Project Report On Practical Training: Submitted By:-Kamal Singh B. Tech. VII Sem Yit Jaipur

PROJECT REPORT ON PRACTICAL TRAINING
Submitted By:-
Kamal Singh
B. Tech. VII sem
YIT JAIPUR
ABOUT IT
 Autolite Group is a focused, dynamic and

progressive group providing customers with
Innovative products at economic prices.
 The Group has core competencies in
manufacturing of Automotive Head lamp,
Work lamp, LED lamp, Fog lamp, Halogen
bulbs, Incandescent Bulbs & Miniature bulb.
 These competencies are supported by
specialization in engineering design.
Major products of Autolite India Ltd.
 Automotive Head lamps

 Fog lamps
 LED lamps
 Halogen bulbs
 Miniature bulbs
 Universal Head lamps
 Auxiliary lamps
 Work lamps
 Lamp for Trucks
Halogen Bulbs
Halogen bulbs were refinement of regular light

bulbs offering upto 20% more energy efficient, a
longer life and better light quality. The light from
halogen bulbs looks whiter and brighter than
regular lamps, because it has higher color temp
and its output consist of orange, blues & greens.
Automotive lamp types
 Normally available in 12 V, with many also in 6 V

and/or 24 V versions.
 Single filament, in 55 W and 100 W versions:
 H1 axial filament, older style base
 H2 axial filament
 H3 transverse filament, heat-resistant cable for "hot" lead
 H4 dual-filament headlamp, 55 W to 100 W low
beam, high beam varies from 60 W to 130 W
 H5 (similar to H4 but it have larger connector)
 H7
 9000 series
H4 Halogen Lamp
Manufacturing Process of halogen
lamps:
 Making the coil
 Forming the bulb
 Making the mount
 Sealing
 Evacuating and filling the pressed bulb
 Attaching the base
 Packaging
Making the Coil
The wire is wound into the shape of a coil using

automated machines that resemble high speed
bobbins. To make a round-core filament, each
tum is spirally laid adjacent to the next one on a
cylindrical rod. A rectangular rod is used for a
flat-core filament. For a double filament, the
wire is first wound into a very fine primary coil,
and this is then wound once more around a
second, thicker core. A large amount of wire can
thus fit into a very small space.
Coil diagram
Forming the bulb
 After the glass tube is cut to length, an exhaust tube

must be attached to the top. First the top of the tube
is heated using gas/oxygen fires. A tungsten carbide
wheel folds the softened glass over to form a dome
shape containing a small hole.
 A smaller glass tube called the exhaust tube is
placed in the hole and joined to the larger tube by
melting. This small diameter tube is used as a means
to flush the air out of the lamp during the sealing
operation and evacuate the air and introduce the fill
gas during the exhaust process. This process is
performed on special rotary machines
Bulb forming machine
Making the mount
 Next, the mount is fabricated. First, the bridge is

made by embedding preformed tungsten wires
in a small cylindrical quartz rod. The filament is
welded to these support wires and welded to the
outer lead assembly consisting of the
molybdenum sealing foils and outer leads.
 The completed mount is sent through a
hydrogen furnace at 1,925°F (1,050°C) for
cleaning. This process removes any oxides that
can damage the tungsten filament during lamp
operation.
Mounting machine
Sealing
A machine called a press seal is used to hermetically

seal the mount inside the bulb. The mount is inserted
into the bulb and both parts held securely. The
bottom portion of the bulb is then heated to around
3,272°F (1,800°C) using gas/oxygen burners to soften
the quartz. Stainless steel press pads, operating at
pressures of 20-60 psi, press the quartz to the
molybdenum foils forming the hermetic seal. During
this operation, the bulb is being flushed with an inert
gas (nitrogen or argon) to remove the air and
prevent the mount from oxidizing. The outerleads
protrude from the end of the press and provide a
means to electrically connect the lamp to the lamp
base.
Sealing machine
Evacuating and filling the
pressed bulb
The pressed bulb is filled with the halogen gas on the
exhaust machine. This machine employs vacuum
pumps to evacuate the air from the bulb and a filling
system to introduce the halogen gas mixture into
the bulb through the exhaust tube. The high internal
lamp pressure is achieved by first filling the lamp
above atmospheric pressure and then spraying or
dipping the bulb into liquid nitrogen which cools and
condenses the fill gas below atmospheric pressure.
Gas/oxygen fires then melt the exhaust tube at the
top of the bulb forming the tip and trapping the gas
in the bulb. The gas expands as it warms to the
ambient temperature and thus results in a
pressurized lamp
Exhausting machine
Attaching the base
The base of a lamp provides the electrical

connection and mounting. The geometry is
defined in national and international standards.
There are several different types of bases. For
single-ended lamps, glass, ceramic or metal
bases are used. These are usually bonded to the
glass bulb with special cement that has good
resistance to high temperatures, moisture and
thermal stress or attached mechanically. A
cement-free connection is used for special
applications
Halogen bulb Base diagram
Packaging
After final testing, the lamps are manually or

automatically packaged into boxes,
depending on application. Lamps sold to
retail stores are individually packaged.
Thank you

Project Report On Practical Training: Submitted By:-Kamal Singh B. Tech. VII Sem Yit Jaipur

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PROJECT REPORT ON PRACTICAL TRAINING

 Autolite Group is a focused, dynamic and

 Automotive Head lamps

Halogen bulbs were refinement of regular light

 Normally available in 12 V, with many also in 6 V

The wire is wound into the shape of a coil using

 After the glass tube is cut to length, an exhaust tube

 Next, the mount is fabricated. First, the bridge is

A machine called a press seal is used to hermetically

The base of a lamp provides the electrical

After final testing, the lamps are manually or

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