Making Of Gls Lamps

Heaven’s Light is Our Guide

Rajshahi University of Engineering and Technology (RUET), Rajshahi Report on industrial training

Submitted by, NAME: ROLL NO. COURSE NAME: INDUSTRIAL TRAINING COURSE NO. ME-3600 SESSION: 2005-06 ROLL OF GROUP MEMBERS:

INFORMATIONS

•

NAME OF INSTITUTION:

BANGLADESH LAMPS

LIMITED

•

LOCATION: SADAR ROAD, MOHAKHALI, DHAKA-1206

•

ATTACHMENT PERIOD: FROM 1ST SEPT. TO 23RD

SEPT. 2008

•

COURSE DIRECTOR: MR. SHAHZAD ALI

PLANT MANAGER •

COURSE CO-ORDINATOR : STUDY OF PRODUCTION SYSTEM: MR. SK. A. QUAIUM

PRODUCTION MANAGER STUDY OF MAINTENANCE: MR. SHAMSUL HUDA

MAINTENANCE MANAGER

BANGLADESH LAMPS LIMITED

2

Routine for the students of Rajshahi University of Engineering and Technology Departments: Production, Maintenance, Q.C., Store and Packaging Program schedule from 1st Sept. to 23rd Sept. 2008 Timing: 8.00 AM to 3.00 PM

Date

Day

01.09.0 8 02.09.0 8 03.09.0 8 04.09.0 8 05.09.0 8 06.09.0 8 07.09.0 8 08.09.0 8 09.09.0 8 10.09.0 8 11.09.0 8 12.09.0 8 13.09.0 8 14.09.0 8 15.09.0 8 16.09.0 8 17.09.0 8 18.09.0 8 19.09.0

Mon

Description and Orientation

Tue

Production and process control of Flare m/c Work with Maintenance Dept.

Wed Thu Fri Sat

Contents

Production and process control of Stem m/c Weekend

Dept. N/A Production Maintenanc e Production N/A Production

Tue

Production & process control of Mount m/c Production & process control of Sealing & Pumping m/c Cap filler, Capping mill and Current tester Final Checking & Packing Dept.

Wed

Work with Maintenance Dept.

Thu

Work with Maintenance Dept.

Maintenanc e Maintenanc e N/A

Sun Mon

Fri

Weekend

Sat

Work with Maintenance Dept.

Sun

Work with Maintenance Dept.

Mon

Work with Maintenance Dept.

Tue

Engine Room

Wed

Work with Maintenance Dept.

Thu

Process control from the view Q/C

Fri

Weekend 3

Production Production Production

Maintenanc e Maintenanc e Maintenanc e Maintenanc e Maintenanc e Quality N/A

8 20.09.0 8 21.09.0 8 22.09.0 8

Sat

Quality control of lamp making

Quality

Sun

Store management

Store

Mon

Observation of CFL production

CFL Unit

23.09.0 8

Tue

Conversation day

N/A

INDEX CO NTENTS

PAGE NO.

INTRODUCTION

01-05

DETAILS ABOUT FACTORY

06

PRODUCTION

07-38

MAINTENANCE

39-60

TESTING AND PACKAGING

61-64

4

CFL SECTION

65-69

QUALITY CONTROL SECTION

70-73

74

CONCLUSION

Acknowledgment

5

BANGLADESH LAMPS LIMITED Introduction of company (history): Bangladesh Lamps Limited was established in Bangladesh in the year of 1962 at the time of East Pakistan. They started the production of PHILIPS GSL lamps under supervision of Dutch officers until year 1993 when Transcom Electronics Limited took over the business in Bangladesh region. But they are paying royalty to PHILIPS Netherlands till today and getting inspected on are regular basis as they are using the Dutch brand name and there logo.

Over view of the factory: The factory of Bangladesh lamps limited is divided in to some important departments. They are, 1. Production department 2. Maintenance department 3. Testing and Packaging department 4. CFL (Compact Fluorescent Lamp) department 5. Quality control department.

6

REP OR T SECTI ON ON PR OD UCTI ON

7

1. Production: The production department consists of four individual production machine belts. They are SU1, SU2, BH1 and BH2. These belts can be divided in two groups. A. lower group (SU1, SU2) B. higher group (BH1, BH2) Firstly, the SU1 machine belt was installed in 1962 by the Dutch people at the time of birth of the company in Bangladesh. This is a manual machine which takes 22 persons to operate and it produces approximately 1200 lamps per hour. But this machine is operated for only a single shift daily. The candle and luster bulbs are produced by this machine belt. Secondly, the SU2 belt was installed in 1981 which is the 1stsemiautomatic machine belt which takes 10 persons to operate and it produces approximately 2300 lamps per hour recent. But it has a capacity producing 2400 lamps per hour. The 40w-100w lamps are produced by this machine belt. Then, the BH1 or the hand operated BH1 machine was installed in the year 1986 which is the first automatic frequency controlled machine belt. This automatic machine belt takes 11 persons to operate and has capacity to produce 4200 lamps per hour but it produce 3600 lamp per hour as the capping of the lamps are hand operated in this machine belt. The 40-100 w lamps are produced by this machine belt. Finally, the automatic BH2 machine belt was installed in the year 1998. This the 1st machine installed after the takeover by Transcomelectronics limited in 1993. This machine takes 10 persons to operate which is one person less then BH1 operating person quantity. This machine has also the capacity of producing 4200 lamps per hour. But recent production is 3600 lamps per hour as it 8

has hand operated capping system. This automatic belt is controlled by programmable logic control system (PLC). This is used only to produce 200w lamp.

The last department is the CFL or compact florescent lamp department. These lamps are only assembled here. The parts are imported from other country and the assembling is done by local labors. These lamps are hand fitted.

Highlights of 4 belts: #Belt 1 SU 1

Installation date: In 1962 by the Dutch people Capacity of production: 1200 bulbs per hour Recent production rate: 1200 bulbs per hour Controlling system: Manual Manpower for operation: 22 #Belt 2 SU 2

Installation date: In 1981 Capacity of production: 2400 bulbs per hour Recent production rate: 2300 bulbs per hour Controlling system: Semi-automatic Manpower for operation: 10

9

#Belt 3 BH 1

Installation date: In 1986 Capacity of production: 4200 bulbs per hour Recent production rate: 3600 bulbs per hour Controlling system: Automatic Manpower for operation: 11 #Belt 4 BH 2

Installation date: In 1998 Capacity of production: 4200 bulbs per hour Recent production rate: 3700 bulbs per hour Controlling system: Automatic Manpower for operation: 10 (1 person less than BH1)

Study of production line: A. Flare making machine(12 heads) B. Stem making machine(32 heads) C. Mount making machine(20 heads) D. Sealing machine(24 heads) & Pumping machine(32 heads) E. Cap filler machine (12 heads)

F. Capping mill (54 heads)

10

A.

STUDY OF FLARE MAKING MACHINE

Objective:

To make and glaze flare.

Raw materials: 1. Flange tube (normally 1.1m in length & made of lead glass) 2. Gases (Oxygen, natural gas, air, sulfur dioxide or SO2).

FIG: FLARE

Number of head: 12 Production rate: 2300 flares per hour Manpower needed: 1 (For loading flange tubes in the heads)

11

Working procedure of flare making machine: The flange tubes are placed in the heads of a flare machine manually. This machine has 12 step full operation cycles.

The positions are as follow: Position 1: 2 ways flame heating on flange tube. Position 2: 2 ways flame heating on flange tube. Position 3: 3 ways flame heating on flange tube. Position 4: Flangingthe flare. Sulfur dioxide is used for lubrication.

Position 5: Cooling the flare through the nozzle for increasing the surface hardness.

Position 6: Cooling by air. Position 7: Dropping the flange tube and adjusting the length of flare.

Position 8: Removing uncut tube. Position 9: Air cooling through nozzle for shock cutting. Position 10: Air cooling through nozzle. Position 11: Heating the tube by flame in the cutting zone. Position 12: Scratching by knife on tube & shock cutting of flare (unloading position).

12

Then flares are placed on a glazing turret which is a type of gear and having 24 head or 12 head (for SU1). There are three burners for glazing the rough surface of non flanged side of flares .Then the flares are unloaded and checked manually on a light plate. Finally checked flares are moved to stem machine.

Block diagram of flare making machine:

A.

STUDY OF STEM MAKING MACHINE

13

Objective: To make stem.

Raw materials: 1. Flare 2. Exhaust tube 3. Lead in wire 4. Gases (Oxygen, natural gas, air, sulfur dioxide)

Number of head: 32 Production rate: 4200 stems per hour Manpower for operation: 1(for observation)

14

Working procedure of stem making machine: NAME: STEM

The stem making machine is an automatic machine which takes1 person to load flares in the flare chute and to load lead in wires in the wire feeder. This machine has a 32 step full operation cycle.

The positions are as follow:

Position 1: The flares are fed in stem head from the flare chute. The heads are sensor checked and proceed for lead in wire fitting. The chute ensures that only one flare is supplied to the head.

Position 2 & 3: Insertion of rear lead wires in two stem heads simultaneously through the wire funnels. Wires are only fed when a stem tube is present in the holder. It is necessary to supply two wires at a time because of the short cycle.

Position 4 & 5: Insertion of front lead wires in two stem holders simultaneously. Wires are only fed when a stem tube and rear lead wire are present.

Position 6: 15

Insertion of exhaust tube in stem head from a supply cylinder. Exhaust tube is only fed when a stem tube is present. During supply the fall of the exhaust tube is restrained to present cracks. To ensure that exhaust tube feed takes place without giving rise to product defects. The cylindrical supply system sees to it that only one exhaust tube is fed per cycle.

Position 7: Vertical positioning of stem tube and exhaust tube, relative to one another. A stem tube presence check is also made by a sensor to ensure that the components are in the correct position is the holder before they are joined together.

Position 8 to 10: The 1st, 2nd and 3rd burner pair heat stem tube and exhaust tube gradually to preheat the components.

Position 11 to 17: The 4th to 10th burner pairs bring the glass to melting temperature so it can be joined together and shaped.

Position 18: During this step the exhaust tube is put on exactly the right level by a vertically sowing (adjustable) pressure during indexing from step 17to 18. The correct level of the exhaust tube is an important criterion during sealing and pumping. The holders of the mounting machine have a fixed stop for the exhaust tube. If there should be a difference in exhaust tube length. This would lead to serious difficulties during the formation of the glass button flattening of lead wires, etc.

16

Position 19 to 20: Heating and joining of stem components to obtain an airtight seal between stem tubes and exhaust tube.

Position 21: 14th burner pair and 1st placing position. Heating of the seal and forming of place with placing unit. Forming of place by placing blocks, to facilitate alignment in subsequent operation, e.g. on the mounting machine.

Position 22: Heating of seal and 1st port blowing to keep seal at the right temperature and blow an exhaust port where the exhaust tube and pinch.

Position 23: Blowing air through the exhaust tube so that the exhaust port is formed. In this position the stem tube is inflated with preheated air. To make an exhaust port this is used for flushing and pumping the sealed lamp and for filling it with argon. The stem tube is inflated to round off any sharp angles, which improves the strength of the stem.

Position 24: Annealing of pinch to keep it at the right temperature and prevent cracking due to temperature drop.

17

Position 25: Annealing of pinch by the 18th burner pair. The pinch is reshaped by the 2nd pinching unit by making the ‘T’ mark which is the trade mark of the company. In position 24 and 25 air is blown into the stem tube to keep its model intact and to cool the seal.

Position 26 to 28: A movable cooler cools both sides of the pinch to lower the temperature of the metal –glass joint gradually, so as not to induce any extra tension.

Position 29 & 30: Fixed cooling position in which the hot steam is cooled. Cooling air may be heated up be formed by burners.

Position 31: In position 31 the stems are taken from the holder by a six head turret. A memory in the control unit determines whether the stems are placed in the Lahr or removed through a reject chute as faulty stems.

Position 32: Any stems still in the machine after position 31 are ejected by a remover (e.g. stem with broken exhaust tube). A sensor between position 32 and 1 detects the presence of any stem after position 32. There is also a sensor on the entering side of the conveyer chain to check if there is any stem left in the conveyer. If the sensor senses a stem, no stem is unloaded in the chain in that particular position in position 31.

18

Block diagram of stem making machine:

B.

STUDY OF MOUNT MAKING MACHINE

19

Objective: Mounting the filament with stem or making a mount. Also removing the impurities from the filament.

Raw materials: 1. Stem 2. Filament (material: tungsten) 3. Supporting wire 4. Gases (Oxygen, natural gas, air) 5. Getter (mixture of isopropanol & phosphorus nitrate or P3N5 )

Number of head: 20 Production rate: 4200 mounts per hour 20

FIGURE: MOUNT

Manpower for operation: 2 (one person for observing the coil feeder and other for overall observation)

Working procedure of mount making machine: The mount making machine is an automatic machine which has 20 heads and takes 2 persons to operate. One for loading the filament in the coil feeder and other for loading the shells in the conveyer chain. This machine has a 20 step full operation cycle. The positions are as follow:

Position 1: Loading of stem from chain conveyer through an annealing oven.

Position2: Spreading the lead in wires. There is a sensor which checks the position of stem in the head and gives signal to the coil feeder to load the filament.

Position3: Flattering the lead in wires (nickel coated part) to enlarge the head for clamping the filament. Position4: Bending the flattened end of lead in wire (nickel coated part) to hold the filament. Position5: Feeding of filament with the help of coil feeder and clamping the nickel coated part of lead in wire.

Position6: Protecting the filament by compressed air blowing through a nozzle.

Position7: Moving of lead in wire and filament attachment backward to save the filament from heat.

21

Position8, 9, 10: Heating on exhaust tube (lower part) to make the button for inserting the supporting wire. Supply compressed air for saving the jaw of the head when there is no stem.

Position11: Inserting the supporting wires in the button. Position12: Normal air cooling. Position13: Moving the lead in wire and filament attachment forward.

Position14: Hold the filament with supporting wires by making pig tail.

Position15: Moving lead in wires and supporting wires backward for final shape adjustment between all four wires. For 40w and 60w lamps, the gap between the lead in wires are adjusted by 23 to 25 mm and for 100w the gap is 27 mm.

Position16: Soaking the filament in the solution of getter (phosphorus nitrate, isopropanol) to remove impurities from the filament.

Position17, 18: Drying the getter with hot air. Position19: Unloading the mount. Position20: Blank

22

Block diagram of mount making machine:

C.STUDY OF SEALING MACHINE

23

Objective: To seal the lamp (marked shell and the mount).

Raw materials: 1. Mount 2. Shell (brand name marked) 3. Gases (Oxygen, natural gas, air)

FIGURE: SEALED BULB

Number of head: 24 Production rate: 3600 sealed lamps per hour Manpower for operation: 2(Loading unmarked shells and observation)

Working procedure of sealing machine: The sealing machine is an automatic machine which has 24 head and takes 2 persons to operate. A person used for loading the unmarked shells on a conveyer chain which carries the shells through a marking machine which marks the brand name. The other person observes the full operating process as this is one of the soul parts of the machine belt of production. This machine has 24 step full operation cycles.

The positions are as follow:

Position1: Loading of mount from chain conveyer after checking through a sensor in the conveyer chain.

24

FIG: LOADING MOUNT

Position2: Loading of marked shell over mount through chain conveyer. If mount is not present in the chain, shell will not be loaded.

FIGURE: SHELL

Position3-13: Heating and dropping of lamp shell. 25

FIG: HEATING & DROPPING

Position14: Cutting off cullet by a pair of pencil burners.

FIG: CUTTING OFF CULLET

Position15-17: Glazing of the sealed lamp. Position18: Seal shaping by seal shaper and blowing air from below. A pressure arm holds the sealed lamp from above to prevent it from moving upward while sealing by seal shaper.

Position19-20: Annealing of sealed lamps to prevent cracking due to sudden temperature drop.

Position21-22: Normal air cooling. 26

Position23: Unloading of sealed lamp by a 3 head sucker.

FI G: UNLOADING

Position24: Unloading of cullet.

FI G: UNLOADING CULLET

There is a sensor in the conveyer chain to check the position of mount on the chain. If a mount is missing in a certain position, the 2 head sucker will not load the marked shell on that certain position in the sealing head. Similarly if a marked shell is not loaded, mount will not also be loaded in that certain position. This is called a two way sensor system which is only present only in BH-2 machine belt. The sealing machine of the BH-1 machine belt has 1 way sensor that

27

only works if a mount is not loaded in a position, marked shell will also not be loaded in that certain position.

Block diagram of sealing machine: D.STUDY OF PUMPING MACHINE Objective: To flush with Nitrogen gas and pump Argon gas into lamp. Also making a suitable environment for filament to emit light.

Raw materials: 1. Sealed lamp 2. Gases (Oxygen, natural gas, air)

Number of head: 32 Production rate:

3600 per hour

Manpower needed: 1 (for observation) Working steps of pumping machine: The pumping machine is an automatic machine which has 32 heads and takes only 1 person for observation. The sealed lamps are transferred to the pumping machine by a transfer table or transfer turret and a 3 head sucker. There is a sensor in the loading position of the turret which checks the placing of sealed lamp by checking the length of the exhaust tube. If a sealed lamp is missing, or a defective lamp is present, a remover removes it before unloading at the unloading position. Also the left hand screw lever of the Nitrogen pump is locked by the sensor at that certain position in the pumping machine. This machine has a 32 step full operation cycle.

28

The positions are as follow:

Position 1: Loading of seal lamp from transfer turret after checking of exhaust tube length by sensor.

FIG: LOADING & SENSING

Position 2: Connection to rough vacuum.

29

Position 3, 5, 6, 9, 11, 13, 15, 17, 19, and 21: Pumping with decuple vacuum pump (10 fold pumps).

FI G: PUMPING

Position 6: Leak detection by leak detecting device which is a sensor to check leakage in sealed lamps.

Position 4, 7, 8, 10, 12, 14, 16, 18 and 20: Flushing with Nitrogen gas supplied through capillary. The supplied Nitrogen gas is also purified by flowing through purifying chips. This ensures vapor free Nitrogen gas.

Position 22-24: Preheating exhaust tube and Argon flushing through capillary.

Position 25: Final filling of Argon and pinching of exhaust tube. Position 26: Cooling by compressed air. Position 27: Unloading gas filled lamp. Position 28: Blank. 30

Position 29: Breaking the defective lamp. Position 30: Removal of extra exhaust tube part. Position 31 & 32: Blank

Block diagram of pumping machine: E.STUDY OF CAP FILLER MACHINE:

Objective: To fill cap with cement.

Raw materials: 1. Cap (material: stainless steel or SS) 2. Cement (mixture of resin cement powder, butanol and spirit).

Number of head: 12 Production rate: 3600 per hour FIGURE: CAP

31

Manpower needed: 1 (to fill cement in the cement feeder) Working procedure of cap filler machine: The cap filler machine is an automatic machine which has 12 heads and takes only 1 person to operate that is feeding cement in the cement feeder. The caps are fed to the turret from a cap feeder through a channel line. The cap feeder machine has a 12 step full operation cycle. The positions are as follow:

Position 1: Loading of cap by a cap feeder through a channel line. Position 2: Blank. Position 3: Setting of cap in the turret by a rotating adjuster. Position 4: Blank. Position 5: Setting of cap again by a vertical adjuster. Position 6: Blank. Position 7: Filling of cement in the cap. Position 8 to 11: Blank. Position 12: Unloading of cement filled cap by a conveyer belt to the capping mill.

32

Blockdiagram of cap filler machine:

F. STUDY OF CAPPING MILL Objective: Capping of seal & pumped lamp, flashing (both in low and normal voltage) and soldering.

Raw materials: 1. Pumped lamp 33

2. Gases (Oxygen, natural gas, air) 3. Solder 4. Solder flux.

Number of head: 54 Production rate: 4200 lamps per hour Manpower needed: 2

Working steps of capping mill:

Position1-13: the lamps are loaded manually in the heads of the machine after fitting cemented caps with the lamps. Position14-25: heating for hardening the cement. Position26-29: normal air cooling. Position30-36: flashing of the lamps. Position37: blank. Position38: cutting of the fuse wire by pencil burner. Position39-43: blank. Position44: resin or soldering flux is put on cap eye. Position45: soldering on inner eye of the cap. Position46: soldering on outer eye of the cap. Position47-50: cooling by blow air. Position51: final checking. Position52: Blank Position53: unloading the lamp. Position54: blank. 34

Block diagram of capping mill:

35

REP OR T SECTI ON ON MAI NTE NANCE

2. Maintenance: Maintenance section mainly handles all of periodic maintenance. It consists of cleaning, repair, replacement, lubrication system handling, some other crucial events related to production belt.

Classifications of Maintenance: 36

Maintenance works in periodical time in some important types. These maintenances are, • • • •

Breakdown Maintenance Preventive Maintenance Corrective Maintenance Maintenance Prevention

This type handles in definite periodical time stated by maintenance section. Working times are deals in production site are, • • • • •

Weekly maintenance Monthly maintenance Half-yearly maintenance Yearly maintenance Two-yearly maintenance

Details of the types of maintenance are given below,

Breakdown Maintenance: Breakdown maintenance describes the measures, the purpose of which is to correct faults i.e. to restore damaged equipment to its proper functional state. It is often referred as repair work.

Preventive maintenance:

Direct preventive maintenance to all measures aimed at preventing development of faults in equipment. Examples of direct preventive maintenance are cleaning, lubrication planned replacement and renewal, overhauling. Direct preventive maintenance is often carried out after certain number of certain number of operating hours. Indirect preventive maintenance or condition monitoring cover all operation intended to determine the need for direct preventive maintenance or repairs. Indirect preventive maintenance works are carried out in-response to a significant deterioration in a machine / 37

equipment indicated by a change in a monitored parameter of the equipment condition or performance. This is also known as condition based maintenance. Indirect Preventive Maintenance Direct Preventive Maintenance (Condition Monitoring) 1. Measurement of bearing 1. Adjustment of bearing clearance. clearance. 2. Measurement of ball2. Replacement of ballbearing shock pulse. bearing.

Corrective Maintenance:

Here the preventive maintenance approach is further improved to take steps that same breakdown is not repeated.

Maintenance Prevention: This is a development from corrective maintenance; it is done at the design phase so that equipment needs less maintenance and if needed it becomes easier.

Maintenance during Industrial training: Some important maintenance were happened during industrial training which are given below in details,

• Study of a gear box Objectives: 1. Open and separate gear box. 2. Assemble gear box. 3. To find out the type of gear box.

Apparatus: 38

1. 2. 3. 4.

Allen key. Puller. Screw driver. Ball pin hammer & Plastic hammer. 5. Different type of wrench.

Observation: Type of gear: Worm gear.

Power transmission: Right angle (90 deg. Axis)

Bearings in gear box: 1. Two ball bearings and one thrust bearing with worm of the gear box. 2. Two ball bearings with worm gear of the gear box.

Bearing details: Type of ball bearing Manufacture- Japan (NTN Company) Bearing No. 6007

Type-Ball bearing Manufacture- Japan (NTN Company) 39

Bearing no - 6022

Number of teeth in worm gear: 40 teeth & 7 threads.

Gear ratio: mg = ng / nt

where,

=40 / 7

ng = No. of teeth of

gear =40 =5.7148

nt = No. of threads =

7

Material of worm gear: Cast iron

Introduction of worm gear: Worm gear used to transmit power between nonintersecting shafts, nearly always at right angles to each other. Comparatively high velocity ratios maybe obtained satisfactorily in a small space, through perhaps at a sacrifice in efficiency as compared to other types of gear.

• Self shaper unit:

40

Category: Sealing unit. Owner machine: BH-1

Self shaper unit mainly used to finalize the shape of sealing lamp. It is important in adjustment with cap in capping mill. It is mainly built in cast iron. It consists, A. Two arm connected with a hinge B. Two roller bearings acted as follower

OPERATION: The accuracy of self shaper unit was getting lower from the desired value because of the defect in hinge section. This defect mainly acts devastative when cap join with sealed lamp in capping mill. The problem was solved by replacing the hinge parts in maintenance section.

• Oven of pumping machine: Category: To clean out the moisture and vacuum the lamp. Owner machine: BH-2

Oven of pumping machine mainly used for cleanout the moisture and vacuum the sealed lamp fully for preparing nitrogen (N2) flashing.

OPERATION: 41

Oven mainly faces defect in its layer, which is built by SS sheet. This sheet damaged for continuously heat treatment during operation. This damaged part was replaced by newly made with SS sheet in maintenance room.

• Arc welding: Job: MS bar & table. Joint type: Bar joint Pressure tube or Manometer: For balance air, gas & liquid oxygen through the machineOxygen: 1500-1400 mm of water Air: 1400-1200 mm of water Gas: 400-300 mm of water

• Different parts of machine Gas Traps: It is mounted on the pumping machine turrets to prevent glass remounted entering between the two discs of distributor valve.

Drying Bottles: It is included in the filling and flashing gas lies to absorb any moisture. The moisture content glasses must be reduced to <=1 ppm H20. If the drying bottles section filled with molecular sieves has changed color for 2/3 or more the bottle must be exchanged.

42

•

Burners:

Introduction: A burner shapes the flame so that it can be aimed at the right spot optimum heat supply, thus transforming the product handled to the state desired in the prescribed time. A machine burner is equipment capable of producing one or several clearly distinguishable flame cores, and mounted on the machine for mechanical glass processing. A machine burner can be fed with combustible mixture made at some distance from the burner port in a mixing device. Burner and mixing device are interconnected by a mixture feed line. Such a burner is a pre-mix burner.

A mixing device can be serving one or several burners. There are also machine burners which have their fuel gas and oxygen supplied separately. If the combustible mixture is formed by the injector principle, the injector outlet being at the same time the burner port, we spark of mix burner. Burner for which the combustible mixture is formed beyond the burner the burner port is parallel-flow burners.

Pre-mix burners: The combustible mixture which is to feed a pre-mix burner has a certain combustion rate, depending on its composition. The pre-mix burner depends on the combustion rate (gauze, slot, or no stabilization).

If combustion rate between 0.25 and 0.7 m/s, a burner with gauze stabilization must be used.

43

For combustion rate between 0.6 and 3 m/s, a burner with slot stabilization must be used. Non-stabilized burners can be used for combustion rates above 2.5 m/s.

These limits for each burner types are to be regarded as pilot values. 1.

Burner with gauze stabilization (G.S burner):

A roll of nickel gauze gives the mixture flowing at low speed from the stabilization

FIG: G.S. BURNER port a homogenous flow rate. This gives a stable auxiliary flame which stabilizes the main flame.

2.Burner with slot stabilization ( S.S burner ) : A combustible mixture with a combustion rate of at least 0.6 m/s flows through slot at such a low flow rate that a stable auxiliary flame is formed. This stabilizes the main flame. 44

FIG: S.S. BURNER 3.

Burner without stabilization (N.S burner):

Burner operating on combustible mixture with combustion rate of at least 2.5 m/s needs no stabilization devices. The main flame is sufficiently stable at the burner pressures and flow rates ordinary use.

FIG: N.S. BURNER

Mix-Burners (MP): These are self mixing Pencil-shaped burners. The mixture is formed in the burner itself. I.e. the injector is incorporated in the burner. This type of burner is mostly used as a cutting torch. It is suitable for mixture with combustible rate of 3 m/s and upward. Suitable mixture is: all fuel gases + oxygen. 45

Parallel-Flow Burners: The parallel flow burners can be subdivided into: 1. Burners of the sandwich type – type S. 2. Burners of the round type –type PP ( Pipe / Pipe ) 3. Burners of the round type –type CP ( Concentric / Pipe ) 4. Burners of the combination type –type PS ( Pipe / Sandwich ) Types of PP & PS are not used at present.

• Injector For burners connected to a premixed, combustible gas mixture in a injector. The use of such injectors has been laid dawn in instructions for reason of safety. Injector prevents the gas streams for preheating into their mutual lines the combustible mixture is found only between injector and burners. In case of flash back, explosion will not propagate beyond the injector, an additional advantage in that the injector permits a better regulation of the auxiliary supplies.

Auxiliary supply: Class I gas

Class II gas

Coal gas

Natural gas

Other auxiliary supplies Oxygen

Mine gas

Propane

LP air

Hydrogen

Methane Butane

Auxiliary supply pressure: For trouble free operation of injectors and burners, the pressure of auxiliary supplies should lie between the values below These values are set with reducing values and can measure with pressure gauges on the operating machine.

46

From-To Pressure

Mm WG-mm WG

From-To Pa-Pa

Auxiliary supply Class I gas

150---------300

147090-294180

Class II gas

250---------350

247150-343210

Air

1000-------1150

980665-1127690

Oxygen

1200-------1500

1176720-1470900

Auxiliary supply

Pressure mm WG

Coal gas Mine gas

150-300

Town gas Hydrogen Natural gas Propane

400-600 250-350 200-350

Butane Air Oxygen

1000-1150 1200-1500

• Manometer: A manometer is an improved form of a piezometer tube. With the help of a manometer, we can measure comparatively high pressures and negative pressures also. It consists of a tube bent in U-shape, one end which is attached to the gauge point and other is open to the atmosphere as shown in figure:

47

FIGURE: MANOMETER

Practical reading in manometer:

Auxiliary supply

Pressure mm WG 340 1260 1410 60 (mm of Hg)

Gas Air Oxygen Vacuum

48

• Study of Engine Room Introduction: The most important part of any factory is engine room. All power supplies are come from this engine room. In this factory this room has compressor, blower, dryer & vacuum. The supplies are given by pipe line which has a suitable design .Flows are maintained by regulator. There are also alternator pipe lines which are used if the main pipe line damaged though periodic checking are taken. This preparation is taken so that the production unit must not be hampered by any uncertainty.

Generation units: Three Compressors, two compressor always running when production continue and one standby for immediate support. • Three Blowers, two blowers always running and one standby. • Three vacuum units, two units always running and one standby. •

FIG: BLOWER AND DRYER

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Others supplies: One Dryer, all compressed air dry in this unit and then store in the receiver cylinder. • Liquid oxygen supplies from the out side of the factory and regulate it at the engine room then supply to the production unit. • Tetas gas supply from the out side of the factory and regulate it at the engine room then supply to the production unit. •

FIG: VACUUM

Fuel of engine room: All through generation unit generate the required product only consume electricity. So, the electricity is mainly used as fuel at the engine room.

Description of Generation units: Compressor: Every compressor runs with one high power motor. The motor drive the compressor unit and air compressed and then dry in dryer unit and next store in the receiver cylinder. There are two receiver cylinders for three compressors. After receiver cylinder,

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compressed air regulates by valve regulator and then passes through the production lines and other.

FIG: COMPRESSOR

The rating of motor of compressor I:

V Hz

400± 10% 50

A KW 3- MOT

130 75

Cos Q 0.88 n 2978 1/min Gew / wt 475 Kg Temp max 45’

The rating of motor of compressor II: 51

Manf. in Manf year N0 Pmax

Belgium 2007 AP1511707 7.5 bar

Type Qmotor Nmotor Qv

GA45plus 45kw-60hp 2965 r/min 1427 l/s

The rating of motor of compressor III: Manf. in Manf. year Type

India 2008 GA75AWP

Pmax Free air delivery Qmax

7.5bar 246 l/s 75KW

The rating of vacuum machine: Manf. in Manf. year Type Q

Germany 1979 RV46 274 m3/h

P1 abs P2 N

0.15 bar 1.0 bar 960 r/min

The rating of blower machine: Manf. in Type V1 T1 P1

Germany RV226HIG 0.3333 m3/s 15.00C 1.2 Kg/m3

Pt P2 N Pw

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250 m bar 1.25 Kg/m3 1020 r/min 11.7 KW

Blog diagram of engine room: Factory

Production line

Regulato r Governor Blower2

Receive r 1

Receive r2

Compressor 2

r

Vacuum 2 Blower 1

Drye

Compresso r1 53

CH4 CH4 Control Control unit unit (main) (main)

Vacuum 3

Vacuum 1

o2

Blower 3

om outside Reserve Switch boards

Liquid Control unit (main) Fr

Compresso r3

Cabinet

Titas gas supply Gases, power

All machine control board (electrically) Lubrication system of the machines:The system used to lubricate a machine is called lubrication system. Types of lubrication: 1. Liquid lubricants 2. Solid lubricants In this factory both liquid and solid lubricants are being used. Grease is used as liquid lubricant and carbon or Graphite is used as solid lubricant.

Liquid lubricant: Types of liquid lubricant: 1. High temperature grease 2. Low temperature grease Low temperature grease is used in the gear boxes.

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Study and Observation of Clutch: A clutch is a mechanism for transmitting rotation, which can be engaged and disengaged. Clutches are useful in devices that have two rotating shafts. In these devices, one shaft is typically driven by a motor or pulley, and the other shaft drives another device. In a drill, for instance, one shaft is driven by a motor, and the other drives a drill chuck. The clutch connects the two shafts so that they can either be locked together and spin at the same speed (engaged), or be decoupled and spin at different speeds (disengaged).

Single plate friction clutch

FIG: TEFLON

PLATE CLUTCH

This type of clutch is used almost exclusively in automobiles and trucks and has three main parts: 1. Driving member 2. Driven member 3. Operating member 55

The clutch plate is lined with a friction material with the output shaft running through the center. This type has the advantage of a lever that allows the operator to manually engage and disengage the drive via the pressure plates. This type of clutch allows for a smooth take away and gear changes.

Multiple plate friction clutch This type of clutch has several driving members interleaved with several driven members. It is used in motorcycles and in some diesel locomotive with mechanical transmission.

Wet and dry A 'wet clutch' is immersed in a cooling lubricating fluid, which also keeps the surfaces clean and gives smoother performance and longer life. Wet clutches; however, tend to lose some energy to the liquid. A 'dry clutch', as the name implies, is not bathed in fluid. Since the surfaces of a wet clutch can be slippery (as with a motorcycle clutch bathed in transmission oil), stacking multiple clutch disks can compensate for the lower coefficient of friction and so eliminate slippage when fully engaged.

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REP OR T SECTI ON ON TE STIN G AN D PACK AGI NG

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3. TESTING AND PACKAGING: Testing: Operative m/c

: Testing Board

M/c Status

: Manual (Human operated)

No. of testing boards: 4 Operative persons

:4

In this stage of production, the GLS lamps are being tested on a testing board after being quarantined for 24 hours. The process of quarantining is necessary to ensure that the lamps will not fail when they’re temperature is reduced to normal state. There are four operational testing boards. Generally 3 of them are used for GLS lamps and the other is used for testing the Luster and Candle lamps. Testing boards are consisted of several lamp holders. Around the holders there is a box area which is colored black to justify the glow colors of the lamps properly. Operators stand in front of the board and test the produced lamps. Usually this testing operation is done manually by the operators. First, the Lamps are placed on the holder of testing board and electricity is supplied to ensure the glow of the lamps. This glow ensures that the lamps are seal tight and the coils are well clamped to the stem. If the lamps are not seal tight, after being quarantined, they will instantly become oxidized when connected with electricity. If the coils are not clamped properly, the glow will not be as it should be. Usually the lamps show light yellow color while glowing. 58

Then the lamps are turned on and off frequently to ensure that a lamp will not fail if it is turned on and off frequently by the consumers. The lamps are also tested by glowing them both in high and low voltage. Later comes the glow test. The equipment used for glow test is called ‘glow’ which is a very high voltage plate. This plate is slide over the lamps which create an arc between the mount point of the tungsten coil and the contact point of the glow on the surface of the shell. This operation is called glowing. If one of the lamps does not glow properly, it is considered to be rejected. This glow test is done by high voltage and low current supply. Usually 11,000 Volts and low current supply is ensured during glow testing. In this stage the lamps show bright violet color. If any of the lamps does not show the proper color, it is rejected. Lamps which glow properly and show the perfect color during glow test, are send to the next and final stage of production, packaging.

Packaging: Operative m/c

: N/A

No. of human workers: 10-15 After being tested, the lamps are ready for packaging. Usually lamps are packed manually by operators. There is an automatic packing machine which is used only when work load is heavy. Before the lamps are packed markings are ensured on the shell which shows its manufactured date, model of the machine it was produced from, brand name and the trade marking. Similar operations are done with the packets in the storage department. Markings are made on the packets describing the lamps manufacturing date and efficiency of the lamp which it contains. This operation is done for both GLS and CFL lamps.

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For GLS lamps Markings on the shell are done while they are conveyed from pumping m/c to capping m/c. In case of CFL lamp markings are done after production on a printing turret which has printer fixed at certain point. This marking m/c for CFL lamps marks the manufacturing date and a serial no. on each CFL lamps. The sensor on the printer ensures that the serial of marking is maintained strictly. The final packaging is done by placing the lamps in the supply cartoons and sealing them for to be opened by the customers. The trays carry lamps and the cartoon carries lamps. This is the figure for GLS lamps. For CFL, each tray carry 10 units and the cartoon carry 5 trays.

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RE PO RT SE CTIO N ON COM PACT FL U O ROS C ENT LAMP

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4. REPORT ON CFL PRODUCTION DEPARTMENT: The CFL or compact fluorescent lamp is the latest attachment in the production products of Transcom Electronics limited. They have started to assemble the CFL in September of the year 2007 in the brand name of Transcom CFL. Today the production rate is approximately 5000 per day. The parts of the lamp are imported from abroad and assembled manually in the assembling section of the factory. The parts are mainly imported from China and India.

FI G: CFL LAMPS

Approximately 54 persons work in the CFL assembling section including assembling, marking and packaging. Almost 40 persons work in assembling the CFL, 2 persons work for finishing that is 62

sealing the cap, 6 persons work in soldering and rest of the people work in the marking and packaging section.

The marking system is divided in two categories: 1. Marking with hologram sticker of brand mark. 2. Marking of manufacturing date and serial number by printer. Marking with hologram sticker on the body of CFL is done to ensure the customers of the original product as it is said that the hologram sticker cannot be copied. Marking of serial and manufacturing date is done to ensure the identity of the lamp as it is a valid Transcom Electronics product. There is an electronic sensor attached to the printing point to ensure that every CFL is printed serially and if a head is empty, then the printer will not response.

Main component of a CFL: 1. 2. 3. 4.

Cap Holder Curved tube Circuit board

All the 4 components are now imported from abroad that is either India or China. The cap used in the CFL is made of aluminum alloy. The holder are curved tube holder are made of plastic. All these parts are being imported till now, but from now the circuit board of the CFL is to be manufactured in this country.

Components of the cap: 1. Aluminum alloy body 2. Gun metal made eye 3. Black glass (to separate aluminum body from solder)

Components of the holder: Plastic made holder (without thread).

Components of the curved tube: 63

1. 2. 3. 4.

Plastic holder (to attach with the holder) Curved glass tube filled with mercury vapor and Argon gas Tungsten filament (quantity: 2) Wires (to be soldered in with the circuit board)

Components of the circuit: 1. 2. 3. 4. 5. 6.

Diode Transistor Resistor Capacitor Transformer Insulator

Working procedure of CFL: The CFL or compact fluorescent lamp is a kind of electronic ballast started light. The heart of the CFL is the circuit inside the holder which is a kind of inverter circuit. The principle of the inverter circuit is to convert AC current to DC and again convert it to AC current. The input voltage of the circuit is 220V and frequency is 50Hz and the output voltage and frequency are 110-140V & 6-10 KHz respectively.

Briefly: Input:

Voltage

Frequency

220V

50Hz

Output: 110V – 140V

6 KHz – 10 KHz

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The curved tube has 2 points which hold 2 filaments. One of them works as an anode and other works as a cathode when placed in a circuit. The principle of working of this anode and cathode is that anode emits the electron and cathode receives it. But in order to start this process the starter in the circuit creates a spark in between the two points by high voltage of Mercury vapor and the whole environment gets electron charged. The charged environment carries the electrons from anode to cathode and in this process energy is being emitted from the electrons in the form of ultraviolet or UV light. The white halo phosphor coating on the inner body part of the curved tube makes the invisible UV light visible.

Production process of the CFL: 1. 2. 3. 4. 5. 6.

Circuit soldering Plastic cover fixing and checking Cap punching Cap soldering Ageing Cleaning and marking

7. Packaging

Circuit soldering: The curved tube filled with Mercury vapor and Argon gas has two tungsten filaments at two points of the tube that has four wires which are soldered with the circuit board. This whole operation is done manually.

Plastic cover fixing and checking: The soldered circuit and the tube are now fit with the plastic holder manually. Then the lamp is checked by fitting it to a socket.

Cap punching: 65

Before soldering the cap eye, the lamps are punched at the neck of the holder for strong hold as there is neither thread nor cement to hold the cap with holder strongly for long time period. Then the punched lamps are preceded for soldering.

Cap soldering: The punched lamps are then soldered manually. There are 6 workers appointed for soldering the cap eyes.

Ageing: Then the finished lamps are placed in the ageing belt for glowing before packing. This is necessary for obtaining accurate lumen from the lights. The ageing belt has 52 positions and takes 50 minutes to complete a full rotation. The initial position has low voltage but the other 51 positions have same voltage that is the normal supply voltage of 220V. At the end of the rotation of 50minutes, the lamps are removed from the holders and preceded for marking and packing.

Cleaning and marking: The lamps from supplied from the ageing belt are then placed on a conveyer chain for marking of the serial no. and the manufacturing date on the body of the holder by an inkjet printer. There is sensor fixed to the injecting point of the printer to ensure every CFL is printed serially. If a point is empty, the printers will not response. Then the marked lamps are cleaned by cloth to satisfy customers’ eye and preceded for final packaging.

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Packaging: The CFL are packed manually by approximately 6 persons. The packaging is done in two steps. First, a tray is filled with 10 units and then, 5 trays are packed in a cartoon. Thus 50 units are packed in a cartoon and preceded further.

REP OR T SECTI ON ON Q UALIT Y CON TR OL

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5.Quality control: Quality control department mainly works with the quality stages of GLS bulb and its components like flare, stem, mount, sealed lamp etc. For checking the standard margin of making a bulb Quality department contains some specific schedule of checking and inspection. These are as follows, (A)Machine wise checking (B)Strength of glass test (C)Vacuum test (D)Lumen test (E)Longevity test (F)Torsion test of cap

(A)Machine wise checking: In machine wise checking some samples are randomly taken from machines and then these samples were taken for investigations. In checking, quality control operators check the precision and compare these with standard value of GLS bulb.

(B)Strength of Glass test: From the taken samples, flare, stem, mount and sealed lamps are goes to check the glass strength by using some methods. Flares are checked by dropping from a definite height on solid base. For shell, a steel ball dropped over shell with a specific height to observe the strength. If these samples overcome during testing operations and assures the standard level then all the products declares O.K.

(C)Vacuum test:

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For vacuum test, a sealed bulb taken from the samples and operators measures its internal pressure by using moderated manometer which contains mercury. Standard value of pressure is quite below (around 65-72 mm of Hg) of normal atmosphere.

(D)Lumen test: For lumen test a sample bulb taken into the lumen test machine to calculate the lumen of bulb by the help of a computer.

(E)

Longevity test:

For longevity test sample bulbs are lighten in various voltages over some times and gradually calculate the bulb life. In standard level, bulb life value is 1000 hrs.

(F)

Torsion test of cap:

In these test operators checks the condition of a bulb that is capped. Mainly cement quality, position of cap and torsion strength of cap is observed.

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Conclusion:

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