Final BB 1420058-1 PDF

A Report on
INPLANT TRAINING AT WSGR PLANT,
Prepared & Submitted

By
RAHUL VINAYAK TAMHANKAR
Roll No.: 1420058
Under the Guidance Of

SHRI PRATIK PRAVIN SAWANT
Shri Vile Parle Kelavani Mandal’s

SHRI BHAGUBHAI MAFATLAL POLYTECHNIC
Department of Mechanical Engineering
Vile Parle (W), Mumbai-400056
TRAINING PERIOD
18th December 2017 to 2rd June 2018

NO OBJECTION CERTIFICATE
(To whomsoever it may concern)
This is to certify that Mr. Rahul Vinayak Tamhankar (Roll No: 1420058) a student
of Shri Bhagubhai Mafatlal Polytechnic, Mumbai has successfully completed his
VIII Semester Inplant Training from 18th december 2017 to 02 june 2018 in our
WSGR PLANT ENGINEERING (PC-1department) (Coil Winding) at Siemens
Limited,Kalwa Works.
His report does not contain anything which can endanger the secrecy and working
of our company and we have NO OBJECTION for the matters contained in his
Inplant training report.
Mr. Hemant Gaikwad
( Manager , WSGR, Siemens Ltd)
Date:
Place:
CERTIFICATE OF SUBMISSION
This is to certify that the report entitled ‘INPLANT TRAINING AT WSGR

PLANT, SIEMENS LIMITED, KALWA WORKS’ is a bonafide work of Rahul
Vinayak Tamhankar (Roll No: 1420058) & submitted in semester VIII for the
partial fulfillment of Diploma inMechanical Engineering at Shri Bhagubhai
Mafatlal Polytechnic, Mumbai during the academic year 2017-2018.
Internal Guide Head Of department Principal

Shri Vile ParleKelavani Mandal’s
CERTIFICATE OF APPROVAL
This is to certify that the report entitled ‘INPLANT TRAINING AT WSGR

PLANT,SIEMENS LIMITED, KALWA WORKS’ which is prepared and
submitted by Rahul Vinayak Tamhankar (Roll No: 1420058) in semester VIII for
the partial fulfillment of Diploma in Mechanical Engineering at Shri Bhagubhai
Mafatlal Polytechnic, Mumbai during the academic year 2017-2018 is
ACCEPTED & APPROVED
Internal Examiner External Examiner
Date:
Place:
DECLARATION
I, Rahul Vinayak Tamhankar Roll No: 1420058 a student of VIII Semester of

Diploma in Mechanical Engineering, humbly submit that I have completed from
time to time the Implant training work as described in this report by my own skills
and study from 18th december 2017 to 02 june 2018. I certify that I have not copied
the report or its any appreciable part from any literature in contravention of
academics ethics. I declare that this written submission represents my ideas in my
own words. I also declare that I have adhered to all principles of academic honesty
and integrity and have not misrepresented of fabricated or falsified any
idea/data/fact/source in my submission. I understand that any violation of the
above will be cause for disciplinary action by the Institute and can also evoke
penal action from the sources which have thus not been properly cited or from
whom proper permission has not been taken when needed. .
______________
Signature
RAHUL VINAYAK TAMHANKAR

(ROLL NO 1420058)
DATE:
PLACE:
ACKWOLEDGEMENT
I would like to express my sincere gratitude for the successful completion of my In

plant training at M/s SIEMENS LTD. (SWITCHGEAR WORKS) to all the
employees of organization for offering their help and valuable guidance. I would
specially like to thank Mr. HEMANT GAIKWAD (Manager, WSGR) for his
contribution, co-operation and guidelines which made my training period
knowledgeable and exciting. I would like to thank Mr. Sameer Ashtekar (HR
Associate )(Manager) for giving me an excellent opportunity to pursue In plant
training in such an esteemed and world class organization. Further I would like to
thank Mr. Sanjay Bhopatkar ,Mr. Shrikant Kupekar ,Mr. Anil Gophan, and Mr.
Abhishek Mishra, Mr. Aditya Mestri and Mr. Pramod Suryawanshi who have
constantly supported and extended their cooperation throughout my training
period.
I express my sincere thanks to my Guide Shri Pratik Sawant (Lecturer –

Mechanical Engineering Department) for his continuous encouragement and
guidance throughout my training period. I would like to express my sincere
gratitude toMr. Ashok Chore (Head of Mechanical Engineering Department) and
Mr. Umesh Kantute (Principal - Shri Bhagubhai Mafatlal Polytechnic) for
providing this wonderful opportunity and their valuable support for the successful
completion of this endeavor.
INDEX
CHAPTER TOPIC PAGE NO

NO
1 INTRODUCTION TO 1-13
SIEMENS
2 SIEMENS KALWA 14-22

WORKS
3 SWITCHGEAR 23-33
FACTORY
4 INTRODUCTION TO 34-49
CONTACTOR
5 INTRODUCTION TO SAP 50-58
6 ROLE IN DEPARTMENT 59-60
7 PROJECT ON COIL WINDING 61-68

MACHINE
8 BIBLIOGRAPHY 80
TABLE OF CONTENTS
CHAPTER PAGE
TOPIC
NO. NO.
INTRODUCTION TO SIEMENS 1-11
1.1 SIEMENS - A Global Powerhouse 2
1.2 About SIEMENS INDIA 4
1
1.3 History 7
1.4 Founder Generation OF SIEMENS 10
1.5 Business Interests OD SIEMENS in INDIA 11
SIEMENS KALWA WORKS 12-18
2.1 SIEMENS Kalwa Works Divisions 13
2.2 The Motor Factory (WMOT) 15
2
2.3 The Switchgear Factory (WSGR) 16
2.4 The Switchboard Factory (WSWB) 17
2.5 The Transformer Factory (WTRFR) 18
SWITCHGEAR FACTORY 19-39
3.1 SWITCHGEAR 20
3.2 Classification of Switchgear 23
3.3 About Switchgear Plant 26
3.4 Organizational Structure of Switchgear Plant 27
3 3.5 Different Shops Associated with Switchgear Plant 28
3.6 Working of Switchgear Plant 30
3.7 Departments in Switchgear Factory & their Functions 31
3.8 Various Critical Machines Associated with the Switchgear Plant 33
3.9 Products of Switchgear 35
3.10 Working of Switchgear 38
CHAPTER PAGE
TOPIC
NO. NO.
INTRODUCTION TO CONTACTOR 39-55
4.1 Introduction to contactor 40
4.2 Classification Of Contactor 41
543 Construction Of Contactor 42
4.4 Workinf Of the Contactor 45
4.5 Application Of Contactor 46
4
4.6 Configuration Of a Conactor 48
4.7 Life Of Contactors 49
4.8 Coil Winding 52
4.9 Physical Factors Affecting Coil 53
4.10 About Coil 54
INTRODUCTION TO SAP 55-

5.1 Introduction to SAP 56
5.2 Features Of SAP 57
5.3 Customer Relationship Management 58
5
5.4 Feature Of SAP time Management 58
5.5 Implementation of SAP in companies 59
5.6 The SAP window 60
5.7 Standard tool bar buttons 61
ROLE IN DEPARTMENT 63-65
6.1 Nature Of Duties Performed 64
6
6.2 Observations Made 65
PROJECT ON COIL WINDING MACHINE 66-80

7.1 Introduction 67
7 7.2 Principle parts and their functions 68
7.3 Principle of coil winding machine 69
7.4 Design 72
7.5 Inspection and quality control 74
7.6 Coils Manufactured 75
8 8.1 Bibliography 80
LIST OF FIGURES
PAGE
NAME OF FIGURE
FIG NO. NO.
CHAPTER 01
1.1 Werner von Siemens, founder of Siemens 2
1.2 SIEMENS’ Headquarters, MUNICH 3
1.3 Research & Development Building at Siemens Kalwa Works 4
1.4 Siemens Kalwa Works 5
1.5 Siemens’ Factories Located Throughout India 6
Timeline of Milestones achieved by SIEMENS throughout 1867 to
1.6
2016 7
1.7 Milestones of a 170 year history of SIEMENS 8
1.8 Founder Generation of Siemens 10
CHAPTER 02
2.1 Divisions within Siemens Kalwa Works 13
2.2 Motor manufactured in the Motor Factory (WMOT) 14
2.3 Switchgear manufactured at the Switchgear Factory (WSGR) 15
2.4 Switchboards manufactured at the Switchboard Factory (WSWB) 16
2.5 Transformer manufactured at the Transformer Plant (WTRFR) 17
CHAPTER 03
3.1 Basic Applications of Switchgear 21
3.2 Model of working process 30
3.3 Contactor 37
3.4 Bimetal Overload Relay 37
3.5 Push Button 37
3.6 Working of Switchgear 38
CHAPTER 04
4.1 Contactor 40
4.2 Coils 42
4.3 Springs 43
4.4 Contacts 43
4.5 Contcts and coil system 44
4.6 Magnet and Yoke 44
4.7 Timers 47
4.8 Auxiliary Contact 47
4.9 Coil 48
4.10 Single Layer Winding 52
CHAPTER 05
5.1 The SAP System 56
5.2 SAP SCREEN Window 59
5.3 Tool Bar 60
5.4 Command Field 60
CHAPTER 07
7.1 Synthesis coil winding machine 67
7.2 Winded coil 74
7.3 Improper layring 76
7.4 Tensioner mounting 77
7.5 Broken bobbin 78
Shri Bhagubhai Mafatlal Polytechnic SIEMENS Ltd.
CHAPTER 01 INTRODUCTION TO SIEMENS
Inplant Training Report Page 1

1.1 SIEMENS – A GLOBAL POWERHOUSE
Fig.1.1 Werner von Siemens, founder of Siemens
Siemens AG is a German conglomerate company headquartered in Berlin and Munich and the largest
Manufacturing and Electronics Company in Europe with branch offices abroad.
The principal divisions of the company are Industry, Energy, Healthcare, and Infrastructure & Cities,
which represent the main activities of the company. The company is a prominent maker of medical
diagnostics equipment and its medical health-care division, which generates about 12 percent of the
company's total sales, is its second-most profitable unit, after the industrial automation division. The
company is a component of the Euro Stoxx 50 index. Siemens and its subsidiaries employ
approximately 362,000 people worldwide and reported global revenue of around €75.6 billion in 2015
according to their annual report. The von Siemens family remain the largest shareholder with a stake
of 6.9% percent, based on a market cap of €112billion, the Siemens family holds €7.7 billion worth of
common stock in the company and received €201million in dividends in 2016. In fiscal 2016, which
ended on September 30, 2016, Siemens generated revenues of €79.6 billion and net income of €5.6

billion. At the end of September 2016, the company had around 351,000 employees worldwide.
Siemens India had more than 16,000 employees (including all group companies of Siemens in India)
and revenues of Rs.1, 08,089 million.
Fig1.2 SIEMENS’ Headquarters, MUNICH

1.2 ABOUT SIEMENS INDIA
With a focus on electrification, automation & digitalization, SIEMENS INDIA stands for engineering
excellence, innovation, & reliability. As one of the world’s biggest producers of Energy-Efficient,
resource-saving technologies, SIEMENS is a pioneer in infrastructure & energy solutions, as well as
automation & software for industry. The company is also a leader in medical imaging equipment,
laboratory diagnostics, & clinical IT. SIEMENS also provides business – to – business financial
solutions, rail automation & wind power solutions.
Fig.1.3 Research & Development Building at Siemens Kalwa Works
Partnering India: Integrated solutions for a digitalized and sustainable

future
Siemens' long-term commitment in India began in 1867, when Werner von Siemens personally
supervised the setting up of the first telegraph line between London and Calcutta. Today, Siemens has
22 factories located across the country, 8 Centers of Competence, 11 R&D centre and a nationwide
sales and service network.

Fig.1.4 Siemens Kalwa Works
Siemens India manufactures steam turbines, turbo compressors, high-voltage switchgear (circuit
breakers, disconnectors and gas-insulated switchgear), switchboards, remote monitoring systems
(RMS), fire detectors and suppression systems, motors and generators, relays and Smart Grid systems,
transformers, and advanced medical imaging equipment. The factories replicate global, best-in-class
manufacturing systems and practices. It also has a facility to overhaul and repair gas turbines,
compressor blades and rotors. For over six decades, Siemens India has been the preferred technology
solutions provider, conceptualizing and implementing various flagship projects in Mobility, Energy
Management, Power and Gas, Smart Cities, Intelligent Infrastructure, Industrial Applications,
Healthcare and Smart Financing. Siemens India is also strengthening its digitalization portfolio and
working on select applications in the country.

Fig.1.5 Siemens’ Factories Located Throughout India
In India the business operations of Siemens are carried out under the following names:
- SIEMENS LTD.
- SIEMENS TELECOM LTD.
- SIEMENS BUSINESS COMMUNICATION SYSTEM LTD.
- SIEMENS COMMUNICATION SOFTWARE LTD.
- SIEMENS INFORMATION SYSTEM LTD.
SIEMENS INDIA- Manufacturing units

 Mumbai (Worli) : Head office
 Kalwa
 Nasik
 Aurangabad
 Goa

1.3 HISTORY
An enduring partnership
Siemens has been a strong partner to India – from setting up the Indo-European telegraph line in 1867
to spearheading the Smart Cities project in 2015 and beyond.
Fig 1.6 Timeline of Milestones achieved by SIEMENS throughout 1867 to 2016
Siemens offers integrated solutions for India's sustainable future - efficient manufacturing, integrated
automation, intelligent infrastructure, complete mobility and sustainable energy.
Fig 1.7 Milestones of a 170 year history of SIEMENS
Milestones of Siemens’ History
1847: Werner Von Siemens together with Johann Georg Halske, he founded the Siemens & Halske
Telegraph Construction Company, Berlin, in 1847.
1848: Construction of the first electrical long-distance telegraph line in Europe, Berlin - Frankfurt.
1853: Construction of Russian State telegraph network starts which was started in 1852 was
completed in 1855).
1870: Inauguration of Indo-European telegraph line from London to Calcutta which was the first
transcontinental cable line.
1897: Siemens & Halske becomes a Stock Corporation.
1954: Assembly and repair undertaken in a small workshop under Mahalakshmi Bridge Mumbai.
1957: Switchboards manufacture began at Worli, Mumbai.
1960: Manufacture of Switchgear began at Worli in Mumbai.
1966: First batch of Electric Motors were produced at Kalwa, Thane.

1970: Transfer and expansion of Switchgear production at Kalwa
1975: Transfer and expansion of Switchboard production at Kalwa
1986: Heavy investment in Tool room and production shop was done with the inception of NC and
CNC machine.
1993: Assembly workshop of Medical products was set-up in Goa.
1995: Launch of Siemens Mobile phones.
1998: Separate subsidiary to handle telecom Business.
2004: Corporate Technology Center, a hub for technology R&D for Siemens worldwide, set up in
Bangalore
2005: Small turbines production starts at Vadodara
2006: 50th year of manufacturing in India
2009: Produces first 145kV gas insulated switchgear (GIS) from the recently-inaugurated GIS factory
at Aurangabad. Start gas-insulated switchgear unit in Aurangabad. Merged Siemens Building
Technologies with itself.
2011: Rolls out world’s first 1200 kV SF6 circuit breaker from Aurangabad factory. Crosses Rs.100
billion in revenues. Announces amalgamation of Siemens VAIMetals Technologies Pvt. Ltd. and
Morgan Construction Company Pvt. Ltd. Merges Siemens Healthcare Diagnostics with itself.
2012: Twin factories in Goa for energy automation and medium voltage. Announces amalgamation of
Siemens Power Engineering\

1.4 FOUNDER GENERATION OF SIEMENS
Werner von Siemens (1816 – 1892) Sir William Siemens (1823 - 1883)
Johann Georg Halske (1814 – 1890) Carl von Siemens (1829 – 1906)
Erwin
Moritz Reiniger (1854 – 1909) Sigmund Schuckert (1846 – 1895)
Fig1.8 Founder Generation Of Siemens

1.5 BUSINESS INTERESTS OF SIEMENS IN INDIA
The following shows the diversified business interests of Siemens:
 Information and Communication: Siemens helps in communications with their network

solutions and portfolio of cordless and mobile phones and latest-generation PCs.
 Automation and Control: Siemens helps other industries optimize production, cut costs and
boost plant productivity by offering solutions in the field of production and logistics
automation. The Automation and Control segment comprises three Groups (i)Automation and
Drives, (ii)Industrial Solutions and Services, (iii)Siemens Demotic
 Power: Siemens provides affordable power and heat with environment friendly power plants
& makes energy transport economical and safe. Siemens' Power business comprises Power
Generation (PG) and Power Transmission and Distribution (PTD). The Power segment
comprises two Groups:
(i) Power Generation, (ii) Power Transmission and Distribution:
 Transportation: Siemens integrates transportation systems and improves vehicle safety and
comfort. The Transportation segment comprises two Groups:
(i)Transportation Systems, (ii) Siemens VDO Automotive
 Medical: Siemens provides complete healthcare solutions and support diagnoses and therapy
in hospitals. Our goal is to be the world’s most successful solutions provider in the healthcare
industry.
 Lighting: Siemens provides economical, long-life lighting for every application. In the
Lighting segment, OSRAM has transformed itself from a conventional light bulb
manufacturer into a true high-tech company. This lightning system proved a great feast of
service & a lot of number of the applications.
 Financing & Real Estate: Our financing and real estate activities are grouped into two
business units: Siemens Financial Services (SFS) and Siemens Real Estate (SRE).
 Information Technology: With SIEMENS’ Hi Path IP convergence product family, they
enrich enterprise data networks with voice applications and integrate communications into
business processes, significantly boosting their customers' productivity.

CHAPTER 02 SIEMENS KALWA WORKS

2.1 SIEMENS KALWA WORKS DIVISIONS
The Kalwa factory is equipped with some of the most modern machinery and testing facilities. It
started with the production of motors and later diversified in 1973 to produce Switchgear and in 1975
to produce Switchboards. Today it is the most important business center for Siemens India working in
Kalwa and contributing almost 45% of the total production of Siemens in India. No wonder it is the
heart of the manufacturing activities in India.
Fig.2.1 Divisions within Siemens Kalwa Works

2.2 THE MOTOR FACTORY (WMOT)
The motor factory produces high quality motors with economical energy consumption, resilient
enough to withstand wide voltage and frequency fluctuations, a condition widely prevalent in India.
The factory is equipped with dedicated and general-purpose CNC machines that ensure accuracy at the
micron level. Computerized on the line production planning and control system ensures a built in
quality from the very beginning. The user-friendly designs are a proof of the fact that Siemens has a
considerable knowledge of the industries using their motors. Thus Siemens motors have high
flexibility in use and less manufacturing processes. The motor factory at Kalwa was established in
1965 and is a sub – division of Motors, Drives, UPS division. It supplies standard and special products
meeting specified requirements of the customer attaining simplicity and improvement in its designs.
PRODUCT SPECTRUM:
 Traction Motors
 Induction Motors & Generators
 Various Client Application Motors
Fig.2.3 Motor manufactured in the Motor Factory (WMOT)

2.3 THE SWITCHGEAR FACTORY (WSGR).
SIEMENS switchgear unit is one, which is committed to provide business solutions in the field of
Control Systems and Products (CSP). The year 1973 marked the beginning of the production of
switchgear at Kalwa works.Considering its applications, Switchgear is a general term covering a wide
range of products used for switching and safety of various electrical & electronic accessories. It
manufactures several forms of switching and protective devices. At the Switchgear factory a wide
range of low and high tension equipment is produced. The low tension Switchgear range consists of
contactors, bimetal relays, starters, circuit breakers, fuse switches, motor control gears like push
buttons, pilot lamps limit switches, HRC fuses, fuse bases, etc.
PRODUCT SPECTRUM:
 Control and Limit Switches
 Starters & Contactors
 HRC Fuses, Fuse Switches & Fuse Bases
Fig.2.4 Switchgear manufactured at the Switchgear Factory (WSGR)

2.4 THE SWITCBOARD FACTORY (WSWB)
SIEMENS switchboards have established remarkable leadership in the market. This has through a
deep understanding of the customer’s requirement, resulting in customer-oriented products design
manufactured with latest technology at par with international standard. This unit manufactures
switchboards and circuit breakers with different ranges. The switchboard plant produces range of low
tension and high-tension panels, Outdoor Vacuum Circuit Breakers, Indoor Vacuum Circuit Breakers
and Oil Circuit Breakers up to 36 kV.
PRODUCT SPECTRUM:
Circuit Breakers
 Electrical Panels
Fig.2.5 Switchboards manufactured at the Switchboard Factory (WSWB)

2.5 THE TRANSFORMER FACTORY (WTRFR).
The new Transformer factory addresses heightened demand for power transmission equipment in the
country by designing and manufacturing large transformers of power rating up to 600 MVA and 800
KV voltage class – which is the maximum voltage established presently in India. The factory will also
produce special application transformers such as for HVDC and traction furnace applications. In the
near future, the factory will also be able to strengthen the transmission network through its 1200 KV
class transformers, in view of the 1200 KV lines that are envisaged in the near future. To start with,
the new facility has a capacity of manufacturing transformers totaling 15,000 MVA annually
Fig.2.6 Transformer manufactured at the Transformer Plant (WTRFR)

CHAPTER 03 SWITCHGEAR FACTORY

3.1 SWITCHGEAR
In an Electric Power System, switchgear is the combinations of electrical disconnect

switches, fuse or circuit breaker used to control, protect and isolate electrical equipment. Switchgears
are used both to de-energize equipment to allow work to be done and to clear fault downstream. This
type of equipment is directly linked to the reliability of the electricity supply. Switchgear is necessary
at every switching point in a power system. Between a generating station & final load point, there are
several voltage levels & fault levels. Hence switching & protective devices have been developed in
several forms. When a fault on any power system occurs, it must be quickly detected & disconnected
from the system otherwise it will spread in to the system causing heavy damage of installation. This
detection & disconnection is achieved by switchgear.
The earliest central power stations used simple open knife switch, mounted on insulating panels
of marble or asbestos. Power levels and voltages rapidly escalated, making opening manually operated
switches too dangerous for anything other than galvanic isolation of a de-energized circuit. Oil-filled
equipment allowed arc energy to be contained and safely control By the early 20th century, a
switchgear line-up would be a metal-enclosed structure with electrically operated switching elements,
using oil circuit breakers. Today, oil-filled equipment has largely been replaced by air-blast, vacuum,
or Sulfur hexafluoride equipment, allowing large currents and power levels to be safely controlled by
automatic equipment.
High-voltage switchgear was invented at the end of the 19th century for operating Electric motor and
other electric machines. The technology has been improved over time and can now be used with
voltages up to 1,100 kV.
Typically, switchgear in Electrical substation is located on both the high- and low-voltage sides of
large power Transformer.. For industrial applications, a Transformer and switchgear line-up may be
combined in one housing, called a Unitized Electrical Substation (USS).
Switchgear is a group of products which perform the function of control and protection of electrical
systems Switchgear is necessary at every switching point in power system. Between a generating
station and final load point, there are several voltage levels and fault levels. Hence switching and
protective devices have developed in several forms. When a fault on any power system occurs, it must
be quickly detected and disconnected from the system otherwise it will spread into the system causing
heavy damage of installation. This detection and disconnection is achieved by Switchgear.

Fig.3.1 Basic Applications of a Switchgear
Switchgear is a general term covering a wide range of equipment such as switches, fuses, circuit
breakers, isolators, relays, contactors, control panels etc. Besides the supply network, Switchgear, is
necessary in industrial works, industrial projects domestic and commercial buildings.
3.1.1 Function Of Switchgear:

One of the basic functions of switchgear is protection, which is interruption of short-circuit and
overload fault currents while maintaining service to unaffected circuits. Switchgear also provides
isolation of circuits from power supplies. Switchgear is also used to enhance system availability by
allowing more than one source to feed a load.
3.1.2 Essential Features of Switchgear:
The essential features of switchgear are as follows:
(I) COMPLETE RELIABILITY
With the continued trend of interconnection and the increasing capacity of generating stations, the
need for a reliable switch-gear has become of paramount importance. This is not surprising because
switchgear is added to the power system to improve the reliability. When fault occurs on any part of
the power system, the switchgear must operate to isolate the faulty section from the remainder circuit.
(II) ABSOLUTELY CERTAIN DISCRIMINATION
When fault occurs on any section of the power system, the switchgear must be able to discriminate
between the faulty section and the healthy section. It should isolate the faulty section from the system
without affecting the healthy section. This will ensure continuity of supply.

(III) QUICK OPERATION
When fault occurs on any part of the power system, the switchgear must operate quickly so that no
damage is done to generators, transformers and other equipment by the short-circuit currents. If fault is
not cleared by switchgear quickly, it is likely to spread into healthy parts, thus endangering complete
shutdown of the system.
(IV) PROVISION FOR MANUAL CONTROL
Switchgear must have provision for manual control. In case the electrical (or electronics) control fails,
the necessary operation can be carried out through manual control.
(V) PROVISION FOR INSTRUMENTS
There must be provision for instruments which may be required. These may be in the form of ammeter
or voltmeter on the unit itself or the necessary current and voltage transformers for connecting to the
main switchboard or a separate instrument panel.

3.2 CLASSIFICATION OF SWITCHGEAR
A piece of switchgear may be a simple open air isolator switch or it may be insulated by some other
substance. An effective although more insulated switch (GIS) where the conductors & contacts are
insulated by pressurized Sulfur Hexafluoride (SF6).Other common types are oil (or vacuum)insulated
switchgear. A simple fuse used at our home, or a toggle switch is a simple low tension switchgear.
Several different classifications of switchgear can be made as follows:
 By the current rating.

 By interrupting rating (maximum Short circuit current kAIC that the device can safely
interrupt)
 Circuit breakers can open and close on fault currents

 Load-break/Load-make switches can switch normal system load currents
 Isolators are off load disconnectors which are to be operated after Circuit Breakers, or
else if the load current is very small
 By voltage class:
 Low voltage (less than 1 kV AC)

 Medium voltage (1 kV AC through to approximately 75 kV AC)
 High voltage (75 kV to about 230 kV AC)
 Extra high voltage, ultra high voltage (more than 230 kV)
 By insulating medium:
 Air
 Gas (SF6 or mixtures)
 Oil
 Vacuum
 Carbon dioxide (CO2)
 By construction type:

 Indoor
 Outdoor
 Industrial
 Utility
 Marine
 Draw-out elements (removable without many tools)
 Fixed elements (bolted fasteners)
 Live-front
 Dead-front
 Open
 Metal-enclosed (ME) — A switchgear assembly completely enclosed on all sides and
the top with sheet metal.
 Metal-clad (MC) — A more expensive variety of metal-enclosed switchgear that has
the following characteristics: the main switching and interrupting device of removable
type; grounded metal barriers to separate compartments and enclose all major circuits
and parts; mechanical interlocks; insulated Bus bar and other features.
 Arc Resistant
 By interrupting device:
 Fuses
 Air Circuit Breaker
 Minimum Oil Circuit Breaker
 Oil Circuit Breaker
 Vacuum Circuit Breaker
 Sulfur hexafluoride circuit breaker
 CO2 Circuit Breaker
 By operating method:
 Manually operated
 Motor/stored energy operated
 Solenoid operated

 By type of current:
 Alternating current
 Direct current
 By application:
 Transmission system
 Distribution
 By purpose
 Isolating switches (Disconnector)

 Load-break switches.
 Grounding (earthing) switches
A single line-up may incorporate several different types of devices, for example, air-insulated bus,
vacuum circuit breakers, and manually operated switches may all exist in the same row of cubicles.
3.3 ABOUT SWITCHGEAR PLANT
SIEMENS Switchgear has earned a reputation for itself due to its optimum design and stringent
quality standard. The total quality management concept makes SIEMENS Switchgear highly
dependable, confirming to national and international standards. Dependability and durability rectifies
all switchgear products such as contactors, fuse-switches, relays, circuit breakers, starters, push
buttons, HRC fuses and limit switches. The central building houses a number of departments which
include technical departments like Process Planning, Research development, Tool design, Product
design, manufacturing depts. Like machine shop, press shop, plastic shop, and tool room; assembly
sections of various switchgear products as well as tool stores and finished component stores. Other
subsidiary departments include the main section of the plastic shop and galvanic shop and brazing
shop.

3.4 ORGANISATIONAL STRUCTURE OF SWITCHGEAR PLANT
a) Personnel Department: It looks after the human resource development like maintaining attendance
records, wages of employees as well as workers etc.
b) Tool room: Tool room is a department that looks after the repairing &maintenance of the various
tools used in the factory at various machines. It also manufactures new tools as well as jigs and
fixtures required for different operations.
c) Maintenance: The maintenance department looks after any electrical or mechanical fault in
machines or fixtures in the factory.
d) Calibration Lab: As a manufacturing industry, a large number of different electrical & mechanical
instruments are used. It is also necessary for the instruments to be accurate to maintain accuracy &
meet the requirements. The various instruments are calibrated at the calibration lab, which has highly
equipped machines and standard instruments.
e) Production Cell: The production cell is the complete in charge of the production of the various
products manufactured here.
f) Metal shop: The various metal parts or components that are used in the assembly of the various
products are manufactured at the metal shop.
g) In process inspection: The various parts manufactured at the metal shop are inspected at the in-
process inspection department
h) Incoming Inspection: Some parts of the products are being brought from the vendors. The
different parts are inspected at the incoming inspection department before being available for
manufacturing.
i) Plastic shop: The various plastic components used for the various products in the factory are
manufactured at the plastic shop.

3.5 DIFFERENT SHOPS ASSOCIATED WITH SWITCHGEAR

PLANT
Different shops associated with Switchgear Plant are as follows:
• PRESS SHOP:
The metal working presses (mechanically & hydraulically operated) installed in the press shop range
from 30 tons up to 125 tons. The raw materials like copper, brass, phosphor bronze, and spring steel
are received in coil, strip or sheet form and are fed through pneumatic feeders into press working dies
where the final shape of the part is obtained. This shop also has special processes such as magnet
manufacturing etc. The parts made are either sent for surface treatment, machining or welding.
• MACHINE SHOP:
This shop has various machines performing operations like drilling, tapping, milling, grinding, and
turning of raw materials like castings or bar stock. Manual operations like deburring and cleaning are
perform after machining of parts.
• WELDING / BRAZING SHOP:
This shop has processes such as resistance brazing for contact joining, manual arc welding for
manufacturing structural items of switchgear.
• GALVANIC SHOP:
This shop deploys processes such as silver, nickel, and zinc plating which form the surface coating on
switchgear components as a protective layer against rusting. Degreasing and pickling of parts is also
done here. Efficient water purification and neutralization plants form an essential part of this process.
At present the Galvanic Shop is not in use.
• PLASTIC SHOP:

Raw materials like thermoplastic and thermosetting resin is molded using the compression, transfer,
or injection molding processes to form the final desired shape of the components. The parts are formed
using molding dies made as per the required shape. Subsequent to molding, processes such as
deburring, belt grinding, and shot blasting are performed for finishing the parts, which are sent for
assembly.
• PRE-ASSEMBLY:
This consist of various processes such as riveting, spot welding, soldering through which various in-
house and bought out parts are assembled to form subgroups which are fed to the main product
assembly line after testing.
• ASSEMBLY:
The final product is assembled in the well laid out and balanced lines. The product is thoroughly
tested and packed before dispatch.
• TOOL ROOM:
In the Switchgear factory, the required tools for the products are manufactured. The tools such as jigs,
fixtures and dies are manufactures for the internal and external use.

3.6 WORKING OF SWITCHGEAR PLANT
Fig.3.2 Model of working process
The manufacturing of the switchgear factory is a sophisticated process combining efficiency, quality
& optimum utilization of the machines. The pre-manufacturing section consists of the metal parts
shop, plastic shop, brazing & welding shop & tool room. Components those are critical in design and
dimensions like contacts, magnets, bi-relay components etc. are manufactured in these sections.

3.7 DEPARTMENTS IN SWITCHGEAR FACTORY AND THEIR

FUNCTIONS
 Product Development
 Product Designing.
 Preparation of Designs and Drawings.
 Laying Down Standards and Accepted Norms.
 Assembly and Design Making in Development Shop.
 Testing of New Design Prototypes or Design Verification.
 New Product Development.
 Industrial Engineering
 Plan plant layout
 Conduct work study so as to minimize worker effort
 Formulate process and work cycle
 Assembly process planning
 Type Testing
 Performs development & type test of switchgear products as per IEC (int. standards).
 Vendor Development
 Developing vendor relationships
 Finding local vendors.
 Vendor rating/ evaluation
 Vendor development
 Provide technical support to vendors.
 Assembly
The final product is assembled in well laid out and balanced lines. The product is thoroughly
tested and packed before dispatch.
 Logistics (Material Management)

 Receipt and processing of orders places by sales division.

 Scheduling which involves assignment of priorities based on the urgency and material
availability.
 Procurement and administration of raw material.
 Overall co-ordination between marketing, client, excise etc.
 Management of stores.
 Dispatch of computed consignments
 Product Cell
Once a product is suitable for production, i.e. its design is approved, vendors are decided, and
the data comes down to the product cell. Here, process plan is formulated, assembly lines are
provided, scheduling is done and actual production is achieved as per the production orders. For
the regular running products, day to day production is carried out. Material movement, inventory
control etc. is taken care of.
 Quality Assurance, Quality Service & Calibration

Siemens provides the sales service support to the all business units of the product for building up
the good relation to the customer. This department also handles the customer’s complaints and
provides the solution through the regional service centers.
 Strategic Purchase
Raw material is outsourced. Once vendor for raw material is identified, purchase is initiated.
These purchases are on regular bases and in bulk quantities.
 Billing and Dispatch Centre

After assembling, the finished products are forwarded to the BDC section for delivery to the
customers or the respective region warehouse.
 Plant Engineering
This department especially looks after the maintenance of machine tools in the Switchgear factory
to avoid the breakdowns. It also undertakes the low-cost automation, testing the fixtures and
reconditioning of machines.

3.8 VARIOUS CRITICAL MACHINES ASSOCIATED WITH THE

SWITCHGEAR PLANT
The switchgear factory is equipped with a number of sophisticated m/c that performs complicated
functions swiftly & efficiently. Of these machines like Haulik-Bihler, Sclatter, MAMO, are unique to
the technology of Siemens.
Following are the critical machines in various departments
Table 01 - All Machines in Switchgear Plan
Shops Machines Uses
Mechanical presses Punching, blanking,
ranging from 30t to 125t forming operation
Press Shop
Hydraulic presses Riveting & bending
operations
of 63t&15tcapacity
Magnet Shop MAMO I & MAMO II Magnet manufacturing
Production of lamination
Haulik 32 T(350ppm) for magnet
Production of lamination
Contact Shop
Haulik40 T(650ppm) for magnet
Production of bi -relay
Haulik63 T(250ppm) components

High speed auto tapping

Contact Shop Tapping of contacts
machine
Pre Screwing Assembly of tapped

contacts
machine
Grinding of magnets &
Machine Shop High precision grinding breaker components
machine
Tapping machine Thread cutting
Brazing & Spot welding machine Braze silver tips to
Welding shop & Brazing equipment raw components
Manufacturing plastic
Plastic Shop Compression, transfer,
injection machines parts like contact carriers,
housing, and bulb holders.

3.9 PRODUCTS OF SWITCHGEAR
CONTACTOR
A contactor is an electromagnetic device, which makes breaks and carries rated current at relevant
commands. It is different from a switch as it protects the system from overload and other failures by
using the respective relay, which is not possible by a fuse switch unit. Contactors are used in motor
control; capacitor switching, heating and lighting in single phase and three phases AC as well as DC
circuits.
BIMETAL OVERLOAD RELAYS
The relay is protective device, which is extensively used, in electrical circuits in conjunction with
contactor and other motor control equipment; they provide accurate and reliable protection against
overload, single phasing and overloading due to locked rotor conditions. The relays are suitable for
frequency operation up to 15 switching cycles per hour. When installed individually, relays are
unaffected by ambient temperature of 200c to 550 C.
PUSH BUTTONS & PILOT LAMPS
Push buttons are basically simple switches used to make or break certain control systems. Pilot lamps
are devices which indicate the status of the control circuits i.e., whether ‘ON’ or ‘OFF’.
LIMIT SWITCHES
Limit switches with special contacts are available for operation at extra low voltage in very dirty and
dusty location. They are used in automatic control circuits where mechanical position has to be
converted into electrical signals for controlling remote starters, contactors and electromagnetic
clutches.
STARTERS

Siemens manufactures a wide range of starters for the specific needs of both industry and agriculture.
These starters have many ingenious features which provide dependable protection against overloads,
single phasing and locked rotor condition of motor-starters manufactured to the highest quality of
workmanship and backed by over a 100 years of experience in the field of electrical engineering. The
range is ideally suited for the specific needs of agriculture, industry, residential installations, small-
scale sector, utilities etc. Siemens offer starters for direct – on – line starting, reversing, manual star –
delta starting, semi-automatic star-delta starting & automatic star-delta starting.
PROGRAM SWITCHES
The switches are used for programmed control of machine tools, switchboards, control boards etc.
They can be used in main circuit for direct control of feeders or motors and in various drives according
to the desired program.
SOME PRODUCTS & THEIR SERIES
Table 02 – Product Series
PRODUCT SERIES
3TH, 3TF, 3TR, 3RT, 3TS,
CONTACTORS
SIRIUS S6, S12…
BIMETAL RELAYS 3UR, 3UA, 3UW, 3US, 3UC
AIR CIRCUIT BREAKERS 3WL, 3WT
LIMIT SWITCHES 3SE

PUSH BUTTON & PILOT
3SB
LAMPS
STARTERS S3TE, 3TW
PRGRAMME SWITCHES 3LA
MOULDED CASE CIRCUIT

3VL, 3VT
BREAKER
ELECTRONIC TIMER 3RP

Fig.3.3 Contactor
Fig 3.4 Bimetal Overload Relay
Fig. 3.5 Push Button

3.10 WORKING OF SWITCHGEAR
Thus the products namely Relay, Contactor, Motor, Fuse, Switch working together in a circuit can
be explained with the help of the fig as shown below.
The various components are,
1. MOTOR
2. ANKER
3. YOKE
4. COIL
5. CONTACTOR
6. SINGLE PHASE SUPPLY
7. HRC FUSE
8. SWITCH
9. BI-STRIP
10. RELAY
11. THREE-PHASE SUPPLY
Working principle: Fig
3.6 Working of Switchgear
The motr requires three-phase current for its

working since it is meant for operating at very high ratings. If this high current is directly supplied to
the motor then at the time of overload current the motor may get damaged due to excessive current.
Thus the motor requires safety, which is provided the contactor and relay.
WORKING OF ALL SWITCHGEAR PRODUCTS

The contactor consists of a male electromagnet called ‘ANKER’ and a female electromagnet called
‘YOKE’. Below the Yoke is a coil, which is in a single phasing circuit with the relay. The relay
consists of a NO and a NC contact, bi-strip, rocker-lever mechanism. The single phasing circuit also
consists of a fuse to protect the relay, and a switch for switching ON and OFF the circuit. The three-
phase current required to run the motor is first passed through the bi-strip of the relay and then passed
on to the motor through the contactor.
nitially when the switch is put ON, the circuit is completed and the current flows through the NC
contact of the relay to the coil. The coil then gets magnetized and develops electromagnetic flux.
Meanwhile the three-phase current is passed through the bi-strips and flows to the contacts of the coil
of the contactor. Due to the flux developed in the coil the yoke gets magnetized and attracts the Anker
towards itself. Thus, the three-phase current of the Yoke is passed on to the Anker and then to the
motor.
When overload current passes through the bi-strip, the bi-strip due to its physical property bend on
overload. Thus, the slider on the bi-strip is pulled with the bi-strips, which in turn pulls the lever. The
lever further pushes the rocker and due to spring action the rocker is tripped thus converting the NC
contact to the NO contact. Due to this the single phasing circuit is put OFF and the coil gets
demagnetized. Thus, no flux is developed and the Yoke also loses its magnetic property. Still the
three-phase current is passing through the bi-strip to the contacts of the coil but the Yoke is not
attracted to the Anker and hence current does not reach the motor.
Thus, the motor is being protected from overload current and hence from damage. Further when the
overload current comes to the normal again the bi-strip come back to their normal position and the NO
contacts become NC contact. Thus, the single-phase circuit is again completed and the coil develops
flux to attract the Yoke, which in turn attracts the Anker and runs the motor on the three-phase current
from the Yoke. Thus, the relay and the contactor form the main part of the circuit. Since the three-
phase current is passing through the relay directly to protect the relay an HRC fuse is connected in
circuit with the relay, which has a low cut-off characteristics and thus protects the relay from damage.
Thus, all the switching devices cannot go alone and work together in the circuit thus making the
circuit full proof.

CHAPTER NO 4 INTRODUCTION TO CONTACTOR

4.1 INTRODUCTION TO CONTACTOR

A contactor is an electrically controlled switch used for switching
an electrical power circuit, similar to a relay except with higher
current ratings and a few other differences. A contactor is
typically controlled by a circuit which has a much lower power
level than the switched circuit, such as a 24-volt coil
electromagnet controlling a 220-volt motor switch. Contactors
come in many forms with varying capacities and features. Unlike
a circuit breaker, a contactor is not intended to interrupt a short
circuit current. Contactors range from those having a breaking
current of several amperes to thousands of amperes and 24 V DC
to many kilovolts. The physical size of contactors ranges from a
device small enough to pick up with one hand, to large devices
approximately a metre (yard) on a side. Fig no 4.1 Contactor
Contactors are electrically controlled switching devices used for switching of electrical circuits
especially motor switching circuits ,switching of capacitor lightings.
The basic operation of contactors is similar to that of relays but they can carry much more
current than relays
They cannot provide shortcircuit or overload protection but can only make or break contacts
when the coil is exicited.
Features of Contactors
A contactor is a relay that is used for switching power.

They usually handle very heavy loads like an electric motor, lighting and heating equipments
and so on.
Though their output is used for switching very high loads, they are controlled by a circuit with
very less power.
According to the loads they handle, they vary in sizes from a small device to as huge as a yard.
Though they are used for switching purposes, they do not interrupt a short-circuit current like a
circuit breaker.
They have ratings ranging from a breaking current of a few amperes and 24 DC volts to
thousands of amperes with many kilo volts

4.2 CLASSIFICATION OF CONTACTORS
ACCORDING TO THE CURRENT RATING:
1. POWERCONTACTOR: -The rated current of power Contactor is very high, may be as high as
1200 A. The Contactor will be capable of making and braking any value of current up to the
making and braking capacity.
2. AUXILIARY CONTACTOR: -It is a small Contactor designed for handling current in the
control circuit. These Contactors are generally rated up to 10 Amps.
ACCORDING TO METHOD BY WHICH THE FORCE FOR CLOSING THE MAIN

CONTACTS IS PROVIDED.
ELECTROMAGNETIC CONTACTOR:-A Contactor in which force for closing the normally

open main contact or opening the Normally open main contact is provided by an electromagnet.
PNEUMATIC CONTACTOR: -A Contactor in which the force for closing the main contacts or
normally open main contact is provided by a device using compressed air, without use of electrical
means.
ELECTRO-PNEUMATIC CONTACTOR:-A Contactor in which the force for closing the

normally open main contacts or opening the normally closed main contacts is provided by a device
using compressed air under the control of electrically operated valves.
LATCHED CONTACTOR: -A Contactor moving contact of which are prevented by means of a

latching arrangement from returning to their position of rest when the operating means are de-
energized

4.3 CONSTRUCTIONAL DETAILS OF A CONTACTOR
1) DRIVE SECTION:
In the Drive Section there are parts such as:
a) Electromagnet
b) Coil
c) Springs
THE ELECTROMAGNETIC SYSTEM This is the heart of the remote action of the contactor. It
provides for remote control openings and closing of the contactors. It consists of an energizing coil,
a fixed magnet core and a moving counterpart of it, popularly known as Anker. The coil is directly
placed on the core and electromagnet may be actuated by AC or DC source given to the coil it
energizes magnets and the moving magnet is attracted towards fixed magnet and activates the
contact system. When the coil is de-energized the contacts open and the Anker is brought back to its
original position by return spring. A typical power Contactor consists of a system of main contacts,
an arc quenching electromagnetic system and auxiliary contacts.
COIL SYSTEM The Design of magnetic system is interlink with the size of the coil (i.e. wire
cross section and No. of Turns which determine ampere-turn excitation).The exciting of coil is
carried by Yoke. The two limbs conduct the magnetic flux to the air gap the lengths of which are
determined by
The distance over which the armature has to travel. The forces which will attract the armature to
the limbs depend on the Magnetic induction B in the air gap. The task of the designer is to
determine the current in and the No. of turns on the exciting coil which are required to produce a
given magnetic induction B for a required lifting force
Fig 4.2 Coils System

SPRING:
Drive system consists of return spring & Compression Spring.
Return Spring: The most important function of the return spring is to bring back the moving
contact to its normal position after the coil is De-energized. It also provides long mechanical &
electrical life to the contactor by absorbing shocks and vibrations. It also helps in reducing contact
bounce. Thus return spring plays an important role in the performance of the Contactor.
Compression Spring: Compression springs are placed over the

Anchor. It absorbs the shocks of he moving Contact i.e. armature.
Thus compression spring plays a very important role in reducing the
contact bounce and vibration of the armature.
Fig 4.3 Springs
SWITCHING & SWITCHING MECHANISM :
In Contact system there are two types of contacts: Main Contact & Auxiliary contacts.
MAIN CONTACTS: Main Contacts serve for making and breaking of power circuit. They
must be designed for continuous flow of rated current and for high frequency of opening and
closing operations. The contacts should be able to make 10 times their rated current without undue
erosion & wear and without exceeding prescribed temperature limits.
Fig 4.4 Contacts of Contactor
AUXILLARY CONTACTS: Auxiliary contacts are auxiliary switches fitted & mechanically
coupled switching device for the purpose of indicating the state of the main contacts. They are
designed to carry a continuous current of not over 20A and to interrupt current of over 5A

THE ARC-QUENCHING SYSTEM:
During the time of switching off, arcing occurs at the power contacts. For lower rated
Contactor no protective arrangement is made for this. However, for currents over 40A the arcing
becomes more pronounced and special arrangement to quench the arc should be made. This system
serves for extinguishing the arc between the main contacts. For successful operation and increasing
its electrical life different number of quenching plates are provided so that the arc is pulled away
from the contacts, spread over the plates and is quenched rapidly and totally. The method of arc
quenching depends upon type of current (AC or DC) and by the duty conditions of the Contactors.
For certain range of Contactors special arc chambers are used for this purpose.
Overview
A contactor has three components. The contacts are the electric switch connected to the primary
wires of the contactor. The power contacts gains the power for the contactor and the auxiliary
contacts is used to bring a loop with the rest of the rest of the dev it is attached to.
These contacts are connected to the contact springs. The electromagnet (or "coil") provides the
driving force to close the contacts. The enclosure is a frame housing the contacts and
electromagnet. Enclosures are made of insulating materials like Bakelite, Nylon 6, and
thermosetting plastics to protect and insulate the contacts and to provide some measure of
protection against personnel touching the contacts. Open-frame contactors may have a further
enclosure to protect against dust, oil, explosion hazards and weather. Another part of the contactor
is the coil. The coil is manufactured in a rectangular shape with two square holes in it. These holes
provide a space for the magnet yoke to protrude through so that the two feet of the yoke can make
contact with the armature when the armature moves to the closed position. The yoke is made of
laminated steel so that it doesn't retain the residual magnetism when the coil is de-energized
Fig 4.5 Contacts & coil system Fig 4.6 Magnet & Yoke of
Contactor

4.3 WORKING OF A CONTACTOR

Contactor an electromagnetic device must have power applied to the coil to remain pickup or say in
actuated position. The most important part of Contactor is an electro-magnet, which consists of coil
of enamel, insulated copper wire placed on an iron core. Briefly reviewing the operation when a
current flow to the coil, the iron of magnet becomes magnetized, attracting the iron bar (upper
magnet) called as anchor.
The magnetic circuit of Contactor consists of a magnet assembly and coil and on armature (upper
magnet). The coil placed in the central limb of the lower magnets, to induce magnetic flux into the
magnetic circuit. The armature is the moving part of the magnetic circuit when it has been attached
to its seal in position it completes the magnetic circuit.
In the construction of Contactor the upper magnet i.e. anchors is mechanically connected to a set of
contacts so that when armature moves to its closed position, the contacts also closes. As the lower
magnet is fixed, it pulls the upper magnet i.e. the armature downward. The moving contact makes
the contact with the fixed contact and the supply is passed to the secondary side.
When the contacts are made there is a bounce, this bounce is reduced by a spring, which gives the
required contact pressure and reduce the wear of contacts.
When the supply is cut-off the magnet de-energies and the moving contacts are separated from the
fixed contacts. The upper travel is due to return spring. They employ double brake system in small
Contactor for contact reliability. When the contacts are separated an arc is formed between them.
Arcing may cause short circuit between any two phases. Arc formation also leads to wear and tear
of contacts thus reducing their life. So for the protection against the arc an arc chamber is provided.
The arc chamber must have a good mechanical strength, because it has to withstand the stresses
occurring due to the arc. In an arc chamber the arc is deflected by the deflector Plates and is finally
quenched by the arc quenching plates.
For contactors energized with alternating current, a small part of the core is surrounded with a
shading coil, which slightly delays the magnetic flux in the core. The effect is to average out the
alternating pull of the magnetic field and so prevent the core from buzzing at twice line frequency.
Because arcing and consequent damage occurs just as the contacts are opening or closing,
contactors are designed to open and close very rapidly; there is often an internal tipping point
mechanism to ensure rapid action.

4.4 APPLICATIONS OF CONTACTOR :

The major utilization of Contactors is in field of Motor Switching and Protection. It is therefore
natural that the design of Contactor should be oriented towards the requirements of motor switching
and its related fields.
Motor Switching.
Reversing of Motor.
For direct selection of alternative supply for 3 - motor.
For automatic starting of several 3 - .
For Capacitor switching, heating loads, Transformer loads.
Special Hoisting Duty applications.
Providing control over furnaces
REQUIREMENTS OF A CONTACTOR :
High making and breaking capacity.

High service reliability.
Long electrical as well as mechanical life.
Ease of contact inspection and reliability.
Frequent Switching.
Difference between a contactor and a relay

The main difference between contactors and relays is the loads that they are meant to handle.
Contactors are used for loads that have high voltages, high currents, or both. Contactors are used
for devices that pass more than 15 amps or loads of more than 3kW. For lower amounts, ordinary
relays are used.
 Since a contactor is required for a higher load, a relay is always cheaper than a contactor.
 A relay is normally used in appliances below 5KW, while a contactor is preferred when the
appliance is heavier.
 A relay is used only in control circuit while a contactor can be used in both control and power
circuits.
 In general contactors are little slower than relays
 Contactor is so designed that it can be repaired while it is not normally done in the case of
relays.
 A contactor handles much higher current flow than relays

CONTACTOR TIMERS
Contactor timers are oftentimes used in lighting systems, allowing the lights to be turned on at
specific times and turned off at others. They are devices that control the function of a contactor
based on some sort of a timing device, whether it is a clock or a simple countdown timer. Contactor
timers don't necessarily have to operate under extremely high currents.
Fig 4.7 Contactor Timers
Auxiliary Contacts
Auxiliary contacts may be part of the design of a contactor or may be added to a contactor by way
of a separate component that is attached or removed as a module. Auxiliary contacts oftentimes
function to provide control information to a logic controller that can signal devices to turn on or off,
or to do so in specific orders, based on that input, in most applications The auxiliary contacts are
usually mechanically affixed to the main contacts and they change state as the state of the main
contacts changes. They are also used as hardware control units. On pushbutton controllers, they
oftentimes are incorporated in the design of start buttons.
Fig 4.8 Auxiliary Contacts

4.5 CONFIGURATIONS OF CONTACTOR
Pole and throw configuration of a contactor
Pole and throw are used in describing the number of circuits that a contactor can be hooked to and
the number of different positions that the contactor can be in. The simplest type of switch is a single
pole, single throw switch, which controls the on or off status of one circuit. Altering the number of
poles and throws allows contactors to be utilized to control very sophisticated circuitry. In some
situations, the poles and throws on a switch are wired in unconventional ways to provide another
functionality to the circuit.
Normal state configuration of a contactor
The normal configuration of a contactor describes the disposition of the contacts when current is
not applied to them. Most contactors are normally open, meaning that they close in the presence of
current. There are variations, but this configuration is one of the defining characteristics of
contactors and one of the things that separates them from standard relays. The application of this is
easy to understand, using a common example. In start buttons for machinery, contactors can be
provided with a current when the button is depressed, and will remain closed until that current is
removed. Industrial start up buttons are among the most common applications for contactors in
regards to hardware controls.
Coil voltage of a contactor
4.5.1 Coil voltage is one of the ratings under which

contactors are
sold. The voltage on a contactor can be alternating current or direct
current. The coil voltage may be chosen to accommodate lower
voltage devices or higher voltage devices, with contactors sometimes
having the same voltage as the load that they are controlling.
4.5.2 The coil voltage of a contactor is one of the ratings that
makes it appropriate or inappropriate for specific
applications. The coil voltage has to be selected with the
circuit being controlled in mind and in accordance with the
rating of the device, going over which may cause
malfunctions or premature wearing of the contactor.
4.5.3 On lower voltage contactors, air break suppressors and
vacuum suppressors are oftentimes employed to control Fig 4.9 Coil
arcing.

Contact voltage rating
4.5.4 The voltage rating of a contactor describes the voltage at which it is designed
to function properly. Going over this rating can cause issues with the components
and possible failures. Voltage ratings are sometimes referred to simply as "ratings",
but all literature about contactors will specify.
4.5.5 Contactors are, to a great degree, defined by their typically high contact voltage
ratings. These devices can handle voltages well into the high voltage range. The
contact voltage rating oftentimes plays a part in the type of arc suppression system
utilized on the device. For instance, high voltage contactors sometimes utilize inert
gases and vacuums to control arc. Some of them used charges of compressed air.
These types of suppression systems are usually found on contactors rated to work at
over 1000 V.
4.6 LIFE OF CONTACTORS

Life of Contactors is expressed in No. of operations the contactor can perform successfully
without any breakage or damage, for specified no. of Operating Cycles/ hr. One operation consist of
one On as well as OFF operation. There are two types of life of a Contactor:
1. Electrical life
2. Mechanical Life
1. ELECTRICAL LIFE:
This is declared for various utilization categories as given in IS: 13947. For ease of applications
these are related to full load current as well. The Electrical Life of the Contactor is determined by
the no. of switching cycles it can perform before its contacts are worn out and no damage is caused
to the coil.
Thus Electrical life of Contactor depends upon:
1. Contacts 2.Coil
These parts are mainly influenced by the switching duty and therefore on the voltage, current and
the arc duration. The effect of the current is clearly seen from the Electrical Life curves. Electrical
Life curves are the graphs of No. of operations V/s current flowing through the Contactor. As the
value of the current increases the life of the contactor reduces. Increasing value of the current
flowing through the contacts cause wear & Tear of the contacts. Invariably Silver based material is
used for Contact tips in order to decrease the contact resistance.

2 .MECHANICAL LIFE:
Mechanical Life of the Contactor is expressed in terms no. of make-break operations which can be
performed under No-load conditions. It is determined by the friction between the Mechanical
moving parts... Greater the forces which have to be overcomes, larger the driving mechanism and
stressing on the materials. Higher mechanical life can be obtained by reducing the mass of the
moving system & keeping minimum frictional force. Both these objectives are met with use of
relatively light weight Plastics. Compatible Plastics are selected with excellent abrasion resistance.
Electrical Life of Contactor is estimated to 1 Lakh operations then the Mechanical life can be
estimated to 10x times the Electrical Life.
THE BASIC DIFFERENCE BETWEEN
CONTACTOR WITH AC CONTROL VOLTAGE & DC
CONTROL VOLTAGE
a) In AC system magnets are made of thin laminations to avoid eddy current losses. In DC
type, since there is no problem of eddy current and hysterics loss a solid iron cylinder yoke
forms core for the coil and the iron plate acts as a pole.
b) Magnets for DC operation have solid core solenoid magnet consisting of magnetic iron parts
which move towards each other until magnet pole faces touch each other. In order to avoid
sticking of the magnets even after coil de-energisation due to residual magnetism, a small
air gap is introduced in two magnet poles. In DC type for providing gap a small piece of
non-magnetic material generally copper or phosphor Bronze is used.
c) The Yoke of AC operated contactors have short circuit rings fixed on its poles. In AC
Contactor the main magnetic flux is sinusoidal as the supply current. Without short circuit
ring the magnets would tend to open when flux crosses zero value resulting in opening and
closing of the magnets and contacts (chattering).The magnets vibrate with twice the
frequency as that of supply frequency, to avoid this short circuit ring is provided. The
current induced in the ring develops its own flux which is lagging in nature. Thus it
provides the force required to keep the Contactor in actuated position when the main flux is
crossing zero value, thus eliminating humming.
d) In AC system as inductance comes into picture, AC impedance is lesser than DC resistances
the No. of turns required for DC for a particular voltage is greater than that required for the
same AC voltage coils the DC coil is bigger than the AC coil.
e) Temperature rise of the contactor constitutes the heating effect due to electric current which
passes through the coil. The heat generates proportional to I2R. As in DC, resistance is
higher than AC, the heat generated and the Temperature rise is more in DC contactor.

CONTACTS
The contact system of Contactor consists of fixed contacts and Moving Contacts. The
Electrical Life of the contactor depends on the life of the contacts. The service Life and reliability
of Electrical contacts depend largely upon the properties of the material used for their manufacture.
DESIRED CONTACT PROPERTIES:
The Contact Material must be capable of Making, Breaking and carrying the current. Thus the
Contact material must have high electrical and thermal conductivity, high resistance to corrosion
and a current conducting oxide film which must be arc resistant, i.e. have a high melting and
evaporating point, and must be readily workable and comparatively inexpensive.
To make the circuit:
.High hardness to withstand impact on closing to permit developing the required contact
pressure.
Freedom from welding due to bouncing which may take place during closing.
Relatively low contact pressure.
Surface properties that allow metallic contact to be established during closing operation.
To carry the current:
Good Electrical and Thermal Conductivity and low contact surface resistance to reduce
wearing.
High melting temperature to resist excessive deformation, freedom from formation of
permanent welds at contact pressures within the range of currents carried.
Relatively high contact pressure and large Terminals to improve the capacity to carry currents.
To Break the current:
1. Good resistance to welding and arcing damage, to allow separation of contacts and to conserve
contact material.
2. High Melting point to reduce loss of material

4.8 COIL WINDING
WHAT IS A COIL?
 An electromagnetic coil (or simply a "coil") is formed when a conductor (usually an insulated
solid copper wire) is wound around a core or form to create an inductor or electromagnet.
 One loop of wire is usually referred to as a turn, and a coil consists of one or more turns. For
use in an electronic circuit, electrical connection terminals called taps are often connected to
a coil.
 Coils are often coated with varnish and/or wrapped with insulating tape to provide additional
insulation and secure them in place.
WINDING:
The process of wrapping wire onto a bobbin is called as Winding. There are 4 types of basic winding.
Single Layer Winding
In this type of winding, the complete slot is containing only one coil side of a coil. This type of
winding is not normally used for machines having commutators.
Fig no 4.10 Single layer winding
In single layer windings permit the use of semi enclosed and closed types of slots. Also the coils
can be pushed through the slots from one end of the core and are connected during the process of
windings at the other end. Here the insulation can be properly applied and consolidated which is
advantageous in large output machines with high voltage.The single layer windings used in high
voltage machines use small groups of concentrically placed coils.

Double Layer Winding
It consists of identical coils with one coil side of each coil in top half of the slot and the other coil
side in bottom half of another slot which is nearly one pole pitch away.
In the Fig. 2(a) there are two coil sides per slot while in (b) there are eight coil sides per slot. Each
layer may contain more than one coil side if large number of coils are required. For placing double
layer windings, usually open slots are used.
4.7 PHYSICAL FACTORS AFFECTING INDUCTANCE OF A COIL:

Inductors are classified according to core type. The core is the centre of the inductor just as the core
of an apple is the centre of an apple. The inductor is made by forming a coil of wire around a core.
The core material is normally one of two basic types: soft-iron or air. There are several physical
factors which affect the inductance of a coil.
1. Number of turns in the coil: Inductance of the coil varies as the square of the number of turns.
2. Diameter of the coil: Inductance of a coil increases directly as the cross-sectional area of the core
increases.
3. Length of the coil: Increasing the length of a coil while keeping the same number of turns
reduces the value of inductance.
4. Type of material used in the core: Inductance of a coil increases directly as the permeability of
the core material increases.
5. Number of layers of winding in the coils: Inductance of the coil increases with each layer
added.

4.10 ABOUT THE COIL:
1. Coil bobbin: This is a plastic component on which the winding wire is wound. It has a
rectangular hole which is used to place the coil assembly in the contactor over the Yoke.
2. Winding wire:It is a copper wire which is wounded on the coil.
3. Id Strip:-It is strip which is covered on the coil which the the MLFB of the coil
4. Redox Wire:-This wire is soldered to the start point and the end part of the coil.
5. Deck:-This is a plastic part which is attached to the bobbin.The two connections of the coil are
connected to the deck.
6. Terminals:-Ther are two metal strips to which the end and start points of the coils are soldered.
7. ID Plates:- These are small plastic id’s which have a colour coding and the description of the
voltage of the coil.
8. Aralditing of coils:-Aralditing is done over the coils to prevent the coil wire from breaking and
ensuring long life of the coil.
9. Cover Plates:- This is a plastic part which is put on the coil.
Testing of Coils
There are three tests of the coils

1) Resistance Test
2) Current Test
3) Continuity test

CHAPTER NO 5 INTRODUCTION TO SAP

5.1 INTRODUCTION TO SAP
“THE SAP SYSTEM”
Fig no 5.1 Sap window
SAP: A Pioneer in the business re-engineering process

SAP [System, Application and Product in data processing] is one of the widely used ERP
[Enterprise resource planning] software packages in the industry. It was established by SIEMENS
AG in 1972. Its latest package shanty 9 was introduced in 1998. SIEMENS uses the advanced
version of SAP called 4.0with lots of features in it.
ERP works on the principle of the supply chain management. It can describe as integrated
management of raw matrial supply to the delivery of the finished products. This integration
includes raw material suppliers and distribution and closes the loop with the customers
5.1 Features and function of SAP:
SAP Business One – Features and Functions

SAP Business One provides you with instant access to your critical business information, when you
need it, to run your business. This comprehensive application covers all your core operations,
giving you keen insight so you can confidently make informed business decisions.
Accounting and Financials

Financial accounting -Handle all your financial transactions, including general ledger, journal
entries, budgeting, and account setup and maintenance in one system, with comprehensive tools and
reports.
Budgeting -Manage budget creation, allocation, and distribution. Provide budget tracking,
reporting, and alerts that notify the responsible users whenever a transaction exceeds a monthly or
annual budget limit.
Banking -Track all banking processes such as cash receipts, check writing, deposits, advance
payments, credit card payments, and account reconciliation.
Financial reporting -Provide easy-to-use financial reports, including balance sheets, profit and
loss statements, cash flow analysis, transaction reports, multiperiod comparisons, and budget
reports.
5.2 Customer Relationship Management (CRM)

Sales opportunity management-Manage the entire sales process through different sales stages.
Track sales opportunities and activities, analyze their outcome, and forecast revenue potential. You
can monitor and analyze sales opportunities using dashboards and sales reports.
Web-CRM-Give your sales team the secure access to customer data over the Web wherever they
are. Provide a Web-based interface to your customers so they can log inquiries and check order
status -- all in real-time.
Customer service and support-Allow your customer service and support team to administer
customer warranty, service contracts, manage service calls, and track all customer interaction
activities.
Business partner management-Manage the master data for your resellers and channel partners to
track sales leads and opportunities, including profiles, contact summaries, account balances, and
sales pipeline analyses.
Operations and Distribution
Sales and delivery -Generate price quotes, enter customer orders, set up deliveries, update stock
levels, report on customers' current balances, and manage all billing and accounts receivables.

Purchasing -Manage and maintain your vendor contracts and transactions, including the issue of
purchase orders, updates to stock quantities, calculations for the value of imported items, return
Inventory management -Handle inventory levels, item management, price lists, special price
agreements, transfers between warehouses, and stock transactions all via integration with other
processes like sales and purchasing.
Production planning -Manage your production material requirements through a wizard-based

process that enables users to define a planning scenario in five easy steps, and predict demand
based on forecasts.industry and business needs.
E-Commerce
E-commerce -Set up your own online store that is fully integrated with inventory and financials,
including online catalog, shopping cart, order processing and notification, customer configuration
tools, and online customer services.
5.3 Features of SAP Time Management

• Monitors Human Costs
• Documents Progress of Process
• Process of Invoices
• Records External Employees’ Services
• Confirms Service Management Orders
• Maintains Planning and Progress
• Collects Data Plans and Sheets
5.4 Implementation of SAP in the companies:
There are many companies in India who recruit the professionals for working on SAP environment.
They hire and train them on SAP. Some of the companies who have implemented SAP package are
as follows
ESSAR [GUJRAT]
MAHINDRA AND MAHINDRA LTD
CADBURY
CROMPTON GREAVES
RELIANCE

5.5 SAP Easy Access
Fig no 5.2 Sap Menu bar
The new sap Easy Access user menu is user- specific point of entry into SAP system.
The user menu contains only those items – such as transactions, reports and Web addresses – you
need to perform your daily tasks.
If your system administrator has defined a user menu, it appears when you log on to the system.
If you have not been assigned a user menu, or you need to access items that are not contained in
your user menu:
Open the SAP Standard menu by choosing menu – SAP standard menu. You now have a complete
overview of the SAP System you are currently working with use the navigation area to navigate to
the items you need.
Basic SAP transaction:-

MD04 :- To create production order

CO11:- For confirmation of goods
MMBE:- For stockoverview
MBIB:-For posting of goods
MB90:- For printing of challans
CO02:-For Changing Creating production orders
Me22n:- For cancelling the PO
CO11n:-Single screen entry of confirmations
COGI:-Post process faulty goods movement
CO01:- Create production order
CO03:-Diplay production Order
CO11:- Enter time ticket
5.6 The SAP Window
The SAP window is the user interface to the SAP system.

The elements of a typical SAP window are shown below:
The standard tool bar contains buttons for performing common actions such as save and enter:
Standard Toolbar:
The Standard Toolbar contains the Command field and the standard SAP Toolbar buttons.
Fig 7.3 Tool Bar
Command Field:
Closed Command Field:
Open Command Field:

5.5 Standard Toolbar Buttons:

The SAP buttons displayed on the Toolbar provide quick access to commonly used SAP functions.
If a Toolbar button is gray, it is not available for use on that particular screen. For information on
other frequently used buttons see Getting Started: SAP Buttons.
The functions assigned to the standard toolbar are listed below:
Button Keyboard Des

Shortcut cript
ion
Enter Enter key Click on the Enter button when you want the system to validate
your field entries and move to the next function, or screen, in a
system task. Note that clicking on Enter does not save the
information you entered (see Save below).
Save Ctrl S Click on the Save button when you want to save data or save
changes to data in a system task.
Back F3 Click on the Back button when you want to move back to the
previous screen or menu level.
Exit Shift F3 Click on the Exit button when you want to exit the current menu
level or system task without saving the data.
Cancel F12 Click on the Cancel button when you want to cancel the data you
entered in the current system task.
Print Ctrl P Click on the Print button to print the SAP document displayed on
the screen.
Find Ctrl F Click on the Find button (binoculars) when you want the system to
search for words and alphanumeric combinations in the open
document or display screen.
Continu Ctrl G Use the Continue Search button (the binoculars with the + sign) to
e continue searching for a previously selected search item.
Search
Paging These four Toolbar buttons are called the Paging buttons. You use
them
to move through a long list or report.
Ctrl Page To move to the first page, click the button with two up arrows.
Up
Page Up To move up one page, click the button with the up arrow.

Ctrl Page To move to the last page, click the button with two down arrows.
Down
Help F1 The yellow question mark is the Help button. It displays generic (i.e.,
not MIT-specific) SAP Online Help. Select a field or message, click
the Help button and a definition of the field or message will be
displayed. Not all fields have definitions, and not all MIT
workstations have the SAP Online Help installed (due to disk space
constraints on the specific workstation).
None Create a new SAP session.

(PC only)
Alt F12 Displays a menu that lets you change some of the options on your
(PC only) PC such as cursor size and position. Also allows you to print your
screen
(Hardcopy).

CHAPTER 06 ROLE IN DEPARTMENT

6. 1 NATURE OF DUTIES PERFORMED
 Production planning and control.

 Creating Production Orders of Coils and Contactors.
 Checking the Status of materials of Production.
 Creating confirmation cards.
 Taking the stock of coils, creating their production orders and sending them to
warehouse.
 Checking the Orders of spare coils and manufacturing them
according to the level of urgency.
 Checking the monthly plan of contactors and planning the production of coils.
 Putting Breakdowns for Machines.
 Supplying material to the vendors.
 Planning the monthly requirements 69mm and 101mm connections and sending to
vendor.
 Sending monthly requirement of ID plates and connection to vendor.
 Planning the monthly requirements of ID strips and sending to the printing room
 To make M Report for scrap material.
 Consideration of workers suggestions and forwarding to the higher authority.
 Carrying out confirmations of spare coils and dispatching them.
 Creating Challans for sending material to vendors.
 Talking to the vendors and taking status of their requirements.

 Sending outbound list of the materials to be removed from warehouse.
 Inventory control of all parts.
 Accountability of all parts at the end of the day.
 Regular assignments.

6. 2 OBSERVATIONS MADE
1. How synthesis machine works.

2. How magnets for contactors are manufactured.
3. How winding of coil takes place in Marsilli machine.
4. Different types of coils of different voltages and different materials required.
5. How press machines works and how strip is fed as per requirement.
6. How contactors are assembled.
7. What problems are faced during winding of coil.
8. Types of layouts in different departments.
9. How contactors are inspected.
10. Different types of contactors manufactured.
11. Assembly line of Contactors.
12. Mechanism for separation of scrap in injection molding machine.
13.Working injection molding machine .
14.How coil finishing id done after winding.
15.How the scrap of press machine is distributed equally in the bin.
16. How 6 Spindle Marsilli works.
17..Different modes of material handling
18. Types of layout in coil winding department.
19. Different types of trolleys .
20. Different types of pallet trucks.

CHAPTER 07 PROJECT

7.1 INTRODUCTION
Fig no. 7.2
COIL WINDING MACHINE
This machine is used in coil winding shop of Siemens switchgear factory. This machine
can be used to wound copper wires in the bobbin, which is used in contactors, relays, etc.,
this machine is specially designed to wound copper wires thickness up to 1.2mm in
diameter. These wounded coils from this machine can be applied in different contactors
and relays.
This machine saves lot of time and effort of man required to wound the copper wire in the
required bobbin without overlapping. This machine is also has the advantage of having
very less downtime because it is very much maintenance friendly.

7.2 PRINCIPLE PARTS AND THEIR FUNCTIONS
1. PANEL BOARD: Panel board is used to mount the electronic components for e.g.
PLC, contactors, relays, fuses etc., which is used to input the program for performing
the operation on the machine.
2. STEPPER MOTOR: This motor is mainly used because it is easily controlled by

PLC programming and also used to convert electric energy to mechanical energy. It
acts as a prime mover.
3. LAYERING MECHANISM: Layering mechanism consists of a ball screw,

which feed longitudinal movement to the wire-guiding pulley.
4. OPERATOR PANEL: It consists of a display and a keypad through which an

operator can change the data like speed of the motor, no. of turns, window settings,
etc.,
5. TENSIONER: Tensioner is mainly used to give tension to the copper wire during
the operation of winding so that it wound tightly to the bobbin.
6. SPINDLE: Spindle, which consists of bearing inside to give a smooth rotation, is

used to give a rotation to the bobbin.
7. WIRE GUIDING PULLEY: Wire guiding pulley is used to guide the copper wire
during operation within the window setting of the bobbin.
8. COUPLING: Coupling here is used is flexible coupling which intern is used to

transmit the motion from the stepper motor to the layering mechanism.
9. TIMING PULLEY: Timing pulley is used to drive the motion as well as it is

mainly used because it gives proper timing of stopping and starting of the pulley and it
has a great advantage that due to its gear type profile it avoids slippage.
10. TIMER BELT: Timer belt is used to connect the driven timing pulley to the
driven timer pulley.

11. DEEP GROOVE BALL BEARINGS: Bearings rotates the shaft and the ball
screw freely and prevent the locking of it.
12. BASE PLATE: It is necessary to support all the parts of the machine. It takes all
the necessary weight.
13. TABLE: It carries the weight of base plate on top of the table and a panel on the
left leg of the table.
14. COLLET: Collet is used to hold the mandrel. And the bobbins are hold by these
mandrel and these mandrels are prepared by the users according to their requirement.
7.3 PRINCIPLE OF COIL WINDING MACHINE
The principle of the coil-winding machine is similar to that of doing thread cutting over a
lathe. Here instead of cutting thread of a specified pitch we are winding copper wire of
different thickness over a bobbin, which is rotated by the spindle. The thickness of the
wire decides the pitch of the winding which intern controls the layering mechanism in
such a way that we get uniform non-overlapping winding over the bobbin.
PRODUCT FEASIBILITY
Feasibility is the physical practicability of the product of the manufactured product.

Feasibility decides successful running of a product in the market. If the feasibility of the
product is not checked the product cannot dominate in the market.
Feasibility of the product basically depends on three main factor and are:
1. TECHNICAL FEASIBILITY
2. ECONOMIC FEASIBILITY
3. MARKET FEASIBILITY
TECHNICAL FEASIBILITY:
A product should be technically feasible in all respect. Coil winding machine, which is
basically used for special purpose operation and also in some of the companies. Since,
this machine is of lesser capacity still able to satisfy the requirement or serve the
purpose. It is smaller in size and compact which will be helpful for maximizing the

floor space efficiency. It requires less maintenance. Even if we trained an unskilled

operator he can operate the machine.
ECONOMIC FEASIBILITY:
The product manufactured should be economically feasible. One time investment

should give ten times output. It is cost effective product right from purchase to
maintenance. As this machine very little number of parts, which requires frequent
maintenance. Also manufacturing cost is less, which ultimately affect the cost of the
product. Moreover it results in automation.
MARKET FEASIBILITY:
A product proves to be successful if it is technically as well as economically feasible
i.e. the requirement of the customer should be provided at cheaper rate.
This makes our product i.e. coil winding machine more feasible in the market.
7.4 DESIGN
The term Machine Design is the creation of new and better machines and improving
the existing ones. A new or better is one which is more economical in the overall cost
of production and operation. The process of design is a long and time-consuming one.
From the study existing ideas, a new idea has to be conceived. The is then studied
keeping in mind its commercial success and given shape and form in the form of
drawings. In the preparation of these drawings care must be taken of the availability of
resources in money, in men and in materials required for the successful completion of
the new idea into an actual reality.
GENERAL CONSIDERATIONS IN MACHINE DESIGN:

Following are the general considerations in designing a machine component:
 The type of load and stresses caused by the load.
 Motion of the parts or kinematics of the machine.
 Selection of materials.
 Form and size of the parts.
 Frictional resistance and lubrication.
 Convenient and economical features.
 Use of standard parts.
 Safety of operation.
 Workshop facilities.
 Number of machines to be manufactured.
 Cost of construction.
 Assembling

GENERAL PROCEDURE IN MACHINE DESIGN:

In designing a machine component there is no rigid rule. The problem may be
attempted in several ways. However, the general procedure to solve design problem is
as follows:
 First of all make a complete statement of the problem, indicating the purpose
for which the machine is to be designed.
 Select the possible all groups of mechanism, which will give the desired
motion.
 Find the forces acting on each member of the machine and the energy
transmitted by each member.
 Select the material best suited for each member of the machine.
 Find the size of each member of the machine by considering the forces acting
and the permissible stresses for the material used. It should be kept in mind that
each member does not deflect or deform than the permissible limit.
 Modify the size of the member to agree with the past experience and judgment
to facilitate manufacture. Draw the detailed drawing of each component and the
assembly of the machine with complete specification for the manufacturing process
suggested.
 ASSEMBLY OF MACHINE
1. TABLE WITH PADDLE ASSEMBLY:
2. PANEL WITH PANEL BOARD:
3. SPINDLE MOUNTING UNIT WITH DRIVEN TIMING PULLEY
4. LAYERING MECHANISM UNIT WITH STEPPER MOTOR MOUNTING:
5. COVERING GUARD MOUNTING WITH OPERATING PANEL:
6. TENSIONER MOUNTING
7. ACRYLIC GUARD MOUNTING / SLIDING GUARD:

7.5 INSPECTION AND QUALITY CONTROL
Inspection and quality control are the essential in manufacture of any product.
Inspection is checking of the physical aspects of the product. Inspection is checking of
the physical aspects of the product being manufactured. Quality control involves
checking the quality of product, right from the stage of testing.
The project was made taking all the aspects of quality control into consideration. The
raw materials were checked thoroughly before the star of manufacturing processes.
During the process, checking of dimensions, use of good tools, correct speed, feeds
and other elements were tan care of. All the products that were brought from out side
were standard products so that in case of any trouble, they could easily made available
and replaced.
Also, it was seen that only optimum material is used for production any undue wastage
of material is avoided. The cost of the product was tried to be kept as low as possible but
at the same time no compromise on the quantity.
Thus keeping the benefit of the customer in mind the product was made and maximum
care was taken to ensure prolonged life of the product.
During the manufacturing of project a great amount of stress was given quality control.
All the necessary tests were carried out to maintain the quality of project.
Dimensions check and visual inspection were carried out during the manufacturing and
assembling of layering mechanism.
TOOLS USED
 VERNIER CALIPER
 MICROMETER
 STEEL RULER
 MEASURING TAPE
 TRY SQUARE
 DIAL GUAGE
INSPECTION FOR BEARING

The inner race of the pedestal bearing must rotate without any obstruction. There are
oil holes provided so that the bearings can be oiled regularly. Care should be taken that
the bearings are aligned are in a straight line.
INSPECTION FOR MOTOR
Check the motor for proper running of it, check the current flow, the wire, the rotors coils.
If not working in proper condition get it repaired or replace it.

CARE AND MAINTENANCE

Maintenance is very important function of preserving the machine for long life.
Maintenance should be done to our machine as follows:
 Machine should be pined properly sharpened for protection against corrosion of
metal surface.
 The bearings if the shaft or layering mechanism should be regularly greased for
smooth working of bearing for long period of time.
 The nut and bolt connection should be checked at regular interval of time.
 The bearings if the sliding door should be greased regularly for smooth working.
 Timing pulley should be checked at regular interval of time for worn out.
 Timing belt should also be checked at regular interval of time for damage or for
worn out.
 The wear and tear of the spindle assembly should be checked twice a year.
 The vibrations if noted in the machine should be immediately eliminated as soon as
possible.
 The stepper motor should be checked at regular interval of time.

7.6 COILS MANUFACTURED
There are different types of coils are manufactures within the range of 24V-
415V.These coils are assembled in different types of contactors.
Types of coils winded on Synthesis machine are:-
1. 48 - B0(24V), D0(42V),M0(220V0, U0(240V), P0(230V), F0(110V),R0(415V)
2. 50 - B0(24V), D0(42V),M0(220V0, U0(240V), P0(230V), F0(110V),R0(415V)
3. 52 - B0(24V), D0(42V),M0(220V0, U0(240V), P0(230V), F0(110V),R0(415V)
4. 54 - B0(24V), D0(42V),M0(220V0, U0(240V), P0(230V), F0(110V),R0(415V)
5. 56 - B0(24V), D0(42V),M0(220V0, U0(240V), P0(230V), F0(110V),R0(415V)
Fig no. 7.2

 ASSIGNMENT
Reducing the Scrap of the bobbins.
Percentage of Scrap before Implementation
Coil Ok Rejection This data is collected for 10 days
50 po 90 10
50 fo 100 4
50 po 72 20 No. Of coils manufactured :- 2488
50 po 72 4
50 po 15 0
No. of coils Rejected :- 190
50 po 92 8
50 po 85 11 Scrap Percentage = No. of Rejection * 100
50 po 57 9 No. of Passed coils
48 po 100 3
50 po 9 0 = 7.63%
48 po 66 7 The tolerance for scrap percent is 4%.
48 po 122 8
48 fo 110 4
48 po 103 7
48 po 90 12
50 po 83 13
48 fo 122 4
48 bo 31 3
48 fo 122 3
48 po 103 5
48 po 103 3
48 po 51 0
48 po 103 3.5
48 po 40 2
54 fo 94 2
54 po 86 4
50 fo 97 13
50 po 85 15
50 fo 76 4
50 po 23 4
56 po 86 2

 Reasons of increased scrap
1. Improper Layering
Fig no. 7.3

There was a problem in movement of the layering mechanism because of which there was
level difference in the layer of wire on the bobbin. This improper layering was not
acceptable so it was the main reason for the rejection of coil.
Improvement: - Maintenance of layering mechanism was done. Some changes were made
in that mechanism

2. Tensioner Problem
Fig no. 7.4
There was a problem in the pulley of the tensioner. During winding wire is conveyed to
the spindle from different pulleys of the tensioner. The tension provided should not exceed
specific limit or the wire will break. As there was problem in the pulleys during winding
there was excess tension due to which wire was breaking. As the wire breaks in between
winding the bobbins winded considered as scrap as the coil is not acceptable. This was
another reason for increase in rejection of coil.
Improvement: - Tensioner pulleys changed and provided tension meter on each machine
to check the tension of wire during winging process. The scrap was reduced after this
change.

3. Broken Bobbin
Fig no. 7.5
There was crack in the bobbins because of which rejection of coils was increased. The
middle part of some 50 bobbins is weak so during winding bobbin was getting damaged
which was resulting in more rejection.
Actions taken: - Created M-report for the scrap of the bobbins as it was because of
damaged bobbins. Checked the bobbins before winding and only selected bobbins were
used. Rejection of coils was reduced after this action.

Percentage of Scrap before Implementation
48 po 103 2 This data is collected for 10 days

56 po 70 1
50 po 92 3
54 m7 51 0 No. Of coils manufactured :- 2524
54 po 32 1
54 po 91 1
48 po 99 8 No. of coils Rejected :- 102
50 po 57 2 Scrap Percentage = No. of Rejection * 100
50 po 97 6
No. of Passed coils
54 po 85 6
50 po 58 5 = 4.04%
54 po 91 0
The tolerance for scrap percent is 3%.
50 po 97 3
52 po 91 1
54 po 50 2
50 po 96 5
50 fo 99 4
50 fo 99 9
48 po 103 4
50 po 85 2
50 fo 100 4
50 po 97 3
48 po 35 1
50 po 80 6
50 fo 85 3
50 po 96 3
50 fo 86 4
50 fo 99 6
48 po 103 6
50 po 97 13

 MERIT, DEMERITS AND APPLICATION OF SYNTHESIS

MACHINE
MERITS
 To wind the copper wire as a coil with less human effort.
 Even unskilled labour can operate the machine.
 The time required is comparatively less than the other methods.
 Cost of machine is comparatively less.
 Cost of maintenance is less.
 Efficiency of the machine is high.
 Different thickness of copper wires dia. up to1.2 mm can be wound.
DEMERITS
 The only disadvantage of this machine is the operator is requiring the operating
training of the machine.
APPLICATION
 The wounded coil is used for making contactors.
 The wounded coil is used for making relays.
 It is mostly used in switchgear factory.

8. BIBLIOGRAPHY
 https://www.siemens.com/in/en/home/company/about.html
 http://www.siemens.com/about/en/history.htm
 https://en.wikipedia.org/wiki/Siemens
 SIEMENS Company Literature
 https://en.wikipedia.org/wiki/Switchgear
 http://www.studyelectrical.com/2015/07/what-is-switchgear-features-components-hv-mv-
lv.html
 http://www.nikhilhydraulics.com/4%20Pillar%20Double%20Compacting%20Hydraulic
%20Presses.html
 http://ezinearticles.com/?What-Is-Switchgear-and-How-Does-It-Work?&id=5661156
 https://en.wikipedia.org/wiki/Maintenance
 http://www.cmmspro.com/types-of-maintenance.asp
 https://www.slideshare.net/AbhikRathod/types-of-maintenance-33037550
 http://www.plantengineering.com/single-article/predictive-preventive-and-breakdown-
maintenance-tips/6861d1e79fb8ecb3c9b20703c0a78dd7.html
 https://en.wikipedia.org/wiki/Preventive_maintenance
 Google Images
 http://www.detzo.com/en/portfolio-item/wave-soldering-machine/

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A Report on

INPLANT TRAINING AT WSGR PLANT,

Prepared & Submitted

Under the Guidance Of

Shri Vile Parle Kelavani Mandal’s

18th December 2017 to 2rd June 2018

(To whomsoever it may concern)

Mr. Hemant Gaikwad

( Manager , WSGR, Siemens Ltd)

SHRI BHAGUBHAI MAFATLAL POLYTECHNIC

Vile Parle (W), Mumbai-400056

This is to certify that the report entitled ‘INPLANT TRAINING AT WSGR

Internal Guide Head Of department Principal

SHRI BHAGUBHAI MAFATLAL POLYTECHNIC

Vile Parle (W), Mumbai-400056

This is to certify that the report entitled ‘INPLANT TRAINING AT WSGR

Internal Examiner External Examiner

SHRI BHAGUBHAI MAFATLAL POLYTECHNIC

Vile Parle (W), Mumbai-400056

I, Rahul Vinayak Tamhankar Roll No: 1420058 a student of VIII Semester of

RAHUL VINAYAK TAMHANKAR

I would like to express my sincere gratitude for the successful completion of my In

I express my sincere thanks to my Guide Shri Pratik Sawant (Lecturer –

CHAPTER TOPIC PAGE NO

2 SIEMENS KALWA 14-22

5 INTRODUCTION TO SAP 50-58

6 ROLE IN DEPARTMENT 59-60

7 PROJECT ON COIL WINDING 61-68

INTRODUCTION TO SAP 55-

PROJECT ON COIL WINDING MACHINE 66-80

CHAPTER 01 INTRODUCTION TO SIEMENS

Inplant Training Report Page 1

1.1 SIEMENS – A GLOBAL POWERHOUSE

Fig.1.1 Werner von Siemens, founder of Siemens

Inplant Training Report Page 2

Fig1.2 SIEMENS’ Headquarters, MUNICH

Inplant Training Report Page 3

1.2 ABOUT SIEMENS INDIA

Fig.1.3 Research & Development Building at Siemens Kalwa Works

Partnering India: Integrated solutions for a digitalized and sustainable

Inplant Training Report Page 4

Fig.1.4 Siemens Kalwa Works

Inplant Training Report Page 5

Fig.1.5 Siemens’ Factories Located Throughout India

- SIEMENS TELECOM LTD.

- SIEMENS BUSINESS COMMUNICATION SYSTEM LTD.

- SIEMENS COMMUNICATION SOFTWARE LTD.

- SIEMENS INFORMATION SYSTEM LTD.

SIEMENS INDIA- Manufacturing units

Inplant Training Report Page 6

Fig 1.6 Timeline of Milestones achieved by SIEMENS throughout 1867 to 2016

Fig 1.7 Milestones of a 170 year history of SIEMENS

Milestones of Siemens’ History

1897: Siemens & Halske becomes a Stock Corporation.

1957: Switchboards manufacture began at Worli, Mumbai.

1960: Manufacture of Switchgear began at Worli in Mumbai.

1966: First batch of Electric Motors were produced at Kalwa, Thane.

Inplant Training Report Page 8

1970: Transfer and expansion of Switchgear production at Kalwa

1975: Transfer and expansion of Switchboard production at Kalwa

1993: Assembly workshop of Medical products was set-up in Goa.

1995: Launch of Siemens Mobile phones.

1998: Separate subsidiary to handle telecom Business.