limited

INTRODUCTION Instrumentation limited , Kota is a Govt. of India enterprise established in the year1966-67. It has its plant at Kota with 25 year experience and dedicated work force. The men are well experience and also give exposure to various technologies.

For assembly and testing of hi-tech electronic instrument , totally dust free air conditional hall are used with static protection. Rajasthan electronics and instrumentation limited (REIL), Jaipur is a subsidiary of il and is manufacturing and supplying non conventional energy devices and electronic energy meter. The product manufacture at IL accredited with ISO 9000 series quality system satisfaction. It had supplies over 3000 unit of mini ups to 1 KVA to 150 KVA. It had supplied instrument on turn to basic thermal power plant in Malaysia and 1 service center at Kufa complex in Iraq.

I have visited following sections during my training period:Railway signal relay department Card assembling (PCB center) UPS (Engineering , production, servicing center)

RAILWAY SIGNALING RELAYS (RSR) A relay is an electrical device that open and closes several circuits in response to Current in another circuit. By energizing or de-energizing one relay,, several other circuit can be controlled by contact of that relay. When the relay coil is energized it create a electromagnetic field that attract a relay armature to the coil. Attached to this armature is a mechanism of either opening or closing of the relay contact that are electrically independent from the input voltage to the relay coil. The relay can turn control to the other circuit. These other circuit that are switched, may or may not be at the same voltage as the relay coil whose contact are doing the switching.

Most relays have two types of contact. One set of contact made or closed when the relay is energized. These are known as FRONT CONTACT. Conversely these contacts are open or broken when relay is de-energized. Back contacts of the relay on other hand are made (closed) when the relay is de- energized, broken when the relay is energized.

HOWEVER IL manufactures 3 types of signaling relays, they are :LINE RELAY:- This type of relay are used for classification of line. It give signal to lines for up and down. There are two signals red and green. Here red signal is indicate that line is busy where as the green signal indicate the line is clear. TRACK RELAY:- This type of relay are used for changing the track at railway station. As we know only 2 lines up and down are present & number of lines present at railway station. KEY LOCK RELAY:- These are automatic relay and are used for protection of accident when train arrives & the gate is automatically closed. These all types of relay are controlled at control rooms

Card assembly (PCB center) It is the process of mounting the components on PCB Types of card assembly:THROUGH HOLE SURFACE MOUNT TECNOLOGY

1. Through Hole Technology

In this process components are mounted through drilled holes on the PCB. In this wave soldering machine is used for soldering through hole components. The process consisting of 4 sub process:1. Fluxing 2. Pre-heating 3. Wave soldering 4. Re-work and touchup

Fluxing is done for remove the oxidation and other containments; no clean flux is used as solvent. After fluxing and removal of excess flux, the PCB moves to the pre-heating section, where the solder side of PCB receives hot radiations from heaters and this remove the oxidation and other contaminants After pre-heating we move to wave soldering, different cards on which the components like transformer, high power resistance, capacitance are mounted are placed on system and soldered by wave soldering machine.

Wave soldering machine

The wave soldering is a large scale soldering process by which electronic components are soldered on PCB to form an electronic assembly, the name is derived from the use of waves of molten solder to attach metal component to the PCB. The process uses a tank to hold a molten solder, the components are inserted into or placed on the PCB, the process are much faster and can create a higher quality products than manual soldring of components.

Surface mount technology (SMT)

Surface mount technology(SMT)is an electronic assembly technique where the components are mounted on the printed circuit board without holes drilled through the board for insertion of component leads. This method is very efficient and fast technology. It saves the cost of placing the component and time abut 30% more faster than the work power.

Procedure for SMT:Surface mount assembly is basically a 4 step process. 1. Print the solder paste and glue 2. Place the components. 3. Reflow the paste to form the solder interconnections between the components and the land a of the board. 4. Rework.

Equipment used in SMT

Screen Printer:-to print the solder paste or glue on the board.The places on the PCB where we want to fix the component is made shining by putting this paste.

2.Pick and mount machine:We develop a program showing witch component, its size, width, etc. Here the components are picked up and placed at the appropriate location. There are different nozzles as per the components. They create a vacuum, pick up the component and place on the PCB. Components are fed through three methods reel, tray and tube. Its speed of placing 20,000 components per hour.

Pick and mount machine

3.RE-FLOW OVEN:-

Here hot air comes and melts the solder which grips the particular component. There is a blower which cools the PCB when it is very hot.

4.Image taking:Here 1st of all a master PCB is created with utmost care where all the components are mounted at the correct places. Then, its image is taken by image taking machine. Then this image is compared with the other PCBs image and faults are found if any. If fault is found then PCB is sent to re-work station, where that faulty component is removed by a heater which melts the solder. Then by looking at screen we place that component at right position.

After the PCBs are made they are given an identification number of 10 digits as:XX XX X X XXXX. 1st 2 digits show manufactures code. Next 2 digits are show the year in which PCB was made. Next single digit is for month as 1 to 9 till September & then A,B,C for October, November and December. Next single digit for manufactures unit. Then 4 digit serial number. Thus total 9999 PCBs are identified through this code in particular year and month.

UPS(uninterrupted power supply):The basic function of UPS is to continue power supply to critical load within its specific tolerances during the failure or deterioration of normal power supply. The UPS system basically consist of rectifier, inverter, transfer switch and battery. The basic UPS consist of Rectifier, inverter, external source of stored power, protective devices and accessories for proper operation.

Basic type of UPS:Standby UPS: With this type of UPS, a users equipment normally connected directly to incoming utility power with the same voltage, transient clamping devices used in common surge protected plug strip connected across the power.

Line interactive UPS

The line interactive UPS is similar in operation to a stand by UPS, but with the addition of the multi tap variable voltage auto transformer. This is a special type of electrical transformer that can add or subtract the powered coils of wire, thereby increasing or decreasing the magnetic field and the output voltage of the transformer.

The basic parts of UPS by which it is assembled are:INVERTER CARD:- it work as a DC to AC converter. RELAY & CHARGER CARD:-it contain rectifier which act as AC to DC converter. CONTROL CARD:- this card controls the assembled part of UPS. DISPLAY CARD:- this card is used to display the rating of UPS, such as voltage, current or power.

Architecture of UPS

WORKING OF UPS:
Under normal condition the battery charger supplies the entire power necessary to the inverter for supplying the load, and simultaneously charges the battery in float charging condition. The battery charger affects charging the battery automatically. If power failure occurs, the inverter is supplied the DC power from battery and supplies continuously the stable AC power to load. After restoration of power the UPS come back to normal operation. The transfer switch or static switch is used to transfer load from inverter mode to bypass mode. In case inverter becomes faulty the load is transferred from inverter to bypass automatically. The battery used in home segment is generally Lb-Acid tubular(wet type), batteries are requires maintenance periodically. The most critical part of maintenance of battery is to keep level of acid to required level by adding distilled water. Also the life of battery is 2-3 years.

Made by:DIKSHA MALIK 4th YEAR,ECE