hostile environmental conditions such as high ambient
temperature, damp and dusty atmosphere and under excessive vibrations and shocks. Being
of approved and proven quality, the components are almost maintenance free and ensure
trouble free operation during service.
Environmental control & testing facilities have been created to meet international standards.
Microprocessor controllers, variable voltage and frequency measuring equipments, high
voltage testing kits, evacuation and refrigerant charging machines, insulation resistance
testing kits and instruments for testing and measurement of voltage current, power factor,
frequency and electrical power have been installed for measurement and adjustment of
various parameters for a close watch over the performance of AC units during testing.
6.6 Electrical Panels:
Indian Railways are one of the major users of electrical panels and we enjoy the status of
approved suppliers for Indian Railways. Other users are State Government, Central
Government and private organizations of repute.
The product range includes:
MCC Panels
PCC Panels
PDB Panels
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Feeder Pillars
CDB Boards
AMF Panels
LT Panels
General features:
The Panels conform to IS standards with a degree of protection IP 55. Main features are:
1. Accuracy of dimensions
2. Aesthetically elegant Panels
3. Customised manufacture of Panels.
Variants for railway coaches:
Switch Board cabinets
Buffet & Power Car Panels
SG / EOG variants of Panels
Non AC Panels
Special Features of Panels for Railways:
1. Provision of disconnecting and earthing devices.
2. Insulation monitoring system
3. Anti Skid protection device control
4. Control of electrical appliances in pantry card – heaters, fridges, water coolers, hot boxes
etc.
5. Monitoring and control of AC package units with microprocessor controlled system and
diagnostic facilities with interface with laptop.
6.7 Enclosure Systems:
Sheet Metal enclosures of different variants were launched in 2005. The enclosures meet
requirements for power panels, distribution panels, drive panels, machine tool applications
and various other electrical and electronic applications. A wide range of CNC machines are
being used to carry out various operations. These panels are modular in construction and have
special features as given here under.
A high quality joining frame with special profile enhances technical properties. These
are self standing type with openable doors with degree of protection IP 55.
P a g e | 24
Constructional features:
1. Multi folded profile sheet metal channel:
2. Integrated special lock system with inserts and recessed handles.
3. Reliable protection from ingress of water and dust for the installed equipment with
formed in PU seal.
4. Sturdy and elegant in looks with powder coating paint finish.
5. Modular design.
6. Rugged and self supporting base.
7. Easily openable door and easy installation.
8. Facility for removal of rear, top and side covers.
9. Facilities for accessories such as lifting hooks, cable gland entry holes, cut outs for
display and control equipments.
10. Easy interior installation by using mounting plates( self tapping screws, u nuts, clip on
nuts, earthing strips, Tri bars.
11. Also available as per specific customer’s requirements.
Product range:
1. Integra series: Floor standing frame type construction. Modular in design.
2. Magna series: Modular cabinet system custom built for specific applications and needs.
3. Versa series: Control desk type cabinets.
4. Reva Series: Wall / surface mounted welded enclosures and terminal boxes.
5. Dura Series: Outdoor enclosures / PC enclosures / 19” racks.
6.8 MCB Distribution Boards:
MCB Distribution Boards have a universal design which can accommodate any type
of MCB made as per IS Specification conforming to IS 13032 & IEC : 439 & 529. Quality,
safety, flexibility and convenience of the distribution system are the hall marks of SSK
products. Double Door Distribution Boards have additional feature for adjustment of MCB’s
through height adjustable Din Rail as per IS 11039. The body of the MCB DB is made from
high grade CRCA sheet steel to withstand all types of tropical environment and sheet metal
work is executed through CNC machines to achieve high degree of accuracy and quality,
followed by seven tank phosphating and passivating process and powder coating with
superior quality paint to ensure protection shield to protect the DB from rust, cement &
concrete during construction. It ensures energy saving & economical operation achieved
P a g e | 25
through use of high conductivity ETP copper tin plated Bus Bars. Suitable knockouts are
provided on all four sides at appropriate positions for wider application and ease of cable
entry and sufficient wiring space provided to ensure easy and trouble free wiring.
6.9 Switchgear:
Heavy-duty switchgear for inductive loads gives reliable and trouble free performance. These
include Rewireable Switch Fuse Units, Double Break Fuse Switch Units, Changeover
Switches, Porcelain Fuse Units, Neutral Links etc. with heavy duty double knife contacts and
find extensive applications for electrical installations in Telecommunications, Railways,
Power Systems, Hospitals, computers, public and industrial buildings and industrial
undertakings. The products comply with the requirements of IS 13947 part 1 & 3 & IEC:
60947 part 1 & 2. They are available in ratings from 16A to 400A and above with double,
three or four pole configuration.
The body of the switchgear is made from CRCA sheets and sheet metal work is executed
through CNC machines, followed by seven tank phosphating and passivating process and
special epoxy polyester, ionic bond powder coating achieved through electrostatic technique
with superior quality paint to withstand tropical climatic conditions. Suitable interlocking is
provided to ensure that the switch can be opened in OFF position only and can be switched
ON when the cover is fully closed. Transparent polycarbonate shroud provided for protection
of operator and direct visibility of contacts in high rating changeover switches. Heavy duty
spring loaded ETP copper contacts provided for low watt losses & energy saving thus
reducing operational cost.
SSK Switchgears have a long track record of high quality. Long time users of our switchgear
vouch for good quality. Company has a large and rapid growing base of satisfied customers.
SSK takes extreme pains in maintaining high standards of quality & perfection with an
assurance that all SSK products are backed by genuine warranty of trouble free performance.
7. MAIN DEPARTMENTSThe standard electrical limited is divided into 11 departments: -
Sheet metal shop
Press shop
Paint shop
P a g e | 26
Research & development department
Electroplating shop
Circuit Breaker Division
Tool room
Panel shop
Moulding shop
Switchgear assembly
Quality assurance department
7.1 SHEET METAL SHOP:-
This department Manufactures the enclosures for the distribution board as well as the
panel & do the sheet metal work as cutting, shaping, welding etc.
The raw material used is CRCA (cold rolled carbon annealed) sheets.
The operation cycle in the sequence it is performed is as shown below: -
C.R.C.A. sheet
Cutter (blank sheet)
Power press (punching)
Tapping (if required)
Bending
Drilling
Welding (spot or mig as required).
The board or cabinet formed is then sent for electroplating & painting process to respective
departments.
7.1.a) C.R.C.A (Cold Rolled Carbon Annealed) Sheet
It is imported from ESSAR STEEL INDIA LTD.(Ludhiana). One bundle contains 60 sheets.
Weight is 2.8 MT.
Sizes (2*1250*2500mm, 1.5* 250*2500mm)
The quality check is followed throughout the manufacture.
P a g e | 27
The welding is done to join the sheets to make the bodies for housing the components or the
service cabinet.
Fig:-2
Two types of welding are as followed: -
1) Spot welding
2) Mig welding
7.1.1 Machines used: -
There are various types of machines used such as: -
Power press
Shearing Machine(Mechanical cutter)
Drilling machine
Tapping machine
Welding machine
Punching machine
Bending machine
a) Punching machine
P a g e | 28
Two types of punching machine are used at ssk.
CNC (Automatic) TURRENT PUNCH PRESS
CNC (manually) PUNCH PRESS
A punch press is a type of machine press used to cut holes in material. It can be small and
manually operated and hold one simple die set, or be very large, CNC operated, with a multi-
station turret and hold a much larger and complex die set.
C type presses have a bed plate which is used to lock the die bottom bolster. For
locking the die, T bolts are used and so this plate contains 'T - slots into which t- bolts are slid
in. These slots are placed diagonally and with a slot horizontal to the longer side of the plate,
is the general practice. These slots run up to a central hole made in the plate, the hole being
large enough to accommodate another bush with a hole, the hole being used for dropping the
punched part to the bottom of the press. The top of the tool butted against a vertical sliding
ram with a clamping system which accommodates only a particular diameter of a threaded
cylindrical member called the "shank" of the tool. The bottom portion of the tool is locked to
the bottom bed plate and the top portion of the tool is locked to the sliding ram. Top and
bottom portions of the tool are generally guided by suitable pillar and bush assemblies, (one
or two pairs ), which gives safety to the punching elements of the tool.
Generally the tool is placed slightly above the bottom bed plate by providing two parallel
blocks accurately ground to the same size. This is a necessary action since many tools; scrap
(cut pieces which are a waste) is discharged through the bottom element of the tool, not
necessarily in the centre of the tool. The scrap or the blank ( the required portion ) come out
from the die at different places . These have to be taken out horizontally from between the
parallels placed. Otherwise they get accumulated inside the tool itself and cause severe
damage to the tool.
In very heavy presses with higher tonnage, The sliding ram has also a thick plate with T slots
for locking the top plate of the tool (called the top bolster). In such cases the threaded
cylinder called shank is not attached to the tool. The clamps are either mechanical (manually
operated using spanners ) or air operated varieties.
Turret type punch press machines have a table or bed with brushes or rollers to allow the
sheet metal work piece to traverse with low friction. Brushes are used where scratches on the
work piece must be minimized, as with brushed aluminum or high polished materials.
P a g e | 29
Turret type Punch presses are computer numerically controlled (CNC) able to be run in an
automatic mode, according to a pre-built program, to perform the processing of the material.
a.1) The punch press is characterized by parameters such as:
Frame type
Mechanism of delivering power to the ram (mechanical, electro-mechanical or hydraulic)
Size of working area (e.g., 2500 x 1250 mm)
Force rating (for example, 20 tons)
The type of tool shop and its capacity (e.g., store revolving type, capacity 34 tool)
Speed or productivity (typically characterized by the speed of strokes with a step
movement of 25 and 1 mm)
Speed of movement without shock (speed-load displacement)
Maximum weight of work piece
Safety features
Power consumption
The type of software
Punch presses are usually referred to by their tonnage and table size. In a production
environment a 30 ton press is mostly the machine used today. The tonnage needed to cut and
form the material is well known, so sizing tooling for a specific job is a fairly straightforward
task. According to the requirement the tonnage may even go up to 2000 to 2500 ton presses.
a.2) Features of punching machine at ssk
Punching (VIPROS 225) by AMADA company (shown in Fig 3)
Store revolving tool set used, capacity 34 tools.
Co-ordinates are feed in CNC system
(X-axis, Y- axis, Z- axis, Angle, Time delay, Tool operation)
Capacity/Force:- 196 KN
Power Required:- 27 KVA
Wt. of Machine:_ 9800 kg
Frequency:_ 50-60 HZ
P a g e | 30
Fig.3
Punching Press (Mech)
Company:- Hindustan Hydraulics
3 Phase, 50-60 HZ
Wt. of machine:- 9000kg
Capacity:- 2000kN
Supply I/P:- 415 V, 3.8 A
Fig 4
This is operated by Legs. Only coordinates are fed by CNC system by DELEM company.
b) Bending machines:-
These machines are used for bending of sheet to give them a shape. They are of different
types and types are based on their capacity. They may be manually operated or automatic.
P a g e | 31
CNC system are used for feeding of size and co-ordinates.
b.1) Features of bending machine at ssk.
Company :- Hindustan Hydraulics
Capacity:- 10 ton
Force :- 1100 KN
I/P supply:- 415 V
Working length:- 3100mm
Wt. of Machine:- 8700kg
Leg operated, Feeding system by DELEM.
Fig 5
Company:- AMADA
Capacity:- 80 ton
Power required:- 6KVA
Wt of machine:- 5100 KG
Max. bending length:- 2505mm, 98.6 inch
Temp required:- 0-400c
Different type of tools are used. Generally 14 -16 gauge tools are used.
Fig 6
P a g e | 32
c) Spot welding machine
Spot welding (RSW) is a process in which contacting metal surfaces are joined by the heat
obtained from resistance to electric current flow. Work-pieces are held together under
pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in)
thickness range. The process uses two shaped copper alloy electrodes to concentrate welding
current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large
current through the spot will melt the metal and form the weld. The attractive feature of spot
welding is a lot of energy can be delivered to the spot in a very short time (approximately ten
milliseconds). That permits the welding to occur without excessive heating to the rest of the
sheet.
Fig. 7
c.1) Processing and equipment
Spot welding involves three stages; the first of which involves the electrodes being brought to
the surface of the metal and applying a slight amount of pressure. The current from the
electrodes is then applied briefly after which the current is removed but the electrodes remain
in place in order for the material to cool. Weld times range from 0.01 sec to 0.63 sec
P a g e | 33
depending on the thickness of the metal, the electrode force and the diameter of the electrodes
themselves.
The equipment used in the spot welding process consists of tool holders and electrodes. The
tool holders function as a mechanism to hold the electrodes firmly in place and also support
optional water hoses which cool the electrodes during welding. Tool holding methods include
a paddle-type, light duty, universal, and regular offset. The electrodes generally are made of a
low resistance alloy, usually copper, and are designed in many different shapes and sizes
depending on the application needed.
The two materials being welded together are known as the work pieces and must conduct
electricity. The width of the work pieces is limited by the throat length of the welding
apparatus and ranges typically from 5 to 50 inches. Work piece thickness can range from
0.008in. to 1.25in.
After the current is removed from the work piece, it is cooled via the coolant holes in the
center of the electrodes. Both water and a brine solution may be used as coolants in spot
welding mechanisms.
Using a copper wire as the welding element does the MIG welding. Whereas the spot
welding does not use a welding element as the metals are joined by the action of heat.
c.2) Features of welding machine at ssk.
Company:- Sunrise mek welding
Type:- spot/projection welding
p.f:- 0.4
i/p:- 50 hz, 415 V
2phase
Water cooling system, 1.5 litre
d) shearing machine:-
Used for cutting of sheets of different shapes.
P a g e | 34
Company:- Hindustan hydraulics
I/P:- 415 V
Wt of machine 6200 kg
Capacity 6mm
Working length 3100 mm
3phase
Length is feed , & cutting process is done manually.
Fig 8
P a g e | 35
7.2 PRESS SHOP
Press shop is divided into two parts: -
1) Switchgear press shop
2) MCB press shop
In switchgear press shop main contacts for double break switch and cubical switch,
interlocking strip for cubical switch, arm for double break switch and solid links & link
strips for rewire able, cubical and change over switches are prepared.
In MCB press shop arc chute assembly, fixed contact, moving contact, bimetal carrier, arc
chute plate, stopper, control rail, mounting clip etc. required for the completion of MCB are
prepared.
The dep’t. Also manufactures dyes needed for tool manufacturing used in the plant.
Details: -
The press shop operations are set up dominant. Dyes for various operations are maintained.
New dyes are got approved of quality assurance dep’t. If any fault is found in the dye it is
repaired and re-approved from QAD.
Quality check is followed throughout, first piece inspection procedure is adopted as well as
the random inspection is followed and the reports are made and if any problem exists it is
rectified.
First piece evaluation is done by in charge press shop. Whenever the dye is loaded in press
for production. If the first piece meets the acceptance criteria, the set up is approved and
production is allowed however, if the first piece fails to meet the acceptance criteria,
production is not allowed and the dye worked out or resetting is to make the production
conforming the acceptance criteria.
There are following machines used in press shop:
Mechanical power press
Pneumatic power press
Hydro-pneumatic power press
Hydraulic power press
They are used for small work like making small cutting & different symbols. E.g. ground
symbol , Danger symbol, SSK.etc.
Their rating depends on gauge, different tools are used for this purpose.(12-14 gauge, 18 -
20gauge, 20-25 gauge). Marks & holes are made on cabinets & others.
P a g e | 36
7.3 PAINT SHOPIn this shop, powder paint is applied on the enclosure of the following items: -
Rewireable switches
Double break switches
Change over switches
Cubicle fuse switches
MCB Distribution boards
All export items and cabinet
7.3.1 APPARATUS SET UP: -
1) Powder coating guns (electrostatic application)
2) Powder baking oven
3) Thermic fluid heater
4) Spray booth
5) Micro test thickness gauge
The powder coating guns are used to spray the powder paint on the components in the
spray booth, which then sent to the baking oven. The thermic fluid heater is to produce the
steam required to operate the oven. Micro test thickness gauge is used to check the
thickness of coating of the paint.
1) Powder coating guns
Fig.9
Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main
difference between a conventional liquid paint and a powder coating is that the powder
P a g e | 37
coating does not require a solvent to keep the binder and filler parts in a liquid suspension
form. The coating is typically applied electrostatic ally and is then cured under heat to allow
it to flow and form a "skin". The powder may be a thermoplastic or a thermoses polymer. It is
usually used to create a hard finish that is tougher than conventional paint. Powder coating is
mainly used for coating of metals, such as household appliances, aluminum extrusions,
and automobile and bicycle parts. Newer technologies allow other materials, such as MDF
(medium-density fiberboard), to be powder coated using different methods.
There are several advantages of powder coating over conventional liquid coatings:
1. Powder coatings emit zero or near zero volatile organic compounds (VOC).
2. Powder coatings can produce much thicker coatings than conventional liquid coatings
without running or sagging.
3. Powder coating overspray can be recycled and thus it is possible to achieve nearly
100% use of the coating.
4. Powder coating production lines produce less hazardous waste than conventional
liquid coatings.
5. Capital equipment and operating costs for a powder line are generally less than for
conventional liquid lines.
6. Powder coated items generally have fewer appearance differences between
horizontally coated surfaces and vertically coated surfaces than liquid coated items.
7. A wide range of specialty effects is easily accomplished which would be impossible
to achieve with other coating processes.
Powder coatings have a major advantage in that the overspray can be recycled. However, if
multiple colors are being sprayed in a single spray booth, this may limit the ability to recycle
the overspray.
1.1) Principle of powder coating guns
Charging of powder
Various systems are used to charge the powder. The choice of the process depends on the
application and the desires of the user. Generally, three different charging processes are
distinguished: electrostatic charging, charging with low ionization and tribe charging.
Virtually all manufacturers attain the reduction of air-ionization by the use of a special
centerpiece on the top of the gun (called Super Corona at ITW Gama)
P a g e | 38
Electrostatic charging
The corona discharging is the unrestrained escape of free electrons from an electrical
conductor. The electrostatic gun is equipped at its top with an electrode that expels electrons.
When exiting the powder gun, the powder particles are charged through the deposition of air
ions. The resulting ionized powder particles, similar to the free ionized air particles, are
attracted to all earthed objects. In practice, the earthed object is the work piece, thus the
powder remains bonded to it. The charging principle with constant feed of electrostatic
charge allows the use of this gun type in all application cases and for virtually all powder
categories available on the market.
Fig 10
7.3.2) paint process has five steps: -
Phosphating
Priming
Painting
Baking
Sealing
P a g e | 39
PHOSPHATING: -
By the process of Phosphating, impurities are removed from the surface of the body & body
is coated with a layer of phosphorous.
And it includes nine-tank process.
Table 2
Sr.No.Description
Operating
Ph.
Temp. Of the liquid in
degree Celsius
Time for which
object is kept
insidethe liquid
for minutes
1. Degreasing Tank 10 75-85 10
2. Water Rinsing Tank --- Normal 1
3. Derusting
Tank
1 50-60 5
4. Water Rinsing Tank ----- Normal 1
5. Water Rinsing Tank ----- Normal 1
6. Activation Tank 8.5 – 9.5 Normal 1
7. Phosphating Tank 1 30-35
8. Water Rinsing Tank ----- Normal 1
9. Sealing 3-4 75 - 80
Degreasing tank contains the caustic soda & soda ash. Its purpose to remove the oil
etc. from the surface of object.
Water rinsing tank contains simple water so that the chemical of one tank does go into
the other tanks.
Rustodene tank contains the acid. Its purpose is to remove from the surface of the
object.
Phosphatizing tank contains zinc phosphate. It is done for better bonding of paint with
the metal base.
Passivation tank contains the dichromate solution & it is to done to increase the
resistance of the metal against the humidity
P a g e | 40
PAINTING:
In this process is sprayed on the body by the electrostatic gun Electrostatic has two pipes, one
contains the compressed air & another contains powder. Power is positively charged & body
is negatively charged, this makes the powder adhesive.
Fig 11
BAKING:
In this process painted body is passed through the diesel-fired furnace up to required temp. Of
182-220 degree Celsius & the powder melt & from a paint layer on the surface &the
thickness of the paint layer is 55 microns
Fig 12
P a g e | 41
SEALING:
It is done for fast drying and to increase the resistance to humid conditions. The chemical
used is sodium dichromate at 70-80 degree Celsius for rinsing.
7.3.3 TESTS APPLIED AFTER PAINTING THE BODY:-
1) Scratch test:a) Take painted object
b) Make the crossed line on a part of the body.
c) Put the cell tape of 1-inch width on the marked area.
d) Then pull it & again put it on the same area.
e) Pull it again. Repeat the test 5-6 times using the same piece of cello tape
f) Observe the peeling of the paint. If it peels off, then it is rejected.
2) Bend test:a) Fix half of the painted panel in vice, keep one of bakelite piece on each side of panel
to avoid scratches from the vice.
b) Bend it up to 90 degree by exerting the pressure by hand.
c) Observe cracks on the coating of the paint. If it shows the cracking, piece is rejected.
7.4 ELECTROPLATING SHOPElectroplating is done on the basis of electrolysis.
Electroplating is a act of depositing a superior or noble metal on an inferior or a baser metal
by means of electrolysis of an aqueous sol. of a suitable electrolyte. For example metals like
iron, which are easily corroded by air, moisture & carbon dioxide, are coated electrolytic ally
with deposits of nickel and chromium, which are highly resistant to chemical attack. The
electrolytic bath used in the plating has an electrolyte that depends on the nature of metal to
be deposited.
7.4.1 STEPS FOR ELECTROPLATING:
1) Loading
2) Degreasing in kerosene
3) Soaking in wooden
4) Acid cleaning
5) Washing
6) Plating
P a g e | 42
7) Drying
8) Unloading
9) Thickness measurement
Here the electroplating process is done as per the document work instruction on various
components. All copper and brass component, fuse switches change over switches, all MS
components, in fact all metallic components, are electroplated and painted (if required).The
pieces are checked for cleanliness. The whole process is quality controlled.
7.4.2 TYPES OF ELECTROPLATING
Acid zinc electroplating
Acid tin electroplating
Silver electroplating
Copper electroplating
ACID ZINC ELECTROPLATING:
Zinc electroplating is done on iron to protect it from rust.
Equipment used: - Barrel and tank.
Temp. : - Room temp.
Voltage applied to barrel: - 9-12 volts
Anode: - zinc
Cathode: - iron
Thickness: - 10 –15 microns
After plating zinc is passivated.
Passivation is done: -
a) For decoration
b) To increase the resistance against humidity.
ACID TIN PLATING: -
Tin plating is applied on the copper and brass components.
Chemical composition: - stannous sulphate, sulphuric acid and brightener.
Equipment used: - barrel and tank
Temperature: - room temp.
Voltage applied to barrel: - 5 -8 volts
Anode: - pure tin
Cathode: - copper, brass
P a g e | 43
Thickness: - 8 –12 microns
Procedure: -
Bleach the tank with sulphuric acid. After leaching, drain the leaching solution & rinse the
tank with water. Then fill the tank with distilled water. Add stannous sulphate & dissolve it.
Then add brighter & start plating. Give anode to pure tin & cathode to brass or copper &
supply voltage. Tin with be plated on brass or copper.
SILVER PLATING: -
Chemical composition: - silver salt, silver cyanide, potassium cyanide, brighter.
Equipment used: - barrel and tank
Temperature: - room temp.
Voltage applied to barrel: - 1.5 volts
Anode: -pure silver
Cathode: - copper, brass
Thickness: - 2-4 microns
PROCEDURE: -
Silver sol. is prepared in the storage tank. For it leach &clean the tank. Then fill it with 2/3rd
by water. Add silver salt and activated carbon. Provide anode to silver and cathode to brass
and copper as anode metal losses weight and collects over cathode metal.
COPPER PLATING: -
Copper is coated on mild steel.
Chemical composition: - copper salt, sodium cyanide.
Equipment used: - barrel and tank
Temperature: -50 degree Celsius.
Voltage applied to barrel: - 7 -8 volts
Anode: - pure copper
Cathode: -steel
Thickness: - 4 –6 microns
P a g e | 44
PROCEDURE: -
Fill half of the tank with water. Heat it up to 50 degree Celsius. Add copper salt and dissolve
it. Now filter the solution. Give anode to copper and cathode to iron & supply the voltage.
Before the start of electroplating work, the material is checked for cleanliness. The
water layer on the parts must not break up. If it breaks material is not cleaned. The cleaning
process is done with use of nitric acid and sulphuric acid.
7.4.3 INSPECTION: -
Coating thickness: -it is measured and compared with the required thickness. Incase of
deviation the process is adjusted.
Surface finish: - it is compared with representative sample. Correction action is followed
when required.
Pollution control: - effluent from process of plating is fed to the DM. Water plant and the
processed water is reused for washing of plated or un-plated components. The treatment is
done as per the work instruction.
1) There are two types of streams coming out of electroplating plant:
a) Cyanide base stream stored at side 1.
b) Chrome (hexa), heavy metals stored & acid stream (stored at side 2).
7.4.4 TREATMENT METHODS
Cyanide base stream
1) Add bleaching powder through feeding tanks fitted with stirrer for proper mixing.
This breaks cyanide into CO2 + N2.
2) The components removal of cyanide in water is indicated when starch iodide paper
turns blue.
Chrome, heavy metals & acid stream
Treat the stream with sodium metal bisulphate at ph=2. If ph is more than 2, add dilute
sulphuric acid to bring the ph = 2. Hexavalent chrome gets converted into the trivalent
chrome.
3) The conversion of the hexavalent chrome to trivalent stage is indicated with the
change of light yellow co lour of water.
4) Raise the ph of the solution between 10 –11 with the help of lime and polywin.
P a g e | 45
5) At ph= 10-11, the heavy metal & trivalent chrome gets precipitated.
6) After this the water of both the stream is fed into the sludge-setting tank.
7) Sludge setting tank water is allowed to stand for 8-10 hours. As a result sludge settles
down.
8) The clean water is then brought to ph adjustment tank through the clarifier.
9) In the tank ph is adjusted between 6-9 with the help of dilute sulphuric acid.
10) The settled sludge is stored in polythene bags.
11) After adjusting the ph, the water is fed into the DM water plant. The following
parameters are required before the water used for washing purposes.
7.4.5 STORAGE AND SAFETY: -
The chemicals are stored in section store (chemical). Potassium cyanide, copper cyanide
sodium cyanide etc. that are highly toxic in nature are stored in separated sub-section. These
are stored and handle as per documented work instruction.
Gas mask are provided and used while handling chemicals of toxic nature.
8. SWITCHGEAR DIVISION
8.1 PRODUCTS BEING MANUFACTURED ARE: -
Rewirable Switch Fuse Unit
Double Break Fuse Switch
Cubicle Fuse Switch
Cubicle Isolator
Changeover Switch
MCB Distribution Board
8.1.a) REWIRABLE SWITCH FUSE:-
INTRODUCTION:-
Rewirable switch fuse unit is used for the protection of electrical appliances against over
voltage. Its design is most ideal for effective control of repeat switching operations of air-
conditions, refrigerators, geysers and other house-hold electrical appliances. Extensively used
as industrial main control switch.
P a g e | 46
Range : 16 -100A
No. of poles : SPN, DP&TPN
Rated voltage : 240/415A.C
Insulation voltage : 660V
Utilization category : A.C-23A
Fig 13
8.1.b) ON LOAD CHANGEOVER SWITCH:-
INTRODUCTION:-
On load changeover switches are designed for application in low voltage distribution circuit
and motor circuit. They are used at place where continuity of supply from main supply and
vice versa is required. These compact on load changeover switches having a unique modular
construction capable of making, carrying and breaking current under normal condition with a
utilization category of 23A at the rated operational current. The entire switch mechanism is
P a g e | 47
housed in a polyester reinforced moulded frame having high dielectric strength and thermal
with stand capacity.
Range 63 – 1000A
No. of poles four
Rated voltage 415A.C
Insulation voltage 660V
Utilization category A.C-22A
8.1.c) DOUBLE BREAK FUSE SWITCH:-
INTRODUCTION:-
Double break fuse switches are designed for safe & efficient power distribution. They have
double break isolation enables incoming supply to be connected to either bottom or top
terminals.
Range 63-400A
No. of poles TP TPN & FP
Rating insulation voltage 415V
Utilization category 660V
Specification IS: 13947(P-3) &IEC; 947-3
8.1.d) SWITCH DISCONNECTOR FUSE:-
A wide range of front operated panel mounting switch disconnector fuse is offered for
various power distribution applications. These switches have high short circuit making and
breaking capacity and are suitable for stringent AC-23 utilization category. These can be used
for both AC and DC applications.
Range: - 32A to 800A
EXECUTION:-
Double pole
Triple pole
Triple pole with switched neutral
Four pole
APPLICATIONS: -
1) These have been specially designed for most stringent motor duty inductive and
capacitive load applications.
2) These switches are compact in size and front operated and thus ideal for power
panels.
P a g e | 48
8.2 DISTRIBUTION BOARDS:-Distribution boards provide flexibility and a systematic approach to ever increasing need
for effective methods of the electrical distribution in domestic, commercial and industrial
application. Distribution boards have been specially designed to meet all the technical
requirements and ensure the distribution boxes blend with the décor of the place of the
installation.
Distribution boards with their features and their range offer a compact, practical and
economic solution to any electrical network in residential/commercial complexes,
industries etc.having single phase or three phase connections. The distribution board is
not merely an enclosures but complete system in itself comprising of ETP copper bus bar,
brass neutral link, earth link,earthing studs and interconnection wires for effective
distribution of current.
8.2.1 FEATURES:-
All DB’s painted in epoxy polyester powder coating
. Earth bar fitted on upper end plate, having same number of holes as number of
MCB’S.
Neutral has same number of outgoing holes as number of MCB’S.
Upper and lower end plates are detachable, have knockout and inter replaceable.
8.2.2 Classification of the circuit breaker
a) According to the number of poles
Single pole circuit breaker
Two pole circuit breaker with one protected pole
Two pole circuit breaker with two protected poles
Three pole circuit breaker with three protected poles
Four pole circuit breaker with three pole protected
Four pole circuit breaker with four pole protected.
P a g e | 49
b) According to the protection against external influences
Enclosed type
Unenclosed type
c) According to the method of mounting
Surface-type
Flush- type
Panel board type
d) According to the method of connection
Circuit breaker the connection of which of it is associated with mechanical mounting, for
example
Plug in type
Bolt on type
Screw in type
e) According to the instantaneous tripping current
B-type
C-type
D-type
f) According to the I2T characteristics
MCB RATING CHAT FOR DOMESTIC APPLICATIONS
P a g e | 50
SR.NO APPLIANCES CAPACITY MCB RATING
01
02
03
04
05
REFRIGERATOR 165LT/350LT
T.V. V.C.R MUSIC SYSTEM
VACCUME CLEANER WASHING
MACHINE
WASHING MACHINE WITH HEATER
IRON
400W/750W
400W
400W
1300W
750W
4A-6A
4A
4A
10A
6A
06
07
08
09
10
11
12
13
GEYSER
HOT PLATE
AIR CONDITIONING
PHOTOCOPIES
WATER COOLER
POWER PLUG
ONE LIGHTING CIRCUIT
ONE POWER CIRCUIT
1000,
2000,
3000W
1000W
1TON
1.5TON
2TON
1500W
700W
1000W
10 PTS
1000W
2 PTS
3000W
6A10A16A
10A
10A
16A
25A
16A
6A
10A
10A
20A
P a g e | 51
Table 3
MCB RATING FOR MOTOR APPLICATIONS
MOTOR
H.P
KW MCB RATING (AMPRS)
STAR - DELTA D.O.L
1.0
1.5
2.0
3.0
4.0
5.0
6.0
7.5
10.0
12.5
15.0
17.5
20.0
0.75
1.10
1.5
2.25
3.00
3.75
4.50
5.50
7.50
9.30
11.00
13.00
15.00
-
-
-
-
-
10A
10A
16A
16A
20A
25A
25A
32A
2A
3A
4A
6A
6A
10A
10A
16A
16A
20A
25A
32A
40A
P a g e | 52
25.0
18.50 40A 50A
Table 4
Construction:-
9. TESTING LIST
For certification purposes, Type test are carried out in sequences
P a g e | 53
Each type test (or sequences of type test ) is carried out on circuit –breakers in a clean or
new conditions.
Test conditions The circuit breaker is mounted individually, vertically and in free are at an ambient
temperature between 20 degree c to 25 degree c. unless otherwise specified , and is
protected against undue external heating and cooling .Circuit breaker designed for
installation in an individual enclosure are tested in the smallest of such enclosures
specified by the manufactures. unless otherwise specified, the circuit breaker are wired with
the appropriate cable specified in table and are fixed on a dull ,black printed ply wood board
of about 20 mm thickness ,the method of fixing the complying with any requirements related
to the mean of mounting required by the manufacturer. Where a tolerance is not specified,
type test are carried out at values not less severe than those specified in this standard. Unless
otherwise specified, test are carried out at a rated frequency tolerance of 5 HZ .During the test
, on maintenance or dismantling of the sample is allowed.
Fig 14
9.1 For the test of sub clauses the circuit breaker is connected as follows
The connections are made by means of single core, PVC insulated copper cables, according
to the IEC Publication 227.
1. The test are carried out with single –phase current ,with all poles connected in series ,
except for the tests sub –clauses 8.10.2 and 8.11.
2. The connection is in free air and spaced not less then the distance between the terminals.
3. The minimum length of each temporary connection from terminal to terminal is:
1m for cross section up to and including 10mm2,
2m for cross section larger than 10 mm2.
P a g e | 54
The tightening torque to be applied to the terminal screw are two third of those specified in
table .
Cross – sectional (S) areas of test copper conductors Corresponding to the rated currents.
S mm2 Values of the rated current In A
1
1.5
2.5
4
6
10
16
25
35
50
In< 6
6< In < 13
13< In<20
20<In <25
25<In<32
32<In<50
50 < In<63
63<In<80
80< In<100
100<In<125
Table-5
9.2 List of test on Miniature Circuit Breaker (M .C.B.) as per the IS: 8828 IEC: 898
1. Indelibility of marking.
2. Reliability of screws.
3. Current –carrying parts and connection.
4. Reliability of terminals of external conductors.
5. Protection against electroshock.
6. Dielectric properties.
7. Temperature rise.
8. 28 –days test.
9. Tripping characteristics.
10. Mechanical &electrical endurance.
11. Short circuit.
12. Resistance to mechanical shock & impact.
13. Resistance to heat.
14. Resistance to abnormal heat & to fire.
15. Resistance to rusting.
9.2.1 Test of indelibility of Marking
P a g e | 55
The test is made by rubbing the marking by hands for 15sec with a piece of cotton soaked in
a water and again for 15 sec with a piece of cotton soaked in aliphatic solvent hexane with a
content of aromatics of 0.1% by volume, a kauributanol value of 29,an initial boiling point is
approximately 65 degree c a dry point of approximately 69 degree c and a density of
approximately 0.68 g/cm3.Marking made by impression ,molding , pressing, or engraving is
not subjected to this test. After this test marking shell be easily – legible .The marking shall
also remain easily legible after all the test of this standard .It shall not be easily possible to
remove label and they shell show on curling.
9.2.2 Test of reliability of screw, current carrying parts and connections
Compliance with the requirement of sub clauses 7.1.4 is checked by inspection and
for screw and nuts which are operated when connecting up the circuit breaker by
the following test.
Fig 15
The screw and nut are tightened and loosened: Ten times for screw in engagement with a
thread of insulating material, five times in all other cases. Screw or nuts in engagement with a
thread of insulating material are completely removed and reinserted each time.
Fig. 16
The test is made by means of a suitable test screwdriver or spanner applying a torque as
shown in table The screw and nuts shell not be tightened in jerks. The conductor is moved
each time the screw or nut is loosened.
Nominal diameter of thread mm Torque Nm
P a g e | 56
1 2 3
Up to and including 2.8
over2.8 Up to and including 3.0
over 3.0 Up to and including 3.2
over 3.2 Up to and including 3.6
over 3.6 Up to and including 4.1
over 4.1Up to and including 4.7
over 4.7 up to and including 5.3
over5.3 Up to and including 6.0
over 6.0 Up to and including 8.0
over 8.0Up to and including 10.
0.2
0.25
0.3
0.4
0.7
0.8
0.8
1.2
2.5
-
0.4
0.5
0.6
0.8
1.2
1.8
2.0
2.5
3.5
4.0
0.4
0.5
0.6
0.8
1.2
1.8
2.0
3.0
6.0
10.0
Table 6
Column 1: Applies to screw without head if the screw, when tightened, does not protruded
from the hole, and to other screw which cannot be tightened by means of screw driver with a
blade wider than the diameter of the screw.
Column 2: Applies to other screws which are tightened by means of screw driver.
Column 3: Applies to the screw and nuts which are tightened by means other than the screw
driver.
9.2.3 Test for reliability of terminals for External Conductor
In this test a rigid copper conductor having the larger cross –section areas is placed in a
terminal (for nominal cross section areas exceeding 6mm2 ,a rigid stranded conductor is
used while for other nominal cross section areas , a solid conductor is used).
P a g e | 57
Fig.17
These last test are made by means of a suitable screwdriver or spanner applying a torque as
shown
Cross section of conductor
accepted by the terminal (mm2)
Up to 4 Up to 6 Up to 10 Up to 16 Up to 50
Pull(N) 50 60 80 90 100
Table 7
9.2.4 Test of protection against Electric shock
The test is made with a standard test finger on the sample mounted on the as for normal use
and fitted with the conductor of larger or smaller cross section. The stranded test finger is
designed that the each of the joined section can be turned through an angle of 90 degree with
respect to the axis of the finger ,in the same direction only. The test finger is applied in every
possible bending position of a real finger, an electrical contact indicator being used to show
contact with live parts. It is recommended that the lamp is used for the indication of the
contact and that the voltage be not less than 40 V.Circuit –breaker with enclosure of
thermoplastic is subjected to the additional test, which is carried out at a ambient temperature
of 35 degree c tolerance 2 degree c .the circuit breaker being at this temperature circuit
breaker are subjected for 1 min for a force of 75N ,applied through the tip of a straight un
jointed test finger of the same dimension of the standard test finger. This finger is applied to
all places where yielding of insulating material could impair the safety of the circuit breaker,
but not applied to the knock –outs. During this test , enclosures and covers shell not deform
to such an extent that live parts can be touched with the un jointed test finger.
9.2.5 Test of Dielectric properties
Following test are done under this:
Resistance to humidity.
Insulation resistance of the main circuit.
Dielectric strength of the main circuit.
Dielectric strength of the auxiliary circuit.
Value of test voltage.
P a g e | 58
Fig.18
9.2.6 Test of Temperature rise
The Ambient air temperature shall be measured during the last quarter of the test period by
means of at least two thermometer or thermocouples symmetrically positioned around the
circuit breaker at about half its height and at a distance of about 1meter from the circuit
breaker
9.2.7 28-Days test
The circuit breaker is subjected to the 28 cycles .each cycle comprising of 21 h with a
current equal to the rated current at an open circuit voltage of at least of 30 V and 3 h
without current under the test condition. The circuit breaker is in the closed position the
current is being established and interrupted by an auxiliary switch .during this test the circuit
breaker shell not trip. During the last period of current flow the temperature rise of the
terminal shell be measured .The temperature rise shell not be rise the value measured during
the temperature rise test by more than 15 k .Immediately after this measurement of this
temperature rise the current is steadily increased with in 5 s to the conventional tripping
current. The circuit breaker shell trip with in the tripping time.
9.2.8 Test of tripping characteristics
Various tests which are performed to know these characteristics
Test of time –current characteristics
Test of instantaneous tripping
Test of effect of single pole loading on the tripping characteristics of multi pole
Circuit –breaker.
Test of effect of ambient temperature on the tripping characteristic
9.2..9 Test of mechanical and Electrical Endurance
P a g e | 59
The circuit breaker is fixed to a metal support unless it is designed to install in any other
enclosure .the test is made at a rated voltage, at a current adjusted to the rated current by
means of resisters and reactor connected in series to the load terminals .If air cored reactors
are used, a resistor taking approximately 0.6% of the current through the reactors is
connected in parallel with each reactor. The current shell has sustainable sign wave form and
the power factor shell be between 0.85 and 0.9. For single pole circuit breaker and for two
pole circuit breaker with two protected poles, the metal support is connected to the one part
of the supply for the first half of the total no of operation and to the other side of the second
half. For two poles circuit breakers with one protected pole ,the metal support is connected to
the neutral of the supply .For single pole circuit breaker the shell be carried out at the lower
voltage values . (Preferred values: 220 v or 240 v)
9.2.10 Short circuit test
Standard test for the verification of the short – circuit performance consist of sequence of
Fig.19
Making or breaking operation ,appropriate to the performance to be checked which are
summarized in the table.
Kind of test Circuit breaker to be tested
Test at reduced short circuit current All circuit breaker
Test at 1500 A
Test at service short circuit capacity I cn > 1500 A
Test at rated short circuit capacity
Table 8
P a g e | 60
Fig.20
Fig.21
All circuit breaker are tested at 500 A or In which ever is the highest , and at 1500 A.
Circuit breaker having rated short –circuit capacity above 1500 A are additionally tested
9.2.11 Test of resistance to mechanical shock and impact
The circuit breaker is subjected to the mechanical shocks by using an apparatus as shown in
figure. A wooden base A is fixed to a concrete block and a wooden platform B is hinged to
base A this platform carries a wooden board C which can be fixed at a various distance from
the hinge and in two vertical positions.
P a g e | 61
Fig.22
The end of board B bears a metal stop plate D ,which rests on a coil spring having a constant
c of 25 N/mother circuit breaker is secured to the vertical base board in such a way that the
distance of the horizontal axis of the sample is 180 mm from the platform ,the vertical board
being in turn so fixed that the distance of the mounting surface is 200 mm from the hinged
as shown in figure On the surface C opposite the mounting surface of the circuit breaker ,a
supplementary mass is fixed so that the static force on the metal stop –plate is 25 N in order
to ensure that the movement of inertia of the complete system is substantially constant .
9.2.12 Mechanical Impact test
Compliance is checked on those exposed parts of the circuit breaker mounted as for normal
use which may be subjected to mechanical impact in normal use by the test for all type of
apparatus (circuit breaker)
Fig: 23
For screw in type circuit breaker
For circuit breaker to be mounted on a rail
For plug in type circuit breaker
P a g e | 62
Fig: 24
Circuit breaker only intended to be totally enclosed are not submitted to this type test. typical
impact apparatus has been shown .the pendulum consist of steel tube with a external diameter
of 9.0 mm and a thickness of 0.5 mm ,it is suspended in such a way that it can swing in a
vertical way panel . A striking element of 0.15 kg is rigidly fixed to the lower end of the
pendulum with its axis below one meter below axis of suspension the striking element has a
hemispherical face.
9.2.13 Test of resistance to heat
the samples without removable cover ,if any are kept for 1 h in a heating cabinet at a
temperature of 100 +- 2 degree c ,removable cover if any are kept in a heating chamber at a
temperature of 70=- 2 degree c .during the test they shell not undergo any change impairing
their further use and sealing compound if any shell not follow to such an extent that lives
parts are exposed .
9.2.14 Resistance to the abnormal heat and to fire
The external parts of the circuit breaker made of insulating material necessary to retain in
position current – carrying parts and parts of the protective circuit by the test made at a
temperature of 960+- 15 degree c.for other external parts made of insulating material by the
test made at a temperature of 650 =- 10 degree c
9.2.15 Test of resistance to rusting
All greases is removed from the parts to be tested by immersion in a cold chemical degreaser
such as Methyl chloroform or refined petrol, for ten min. the parts are then immersed in for
ten min in a 10% solution of ammonium chloride in water at a temperature of 20+-5 degree c
without drying but after shaking off any drops the parts are placed for 10 min in a box
containing air saturated with moisture at a temperature of 20+- 5 degree c. After the parts
have been dried for 10 min in a heating cabinet at a temperature of 100+-5 degree their
surface shell show no sign of rust. For small springs and for in accessible parts exposed to
abrasion a layer of grease may provide sufficient protection against rusting. Such parts are
P a g e | 63
only subjected to test if there is doubt as to the effectiveness of the grease film and the test is
made without previous removal of the grease
10. MOULDING SHOP
Activities: -
The machines- molded components manufactured here are used in switchgear assembly and
MCB assembly.
10.1 Machines used: -
There are following machines as given below:
1) Injection molding machine Type-1
2) Injection molding machine Type-2
Machines are CNC based. And of Larson & Tubro Company.
In the first type of machine the raw material is plastic granules of POLY CARBONATE
Resin.
And the main parts are: hopper and barrel.
The plastic beans are injected in the dye in almost fluid state and they get the required shape
as per dye and are cooled for required shape.
Water is used as the coolant for the mould and the hydraulic oil is used for maintaining the
required pressure at various points. Different dyes are used for making or obtaining the
different shapes.
In the machine of type-2 the basic difference is of raw material.
Here the raw material is BAKELITE.
In this case no cooling is required or provided rather heaters are provided for moulds as,
Bakelite has a property of hardening when heated.
10.2 Injection molding machines
Injection molding is a manufacturing process for producing parts from both
thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed,
and forced into a mold cavity where it cools and hardens to the configuration of the
P a g e | 64
cavity. After a product is designed, usually by an industrial designer or an engineer, molds
are made by a mold maker (or toolmaker) from metal, usually either steel or aluminum, and
precision-machined to form the features of the desired part. Injection molding is widely used
for manufacturing a variety of parts, the smallest component of switches & other plastic
Frames.
Fig.25
10.2.1 Process characteristics
Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity
Produces a solid or open-ended shape that has conformed to the contour of the mold
Uses thermoplastic or thermoses materials
A parting line, spruce, gate marks, and ejector pin marks are usually present. None of
these features are typically desired. They are the results of the parting of the mold for
ejection of the formed part.
10.2.2 Equipments
Injection molding machines consist of a material hopper, an injection ram or screw-type
plunger, and a heating unit. They are also known as presses, they hold the molds in which the
components are shaped. Presses are rated by tonnage, which expresses the amount of
clamping force that the machine can exert. This force keeps the mold closed during the
injection process. Tonnage can vary from less than 5 tons to over 9,000 tons, with the higher
P a g e | 65
figures used in comparatively few manufacturing operations. The total clamp force needed is
determined by the projected area of the part being molded.
Fig. 26 Fig. 27
This projected area is multiplied by a clamp force of from 2 to 8 tons for each square inch of
the projected areas. As a rule of thumb, 4 or 5 tons/in2 can be used for most products. If the
plastic material is very stiff, it will require more injection pressure to fill the mold, thus more
clamp tonnage to hold the mold closed. The required force can also be determined by the
material used and the size of the part, larger parts require higher clamping force.
10.2.3 Molds
The mold consists of two primary components, the injection mold (A plate) and the ejector
mold (B plate). Plastic resin enters the mold through a sprue in the injection mold; the sprue
bushing is to seal tightly against the nozzle of the injection barrel of the molding machine and
to allow molten plastic to flow from the barrel into the mold, also known as the cavity. The
sprue bushing directs the molten plastic to the cavity images through channels that are
machined into the faces of the A and B plates. These channels allow plastic to run along
P a g e | 66
them, so they are referred to as runners. The molten plastic flows through the runner and
enters one or more specialized gates and into the cavity geometry to form the desired part.
Fig.28
The amount of resin required to fill the sprue, runner and cavities of a mold is a shot. Trapped
air in the mold can escape through air vents that are ground into the parting line of the mold.
If the trapped air is not allowed to escape, it is compressed by the pressure of the incoming
material and is squeezed into the corners of the cavity, where it prevents filling and causes
other defects as well. The air can become so compressed that it ignites and burns the
surrounding plastic material. To allow for removal of the molded part from the mold, the
mold features must not overhang one another in the direction that the mold opens, unless
parts of the mold are designed to move from between such overhangs when the mold opens
(utilizing components called Lifters).
.
The standard method of cooling is passing a coolant (usually water) through a series of holes
drilled through the mold plates and connected by hoses to form a continuous pathway. The
coolant absorbs heat from the mold (which has absorbed heat from the hot plastic) and keeps
the mold at a proper temperature to solidify the plastic at the most efficient rate.
P a g e | 67
To ease maintenance and venting, cavities and cores are divided into pieces, called inserts,
and sub-assemblies, also called inserts, blocks, or chase blocks. By substituting
interchangeable inserts, one mold may make several variations of the same part.
Fig 29
Fig 30
P a g e | 68
The temperature Control is done by the machine panel. The machine panel is also feeded with
the Time delay of every process.
Before giving the polycarbonate material to moulding machine, it is firstly heated at 40degree Celsius.then it is feed to machine.The poly carbonate resin is melted at 4000 c. then moves onward towards the dye. At 50 bar pressure the required frame is made.
10.3 Grainer machineThe waste material are send for recycle to grainier machine. This machine converts all waste to grains, which is further used for moulding.
Fig 31
These frames are further used in making switches, holders, door bells, and other underground
wiring components.
fi
P a g e | 69
Fig 32
11. TESTING LABS11.1 Heating oven test
In this test the various poly carbonate and urea switches and holders are to be kept at a Test:
80 degree c for approximate of 8 hours after that the pieces which are been tested are to be
taken to the terminals which are approximately at 80 degree c if this
Fig.33
will create the smoke while testing and after that if it will converted to the fire then the pieces
under test is dejected this ensures that the switches or the other accessories which are
installed in the home is free from fire and all up to a temperature of 80 degree c if the piece
will create smoke only while touching it to the terminals then it will be fine but after that if it
will got ignited then it will never be taken in the account.
11.2 Mechanical strength test apparatus
This test is to be taken on the lamp holder to check that whether the holder is reliable to
sustain the behavior of being with the same characteristics features.
Fig.34
P a g e | 70
In this test a weight of approximate of 1 tone is to be hanged with the pins of the holder to
which the lamp is to be supported to give the light source. This test is to be performed for a
long period of hours.
11.3 Tumbling barrel test
In this test the mechanical strength of the plug socket is to be taken under consideration in
this process the 3 core wire is to be tightened to the socket and then the whole combination
is to be put in the tumbling barrel then the tumbling barrel starts revolving and then the
strength of the connection is to be tested out .
Fig.35
Fig.36
11.4 Mechanical impact test
In this test the switching unit is fixed to the wooden baseband then the whole unit is fixed
to the apparatus the mechanical strength of the switch is tested in such a manner that the 5
stops are to be taken at the distance range of 10cm. another is to be taken at a distance of 15
cm this is to be taken in the account for 10 times.
P a g e | 71
Fig.37
11.5 Endurance test for switches
In homes the approximate amperes is about 2A but in the SSK labs we test it for 6A from the
load bank.
Fig.38
According to standard the switch will work for 4 thousand operations but in lab we test it for
3times multiplier times to the standard .we put resistive and inductive load to it .as per the
rated loads and check its operation. Apparatus for various types of switches testing
P a g e | 72
11.6 Mille volt drop test
In this test it is to be tested that the there should not be any gap in between the electrical
contacts so that there should not be any losses created .due to it some times melting of
contacts may happen.
Fig 39
11.7 Conditioning wire test
In this test CU wire is placed in a temperature of around – 15 degree c .then after some times
it will be twisted on a metal rod to check that weather any cracks or breaks are generated .
11.7 Ampere test
Fig.40
P a g e | 73
Fig 41
P a g e | 74
12. Technical performance of SSK modular switches
Technical performance of SSK modular switches in comparison with the required
specification of ISS conforming to IS : 3854 : 1997 (IS ( test conducted at highly
sophisticated lab)
Nature of test ISI requirement Performance of SSK
modular switches tested in
lab
Electric strength Should withstand for 2KV
(rms) for one minute
It withstood 3KV (rms) for
2 minutes
Temperature rise Should not exceed 45
degree Celsius ,about
40,000 operations on load
It did not increase 14
degree Celsius after 50,000
operations in 6amp
accessories and 18degree
Celsius after
50,000operations in 16 amp
accessories.
Milli volt drop Should not exceed 20mV
(in 6 Amp & 16 Amp
accessories) after 40,000
operations on load .
Not exceeded 7mv
after1,20,000 operations in
6 amp and 9 mv in 16 amp .
Insulation resistance Should not be less than
100M ohms (before
humidity treatment)
Found more than 500 M
ohms ( after humidity
treatment )
Electrical endurance test
(ON-OFF) test
Switches should be tested
at 40,000 operations(ON-
We tested our switches at
120,000 operations on load.
P a g e | 75
OFF) on load ( even after this switches
worked properly).
Mechanical strength Specified only at 0.4Nm
impact energy
Tested at maximum impact
energy 1 nm for all rating
designs .(hammer stroke
test from a distance of 270
mm)
Making &breaking
capacity
The switches and sockets
are required to be tested at
130% of the rated current
and 110% of the rated
voltage for 500 continues
operations, with an interval
of 30 seconds
Our switches and sockets
were tested at 130% of the
rated current and 110% of
the rated voltage for 1500
operations and were found
to be in good working
conditions.
Resistance to heat at
125degree celcius
The outer body of the
molding should be heated
to the temperature of 125
degree Celsius for 60
minutes. Thereafter the ball
pressure test should not
make an impression deeper
than 2mm
Was not affected by
abnormal heat and fire at
850 degree Celsius
Resistance to abnormal
heat & to fire (glow wire
test)
The test is performed on
parts of insulating material
which might be exposed to
thermal stress due to
electric effects and
decoration shall not unduly
P a g e | 76
be affected by abnormal
heat and by fire at a
temperature of 650 degree
Celsius
Table 8
13. PANEL SHOPPanel department is also known as application department. Panels are systematic
arrangements of different electrical equipments. They are used to control of different
machinery.
13.1 TYPE OF PANELS
PLC PANEL
L.T. PANEL
TOUCH PANEL
SCADA SYSTEM
CONTROL PANEL
H.T. PANEL
RMOTE CONTROL PANEL
HEAT TRACER PANEL
AMF PANEL
APFC PANEL
TOUCH PANEL
P a g e | 77
PLC PANEL
MCC PANEL (MOTOR CONTROL CENTRE)
At ssk I have studied L.T. Panels, Which was ordered from RCF.
13.2 LT Power Panel for AC coach (for RAJDHANI, SHATABDI, GARIBRATH,e.t.c.)
SSK manufacture a wide range of main LT panel with bus coupler, which come with DG
incoming (2 in number) and a transformer incoming of 500KVA (2 in number). Some of the
specifications of our product include:
ACB 1600A 4 pole MDO as transformer incoming (2 in number)
The product have different types of outgoing such as 800A, 630A, 400A, 100A, 250A
etc
All the bus couplers are electrically and mechanically inter locked
ACB 1600A 4 pole MDO as bus coupler (1 in number)
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Fig 42
13.3 The panel consists of:-
1. Lay & Circuit diagram As per RCF requirement.
2. Enclosure or Cabinet a/c to design.
3. Bus bar (woehner)
4. Contactor (ABB Company)
a. SINGLE POLE
b. THREE POLEF
c. FOUR POLE
5. Relays
a) OVR (over voltage relay)
b) UVR(under voltage relay)
c) DC Time Delay Relay
P a g e | 79
d) OSR(over speed relay)
e) LOP(low oil pressure)
f) AFR(Alternator fault relay)
g) AEL(Alternator earth leakage)
h) Generator protection relay
6. Wire Ducts
7. Wire needed near about 6Km in one panel.
8. Fuses (kit kat, HRC)
9. Circuit breakers
a) MCB
b) MPCB
c) MCCB
d) RCCB/ELCB
e) ACB(abb company)
10. DC to DC Converters
11. Rectifiers
12. Transformers
a) shell type(3 phase)
b) core type(1 phase)
13. Selector switch
14. Pilot lights (indicators)
15. Buzzer
16. Push buttons
17. Clipping tool(multi cutter)
18. Current transformers
19. Bus Coupler
13.4 Description of components
Bus bar (woehner):- made of copper
. Busbars can have a cross-sectional area of as little as 10 mm² but electrical
substations may use metal tubes of 50 mm in diameter (1,963 mm²) or more as busbars
Comparision between Woehner Bus Bar system and Traditional Bus Bar system
P a g e | 80
Panel with Woehner Bus Bar Panel with Traditional Bus Bar system
This system is space saving. There is no need ofseparate
bus bar chamber. Switchgear can be mounted directly on
bus bar with base material of Woehner
In this system separate bus bar chamber is required
which increase the size of the panel even the cost
There is no need of bus bar drilling to take connections
for switchgear with this there is no need of using extra
X-section of bus bar & there are no heat losses. With this
one can save time for fitting switchgear very low costs of
wire and lugs & hardware for taking input on switchgear
as compared to traditional
In this one has to use extra X-section area of bus bar,
extra wires, lugs, hardware is required to take input
tappings. Drilling is required in bus bar which produces
heat where wires are tight with nut and bolts.
Any make of switchgear can be replaced with each other
in panel without going for any changes & time
consumption is vey less.
Where as In this if you have to replace switchgear of
another make lots of mechanical alterations like
drilling etc.
This system helps to bring panel almost maintenance free
Less than half of area remains where tightening is
required. If there is no losing the life of switchgear will
automatically increases.
In this more time is require for maintenance which results
more production loss.
Table 9
Fig 43
Contactor (ABB Company)
Rating:- 300A , 600V AC
P a g e | 81
UVR(under voltage relay):- operation range 750V ac, 50-80HZ,+-15%
(25VA@750V/AC/50HZ
OVR (over voltage relay):- operation range 12- 48V
DC Time Delay Relay:- operation range 12- 48V
OSR(over speed relay):- operation range 12- 48V
LOP(low oil pressure):- operation range 12- 48V
AFR(Alternator fault relay):- operation range 12- 48V
AEL(Alternator earth leakage):- operation range 12- 48V
Wire Ducts:- Halogen free material is non toxic, lead free , environmentally safe and will
not release non toxic or corrosive gas which is endanger public safety or damage
sensitive electronic equipment.
Fuses :-
Wohner HRC fuse(100 A, 690 V)
Kit kat fuse(415-240V, 16 A- 32A, fuse wire 0.5mm)
Siba HRC Fuse(80A, 25VA)
Ammeter:- range 0-800A
Frequency meter:- 45-55HZ
Fuse size
Wire GaugeRecommended
Maximum Fuse Size
00 awg 400 amps
0 awg 325 amps
1 awg 250 amps
2 awg 200 amps
4 awg 125 amps
6 awg 80 amps
8 awg 50 amps
10 awg 30 amps
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12 awg 20 amps
14 awg 15 amps
16 awg 7.5 amps
Table 11
Voltmeter:-range 0-800V
MCB:- 240/415V ac & 60/220V
MPCB
MCCB:- MOULDED CASE CIRCUIT BREAKER
Range : 25A to 1600A
Rated Voltage : 240/415V AC. DC Mccb’s also available
Execution : SP, TP&FP with switched neutral
Breaking Capacity : up to 50KA
Fig 44
RCCB/ELCB
ACB(abb company)
shell type(3 phase) transformer:- 750V primary, 415-110V Secondary,
Capacity 0.3KVA
core type(1 phase) transformer:- 750V primary, 24 V Secondary,
Capacity 200VA
Selector switch:- 4 way selector switch
Pilot lights (indicators):- For different relays & faults. Operated at 24 V.
Buzzer:- solid state type, 24V dc, 96-104Db,Range:-50m
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Push buttons:- for starting alternator, Buzzer & other relays.
Clipping tool(multi cutter):-Used for climping the ends of wire(1.5mm). Range is
1.5--6mm.
Panel Feed Wires
These wires are also type THHN, like the main feeders. A typical 100-amp service
would have a #2 THHN set of wires. They would then be rated at 125 amps. This would
protect the wires if the amperage was a full 100 amps
Non-Metallic Sheathed Wire (NM)
This wire, commonly called Romex, is a plastic coated wire that has either two or
three conductors and a bare ground wire. This is the typical wiring used in most homes. The
rating for this wire is either 15 amps, 20 amps, or 30 amps, depending on the installation.
Residual Current transformers:- 690V,12KV
Connectors:- Patchbays make it easier to connect different devices in different orders for
different projects, because all of the changes can be made at the patchbay. As well, patchbays
make it easier to troubleshoot problems such as ground loops; even small home studios and
amateur project studios often use patchbays, because it groups all of the input jacks into one
location. This means that devices mounted in racks or keyboard instruments can be connected
without having to hunt around behind the rack or instrument with a flashlight for the right
jack. Using a patchbay also saves wear and tear on the input jacks of studio gear and
instruments, because all of the connections are made with the patchbay.
Comparison between Fuse Disconnector and MCCB
S.No. Disconnector with HRC Fuse MCCB
1. The breaking capacity is >80KA Not more than 20KA
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2. Cost of HRC Fuse less More expensive
3. It must be repairable Not repairable
4. Not affected by ambient Fully depend on ambient
5. Fusing – 1.6 time
Non Fusing – 1.2 time
Tripping time not controlled on
overload
6. After heavy short circuit only HRC Fuse to be
replaced
After heavy short circuit
MCCB is totally damaged
7. The incoming, outgoing terminals are suitable
as per cable size
Fixed terminals
8. Not defected by vibrations Due to electromechanical design, more
affected by vibrations
9. Less temperature rise High temperature rise
10. Not affected by weather Affected by weather
11. Un-interrupted duty Interrupted duty
12. Less weight Heavy weight
13. Unbreakable Breakable
14. Dielectric strength is more after short
circuit/overloading
Dielectric strength is less after short
circuit/over loading
15. Insulation resistance is more after
overload/short circuit
Insulation resistance is less after
overload/short circuit
Table 10
14. Air Conditioner(Cool Pack)
An air conditioner is a system, or machine that removes heat from an area using a cycle in which heat is moved out of the area where it is hot.
In construction, a complete system of heating, ventilation, and air conditioning is referred to as HVAC. Its purpose, in the home or in the car, is to provide comfort during hot days and nights.
P a g e | 85
Refrigeration cycle
A simple stylized diagram of the refrigeration cycle: 1) condensing coil, 2) expansion valve, 3) evaporator coil, 4) compressor.
Fig 45In the refrigeration cycle, a heat pump transfers heat from a lower temperature heat source into a higher temperature heat sink. Heat would naturally flow in the opposite direction. This is the most common type of air conditioning. A refrigerator works in much the same way, as it pumps the heat out of the interior into the room in which it stands.
This cycle takes advantage of the universal gas law PV = nRT, where P is pressure, V is volume, R is the universal gas constant, T is temperature, and n is the number of moles of gas (1 mole = 6.022×1023 molecules).
The most common refrigeration cycle uses an electric motor to drive a compressor. In an automobile the compressor is driven by a pulleyon the engine's crankshaft, with both using electric motors for air circulation. Since evaporation occurs when heat is absorbed, andcondensation occurs when heat is released, air conditioners are designed to use a compressor to cause pressure changes between two compartments, and actively pump a refrigerant around. A refrigerant is pumped into the cooled compartment (the evaporator coil), where the low pressure causes the refrigerant to evaporate into a vapor, taking heat with it. In the other compartment (the condenser), the refrigerant vapour is compressed and forced through another heat exchange coil, condensing into a liquid, rejecting the heat previously absorbed from the cooled space.
Ratings:-
COOL PACK:-Model no.
Capacity-1000 Watt
Temp range:- 100C to 450C
Refrigerant :- R22, 132A, 400 gm
Voltage 230VA, 50HZ, 3.5 FLA
15. DIFFERENT PRODUCT RANGE OF SSK
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15.1 Switchgears
Cat No. 813
REWIREABLE SWITCH FUSE COMBINATION UNITS
63A ,415V AC, T.P.
.
Cat No. 816
REWIREABLE SWITCH FUSE COMBINATION UNITS
100A 415 VOLTS AC T.P. ISI
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Cat No. 819
DOUBLE-BREAK FUSE SWITCH COMBINATION UNITS 400A 415 VOLTS AC FOUR POLE
Cat No. 831
METAL CLAD CHANGE OVER SWITCHES
200A 415 VOLTS AC TPN (FOUR POLE) .
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Cat No. 826
METAL CLAD CHANGE OVER SWITCHES
32A 415 VOLTS AC TPN (FOUR POLE)
Cat No. 843
DISTRIBUTION FUSE BOARDS 4 WAY 16A 240 VOLTS AC
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15.2 Electrical switches
15.2.1Heritage collection
Gold finish
HGF-701, HGF-708, HGF-752 (Rs.3310.00)
ONE WAY SWITCH 16A 230V AC, FLAT PIN SOCKET 13A 230V AC WITH COVER
FRAME 2 MODULES 5"X3" WITH 24KT GOLD PLATED.
HGF-701, HGF-710, HGF-753 (Rs.5080.00)
02 PCS.ONE WAY SWITCH 16A 230V AC, STEP FAN REGULATOR FOR FAN ONLY
WITH COVER FRAME 3 MODULE 8"X3" WITH 24KT GOLD PLATED .
HGF-701, HGF-710, HGF-754 (Rs.6170.00)
03 PCS.ONE WAY SWITCH 16A 230V AC, STEP FAN REGULATOR FOR FAN ONLY
WITH COVER FRAME 4 MODULES 5"X5" WITH 24KT GOLD PLATED
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Antique finish
HAF-701,HAF-707,HAF-752 (Rs.3020.00)
JONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER
FRAME 2 MODULE 5"X3" WITH ANTIQUE FINISH COVER .
HAF-701,HAF-710,HAF-753 (Rs.4800.00 )
02 PCS.ONE WAY SWITCH 16A 230V AC,STEP FAN REGULATOR FOR FAN ONLY
WITHCOVER FRAME 3 MODULE 8"X3" WITH ANTIQUE FINISH COVER .
HAF-701,HAF-707,HAF-754 (Rs.5375.00)
03 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER
FRAME 4 MODULE 5"X5" WITH ANTIQUE FINISH COVER .
Chrome finish
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HCF-701,HCF-708,HCF-752 (Rs.3135.00)
ONE WAY SWITCH 16A 230V AC,FLAT PIN SOCKET 13A 230V AC WITH COVER FRAME 2
MODULE 5"X3" WITH CHROME FINISH COVER .
HCF-701,HCF-707,HCF-753 (Rs.4340.00)
02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER
FRAME 3 MODULE 8"X3" WITH CHROME FINISH COVER .
HCF-701,HCF-707,HCF-716,HCF-720,HCF-715,(Rs.8140.00 )
02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC,
TELEPHONE LINE JACK 2 WIRE T.V. SOCKET SINGLE OUTLET
COMPUTER JACK RJ45 FOR DATA TRANSFER COVER FRAME 6 MODULE 8"X6"
WITH CHROME FINISH COVER .
Satin finish
HSF-701,HSF-707,HSF-753 (Rs.4340.00)
2 PCS. ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH
COVER FRAME 3 MODULE 8"X3" WITH SATIN FINISH COVER .
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HSF-701,HSF-710,HSF-707,HSF-754 (Rs.5835.00)
02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC AND STEP FAN REGULATOR WITH 8"X3" CHROME FINISH COVER .
HSF-701,HSF-707,HSF-716,HSF-755 (Rs.7835.00 )
04 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC,
TELEPHONE LINE JACK 2 WIRE COVER FRAME 6 MODULE 8"X6" WITH
SATIN FINISH COVER
15.2.2 Modular series
Signature ZEN series
ZEN-159
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ELECTRONIC ENERGY SAVER FOOT LIGHT WITH
5"X3" COVER PLATE (L.E.D BASED)
ZN-157
ENERGY SWITCH 30A WITH KEYTAG
ZN-146
STEP FAN REGULATOR FOR FAN ONLY
.
Signature NV Series
NV-102
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BELL PUSH 6A 230V AC
NV-219
5 PIN SOCKET 6A 230V AC SHUTTERED
NV-211, NV-220A
DOUBLE POLE SWITCH 32A 230V AC
WITH PORCELAIN BASE & INDICATOR
AND 6 PIN SOCKET6A/25A 230V AC SHUTTERED .
Signature LX Series
LX-209
SINGLE BELL PUSH 6A 250V AC IS WITH L.E.D.
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LX-243
SWITCH SOCKET COMBINED 5 PIN (6A 250V AC)
FITTED WITH POWDER COATED STEEL PLATE & COVER FRAME
(SUITABLE FOR 4”X3” BOX)
LX-135
ENERGY SWITCH 30A WITH KEY TAG HORIZONTAL
Signature EL Series
EL-243
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SWITCH SOCKET COMBINED, 5 PIN (6A 250V AC)
FITTED WITH POWDER COATED STEEL PLATE & FRAME
(SUITABLE FOR 4"X3") .
EL-208
SIGNATUE EL 8"X6" FITTED PLATE
EL-201. EL-200, EL-220
TWIN SWITCH 6A 250V AC ONE WAY ISI AND
SINGLE SWITCH 6A 250V AC ONE WAY ISI AND
5 PIN SOCKET 6A 250V AC SHUTTERED
Euroline series
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SS-105
SINGLE BELL PUSH 6A 250V AC ISI
SS-101, SS-124
TWIN SWITCH SP 6A 250VAC ISI AND STEP FAN REGULAR
SS-101, SS-140
TWIN SWITCH SP 6A 250V AC ISI AND
2/3 PIN SHUTTERED SOCKET 6A 250V AC .
Fantasy PLUS series
F-955, FP-002
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BELL PUSH 6A 250V AC ISI
SOCKET SIZE WITH INDICATOR FITTED 3"X3" FRAME
F-950, F-951, FP-005
SWITCH SP WITH INDICATOR 16A 250V AC ISI
AND SOCKET UNIVERSAL 6A/16A 250V AC
SHUTTERED ISI FITTED 5"X3" FRAME
F-900, F-911, FP-005
SWITCH 6A 250V AC ONE WAY ISI AND
STEP FAN REGULATOR FITTED 5"X3" FRAME
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Signature TL Series
1) 3 Gang Two Way 10AX Switch
2) 6 Gang Two Way 10AX Switch
3) Single 13A Socket with Single 13A SP Switch
15.3.3 SSk Accessories
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F-900
SWITCH 6AMP 250V AC ONE WAY ISI
F-904
5 PIN SOCKET SHUTTERED 6AMP 250V AC
F-952
SWITCH DP WITH INDICATOR 16A 250V AC ISI
Topline PC
Cat No. PC-506
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INDICATOR 250V AC
Cat No. PC-505
WALL SOCKET UNIVERSAL 2/3 PIN 6A 250V AC
Cat No. PC-581
STEP FAN REGULATOR SWITCH SIZE FOR FAN ONLY
Topline series
Cat No. 509
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T.V. CONNECTOR SOCKET SIZE
Cat No. 555
WALL SOCKET 2 PIN 6A 250V AC
SSK 555series
TL-7031
T.V. CONNECTOR SWITCH SIZE
TL-7041
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STEP FAN REGULATOR SOCKET SIZE
TL-7011
WALL SOCKET UNIVERSAL 2/3 PIN 6A 250V AC
Topline super plus
Cat No. N-128
WALL SOCKET UNIVERSAL 6/16A 250V AC ISI
Cat No. N-596
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SWITCH SOCKET COMBINED UNIVERSAL 6A
250V AC ISI 2/3 PIN
Cat No. N-125
SWITCH SP WITH INDICATOR 16A 250V AC ISI
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16. OBSERVATIONS
The observation of this study made on advertisement and sales promotion policy are as
follows:
1. SSK Engineering Company is trying to involve or adopt new schemes to promote sales.
2. Some machines are old, company should require to change for more efficiency.
3. The trend of 1 % advertisement expenditure is not too rigid and can be changed market
situation.
4. Proper marketing setup like sales engineer and filed staff has smooth relations with
authorized dealers and generate new business.
5. Special attention is given to attend the complaints from the customers of authorized
dealers by providing them with reliable after sales service.
6. The placement of goods by company is also speedy.
7. Some operational & maintainance engineers are required for fast service.
8. Strictly quality control consists consumer service also promotion sales.
9. While managing advertisement campaigns, the SSK ENGINEERING COMPANY. Keep
a regular watch on activities of competitors so that their sales are not affected at all.
10. Most of the customers [me also :)] are not satisfied regarding the price policy.
P a g e | 106
17. CONCLUSION
SSK ENGINEERING COMPANY is big and popular company. It is scaling new heights of
expectance. The company is started in 1958 in kaputhala and from there it is trying to reach
the heights of excellence. I come to know about the achievement form company profile
where all the departments of the company is mentioned and environment of the concern is
also depicted from there. Categorization of product is given so to know the details of the
product range.
The industrial training of six months at SSK has given us a chance to polish the
theoretical knowledge of three and a half years into the very effective practical knowledge. In
last 3 years, No doubt we had gone through a lot of labs, and thereby, learnt a lot of things
but SSK teaches us how important those labs are for our Engineering, how those labs help in
achieving the targets in industries. We worked in Electroplating shop, Phosphate shop, Paint
shop, sales department and many more. The most interesting thing in SSK was that we
always learnt something new or for that matter a new aspect of a job every time out of the
same workshops. In this training, I realized where my interest lies in real. I understood my
strengths and weaknesses in my field of Electrical Engineering, thereby, now I have a chance
to improve myself in my weaker areas. I also got aware of few things out of my discipline,
such as I worked with advertising department; sales department etc. and I realized that these
things are equally necessary to know to work in a company. Lastly, these six months were the
most important part of my under graduation. Indeed, this training part has actually turned out
us as Engineers. I am blessed to have such training in my hands.
P a g e | 107
18. APPENDIX
I
Fig no:- Discription Page. No.
1 Company motto 5
2 Mig Welding 23
3 CNC punching machiine 26
4 Punching press 26
5 HH bending machine, CNC 27
6 Amada bending machine 27
7 Spot welding machine 28
8 Shearing machine(front & Back)
30
9 Powder coating gun 32
10 Cabinet & Supply for gun 34
11 Painting process 36
12 Baking of paint 36
13 Rewireable switch fuse 41
14 Short circuit testing device of change over switches
49
15 Thread forming tapping screw 51
16 Thread cutting tapping screw 51
17 Reliability test 53
18 Dielectric property test 54
P a g e | 108
19 Short Circuit test diagram 55
20 Abbreviations 56
21 Second diagram test 56
22 Test of resistance to shock 57
23 Mechanical impact test 57
24 Test figures 58
25 Moulding machine 60
26 Dye of moulding machime 61
27 Preheater system for polycarbonate resin
61
28 Moulds 62
29 View of machine 63
30 Different frames 63
31 Waste polycarbonate & Grainer machine
64
32 Switch internal part 64
33 Heating oven for switch 65
34 Mechanical strength test 65
35 Tumbling barrel test 66
36 Circuit diagram 66
37 Mechanical impact test 67
38 Endurance test device 67
39 Milli volt drop test 68
40 Ampere test 68
41 Components used to manufacture modular switches
69
42 Outer look of panel 73
P a g e | 109
43 Bus bar 76
44 Mccb 77
45 Refrigeration cycle 80
II
Table no Description Page no
1 Human resource in company 6
2 Phosphating process 35
3 MCB rating chart for domestic application
46
4 MCB rating for motor application.
47
5 Cross sectional area of copper 50
6 Screw parameters 52
7 Cross sectional 53
8 Test kind 55
9 Technical performance of ssk switch
70
10 Comparison of different bus bar 75
11 Fuse size 77
12 Comparison b/w fuse & Mcb 79
13