Industrial Training Report On Tubelights
Industrial Training Report On Tubelights
Industrial Training Report On Tubelights
Jamnalal Bajaj was the founding father of Bajaj group. He was adopted fifth
son of Mahatma Gandhi. He created truth in the people for the group. He valued honesty over the profit, actions over the words and common good over the individual gain.
Kamal Nayan Bajaj, elder son of Jamnalal Bajaj followed the footstep of his
father and gave growth to Bajaj group with a characteristic foresight and pragmatic vision. He launched a diversification programme which gave the current name Bajaj both shape and size. His unique management style created a working environment that can match well the sprit of nationalism.
Ramkrishna Bajaj took over the reign of Bajaj Group in 1972 after
KamalNayan Bajaj and steered the group from strength for 22 years. He had also actively participated in the freedom struggle of the country. In post independent India, he had led the organizationth movement. All along, he actively strengthened the foundations of business through ethics and practices both within the group and amongst the business community as well.
Shekhar Bajaj current chairman of Bajaj Electricals Ltd. Started his career
with Bajaj Sevashram after which he worked at Bajaj International, the group export company. Mr. Shekhar Bajaj joined the Bajaj Electricals in 1980 and became the managing director in 1987. Mr. Bajaj is the chairman of Bajaj group companies- Bajaj International and Hercules Hoist Pvt. Ltd. And on the Board of Directors of Bajaj Auto and IDBI Bank. He had been the president of ASSOCHAM, former president of Indian Merchant Chambers (IMC) .
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Hind Lamps Ltd. entered into Miniature lamps manufacturing in 1957 and went into manufacturing of fluorescent lighting in the year 1961.
GLS Lamps Cap manufacturing was taken up by the company in 1954 with a capacity to produce 4 million caps per annum.
In the year 1961, production of TL shells commenced on vertical Tube drawing process and Tube Drawing Machines (Danner Process) in the year 1984-85. It was further enhanced in the year 1994-95 to 18 million TL Shells per annum.
Glass factory than ventured into Lead Glass Tube drawing with one line in the year 1994, added another line in the year 1996-1997 with a capacity of over 2000 MT per annum
V. CORPORATE VISION
Hind Lamps aim to bring greater happiness to its customers by improving their quality of life, enhancing stakeholder value. The main vision of the company is to give cost competitive product in the field of lamps. The company mainly produces lamps for following companies such as: Bajaj Crompton Arya Eveready
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Starter
Ionization of Electrons
A.C. Supply
Choke
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firstly the choke generates a high voltage pulse across the tube when the starter's contacts open. That pulse causes the gas in the tube to ionise and become a low-resistance plasma and secondly, because it is wired in series with the tube, the choke greatly reduces the current drawn by the tube once it contains the low-resistance plasma.
NOTE:- A Tube Light Is a High Vacuum and Low Pressure Device, so it is also termed as a Vacuum Light
Figure 2. Starters
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Shell Washing
Coating Drying
Suspension Making
Sintering
Wiping
Pumping Capping Soldering Flashing Good lamp Loading Cap Filler Cement Making
SQC
Scrap
Packing Store
Dispatch
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Glazing: Medium/Heavy Bead-0.75-1.60mm Turned Inwards Undulation of Cutting edge(U): 1.5 mm max.
Filament/Cathode
Length: 11.5-12.5mm Body Length: 3.5-4 mm Leg Length- 4-4.5 mm No. Of Turns: 5
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Flange Tube
Diameter: 11.50-11.90 mm Wall of Thickness: 0.8-1.0 mm Cut Length: 1140 mm
Exhaust Tube
Diameter: 4.75-4.99 mm Wall of Thickness: 0.65-0.75 mm Cut Length-100 mm
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1. 2. 3. 4. 5. 6.
Suspension Making Coating Sintering Wiping Branding Sealing I. Flare Machine II. Feet Machine 7. Pumping 8. Capping I. Soldering II. Caphole 9. Burning frame 10. Packing
1. SUSPENSION
It is a process in which the coating solution is prepared with the help of various chemicals used in the suspension room. Suspension Solution is made up of Liquid Ammonia Allon-C (Aluminium Oxide Powder) DM Water Fluorescent Powder Water Based Binder Adinol
In this room the suspension/Fluoresent powder is prepared and it takes approx.. 8 hours to prepare and make it for use.
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3. SINTERING
Sintering process is lead to the drying of the chemicals used during the coating process. As we knows , we uses Ammonia, Allon-C , DM Water, Binder and the fluorescent powder as a suspension solution for the coating. Here we will provide the coated glass shell to the furnace at which approx.. 600oC of temperature is maintained, Here we will dry all the chemicals like as Ammonia, Allon- C, DM Water, Binder etc. At final output we get only fluorescent powder binded on to the glass shell.
4. WIPING
Wiping is the brushing of the sides of the glass shell after the coating process. It is done due to the proper capping at the ends and there is no chemicals produced at the ends when they are mounted with the Aluminium Caps and the mounts .It is done because as the fluorescent powder is proced at the ends they will produce defects at the packing ends of the glass shell. In this process the sintered glass shell is brushed at both of the ends with a fixed brush and after that at the conveyer chain it is flushed off with the help of air pressure.
5. BRANDING
In this process the stamp of the company or the manufacturer is imposed on the glass shell after the coating and the wiping process.
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7. PUMPING
In this process the gases and the mercury is filled up into the tubelight and is to be packed at the both of the ends. Electric Oven-Vacuum-Mercury Dosing-Gas Filling-Tipping These some processes are to be done at the pumping machine.
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Gas used : Argon 80% and Neon 20%. Vacuum Pressure: 45 gm Solder Composed of Lead & Tin. Quantity of Mercury Filled: 45 mg/Lamp.
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1. At FLARE Machine
We should check the following parameters regarding to the FLARE for the betterment of the quality:A. B. C. D. E. F. Length Diameter Drop test For checking the Strength (Min. 30 cm) Poor Casting Poor Glazing Chip off
2. At FEET Machine
We should check the following parameters regarding to the FEET for the betterment of the quality:A. B. C. D. E. F. Feet strength (Min. 6cm on scale) Exhaust Tube length below Flange (59-61 mm) Single Wire Burnt Wire Without Hole Big And Small Wire
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3. At MOUNT Machine
We should check the following parameters regarding to the MOUNT for the betterment of the quality:A. B. C. D. E. Flatening Width (0.6 mm) Pole Distance (11-11.5 mm) Mount Geometry Emitter Weight(5.8-7 mg) Coil Punching
4. At SEALING Machine We should check the following parameters regarding to the SEALING of the Glass Shell for the betterment of the quality:A. B. C. D. E. F. G. Sealing Length Tip Length Sealing shape Filling pressure(2.4-2.6 mg of Hg) Flat Sealing Seal Hole Powder Heat
5. At PUMPING Machine
We should check the following parameters regarding to the PUMPING of the Gases and the Vacuum for the betterment of the quality:A. Lamp Not Working B. Poor Vacuum
6. At CAPPING Machine
We should check the following parameters regarding to the CAPS for the betterment of the quality: A. Cement Weight(2-2.5 gm) B. Burnt Plate C. Blister on Plate
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1. Outline of Glass bulb 2. Low pressure inert gas (argon, nitrogen, krypton, xenon) 3. Tungsten filament 4. Contact wire (goes out of stem) 5. Contact wire (goes into stem) 6. Support wires (one end embedded in stem; conduct no current) 7. Stem (glass mount) 8. Contact wire (goes out of stem) 9. Cap (sleeve) 10. Insulation (Vitrite) 11. Electrical contact
Type
40 W tungsten incandescent 60 W tungsten incandescent 100 W tungsten incandescent glass halogen quartz halogen high-temperature incandescent
Filament of a burnt-out 50-watt incandescent lightbulb in an SEM in stereoscopic mode, presented as an anaglyph image. Filament of a 200-watt incandescent lightbulb highly magnified
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Shell Washing
Shell Drying Direct Delivery Of Shell Electrostatic coating of shell Shell Loading
Marking
Pumping
Capping,Soldering
Cap Filler
Cement Making
SQC
Scrap
Packing Store
Dispatch
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Filament/Cathode
Length: For 25&40W- 27.5-28.5 mm Leg Length: 1.5-2.5 mm Length: For 60&100W- 33.5-34.5 mm Leg Length- 1.5-2.5 mm
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Flange Tube
Diameter: 11.25-11.75 mm Wall of Thickness: 0.7-0.9 mm Cut Length: 1140 mm
Exhaust Tube
Diameter: 3.50-3.75 mm Wall of Thickness: 0.6-0.8 mm Cut Length-110 mm
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1. FLARE MACHINE
Firstly, the tube is feeded and is pre heated, cut and mounted into a flare at different different positions of the machine head as 1,2,3. This machine has two burners named melting burner and Cutting Burners. Gases- Oxygen+LPG+Blower. SO2 is used for the lubrication at the reamer plate or flare tool. Length Adjuster-Cutting Burner-Glazing Burner9For Smoothing) Then the manufactured flare is sent to the next production line to feet machine for further productions.
2. FEET MACHINE
In this Proceess the mount is prepared for the GLS and this is prepared with the help of feet machine. In this machine the lead in wire is feeded into the flared tube. First of all the flare is put into the hopper, and this flare is moved to another position and at that position the catcher puts up the Lead in wire and puts two wires into the flare and then a exhaust tube is put into the flare and the process continues at different different burners and then the mount is prepared . And then it is annealed at different temperatures/gas pressures . It is done to make the mount crack free.And at the mount machine we will use an emitter to increase the resistivity of the filament. Red Phosphorus & IP Soln.Filament: Tungsten
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3. PUMPING
In this process the Various Gases like Argon & Nitrogen is filled up into the glass shell and is to be packed at the end.In this process the Flushing and filling of gases takes place with the help of Nitrogen. These some processes are to be done at the pumping machine. Gas used : Argon 86% and Nitrogen 14%. Vacuum Pressure: 62 Cm of Hg Solder Composed of Lead & Tin.
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There are some of the various defects are to be seen during the production. That will become the challenge for the Quality department to control these defects. There are two departments to control the quality standards, these are:1. PCD(Process Control Department) 2. SQC(Statistical Quality Control)
1. At FLARE Machine
We should check the following parameters regarding to the FLARE for the betterment of the quality:A. B. C. D. E. F. Length Diameter Drop test For checking the Strength (Min. 30 cm) Poor Casting Poor Glazing Chip off
2. At PUMPING Machine
We should check the following parameters regarding to the PUMPING of the Gases and the Vacuum for the betterment of the quality:A. Lamp Not Working B. Poor Vacuum
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3. At FEET Machine
We should check the following parameters regarding to the FEET for the betterment of the quality:A. B. C. D. E. F. Feet strength (Min. 6cm on scale) Exhaust Tube length below Flange (77-78 mm) Single Wire Burnt Wire Without Hole Big And Small Wire
4. At MOUNT Machine
We should check the following parameters regarding to the MOUNT for the betterment of the quality:A. B. C. D. E. F. Flattening Width (0.90-0.98 mm) Pole Distance (25-27 mm for 60/100W)(21-23mm for 25/40W) Mount Geometry Emitter Weight(4-5 mg) Coil Punching Getter Heat
5. At SEALING Machine
We should check the following parameters regarding to the SEALING of the Glass Shell for the betterment of the quality:A. B. C. D. E. F. G. H. I. Sealing Length (872 mm) Tip Length (9mm max.) Sealing shape Filling pressure(62 mg of Hg) Flat Sealing Seal Hole Powder Heat Length Over All Length(OAL)
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6. At CAPPING Machine
We should check the following parameters regarding to the CAPS for the betterment of the quality:A. B. C. D. Cement Weight(1.3-1.9 gm) Cap Off Burnt Plate Blister on Plate
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XVI. CONCLUSION
As all of us are familiar with the Tube light and the Bulbs that all of us are using at our homes, in now a days every person is using a bulb or a tube light for its use. So the Fluorescent Tubular Lamps and the General Lighting Services are the broad used terms in the field of the Electrical Engineering. The production of such type of the products is a challenging term for any of the industry to organize all the things in a proper manner. Hence the production of the tubular lamps and the Incandescent bulbs will lead to the development in the field of Electrical. The various advancements in this technology will lead to the development of the various CFLs (Compressed Fluorescent Lamps) using the same principle of the Tube Light and are producing a huge amount of intensity of light for our use in Nights or Day in various different ways and different modes like as cool day, brighter etc.
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XVIII. REFERENCES
http://en.wikipedia.org/wiki/Shikohabad#History http://en.wikipedia.org/wiki/Bajaj_Electricals http://en.wikipedia.org/wiki/Incandescent_bulb http://en.wikipedia.org/wiki/Tube_light http://en.wikipedia.org/wiki/Bajaj_Group
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