INSTITUTE OF TECHNOLOGY

UNIVERSITY OF MORATUWA

REPORT ON INDUSTRIAL TRAININGAt

LOADSTAR (pvt) LTD,

Ekala, Ja - Ela.

NAME : K. A. M. KUMARA

REGISTRATION NO : 10/ IT/ ET/ 164

COURSE : NATIONAL DIPLOMA IN TECHNOLOGY

FIELD : ELECTRONIC AND TELECOMMUNICATION

PERIOD : 16TH SEPTEMBER, 2013 – 16TH MARCH 2014

I

Preface

During my six months of in - plant training period. I have gathered more knowledge about not only industrial

electronics but also electrical installations, applications of electronic in electrical field and mechanical field. In

Loadstar, I gained theoretical knowledge about the electronics in industrial usage. In my training period, I

learnt that how to apply those theoretical knowledge practical activities. I basically understood there is a big

difference between theoretical knowledge & practical knowledge.

In here, present my practical experiences which I gained within last six months. In this report, I present that

back ground of the training organization, its structure, staff levels, etc. And also, I express my training

experiences in Loadstar (pvt) Ltd. Further, under this, I describe industrial electronic devices, CNC machines,

Computer embedded systems… etc

On the other hand, I mention that problems which were encountered during my training period.

II

Acknowledgment

I have successfully completed my six months of second industrial training period. There were many people

gave kind co-oporation to succeed my industrial training. First of all, I must thank Director & the academic staff

of Institute of Technology for arranging such a valuable training session for NDT students. I should thank Mr.

T. R. D. Perera Training Engineer of Institute of Technology. He gave great support, when coordinating

training places.

Then, I give my special honor to the Training - in - charge, Mr. Sujeewa, Training and HR division, Engineer,

Mr. Harshaka Kaludewa, Manager - Engineering, Head of the Electronic and Electrical Division, Mr. Sheron

Wickramathilake, Engineer, Mr. Nuwan Engineer, Mr. Mahesh & Engineer, Mr. Chintaka of Loadstar pvt Ltd.

They personally pay more attention for my training. Also, Mr. Nuwan & Mr. Chintaka Engineers at project

which I worked. I learnt many things from them regard on training.

My heart felt gratitude should go to Mr. Nuwan for making me a lot of opportunities for get valuable

experiences. He gave a great help to succeed my in-plant training. Also I must thank electricians including Mr.

Shantha, Mr. Sarath, Mr. Asanka & Mr. Jude in our company.

Special thanks for Manager - Engineering in Midigama Tyre Division, Mr. Dayananda and there electrical

team.. But not last, I remember all the skill & unskilled people at Loadstar pvt Ltd.

K. A. M. Kumara,

10/ IT/ ET/164,

Institute of Technology,

University of Moratuwa.

III

Contents Pages

1.0 Introduction to the Loadstar (pvt) Ltd ……………………………………………….. 1 - 5

1.1 Adminstrative Structure of Loadstar (pvt) Ltd 2 - 2

1.2 Vision & Mission 3 - 3

1.2.1 Vision of the Loadstar (pvt) Ltd 3 - 3

1.2.2 Mission of the Loadstar (pvt) Ltd 3 - 3

1.3 Objectives 3 - 3

1.3.1 Services offered Loadstar (pvt) Ltd 3 - 3

1.4 Management Practices 3 - 6

1.4.1 Recruitment procedures 3 - 4

1.4.2 Overtime payments 4 - 4

1.4.3 The shop and office employees Act 4 - 4

1.4.4 Types of Leave 4 - 4

1.4.5 EPF 5 - 5

1.4.6 ETF 5 - 5

TRAINING EXPIRIENCES

2.0 Industrial Electronic Devices ….…………………………………………………………… 6 - 15

2.1 Pressure 6 - 8

2.1.1 Pressure Sensors 6 - 7

2.1.2 Pressure Transmitters 7 - 8

2.1.3 Pressure Transducers 8 - 8

2.2 Temperature 9 - 10

2.2.1 Temperature Controllers 9 - 9

2.2.2 Resistance Temperature Detectors- RTDs 9 - 10

2.2.3 Thermocouple sensors 10 - 10

2.3 Time 11 - 12

2.3.1 Timers and counters 11 - 12

2.3.1.1 Multi Range Digital Timer 11 - 11

IV

2.3.1.2 Twin analogue Timer 11 - 12

2.3.1.3 Counter 12 - 12

2.4 Location Reading 13 - 15

2.4.1. Proximity Sensors 13 - 13

2.4.2 Inductive Sensors 14 - 14

2.4.3 Capacitive Sensors 14 - 14

2.4.4 Photoelectric Sensors 15 - 15

2.4.4.1 Photoelectric Sensor types 15 - 15

3.0 CNC Vertical Lathe Machine ………………………………………………………………... 16 - 27

3.1 Variable Speed Drives - VFD 17 - 17

3.2 Delta VFD - B Spindle Drive 17 - 20

3.3 Washing – SPM – 3400 Servo Drives 20 - 21

3.4 IGBTs 22 - 22

3.5 IPM – Integrated Power Module 22 - 23

3.6 CNC Control Panel – GSK928TEa Turning CNC system 23 - 24

3.7 Program Structure of CNC Machine 24 - 26

3.8 MSTF Commands and Functions 26 - 27

3.9 G Commands and Functions 27 - 27

4.0 Generators …………………...………………………………………………………………… 27 - 31

4.1 AVR – Automatic Voltage Regulator 27 - 30

4.1.2 Main functions of AVR 29 - 30

4.2 AGC – Automatic Governor Controller 31 - 31

5.0 Power Augmentation Projects …….………………………………………………………. 32 - 37

5.1 Power augmentation project in CMP 32 - 34

V

5.2 Electrical installation project for main power distribution in ETD – I 35 - 37

5.2.1 Action Plan 35 - 35

5.2.2 Proposed Electrical Installation for main power Distribution ETD - I 36 - 36

5.2.3 BOQ- Requirement for supplying Auto Change ATS Panel for Loadstar ETD-I 37 - 37

6.0 Safety Methods ………..……………………………………………………………………… 38 - 40

6.1 Introduction 38 - 38

6.2 Fire Safety 39 - 39

6.3 Workshop Keeping 39 - 39

6.4 Safety Signs 39 - 39

6.5 Safety Rules at Loadstar pvt Ltd 39 - 40

7.0 Conclusion …………………………………………………………………………………….. 41 - 41

Certification ………………………………………………………………………………………… 42 - 43

Notes ………………………………………………………………………………………………… 44 - 44

VI

Figures/ Tables Page

Fig 1.1 Administrative Structure of Loadstar (pvt) Ltd 2

Fig 2.1.1 Pressure Sensor 6

Fig 2.1.2 Pressure Transmitter 7

Fig 2.1. 3 Pressure Transducer 8

Fig 2.2.1 Temperature Controller 9

Fig 2.2.3 Thermocouple measuring cicuit 10

Fig 2.3.1.1 Multi range digital timer 11

Fig 2.3.1.2 (a) Twin analogue Timer 11

Fig 2.3.1.2 (b) Twin analogue Timer 11

Fig 2.3.1.3 Digital counter 12

Table 2.4.1 I/O Circuit Diagrams 13

Fig 2.4.2 Inductive sensors 14

Fig 2.4.3 Capacitive sensors 14

Table 2.4.3 DC 3 – Wire Models (PNP) 14

Fig 2.4.4 Photoelectric sensors 15

Fig 2.4.4.1 (a) Direct Reflection sensor 15

Fig 2.4.4.1 (b) Reflection with Reflector sensor 15

Fig 2.4.4.1 (c) Through Beam sensor 15

Fig 3.0 CNC vertical lathe machine 16

Fig 3.2 (a) Delta VFD 17

Fig 3.2 (b) Delta VFD – connection diagram 18

Fig 3.2 (c) V/F curve 19

Fig 3.3 Wiring diagram of Washing –SPM - 3400 21

Fig 3.4 IGBT 22

Fig 3.5 Typical AC motor Drive application 23

Fig 3.6 (a) CNC Control Panel - GSK928TEa Turning CNC System 23

Fig 3.6 (b) Pin diagram – CNC controlling panel 24

Fig 4.0 Connection diagram of 3 Phase AC Generator 27

VII

Fig 4.1 Block diagram of AVR 29

Fig 4.1.1 Connection diagram 30

Fig 5.1 (a) Power Distribution - CMP 33

Fig 5.1 (b) Proposed single line diagram for mixers 34

Table 5.2.1 Action Plan 35

Fig 5.2.2 Proposed electrical installation for auto change ATS panel 36

Table 5.2.3 BOQ for proposed Auto change ATS panel 37

- 1 -

1.0 Introduction to the Loadstar (pvt) Ltd

Loadstar is a joint venture between the Jinasena Group and the Solideal group of Belgium. Loadstar

manufactures solid and pneumatic tires, wheels and tracks under the Solideal brand and has been awarded

the Most Outstanding Exporter of Sri Lanka award by the National Chamber of Exporters of Sri Lanka (NCE)

in 2007 and won the National Cleaner Production award in 2008, 2009 (NCC) Silver.

Loadstar employs over 5,000 people across six plants.

Loadstar is an ISO 9000 certified company since 1996, and is one of the first tire companies in Sri Lanka to be

certified. Loadstar is committed to its customer by consistently delivering high quality products at competitive

prices.(QualityPolicy)

Loadstar endeavors to continually improve all business processes and ensure conformity to the established

quality systems. Loadstar accomplishes this through constantly upgrading of the skills of our employees.

Presently the company consumes a significant percentage of the natural rubber production of Sri Lanka.

Loadstar has continued to grow rapidly over the last 25 years and is continuing its journey with impementation

of lean system and processes.

Production Capacity

The Loadstar has following production lines to increase production capacity.

Ekala Tyre Division 01 (ETD01)

Orex Tyre Division (ETD02)

Kotugoda Tyre Division

Ancillary Product Division (APD)

Jinasena Industrial Park (JIP)

Midigama Tyre Division

Ekala Metal product Division (EMPD)

Kyoto Metal product Division (KMPD)

Steel Band Division (SBD)

Kuruwita Tyre Plant

Cinco

Casting Product Division (CPD)

- 2 -

1.1 Adminstrative Structure of Loadstar (pvt) Ltd

Fig. 1.1

- 3 -

1.2 Vision & Mission

1.2.1 Vision of the Loadstar pvt Ltd

‘To be the premier manufacturer of mobility systems for the productive world by harnessing and nurturing

peoples’ abilities.’

1.2.2 Mission of the Loadstar pvt Ltd

‘We will manufacture quality and cost effective tyres, tracks and wheel systems effectively and efficiently for

our worldwide customers through empowered and self-driven teams, working together to improve our people,

company, society and environment.

1.3 Objectives

1.3.1 Services offered Loadstar pvt Ltd

Pneumatic tyres

Solid tyres

Wheels

Rubberized tracks

1.4 Management Practices

1.4.1 Recruitment procedures

Recruitment is the process of finding and attracting suitably qualified people to apply for job vacancies in the

organization.

Internal Recruitment Methods

1. Job posting and biding

2. Skill Inventories

3. Intranet

4. Succession Planning

- 4 -

External Recruitment Methods

1. Pre applicants

2. Universities

3. Educational Institutes

1.4.2 Overtime payments

The method of calculation of overtime per hour = Monthly Salary x 1.5 / 240

The Wages Board Ordinance

A normal working week cannot exceed 48 hours

All work over and beyond that period is considered overtime.

A maximum of 12 hours of overtime per week is permitted.

If an overtime rate has been pre-determined, then it should be one-and-a quarter times the rate

normally applied to such work.

Holidays with or without pay must be granted on a day within a specified number of days.

In the case of any special class of workers, payment for their work must be not less than one and a

half times the normal rate, without a substitute holiday.

1.4.3 The Shop and Office Employees Act

The period of work for a day is eight hours, and for a week it is forty five hours. Therefore any additional hours

of work is considered overtime. However this provision is not applicable to managers and executives in a

public institution

1.4.4 Types of Leave

There are three types of leaves that are taken by the employees. In Loadstar(Privet)Limited following amount

of leaves can be taken per year.

Annual leaves-14 Days per year-Must informed previously and leave form must be submitted.

Casual leaves-07 Days per year-Must informed previously and leave form must be submitted.

Sick leaves-07 Days per year-If leave period is exceed 03 days at a instance a medical certificate must

attached to the leave form.

- 5 -

1.4.5 EPF

The Employees Provident Fund division was established in 1959 to facilitate administration of the Employees

Provident Fund Scheme (EPF) that came into operation consequent to the enactment of Employees Provident

Fund Act No.15 OF 1958.

The EPF scheme basically covers almost all the employees in the private sector and the corporation sector.

The main objective of this scheme is to provide social security or protection to employees at old age invalidity,

or their dependents after death.

This is a contributory social security scheme where the employees and employers contribute 8% and 12%

respectively, of the monthly total earnings of the employee.

The Commissioner of Labor is responsible for the general administration of the scheme, while Monetary Board

of the Central Bank of Sri Lanka is responsible for the maintenance of individual accounts of the members and

investment of funds.

1.4.6 ETF

The Employees’ Trust Fund was established on 1st March 1981 under the provisions of ETF Act No. 46 of

1980.

The Fund is administrated by the Employees’ Trust Fund Board and at present the ETF Board is functioning

under the Ministry of Finance. The provisions of the Act shall apply to every state & private sector undertaking

belonging to any class or category of state or private sector undertaking as is specified in an order made by

the Hon. Minister and published in the Gazette. Self-employed persons and migrant workers also could

contribute to the Fund on their own and obtain membership. At present the active membership of the fund is

approximately 2.1 Million and covered by 60,000 employers. The value of the members fund was about

Rs.135 Billion as at 31st December 2011.

To decentralize the ETFB activities and to provide a better service to its members the ETFB introduced a

Branch Network in 1995.

- 6 -

TRAINING EXPIRIENCES

2.0 INDUSTRIAL ELECTROINC DEVICES

2.1 Pressure

2.1.1 Pressure Sensors

We reinstalled pressure sensors in Endless rubber track press in Track Division on 01.10.2013. By our

maintenance team, Mr. Ajith, Mr. Anjana and me under the supervision of Engineering Manager, Mr.

Dayananda. He explained that how to install and how is work this sensor.

First of all, current supply for the controlling circuit was disconnected and carefully removed the sensor.

Today many measuring principles are used in electronic pressure measurement instruments. Most methods

are based on the measurement of a displacement or force. In other words, the physical variable “pressure”

has to be converted into an electrically quantifiable variable. Unlike mechanical pressure measuring methods,

this conversion requires an external power source for the pressure sensor. Which converts mechanical signal

into electrical signal and that electrical signal can convert to the electronic signal. Therefore, it can transmit to

the control unit by using communication media. We can use Ethernet or intranet system.

This pressure sensor is the basis of electronic pressure measurement systems. While mechanical gauge

element displacements of between 0.004 and 0.012 inches are standard, the deformations in electronic

pressure sensors amount to no more than a few microns. Thanks to this minimal deformation, electronic

Fig. 2.1.1

- 7 -

pressure measurement instruments have excellent dynamic characteristics and low material strain resulting in

high resistance to alternating loads and long-term durability.

Listed below are pressure sensor technologies used in its transmitter, transducer and sensor instruments:

Ceramic Thick Film Sensor (top left and top middle images)

LVDT (Linear Variable Differential Transformer) Sensor

Piezoresistive (Piezo) Sensor (center and center right images)

Thin Film Sensor (bottom left, bottom middle and bottom right images)

A wide range of robust mV/V, mA, VDC and HART-compatible melt pressure sensors (transducers and

transmitters) designed specifically for the harsh, rugged environments of the extrusion and polymer

processing industries. Pressure sensing is to draw upon lead the industry in innovation, precision, quality and

reliability. Melt pressure transducers and transmitters deliver superior performance because of their field-

proven diaphragms which can be protected from abrasion and corrosion by suitable coating.

Most of pressure transducers and transmitters can have temperature sensors built in, permitting absolute (vs.

software) temperature compensation and improving accuracy dramatically by reducing pressure-reading drift

due to ambient and process temperature changes.

From specifying various diaphragm materials to accommodating different port configurations and process

connections. We manufacture a variety of instruments including dependable, user-friendly indicators, controls

and signal conditioners for pressure and temperature monitoring applications.

2.1.2 Pressure Transmitters

Pressure Transmitters, a sub-group of pressure transducers, feature

additional reset and calibration options. With some sensor types it is

possible, for example, to re-set the measuring span over large

ranges. This calibration option is usually referred to by such terms as

“scale down”, “span reset” or “turn down”. For instance, a transmitter

with a measuring range of 0 to 400 psi and a range reset 1/10 can be

calibrate to a measuring range of 0 - 40 psi while still giving a full

output signal (4 - 20 mA, for example).

Fig. 2.1.2

- 8 -

It is also possible to shift the zero point over a wide range and to calibrate the damping of the output signal

between 0 and 32 seconds. Some smart transmitters also have logging capabilities, can be calibrated, tested

and reset via the control desk or hand terminals.

Transmitters are often used in process applications where they can be combined with various chemical seals.

2.1.3 Pressure Transducers

Pressure transducers are an advanced form of the pressure sensor element. The simplest form of an

electronic pressure measurement system is the pressure sensor. It is the pressure sensor which changes the

physical variable “pressure” into a quantity that can be processed electronically. A pressure transducer is the

next level of sophistication. In a pressure transducer, the sensor element and housing are in electrical contact

and have a pressure connection.

Typical output signals from pressure transducers are between 10 mV and around 100mV, depending on the

sensor type. These signals are not standardized, however, nor are they compensated. With thin-film type

pressure transducers it is customary for just the sensor element to be welded to the pressure connection and

then bonded electrically. Piezoresistive pressure transducers, on the other hand, require far more production

steps since the semiconductor sensor element has to be protected from the effects of various media by a

chemical seal.

Fig. 2.1.3

- 9 -

2.2 Temperature

2.2.1 Temperature Controllers

We reinstalled temperature controller of the mould in Track Division on 30.09.2013. By our maintenance team,

Mr. Ajith, Mr. Anjana and me under the supervision of Engineering Manager, Mr. Dayananda. He explained

about how to install and how to work and controlling of the TC. And also, were had repaired display of this

controller.

First of all, current supply for the controlling circuit was disconnected and carefully removed from thermo

couple.

Temperature controller is an instrument used to control

temperature. The temperature controller takes an input from a

temperature sensor and has an output that is connected to a

control element such as a heater or fan.

To accurately control process temperature without extensive

operator involvement, a temperature control system relies upon

a controller, which accepts a temperature sensor such as a

thermocouple or RTD as input. It compares the actual

temperature to the desired control temperature, or set point, and

provides an output to a control element. The controller is one part of the entire control system, and the whole

system should be analyzed in selecting the proper controller. The following items should be considered when

selecting a controller:

Type of input sensor (thermocouple, RTD) and temperature range

Type of output required (electromechanical relay, SSR, analog output)

Control algorithm needed (on/off, proportional, PID)

Number and type of outputs (heat, cool, alarm, limit)

2.2.2 Resistance Temperature Detectors - RTDs

Resistance Temperature Detectors (RTD), as the name implies, are sensors used to measure temperature by

correlating the resistance of the RTD element with temperature. Most RTD elements consist of a length of fine

coiled wire wrapped around a ceramic or glass core. The element is usually quite fragile, so it is often placed

inside a sheathed probe to protect it. The RTD element is made from a pure material whose resistance at

various temperatures has been documented. The material has a predictable change in resistance as the

temperature changes; it is this predictable change that is used to determine temperature.

Fig. 2.2.1

- 10 -

Common Resistance Materials for RTDs:

Platinum (most popular and accurate)

Nickel

Copper

2.2.3 Thermocouple sensors

A thermocouple is a sensor for measuring temperature. It consists of two dissimilar metals, joined together at

one end. When the junction of the two metals is heated or cooled a voltage is produced that can be correlated

back to the temperature. The thermocouple alloys are commonly available as wire.

A thermocouple is available in different combinations of metals or calibrations. The four most common

calibrations are J, K, T and E. There are high temperature calibrations R, S, C and GB. Each calibration has a

different temperature range and environment, although the maximum temperature varies with the diameter of

the wire used in the thermocouple. Although the thermocouple calibration dictates the temperature range, the

maximum range is also limited by the diameter of the thermocouple wire. That is, a very thin thermocouple

may not reach the full temperature range.

Thermocouple measures in wide temperature ranges and can be relatively rugged; thermocouples are very

often used in industry.

The following criteria are used in selecting a thermocouple:

Temperature range

Chemical resistance of the thermocouple or sheath material

Abrasion and vibration resistanceInstallation requirements (may need to be compatible with existing

equipment; existing holes may determine probe diameter)

Fig. 2.2.3

- 11 -

2.3 Time

2.3.1Timers and Counters

We installed twin timer into motor controlling circuit on behalf of water level controller in Track Division on

07.10.2013. By our electrical maintenance team, Mr. Ajith, Mr. Anjana and me under the supervision of

Engineering Manager, Mr. Dayananda. He explained that how to install, how to work this timer and how to

program.

There are two kinds of equipment such as timers and counters. They are getting mostly same output. Also, we

used NE555 IC for counter or timer functions. There are two types of timers, like that digital and analogue.

Also, it can use in multi range.

Up counters and down counters are the types of counters. We used them in various motor applications in our

training.

2.3.1.1 Multi Range Digital Timer

Characteristics:

7-segment-display for clear display and effective monitoring

Protection against power surge and high frequency

interference

9.99 second~9990 hour time range

2 modes selectable via a slide switch: Mode A (2C) for

DPDT time-limiting output contacts and Mode B (1A 1C) for

SPDT instantaneous and time-limiting output contacts

External pause contact available on G type

2.3.1.2 Twin Analogue Timer

Fig. 2.3.1.1

Fig. 2.3.1.2 (a) Fig. 2.3.1.2 (b)

- 12 -

Characteristics:

Customized CMOS IC for low power consumption, high operation stability and extreme timing

accuracy

Independent adjustment for continuous ON-OFF operation and time

16 different time ranges available

2 operating voltage in a single unit, AC110V and 220V

5(A, B, C, D, E) timing series available

Each timing series has 4 time ranges selectable via DIP switch

2.3.1.3 Counters

Characteristics:

Counter or Timer function selectable

Scroll-through menu for all parameters

Proximity and photoelectric switches compatible

High-speed response allows 10k counts per second

Online change of set value possible

4 levels of key protection provided

Memory function available

3 user selectable mode: Count Up, Count Down and Count Up/ Down.

Fig. 2.3.1.3

- 13 -

2.4 Location Reading

2.4.1 Proximity Sensors

We installed new proximity sensors mould press in Track Division on 21.10.2013. By our maintenance team,

Mr. Ajith, Mr. Anjana, Mr. Chintaka and me under the supervision of Engineering Manager, Mr. Dayananda.

He explained that how to install and how is work this sensor.

First of all, we identified the critical places and installed obstacles for sensing role.

Proximity sensors detect the presence of objects without physical contact. Typical applications include the

detection, position, inspection and counting on automated machines and manufacturing systems. They are

also used in the following machinery: packaging, production, printing, plastic molding, metal working, etc.

And also, Proximity Sensors are available in models using high-frequency oscillation to detect ferrous and

non-ferrous metal objects and in capacitive models to detect non-metal objects. Models are available with

environment resistance, heat resistance, resistance to chemicals, and resistance to water.

There are various types of sensors like inductive, capacitive, magnetic, photoelectric sensors…. Etc.

Table. 2.4.1

- 14 -

2.4.2 Inductive Sensors

Inductive proximity sensors detect the presence of metallic objects.

Their operating principle is based on a coil and high frequency

oscillator that creates a field in the close surroundings of the

sensing surface. The presence of metal in the operating area

causes a change in the oscillation amplitude. This change is

identified by a threshold circuit, which changes the output of the

sensor. The operating distance of the sensor depends on the coil’s

size as well as the target’s shape, size and material.

2.4.3 Capacitive sensors

Capacitive sensors are used for non-contact detection of metallic objects & nonmetallic objects (liquid, plastic,

wooden materials and so on). Capacitive proximity sensors use the variation of capacitance between the

sensor and the object being detected. When the object is at a preset distance from the sensitive side of the

sensor, an electronic circuit inside the sensor begins to oscillate.

The rise or fall of such oscillation is identified by a threshold

circuit that drives an amplifier for the operation of an external

load. A screw placed on the backside of the sensor allows

regulation of the operating distance. This sensitivity regulation is

useful in applications, such as detection of full containers and

non-detection of empty containers.

Fig. 2.4.2

Fig. 2.4.3

Table 2.4.3

- 15 -

2.4.4 Photoelectric sensors

Photoelectric sensors use light sensitive elements to detect objects and are made up of an emitter (light

source) and a receiver.

2.4.4.1 Photoelectric sensor types

Direct Reflection (Diffused):

Emitter and receiver are housed together and use the light reflected directly off the object for detection.

Reflection with Reflector (Retro-reflective):

Emitter and receiver are housed together and require a reflector. An object is detected when it interrupts the

light beam between the sensor and reflector.

Through Beam:

Emitter and receiver are housed separately and detect an object when it interrupts the light beam between the

emitter and receiver.

Fig. 2.4.4

Fig. 2.4.4.1 (a)

Fig. 2.4.4.1 (b)

Fig. 2.4.4.1 (c)

- 16 -

3.0 CNC VERTICAL LATHE MACHINE

I trained in CNC section from 31.10.2014 to 31.12.2014. In this period, I could experience in electronic equipment and there applications in CNC machines under the supervision of Engineer. Mr. Chintaka Balasuriya.

Our team was worked in very responsibly in every member such as supervisor Mr. Asanka, Mr. Anushka, Mr. Abawatta and including with me.

Chinese vertical lathe machine was repaired and reinstalled some components in this project.

This following solid works diagram is the machine which we repaired.

This machine used for tapering or grilling metal plates of wheels. This was imported from china. This system was in Chinese language. Therefore we should have converted it into English. Also we had full repair servo drives. Mainly this has number of electronic equipment which we totally repaired.

1. Spindle Drive2. Servo Drives3. Switch mode power supply (110 V)4. Control panel

Servo motors

Spindle

Spindle Motor

Fig. 3.0

- 17 -

And also, the several steps were done in this project perhaps repair the above components. They are,

1. Reinstalled power and control power circuit panel2. Repaired spindle motor and reinstalled its’ bearings3. Checked and repaired limit switches and proximity sensors4. Rebuild the system for production5. Programmed the system

3.1 Variable Speed Drives - VFD

Variable Speed Drives (often known as AC Drives or Inverters) they are most often used to control standard ‘squirrel cage’ motors which are widely used as the workhorse of industry. Standard inverters (using simple open loop control) are used in the majority of

VSD applications such as pumps, fans and mechanical handling devices.

High performance drives with superior speed holding and dynamic response (often called "Flux Vector" drives) are available for more demanding applications such as Machine Tool Applications, chemical and plastic processing, web handling and hoisting where torque control dynamics and speed holding are more critical.

Many VSDs have communication capabilities which enable information from the drive to be accessed remotely over a network such as Profibus or Can Bus etc.., thereby simplifying maintenance and diagnostic procedures. Other applications may require special features such as precise position.

In this project, we used Delta VFD – B spindle drive and Washing – SPM – 3400 Servo Drives for above purpose.

3.2 Delta VFD – B spindle drive

This is sensor less Open and Closed Loop Vector AC Drive. The VFD-B series represents Delta's NEMA1 general purpose AC drive. The VFD-B series drive is rated to provide constant torque, featuring open and closed loop vector control. Although, this drive offers an optional 2000 Hz high speed output that can be factory programmed at the what we necessary.

And also we can use these drives for Air conditioners for large buildings; woodcarving machine; punching machine; wastewater treatment systems; crane drive and swivel; washing machine; vertical stamping machines; compressor; elevator; escalator; circular loom; flat knitting machine; pasta machine; four-sided woodworking planer, etc.

Fig. 3.2 (a)

- 18 -

Specifications:

Output frequency 0.1 ~ 400 Hz Adjustable V/f curve and vector control Master/Auxiliary and 1st / 2nd frequency source selectable 16-step speed control and 15-step preset speed process control Built-in PID feedback control Auto torque boost & slip compensation Built-in MODBUS communication, baud rate up to 38400 bps Support communication module (DN-02, LN-01, PD-01)

The connection diagram of the drive is following.

Fig. 3.2 (b)

- 19 -

Electronic Variable Speed Drives can produce variable frequency, variable voltage waveforms. If these waveforms are applied to the stator windings there will be a shift of torque-speed curve, maintaining a constant pull-out torque, and the same slope of the linear operation region of the curve. In this way, the motor speed is going to be proportional to the applied frequency generated by the VSD.

The adjustment of the motor speed through the use of VSDs can lead to better process control, less wear in the mechanical equipment, less acoustical noise, and significant energy savings. However, VSDs can have some disadvantages such as electromagnetic interference (EMI) generation, current harmonics introduction into the supply and the possible reduction of efficiency and lifetime of old motors.

We could vary the frequency for get required speed according to following graph.

The electrical inverter is a high-power electronic oscillator. It is so named because early mechanical AC to DC converters were made to work in reverse, and thus were "inverted", to convert DC to AC. In one simple

Fig. 3.2 (c)

- 20 -

inverter circuit, DC power is connected to a transformer through the centre tap of the primary winding. A switch is rapidly switched back and forth to allow current to flow back to the DC source following two alternate paths through one end of the primary winding and then the other. The alternation of the direction of current in the primary winding of the transformer produces alternating current (AC) in the secondary circuit.

The electromechanical version of the switching device includes two stationary contacts and a spring supported moving contact. The spring holds the movable contact against one of the stationary contacts and an electromagnet pulls the movable contact to the opposite stationary contact. The current in the electromagnet is interrupted by the action of the switch so that the switch continually switches rapidly back and forth.

The switch in the simple inverter described above produces a square voltage waveform as opposed to the sinusoidal waveform that is the usual waveform of an AC power supply. Using Fourier analysis, periodic waveforms are represented as the sum of an infinite series of sine waves. The sine wave that has the same frequency as the original waveform is called the fundamental component. The other sine waves, called harmonics, that are included in the series have frequencies that are integral multiples of the fundamental frequency.

The quality of the inverter output waveform can be expressed by using the Fourier analysis data to calculate the total harmonic distortion (THD). The total harmonic distortion is the square root of the sum of the squares of the harmonic voltages divided by the fundamental voltage:

The quality of output waveform that is needed from an inverter depends on the characteristics of the connected load. Some loads need a nearly perfect sine wave voltage supply in order to work properly. Other loads may work quite well with a square wave voltage.

3.3 Washing – SPM – 3400 Servo Drives

SPM-3400 serials of AC servo driver are a set of fully digital AC servo system having mainly adopted Special motion control chip (DSP), extensive Field Programmable Gate Array (FPGA) and Intelligent Power Module (IPM), etc.

SPM-3400 has a series of virtues such as high integration level, small volume, fast response speed, complete protection, high reliability, simple installation, etc. It is very suitable for the field of industrial automatic control such as high-accuracy numerical control lathe, automatic product line, machine building, etc. Comparing with past driver, the SPM-3500 AC servo system has advantages as the followings:

1. Simple and flexible controlThrough modifying the parameters of the servo driver, can choose the work mode of the servo driver system, in order to meet the requirements of different applied environment.

2. Complete status displaySPM-3400 has a series of information for status display, helping users look over the relevant state parameters of the servo driver in the course of debugging and running; meanwhile, also offers a series of trouble diagnostic message.

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3. Wide range of speed (relate to the motor and feedback components) SPM-3400 servo system has the maximum speed with 3000rpm and the minimum speed with 0.5rpm, the speed range is about 1:6000.

4. Small volume, easy to installSPM-3500 servo driver: compact structure, small volume, very easy to install and dismantle.

5. Avoid losing stepThe photoelectric encoder of servo driver sends position feedback signal into the servo driver, form the closed loop control system.

Basically, this has control circuits and power circuit. In our project, we had repaired IPM (Integrated Power Module) of the power circuit. New industrial and appliance motor drives have become more advanced in performance and more compact in size. This is largely due to advancement in power silicon technology, such as IGBTs (Insulated Gate Bipolar Transistors) and high-voltage integrated circuits (HVICs).

Fig. 3.3

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3.4 IGBTs

IGBT means Insulated Gate Bipolar Transistor. Gate-drive circuits are implemented in enhanced voltage CMOS with supply rail up to 25 V and provide necessary gate-drive voltage to the IGBT. Analog and digital circuit blocks are implemented in BiCMOS. The circuit library includes pulse-width modulator (PWM), voltage control oscillator, precision sense amplifier, fast fault comparator and other power conversion control functions.

3.5 IPM – Integrated Power Module

This component mainly consists of IGBTs. We experienced and repaired IPM in power card in servo drives in our project.

An integrated power module processes power according to the information content at the control interface. Functions that are covered by integrated power modules include power supply bus types, passive components integrated into the bus and passive components integrated into the load, among others. An integrated power module provides the physical containment package for several power components, usually Power semiconductor devices. Examples of power module structures are a switch (MOSFET, IGBT) with antiparallel diode, half bridge (inverter leg with two switches and their corresponding diodes) or three-phases inverter (six switches and the corresponding diodes).

Fig. 3.4

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Integrating industry benchmark three-phase high voltage ICs and rugged trench IGBTs in a sleek and innovative single in-line package (SIP), IR’s intelligent power modules (IPMs) deliver a complete power stage solution for today’s energy-efficient appliance and light industrial equipment driven by variable speed motors ranging from 400W to 2500W.

3.6 CNC Control Panel - GSK928TEa Turning CNC System

This is the main controlling panel in CNC machine. We can program and operate the machine according to our program. We replaced the control panel GSK928TEa Turning model on behalf of Chinese system in our project.

Fig. 3.5

Fig. 3.6 (a)

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Above figure is our imported and reinstalled GSK 928TEa Turning CNC system panel.

The pin configuration of the control panel is shown in below.

3.7 Program Structure of CNC Machine

CNC command set edited according to the requirement of machine moving is named as program. According to the sequence of command, the tool traverses along the straight line and the circular arc, or the spindle starts/stops, cooling is ON/OFF. The sequence of command is edited according to the technology requirement of work piece.

Character

Character is the basic unit to compose the program. The character includes English letters, digits and other signs. English letters are address character of each command or data,

D E F G H I J K L M N P Q R S T U V W X Y Z r

Digit is the specific data of each address character: 0，1，2，3，4，5，6，7，8，9

Fig. 3.6 (b)

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Macro : If then else and or = < > （）

If then else: select statement； example: If(x>y) then (z=0 ) else(z=1)；and ：logic and ; or ：logic or ;

> ：more than < ：less than = ：equal to Sign：% - + * . ㄩ /

% ：start sign of program name — ：negative data or reduction

+ ：addition * ：multiplication or modification

. ： decimal point ; ： comment

/ ： division in assignment statement, block skip sign in others ㄩ: blank space.

Block

A word consists of an address character and the following numerical command. For example: N000 12.8 W-23.45.

Block Number

Block number is divided into two formats, i.e. it is with line number and without line number; block number is a line number of block number which is automatically created and also manually input and modified. A block number consists of the letter N and the following 4-digit integer (range: 0000-9999). Block sequence can be at will, its interval also can be unequal. It is suggested that the block number should increase or decrease progressively based on programming sequence in order to conveniently search or analysis programs.

When manual input is executed, block number N * * * * (* is 0～9) is directly input at the beginning of program line. When the integer following block number N is modified, please refer to the block content modification mode in OPERATION 4.1 Edit Operation Mode to modify the integer of block number.

When automatically creating a block number is executed, and P333 is not set to 0, the line number can automatically create, otherwise, it cannot create automatically the line number. Please refer to OPERATION 4.6 Parameter Operation Mode about parameter setting; each program includes many blocks, and each block begins with block number“ N**** ”. after a new program is created, the system automatically creates the first block number “ N0000 ” , and after each block is input to press ENTER, the system automatically creates the next block number. The program number increment is defined by P333 content. The system automatically creates block number for increment according to ¼ integer of P333 content.

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In programming CNC system, we have to use variours commands for get our functions. Mainly there are several commands and functions such as MSTF commands and G commands of their functions.

3.8 MSTF Commands and Functions

M — Miscellaneous Function (Command List)

M function is used to control some operations ON/OFF of machine and run sequence of machine program, and consists of address symbol M and its following two-digit integer.

Examples :

M00 Pause to wait for starting

M02 End of program

M20 End of program machine, L being cycle machine times

M30 End of program for spindle OFF and cooling OFF

M03 Spindle CW

M04 Spindle CCW

S function — Spindle Function

S and the following data are used to controlling the spindle speed and there are two modes as follows:

1) Spindle speed switch value control mode: Sx or Sxx, the system outputs the gear signal to the machine to realize the gear change of spindle speed.

2) Spindle speed analog voltage control mode: Sxxxx specifies the actual speed, and outputs 0~10V analog voltage signal to spindle servo device or converter to realize the spindle speed change.

T function — Tool Function

Machining one workpiece needs several different tools. The motor tool post with 4～8 tool selections can be controlled by the system. To avoid the error caused by the installation or the wear and tear, each tool is placed in the different position when it is cutting the workpiece, the tool change and the tool compensation are employed in the programming.

Toolsetting operation is executed before machining receives the position offset data of each tool(called as tool offset). T command is executed in program running, the system automatically executes the tool offset. So, each tool in programming according to the workpiece drawing dimension is compiled instead of considering the position among each tool in the machine coordinate system. The deviation of machining dimension caused by tool wear can be changed according to the dimension deviation to modify the tool deviation.

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F function — Feedrate Function

It defines the feedrate of tool function i.e. the feedrate function(G98/G99, F command).

3.9 G Commands and Functions

G00 —Rapid Traverse (Positioning)

G01 — Linear Interpolation

G02, G03, G05 —Circular Chamfering Function

G33 —thread cutting

G34 — variable pitch thread cutting

G32 —Tapping Cycle

G50 — Setting a Workpiece Coordinate System

G51 — Recovering Workpice Coordinate System Setting

G26 — X, Z, Y Reference Point Return

G28 — Return to Machine Zero(Machine Reference Point)

G30 — 2nd, 3rd Program Reference Point Return

G04 — Dwell

G96 —Constant Surface Speed Control

G97 —Constant Surface Speed Cancel

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4.0 GENERATORS

We went for a preventive maintenance in power generator (2 kVA) in ETD – I on 20.01.2014. Our team was

supervised by Junior Engineer Mr. Nuwan Liyanage and conducted by number of electricians, Mr. Shantha,

Mr. Sarath, Mr. jude, Mr. Nandasena and me.

Brand of the generator - STAMFORD

On that occation, we had deassembled the generator and done meggar testing for windings of stator. Then we

reinsulated the winding by spraying warmish.

A three area power system with Generation Rate Constraints (GRC) nonlinearity and a four area power system without GRC nonlinearity are considered. Load frequency and voltage control problems are studied with Automatic Generation Control (AGC) and Automatic Voltage Regulator (AVR) respectively using PID and fuzzy logic controllers for these Multi Area Power Systems (MAPS).

4.1 AVR – Automatic Voltage Regulator

It is a three phase sensed Automatic Voltage Regulator and forms part of the excitation system for a brush

less generator. Excitation power is derived from a three-phase permanent magnet generator (PMG), to isolate

the AVR control circuits from the effects of nonlinear loads and to reduce radio frequency interference on the

generator terminals. Sustained generator short circuit current is another feature of the PMG system.

The AVR senses the voltage in the main generator winding and controls the excitation to maintain the

generator output voltage within the specified limits, compensating for load, speed, temperature and power

factor of the generator. Three phase RMS sensing is employed for superior voltage regulation.

Fig. 4.0

- 29 -

Adjustable Soft start circuitry is included to provide a smooth controlled build up of generator output voltage. A

frequency measuring circuit continually monitors the shaft speed of the generator and provides under-speed

protection of the excitation system by reducing the generator output voltage proportionally with speed below a

pre-settable threshold. A further enhancement of this feature is an adjustable volts per Hertz slope and

voltage recovery time, to improve the response of turbo charged engines.

Current limiting may be included to allow control over the amount of sustained short circuit current. Maximum

excitation is limited to a safe period by internal shutdown of the AVR output device. This condition remains

latched until the generator has stopped.

The AVR includes an over-voltage protection feature with internal shutdown of the AVR output device, plus

the ability to trip an optional excitation circuit breaker if required. Provision is made for the connection of a

remote voltage trimmer, allowing the user fine control of the generator's output. An analogue input is provided

allowing connection to a Newage Power Factor controller or other external device.

4.1.1 Main functions of AVR

Potential Divider and Rectifier takes a proportion of the generator output voltage and attenuates it. The

potential divider is adjustable by the AVR Volts potentiometer and external hand trimmer (when fitted). The

output from the droop CT is also added to this signal. A rectifier converts the a.c. input signal into a d.c. signal

representing generator voltage.

The DC Mixer adds the Analogue input signal the generator voltage signal. The 3 Phase Rectifier converts the

output of the current limit CT’s into a dc signal representing generator current.

Fig. 4.1

- 30 -

The Amplifier (Amp) compares the generator voltage or current signals to the Reference Voltage and amplifies

the difference (error) to provide a controlling signal for the power devices. The Ramp Generator and Level

Detectorand Driver infinitely control the conduction period of the Power Control Devices and hence provides

the excitation system with the required power to maintain the generator voltage within specified limits.

The Stability Circuit provides adjustable negative ac feedback to ensure good steady state and transient

perform The Low Hz Detector measures the period of each electrical cycle and causes the reference voltage

to be reduced approximately linearly with speed below a presettable threshold. The Dip and Dwell circuits

provide adjustments for greater voltage roll off and recovery time. A Light Emitting Diode gives indication of

underspeed running.

The Synchronising circuit is used to keep the Ramp Generator and Low Hz Detector locked to the Permanent

Magnet Generator waveform period.

Power Control Devices vary the amount of exciter field current in response to the error signal produced by the

Amplifier.

The Circuit Breaker provides circuit isolation of the control system in the event of an over excitation or over

voltage condition.

The Over Excitation Detector continuously monitors the exciter field voltage and turns off the power device if

this rises above the reference leve,l for greater than the stated time period. An external signal is also provided

to trip the Circuit Breaker.

The Over Voltage Detector continuously monitors the generator stator voltage and turns off the power device

if this rises above the reference level, for greater than the stated time period. An external signal is also

provided to trip the Circuit Breakerance of the control system.

The Power Supply provides the required voltages for the AVR circuitry.

Fig. 4.1.1

- 31 -

4.2 AGC – Automatic Governer Controller

When a generator and its prime mover (a combustion engine in our case) are connected to a system in

parallel with many other prime movers and their generators, the frequency of the generator (and the speed of

the combustion engine) are fixed by the system. The system regulators are, or should be, controlling the

amount of generation on line to be equal to the amount of load on line (the motors, lights, computers and

monitors). The amount of generation must be equal to the amount of load for the frequency to be at rated. So,

when our CHP is on line with other power generators, the speed of our generator and prime mover (and the

frequency of our generator) are not controlled by the engine control system or even the PMS; the speed and

frequency are controlled by how well the system regulators match generation and load.

System regulators will use AGC to remotely increase and decrease generation of several, or even many,

generators in order to make the amount of generation equal to the load. Usually, when AGC is active the

system regulators have control of the fuel--and, hence, the load--of the combustion engines. They are raising

and lowering loads of prime movers and generators as motors are started and stopped, and lights are turned

off and turned on, and as computers and monitors are being used or turned off.

AGC is something that is usually the "master" or off; it's not something that's usually operated in conjunction

with some other control mode, because the system regulators are using AGC to balance generation and load

and they don't want their commands to be over-ridden because they are trying to control frequency.

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5.0 POWER AUGMENTATION PROJECTS

I trained in several power augmentation projects in Loadstar under the supervision of Engineering Manager

Mr. Sheron. In this projects, I have number of responsibilities such as preapairing the existing layout of

electrical distribution of relevant factory, designing the proposal of electrical wiring diagram, prepairing BOQ ...

etc. We drawn electrical diagrams by using Microsoft visio software.

There were two projects, which I worked.

1. Power augmentation project in CMP

2. Electrical installation project for main power distribution in ETD – I

5.1 Power augmentation project in CMP

There factory using 3500 kVA load package from CEB. Althogh, the factory needed increase the package

upto 5000 kVA. Therefore, we had to proove our power consumption in more than 80% of 3500 kVA.

For the achive of that purpose, first of all we calculated the total power consumption of the CMP including

lights, motors, AC machines, computers… etc.

Then sketched out the existing distributing wiring diagram of electrical power. It would be as follows:

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Fig. 5.1 (a)

- 34 -

The other purpose of this project was connecting new power generator for selected mixer line or lines. We

proposed two lines for that. The single line diagrams are attached in below.

Fig. 5.1 (b)

- 35 -

5.2 Electrical installation project for main power distribution in ETD – I

We implemented this project on 26.02.2014 in ETD- I factory with Junior Engineer Mr. Nuwan Liyanage, under

the able guidance of Head in Electrical division in ETD- I, Engineering Manager Mr. Bandara and under the

supervision of Engineering Manager, Mr. Sheron.

We used SIEMENS brand for most of electrical equipment.

First of all, we prepaired action plan for this task.

5.2.1 Action Plan

Task Target DateTime

Duration

1. Study the arrangement of existing cable connections 26.02.2014 4 hours

2. Draw the wiring diagram of existing electrical installation 27.02.2014 4 hours

3. Draw the wiring diagram of proposed electrical installation 27.02.2014 4 hours

4. Prepare the BOQ for the project 28.02.2014 4 hours

Then, we prepaired the single line diagram and BOQ for proposed Auto Change ATS Panel with under the great guidance of Mr. Sheron and Mr. Nuwan.

Table 5.2.1

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5.2.2

Fig. 5.2.2

- 37 -

5.2.3 BOQ - Requirement for supplying Auto Change ATS Panel for Loadstar ETD – I

Item No

Description Specifications Qty Rate Amount

1.

3200 AACB

Brand - SIEMENSModel - 3WT8326 - 5UA34 – 5AB24 PoleWithdrawable typeFront Connection

4Nos

2.

1600 AACB

Brand - SIEMENSModel - 3WT8326 - 5UA34 – 5AB24 PoleFixed mounted typeFront Connection

4Nos

3.

Bus BarsCopper 99.9%(Purity)Current carrying capacity should be 3200 A minimum

4.

Enclosures

Outdoor application (IP 54)Powder coating thickness - 100 ± 20% µmMaterial – ZnAl Sheet steelColor – Powder coated to RAL 7032 (beige)Sheet thicknessSide cover, Door, cover plate – 1.5 mmMounting plate – 2 mmFree standing – Structure, Door, Cover plate,Side covers – 1.5 mm

Item

5.Power Analyzer Brand – CIRCUTOR

Model – CVM – NRG968

Nos

6. PFR Brand – ANLYModel – AEVR

4Nos

7.Panel Lamp Reputed

2Nos

8. Emergency Stop Push Button

Reputed 2Nos

9.Indicator Reputed

2Nos

10. Current Transformer Brand – HOBUT 24Nos

11.

Bus coupler

Brand - SIEMENSModel - 3WT8326 - 5UA34 – 5AB24 PoleWithdrawable typeFront Connection

1Nos

Table 5.2.3

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6.0 Safety Methods

6.1 Introduction

Safety is an important factor in the workshop. If we learned work, it means we must be able to do work in safe

way. Any unsafe way was wrong. In the training to work we should learn how to work without hearting

ourselves or our fellow workers.

Unsafe Functions

There are two types of unsafe functions.

Unsafe Acts

Unsafe Conditions

Unsafe Acts

Sometimes workers are not wear leather gloves in the working.

Sometimes workers are carried heavy loads without using forklifts.

The workers did not wear helmets in the workshops.

The workers did not wear belts climbing high roofs.

Unsafe Conditions

Some floor areas are slipping.(Leakages with hydraulic units.)

Forklifts are not well managed.

Bad workshop keeping.

Using old machines.

Using uncovered machines.

I supposed 70% of industrial accidents can be avoided with consider about unsafe acts and unsafe

conditions. Therefore try to minimize industrial accidents using good safety procedure.

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6.2 Fire Safety

Safe is a fire is an important factor in the workshop. Fire can be burnt of whole workshops. Therefore safety

with fire is very important. A fire is caused by a combination of the following factors.

A combustible materials

A sufficiently high temperature

Oxygen

6.3 Workshop Keeping

Workshop keeping is a very important factor in the engineering field. Tidy factory is a safe place to work.

Untidy workshop is a hazard place to work. Good workshop keeping means place for everything in its place.

Good workshop keeping helps to prevent accident and saves lives.

6.4 Safety Signs

All Safety related signs on the company premises conform to internationally reorganized standards with

regard to size color and text.

Water - Green Pneumatic - Light Blue Fire Hydrant - Red Oil - Brown Gas - Yellow Flammable liquids - Brown Acid - Violet Nasty - Black

6.5 Safety Rules at Loadstar (Pvt) Ltd

All accident and occupational illness must be reported immediately to the safety department.

Where specified, personal protection gear (PPE) must be worn. Safety goggles must be worn when caring out the following operations. Grinding, lathe work, handling chemicals, and all situations when listed in safety procedure. Mask should be worn specially in mixing area, sand blasting area and white tyre cleaning area.

Smoke is strictly prohibited in the factory premises.

Riding on forklifts, running or horseplay on company properly is strictly prohibited.

When operating machines and equipment, the relevant safety instructions must be followed at all times.

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Before commencing maintenance work on any plant or machinery, the power supply must be switch off at the isolator.

Do not use defective tools for any type of work. Report the failure to your supervisor immediately.

No one is permitted to report for work in possession of or under the influence of alcohol or drugs.

All waste must be placed in the receptacles provided. Keep your workplace clean at all time. Everyone is responsible for maintaining safety standards in factory.

Ensure that all guards and fences are in place in all rotating and moving machines and equipment.

Safety shoes or boots must be worn at all times where described in safety procedure or operation manual of the machine.

All employees must be fully charged properly serviced and tagged at all time and records maintain.

All employees must be trained in the use of all fire extinguishers and fully understand the proper use of them.

All employees must be known the emergency action at the fire drill.

The speed limit of the all vehicles 5Km/h at factory premises including forklift.

The unauthorized driving of company vehicles including forklift is strictly prohibited.

All flammable liquids must be stored in approved containers within the correct compounds and away from any source of ignition.

All compressed gas cylinders of acetylene welding gases must be stored with protection caps over the value. All oxygen acetylene tanks must be securely held in a cart or against the wall to prevent them from falling.

Unauthorized persons must not enter restricted area.

Gangways and fire gaps must be kept free from the obstructions.

Air hose must not be used for cleaning cloths or human body.

Warning of watches, rings, dangling jewelry or loose clothing is strictly prohibited in production areas.

Long hair should be suitable confined, when working, in all production areas.

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7.0 CONCLUSION

Familiarizing with the industrial environment is the most essential thing that an engineering student should

perform. After completing the engineering educations everyone’s ambition is to perform the career in good

working environment. But if we have not familiarized to the industry and just assigning to the career without an

industrial training during the study period, I believe that definitely we may not able to perform the task well.

Therefore, the ‘Industrial Training’ during the period of studies is the most vital object. Therefore I’m grateful to

the training division of Institute of Technology, University of Moratuwa for organizing such a valuable industrial

training program. I could know how to implement a project in proper manner. Also, I got more experience

about getting responsibilities, time managing and labour handeling.

I obtain the great opportunity under the training program that performed training at many projects. I obtained

the opportunity to involve with the maintenances, repairing, and troubleshooting of various types of

experiences. When performing that, I understood to some extent how to work with different persons who are

in different levels.

With the start of my training, Human Resources Management and Electronic and Electrical Engineering

Department of the Central Engineering Division of the Loadstar gave me a proper guidance to follow my

training program including appropriate training schedule and all the facilities required to perform the training

well. During the training the problem that I faced was the difficulties to contact the engineers for discussing the

technical problems that I needed to explain. The reason was the workload on the engineers was very high.

Nevertheless at those situations they made me the arrangements to such discussions at least with the Junior

Engineers and technicians with more experienced in the Loadstar pvt Ltd.

Actually I am thankful to the Industrial Training Division of Institute of technology University of Moratuwa

(ITUM) and National Apprentice and Industrial Training Authority (NAITA) for organizing this valuable

opportunities for us. Anyway it is better if they can arrange few presentations on how to select a training

establishment and give an idea about each establishment. For that they can ask from every establishment

which provides training opportunities to perform presentations about mentioning establishments work

procedure and the trainees’ role in it.

When considering my training program at Loadstar pvt Ltd, I am very much satisfied on it. Because of the help

and facilities I was given by them and the way they treated me as a trainee was outstanding. Such as in every

time they tried give experience about whatever nessesary for me. Also I believe in that the training period of

25 weeks may not enough to entirely complete studying all the main technical stuff. In other words, I got

overall training in Industrial Electronic field with Electrical practices.

- 42 -

Certification by the trainee

I certify that this Industrial Training progress report has been written by me, On the Industrial

Training Underwent during my Training period from 16.09.2013 to 16.03.2014.

Date: ……………………………....... Signature of student: ………………………………

(K. A. M. Kumara)

Certification by the officer-in-charge

Name : ………………………………………..............

Designation : ………………………………………………...

Signature of officer in charge : …………………………………....................

- 43 -

TRAINING SHEDULE

Name of Organization: Loadstar (pvt) Ltd

Address of Organization/ Worksite: Jinasena Industrial Park, 218, Minuwangoda Road, Ekala, Ja - Ela, Sri Lanka

Trainee’s Name with Initials: K. A. M. Kumara

Registration No: 10/ IT/ ET/164

Division/ Dept/Section

Areas of Training Received as per Training Guidelines

Duration

Electronic and Electrical Division in Midigama Tyre Division

Industrial Electronic devices (sensors, transmitters. Transducers, Timers and Counters) Electronic and electrical maintenance

16. 09. 2013 – 30. 11. 2013

Electronic and Electrical Department - CED

CNC machines, servo drives, servo motors, computer embedded systems and programming

01. 12. 2013 – 05. 01. 2014

Electronic and Electrical Department - CED

Voltage stabilizers, DC welding plants, Electronic devices troubleshooting and repairing (IPM, Fork lifts, amplifiers, filters)

06. 01. 2014 – 31. 01. 2014

Electronic and Electrical Department - CED

Motor controlling and troubleshooting, Power distribution, industrial electrical installations, transformers, generators

01. 02. 2014 – 16. 03. 2014

Signature of Trainee: …………………………… Date: …………………………………..

This is to certify that the trainee concerned received the training stated above.

Name of the Officer - in - Charge of Training: …………………………………………………………….

Signature: ……………………… Contact Telephone Number: …………………………….......

- 44 -

Notes: