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Report of Industrial Training

On
1. Process Capability of Industrial Control Products.
2. Studying the MCCB line, identifying the causes for
rejections and measures taken to overcome them.
At

HYDERABAD WORKS
Submitted by
RAMAN PRATAP SINGH,LAJWANT PRAJPAT
12STUHHME0219,ME0091
In partial fulfilment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING
IFHE - FST
(A Constituent College of ICFAI University)
HYDERABAD , INDIA


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ACKNOWLEDGEMENT
__________________________________________________________________________________

First of all I would like to thank Schneider Electric India Private Limited for giving me this
opportunity to learn, share my ideas, views, and thoughts on various subjects through this
project, undertaken as a part of my curriculum requirements.
This project could not have been completed, if not for the help and encouragement from
various people. Words are inadequate in offering our thanks to the Project mentors
Mr. nilesh sir, for their guidance and cooperation throughout my internship.
1. COMPANY PROFILE
Schneider Electric is a French global company, founded in 1836 by two brothers, Eugene
and Adolph Schneider. It a global specialist in energy management with operations in 130
countries, Schneider Electric offers integrated solutions across multiple market segments,
including leadership positions in energy and infrastructure, industrial processes, building
automation, and data centres/networks, as well as a broad presence in residential applications.
Schneider Electric offers solutions to make energy safe, reliable, efficient, productive and
green from plant to plug.



3. SCHNEIDER ELECTRIC INDIA
22.4bn
Global Sales in 2011
39% of sales in new economies
2 compared to 2004
130,000+ people
In more than 100 countries
4-5%
Sales devoted to R&D
170 years
of history through innovation
and leading brands


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Schneider Electric entered India in 1963 through a first joint venture with Tata group.
In 1995, Schneider Electric established a 100% fully owned subsidiary Schneider Electric
India Pvt. Ltd.
In the year 2000, Schneider Electric further consolidated its position in the Indian market by
acquiring S&S Switchgear and Crompton Greaves LV division.
Hyderabad Factory



Fig: 2.3


Land: 40000 sq.mts Built up area: 12500 sq.mts

Schneider Electric India has added to its manufacturing capacities establishing another state-
of-the-art Plant at Hyderabad. Sprawling over 10-acre land, the plant has 12,500 Sq.m built-
up area. It boasts of machines equipped with cutting edge technologies, and manufactures
world-class Air Circuit Breakers, Medium Voltage (RN2C, RM6), Contactors and Push
Buttons, and caters to the requirements of domestic as well as worldwide markets
Products of Hyderabad plant are

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Table: 2.1
Products manufactured in Hyderabad factory are:



Fig: 2.4 Master pact Circuit Breakers
Fig: 2.5
RN2C Ringmaster













Fig: 2.6 RM6 Ring Main unit Fig:2.7 Tesys Range of Contactors

Tesys D
EasyPact TVS

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Fig: 2.8 Harmony range of push buttons & pilot lamps Fig: 2.9 Tesys-E Range of Contactors













WHAT
IS A
CONTACTOR?
The contactor is a mechanical switching device controlled by an electromagnet; it is able to
make or break high currents by energizing or de-energizing a coil in which a relatively low
current flows its operating mode is discrete (on/off).
Contactor operation:

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Fig 3: Functional diagram of a contactor
About TeSys :
Tesys is a range of contactors manufactured at Schneider Electric Hyderabad Plant.
Tesys comes in two varieties :
1) Tesys D,
2) Tesys-E.
3) Definition -Process: Process refers to any system of causes; any combination of
conditions which work together to produce circuit breaker is an automatically
operated electrical switch designed to protect an electrical circuit from damage caused
by overload or short circuit. Its basic function is to detect a fault condition and
interrupt current flow. The circuit breakers are divided into two types based on their
rating:
Low-Voltage circuit breaker
High- voltage circuit breaker
What is an M.C.C.B?

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A relatively light, fast-acting electrical circuit breaker assembled as an integral unit in a
supporting and enclosing housing of moulded insulating material.
EasyPact CVS- MCCB with adjustable settings .


Fig: 5.1 Easy Pact CVS

Compact NSX
Also called the next generation Circuit Breaker


Fig: 4.5 Compact NSX 250A
with 2.5A micro logic


Easy Pact (Molded Circuit breaker from 15 to 400A

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Fig: 4.6 Easy Pact (15-400A)


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6. Manufacture of Molded case Circuit Breaker (M.C.C.B)

































Fixed contact Arc Splitters Spark Production
Moving contact
Insulation Disc
Breaking Cell Assembly
Sensor Testing
Riveting Assembly Station
Manual Checking
Mechanism assembly
Resistance Test
Base Assembly
Trip Circuit Assembly
Function Test Machine
Label Pasting
Front Cover Assembly
MCCB Laser Marking
Machine

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Breaking Cell Assembly:

Fig: 6.1 Lower segment of the Breaker cell showing fixed
And moving contacts


Fig: 6.2 Components in the lower part of the breaking cell.
Riveti ng Asse mbly
station:
Moving contact
Fixed contact (Upstream)
Lower part of the cell
Fixed contact (downstream)
Spark production
Insulation disc
Arc Splitters (6- pin)

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Fig: 6.3 Riveting Assembly Station Fig: 6.4 Barcode Label printing
Station

Mechanism Assembly:

Fig: 6.5 A Breaker Mechanism Fig: 6.6 the Mechanism Assembly

Steel and Copper Testing:

Fig: 6.7 The Steel and copper
Testing machine

Base Assembly:
At this station the Screw presence and proper
tightening is tested. And once done is sent to the trip unit
assembly.


Machine to be tested is to be
inserted here.
Indictors that test if the metal
used is steel or copper

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Fig: 6.8 Screw presences being tested and tightened
Trip unit Assembly

Fig: 6.9 Fig: 6.10 Fig: 6.11

Fig: 6.12 Fig: 6.13

Function Test Machine (F.T.M)
The product is sent to the FTM (Function test Machine) after the trip unit assembly where it
is tested for different aspects such as continuity, dielectric, resistance, screwing and the
presence of mechanism lever/ right OF/ left OF.


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Fig: 6.14 Fig: 6.15 Fig: 6.16

MCCB Laser Marking Machine:
Once the FTM tested, the breaker which passes the test is sent to the laser marking machine
where the references are printed on the slip according to the breaker. .


Fig: 6.17 MCCB laser marking M/C Fig: 6.18 Reference concerned to the
circuit breaker is printed on this slip.

Front cover Assembly:

Reference and
details are printed
by the laser printer
here.

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Fig: 6.19 Front cover Assembly Station Fig: 6.20 Appearance of the breaker after
The front cover.

Fig: 6.21 Primary Packing Fig: 6.22 Secondary Packing




7. Analysis on the parts that are rejected and scope for improvement


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Fig: 7.1 Fig: 7.2 Fig: 7.3






Defects in moving
contact after assembly
Rust formations on moving contacts.