Internship Report and Project

WOLLO UNIVERSITY
KOMBOLCHA INSTITUTE OF TECHNOLOGY
COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTEMENT OF ELECTRICAL AND COMPUTER ENGINERING
5TH YEAR INDUSTRIAL CONTROL STREAM
HOSTING COMPANY: BELAYNEH KINDIE METAL
ENGINEEING COMPLEX (BKMEC)
DURATION TIME: Two Months
INTERNSHIP REPORT AND PROJECT DONE BY:
Name ID Number
1. FIKIRU HORDOFA WOUR/1421/11

2. GARUMA BELAY WOUR/1451/11
3. REDEIT HAILU WOUR/1983/11
4. SELSEBIL HABTAMU WOUR/2060/11
ADVISOR NAME: MR. BELETE B
SUBMISSION DATE
APRIL, 2015 E.C

KOMBOLCHA, ETHIOPIA
INTERNSHIP REPORT WITH PROJECT
Declaration
We are a students of Wollo University, school of electrical and computer engineering, we have
Finished our internship practicing at Belayneh Kindie Metal Engineering Complex S.C, from
March to April for two months. We declare that documentation entitled as final internship report
which is an authentic record of our work carried out at Belayneh Kindie Metal Engineering
Complex industry.
Name of Students Signature Date

1. Fikiru Hordofa _________ __________
2. Garuma Belay _________ __________
3. Redeit Hailu _________ __________
4. Selsebil Habtamu _________ __________
Advisor Name Signature Date

1. Mr.Belete _________ __________
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Acknowledgement
First of all, we would like to thank our almighty God for his infinite help from our start till the
end throughout our endeavor. Our deepest gratitude goes to Wollo University, School of
Electrical and Computer Engineering, and university Industry linkage for giving this chance of
internship program and also we would like to thankful to Belayneh Kindie Metal Engineering
Complex industry for accepting us and works in the shop for showing us an absolute
benevolence and for their complete willingness and openness to answer whatever question we
have raised out. We want to thank our whole family for their unceasing support of materials,
ideas and prayer. We consider, it as a privilege to articulate a few words of gratitude and respect
to all those deserving company operators who guided us in this internship practice. First, we
would like to extend our profound gratitude and our sincere thanks to our guide Mr. Mehari
Chuchu, company representative, who constantly supported and encouraged us during every step
doing this internship. Then, we are thankful to our advisor Mr. Belete, for his immense support
throughout this internship report. Finally, we are grateful to all friends for particularly supporting
us.
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Executive Summary
This report is mainly a record of our personal experiences in different aspects which we get
during our internship time. It consists of four chapters which all together show the general view
of the entire report. We have put the whole report format in summarized and sequential manner
as follows; the first chapter we have tried to discuss about our hosting company (BKMEC). It
starts by giving due information on company background and continues with its missions,
visions, organizational structure and work flow of the company. The second chapter which is a
part of main body is mainly focuses on, a shop we have been working, a specific tasks we was
executing, a procedure that we have followed whenever performing my tasks and the problems
and challenges that we have been faces. The third chapter covers different skill related concept
that we have assimilated during our internship in terms of, theoretical knowledge, practical,
communication, team work, technique, and work ethics. The fourth chapter contains a project
contributed to a company which is about design for fume extraction on CNC plasma cutting
table. The fifth and final chapter of the report encompasses conclusion and recommendation.
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Table of Contents
Chapter One...................................................................................................................................................1
1 Back Ground of Belayneh Kindie Metal Engineering Complex................................................................1
1.1 Introduction..........................................................................................................................................1
1.2 History of the Company.......................................................................................................................1
1.3 Vision, Mission and Objective of the company...................................................................................2
1.3.1 Vision............................................................................................................................................2
1.3.2 Mission..........................................................................................................................................2
1.3.3 Values of the Company.................................................................................................................2
1.3.4 Objective.......................................................................................................................................2
1.4 product of the company.......................................................................................................................3

1.4.1 Manufacturing...............................................................................................................................3
1.4.2 Assembly.......................................................................................................................................3
1.5 Overall Organization and Work Flow..................................................................................................4

Chapter Two...................................................................................................................................................5
2 Internship Experience.................................................................................................................................5
2.1 Objectives of the Internship.................................................................................................................5
2.2 Getting and Visiting the Company......................................................................................................6
2.3 Shops in the company..........................................................................................................................6
2.3.1. Material preparation shop............................................................................................................6
2.3.2. Fabrication Shop..........................................................................................................................7
2.3.3. Heavy Truck Assembly Work Shop............................................................................................7
2.3.4. Painting shop................................................................................................................................8
2.4 Working Sections.................................................................................................................................9

2.4.1 Overall Process Flow Diagram (PFD) of the Fabrication and Assembly of Products..................9
2.4.2 Control Unit of the Industry........................................................................................................10
2.5 The Shop that I have been working...................................................................................................12

2.6 Our performance in the work shop....................................................................................................19
2.7 Problems that we have faced in the company....................................................................................20
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2.8 Some measures that we were taken to overcome the challenges.......................................................20

Chapter Three...............................................................................................................................................21
3 The Overall Benefit that We Gained From the Internship........................................................................21
3.1 Improving Practical Skills..................................................................................................................21
3.2 Up Grading Theoretical Knowledge..................................................................................................21
3.3 Improving Inter Personnel Communication Skills............................................................................22
3.4 Improving Team Playing Skill...........................................................................................................23
3.5 Understanding about Work Ethics Related Issue...............................................................................23
3.6 Improving Leadership Skills..............................................................................................................23
3.7 Improving Entrepreneurship Skills....................................................................................................23
Chapter Four................................................................................................................................................25
4 Project Contributed to Company..............................................................................................................25
4.1 Problems Observed............................................................................................................................25
4.2 Proposed Solutions............................................................................................................................25
4.3 Abstract..............................................................................................................................................25
4.4 Introduction........................................................................................................................................26
4.5 Problem Statement.............................................................................................................................26
4.6 Goal....................................................................................................................................................26
4.7 Objective............................................................................................................................................27
4.7.1 General Objective.......................................................................................................................27
4.7.2 Specific Objective.......................................................................................................................27
4.8 Scope..................................................................................................................................................27
4.9 Literature Review...............................................................................................................................27
4.10 Methods and Methodology..............................................................................................................28
4.11 Significance......................................................................................................................................30
4.12 Materials Used.................................................................................................................................30
4.12.1 PIC16F877A Microcontroller...................................................................................................30
4.12.2 AC Power Supply.....................................................................................................................31
4.12.3 Gas Sensor................................................................................................................................31
4.12.4 Exhaust and Fan Motor.............................................................................................................31
4.12.5 Overload Relay.........................................................................................................................32
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4.12.6 Transistor..................................................................................................................................32
4.12.7 Filter Unit..................................................................................................................................33
4.12.8 LED...........................................................................................................................................33
4.12.9 Pot HG......................................................................................................................................34
4.13 Flow Chart.......................................................................................................................................34

4.14 Result and Discussion......................................................................................................................35
4.15 Limitation.........................................................................................................................................35
4.16 Conclusion.......................................................................................................................................35
4.17 Recommendation or Future Work...................................................................................................35
Chapter Five.................................................................................................................................................36
5 Conclusion and Recommendation............................................................................................................36
5.1 Conclusion.........................................................................................................................................36
5.2 Recommendation...............................................................................................................................36
5.2.1 Recommendation for the Company............................................................................................36
5.2.2 Recommendation for the University...........................................................................................37
References.....................................................................................................................................................A
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List of figures
Figure 1 History of the Company..................................................................................................................1

Figure 2 Assembled trucks.............................................................................................................................3
Figure 3 BKMEC Organization Structure.....................................................................................................4
Figure 4 Shop of material preparation...........................................................................................................7
Figure 5 Shop of fabrication..........................................................................................................................7
Figure 6 Shop of heavy truck assembly.........................................................................................................8
Figure 7 Shop of Painting..............................................................................................................................8
Figure 20 Flows Diagram of Fabrication and Assembly Product..................................................................9
Figure 27 Protections and Control Flow......................................................................................................10
Figure 8 CNC cutting machine....................................................................................................................12
Figure 9 Compressor....................................................................................................................................13
Figure 10 Filter............................................................................................................................................13
Figure 11 Torch Height Control..................................................................................................................14
Figure 12 Max PRO Power supply..............................................................................................................14
Figure 13 Shearing machine........................................................................................................................15
Figure 14 Bending machine.........................................................................................................................15
Figure 15 Drilling machine..........................................................................................................................16
Figure 16 Pressing machine.........................................................................................................................16
Figure 17 Band sew Machine......................................................................................................................17
Figure 18 Rolling machine...........................................................................................................................18
Figure 19 Lathe machine.............................................................................................................................18
Figure 30 Methods and Methodology..........................................................................................................29
Figure 31 PIC16F877A Microcontroller.....................................................................................................30
Figure 32 AC Power Supply........................................................................................................................31
Figure 33 Gas Sensor...................................................................................................................................31
Figure 34 Exhaust and Fan motor................................................................................................................32
Figure 35 Overload Relay............................................................................................................................32
Figure 36 Transistor.....................................................................................................................................32
Figure 37 Filter Unit....................................................................................................................................33
Figure 38 LED.............................................................................................................................................34
Figure 39 Pot HG.........................................................................................................................................34
Figure 40 process Flow Chart......................................................................................................................34
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List of Acronyms
CEO – Chief Executive Office

BKMEC – Belayneh Kindie Metal Engineering Complex
HD – Heavy Duty
LV – Light Vehicles
GM – Grouped Management
IT – Information Technology
CNC – Computer Numerical Control
LED – Light Emitting Diode
NO – Normally Opened
NC – Normally Closed
MAG – Metal Active Gas
TIG – Tungsten Inert Gas
PLC – Programmable logic Controller
USB – Universal Serial Bus
IDE – Integrated Development Environment
PWM – Pulse Width Modulation
ICSP – In Circuit Serial Programming
VAT – Value Added Tax
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Chapter One
1 Back Ground of Belayneh Kindie Metal Engineering Complex
1.1 Introduction
Ethiopia is among Africa’s most impressive growth performers over the past decade, largest
economy in Africa and the third largest in Eastern Africa. After Nigeria, the country is also home
to the continent’s second largest population of Africa’s above 110 million people. Undoubtedly,
Ethiopia is a relatively untapped investment opportunity in Eastern Africa especially in
agriculture manufacturing tourism and mining sector.
The Government's sets targets for further improvements in these four major areas, together with
significant reforms for continuous improvement of governance and public service delivery. The
industry sector recorded an average growth rate of 16.9% per annum which is the fastest growth
rate compare to others. The government of Ethiopia has given due emphasis to the
manufacturing sub-sector to accelerate production and productivity so as to bring
industrialization and economic growth.
1.2 History of the Company
Belayneh Kindie Metal Engineering Complex is established in June 2017 G.C, with total
investment cost of 500 million birr in Oromia regional state with the objective of playing a
leading role in the national metal products manufacturing and automotive engineering industries.
The company aimed to manufacture truck body, trailers and semi -trailers, assemble heavy truck,
luxury bus, and provision of automobiles. It has a capacity of producing 700 units of vehicles
and 700 units of trailers annually.
Figure 1 History of the Company
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1.3 Vision, Mission and Objective of the company
1.3.1 Vision
The company has a vision of becoming a leader in the national metal products manufacturing
and automotive industries while satisfying customers through high quality product and services.
1.3.2 Mission
The mission of the company is to provide competitive high-quality products and services for
customers with highly skilled business professionals and staff who are equipped with
information technologies (IT). The company is established to assemble heavy duty trucks, luxury
public transport buses and automobile in its own assembly plant and sell the products in
domestic markets.
Organizations Strategic Focus Area
 Quality and standardize of product
 Increase users coverage
 Improve workers' capacity
1.3.3 Values of the Company
 Integrity
 Work for change
 Customer focused
 Quality and safety
 Employee oriented
 Respect
 Team work
 Continuous improvement
 Social responsibility
1.3.4 Objective
The company has the following objectives: -
 To generate income (profit) to the owner,
 To manufacture and supply quality metal products and automotive to its customers,
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 To contribute to the socio-economic development of the nation at large and to the

manufacturing and automotive industrial sector.
1.4 product of the company
Belayneh Kindie metal engineering complex have a capacity of producing 700 units of vehicle
annually currently producing 2 units of truck body and trailer manufacturing and 2 units
assemble of IVECO truck. Also it is going to increase its capacity by opening its branches at
different area.
1.4.1 Manufacturing
 Truck mounted dry cargo body (18 ton)

 3-Axle dry cargo draw bar trailer (22 ton)
 3-Axle high bed semi -trailer (40ton)
 3-Axle dry cargo low bed semi-trailer (60 ton) (future plan)
 Fuel Tanker Truck (21m3)
 3-Axle Fuel Tanker draw bar trailer (24m3)
 3-Axles Fuel Semi-trailer (45m3)s
1.4.2 Assembly
 Iveco truck (380th)

 Medium Bus
 Mini Bus
 Luxury Bus (future plan)
 Automobile (future plan)
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Figure 2 Assembled trucks
1.5 Overall Organization and Work Flow
This structure is developed to achieve the company objective as well as to contribute its rule to
the industrialization of the country. This is the subdividing of work, and can be described as the
way that the roles and responsibilities are allocated to each person in the company.
CEO
Manf.ind.E.O
BK Metal eng.comp.G.M
Internal Quality control and Legal

IT Service
Audit service assurance service service
Production Design, Logistic Human

and Planning Marketing resource and
and Finance
Technical and and Sale
supply Dep’t administration
operation Control Dep’t
dep’t Dep’t
Dep’t Dep’t KIOT 2015 Page 4
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Chapter Two
2 Internship Experience
2.1 Objectives of the Internship
The objective of the internship course is to facilitate reflection on experiences obtained in the
internship and to enhance understanding of academic materials by application in the internship
setting. Internships will provide students the opportunity to test their interest in a particular
career before permanent commitments are made. So that it is more important because of:
 Internship students will develop skills and techniques directly applicable to their careers.
 Internships will provide students the opportunity to develop attitudes conducive to
effective interpersonal relationships.
 Internships will provide students with an in-depth knowledge of the formal functional
activities of a participating organization.
 To receive an introduction to an organization within the information systems industry and
to gain a better understanding of its design and structure.
 To develop an understanding of an organization's various management and technical
skills, the communications techniques and the decision-making processes.
 To apply what was learned during coursework (theory, skill development,
professionalism) to the working world.
 To allow the Intern to assume responsibilities of a non-intern staff member and be able to
function with a minimum of supervision.
 To help the student make better information systems career choices in the future.
 To allow the student to prepare for their future non-Internship job by seeking potential
places of employment, practicing resume and cover letter preparation, gaining references,
and interviewing if applicable.
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2.2 Getting and Visiting the Company
Our institution Wollo university (KIOT) has a program that links a student to different companies
through UIL, which it can able to help the students to meet to the real world of experience in their
specific fields of study that it has a capability of strengthening a practical experience. KIOT
facilitates two options to engage in to different industrial companies, the first one is searching and
find an interested company that we want by our self, the second option is that the university will
assign as anywhere they want which has related with our specific field of study. But we prefer to
choose the former one and start to search interesting companies. We searched for two successive
days and finally among different companies we preferred to select one company which is Belayneh
Kindie metal engineering complex (BKMEC) which is found in Gelan town. After we applied they
accepted us. After some days our friends had told us that they can’t continue the internship at they
applied first and they had asked us that they want to be with us for internship, then we asked the
company for them and the company accepted them.. After we enter into the organization for the
internship our supervisor maheri chuchu allocated us into some section.
For first time we are oriented about the whole system of the organization and the qualification of the
workers. They informed us, the responsibilities and duty for the time we stayed there. In general, we
are oriented the whole system of the BKMEC organization, the future career goals of the
organization and the responsibilities and duties which we had there during the internship period. But
the orientation was not need for us only the internship period, also important for our future life style.
2.3 Shops in the company
There are different shops in the company where different tasks being performed namely; Material
preparation shop, Fabrication shop, Painting shop and Heavy truck assembly work shop.
2.3.1. Material preparation shop

This shop is equipped with different machinery like lathe, milling, shearing, bending, rolling,
CNC plasma cutting, band saw and drilling machines; overhead crane with in the shop floor and
forklift for the transportation products.
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Figure 4 Shop of material preparation
2.3.2. Fabrication Shop

This shop is equipped with welding equipment like MAG, TIG, ARC machines, and different kinds
of hand tools for welding and overhead crane for the transportation of products within the shop floor.
A fuel tanker and the dry cargo bodies are being welded in this shop. Furthermore, the shop shall
have a sand blasting machinery and equipment.
Figure 5 Shop of fabrication
2.3.3. Heavy Truck Assembly Work Shop

Assembly is the process of fitting together various parts in order to create a finished product. Parts
may be subdivided in to component and sub-assemblies. This workshop equipped with brake test
machine, wheel alignment machine, light alignment machine, AC gas filling machine, 4 colon
hydraulic lifting machine, inspection equipment, different jigs and fixture for main and sub-assembly
lines and 3 overhead cranes for the transportation of products within the shop floor.
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Figure 6 Shop of heavy truck assembly
2.3.4. Painting shop

The processes involved in painting shops are: Grinding and polishing, puttying/primary coating,
preparation for painting such as covering of areas painting, Drying and inspection and dispatch.
Figure 7 Shop of Painting
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2.4 Working Sections
2.4.1 Overall Process Flow Diagram (PFD) of the Fabrication and Assembly of Products
Raw materials and

inputs receiving
and storage
Materials
preparation
Machining
Component
assembly
Finishing and
painting
Storage and
shipping
Figure 8 Flows Diagram of Fabrication and Assembly Product
Raw materials and inputs receiving and storage
 Receiving and storage of sheet metals, U-channels, I-Beams, and auxiliary materials.
Materials preparation
 Shearing/cutting, plasma cutting, bending, rolling, band saw cutting, etc.
Machining
 Lathe, milling, and grinding operations
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Components assembly
 Welding, tacking, and other joining operations
Finishing and painting
 Correcting and painting operations
Storage and shipping
 Storage, shipping of final products
2.4.2 Control Unit of the Industry

This Part is brain of the industry because the overall operating system is controlled and governed
by this unit. Every machine in the company can be controlled in two ways this are relay system
and PLC system. The user enters a program usually via software in order to give the desired
result.
1. Introduction to Programmable Logic Controller or PLC
Programmable Logic Controller or PLC is an intelligent system of modules, which was

introduced in the control, & instrumentation industry for replacing relay based logic. It is the
most widely used industrial process control technology. PLC is an industrial grade computer that
is capable of being programmed to perform control functions.
Uses of PLC:-Increased Reliability, More Flexibility, Lower Cost, Communications Capability,

Faster Response Time and Easier to Troubleshoot.
General Functions of a PLC
A PLC is a microprocessor-based controller with multiple inputs and outputs. It has the
following advantages:
 Reduced Space, Energy saving, Modular Replacement, Error diagnostics programmer,
Greater life and reliability, Logic Control, Operator control, Signaling and listing,
Coordination and communication
Components of PLC
 Central Processing Unit (CPU) , Input/output (I/O) , Power Supply and Programming
Device
Input/output (I/O) PLC
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The I/O system forms the interface by which field devices are connected to the controller. The
purpose of this interface is to condition the various signals received from or sent to external field
devices. Input devices such as pushbuttons, limit switches, and sensors are hardwired to the input
terminals. Output devices such as small motors, motor starters, solenoid valves, and indicator
lights are hardwired to the output terminals.
2. Protection and Control Devices
When motors are used, there should be the right controlling system as well as protective devices.
The power flow can be seen below.
3ϕ - supply
Bus bar
Fuse
Contactor
Overload relay/
Thermal switch
Motor/ Load
Figure 9 Protections and Control Flow
All these are connected in series and have their own rating for different KW motors.
Electric circuit should have the following main parts. These are;
 Source of energy
 The conductor
 The control device
 The load
Example assumes the motor control system as sample see below.
The controlling system for three phase motors is most of the time in star or delta. However,
sometimes both connections star and delta are used to control a motor at a time. First will be
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controlled in star connection and with application of timers the connection will change in to
delta. This connection has the advantage of minimizing starting current. A motor ready for work
can be checked whether right to work or not by using the following methods using clamp meter;
 Phase to ground should read nothing or should read in Mega ohm.
 Phase to phase reading between the three phases should be equal.
 Starting and ending terminals of the conductor in the winding should be continuous
2.5 The Shop that I have been working
Even though there are different shops in the company, as an electromechanical engineer I was
preferred to choose the material preparation shop. In this shop there are different kinds of machines
with their respective functions, the whole body of the truck has been finalized in this shop. This
shows that around half percent of the company’s task were being performed by this shop. The steel
metal sheet was first coming to this shop for cutting, drilling, bending, and rolling purpose
accordingly. The shop occupies both electrical and computer systems. For example, Plasma CNC
machine uses the principle of both electrical and computer system in performing its due function. I
was interested to do in this work shop because they are different electrically and computer activity in
this shop. In this shop there are different machine which there are used to different purpose like:
Plasma CNC machine

Plasma CNC machine is a machine device which is used to cut very strong sheet metals with
different size thickness. It has a capacity to cut a sheet metal of thickness from 6mm to 32mm by
adjusting its arc voltage ranged between 50-150v from the THC. An AutoCAD drawing has been
inserted to the plasma then by, a relay will receive the information from the plasma and transfer it to
the plasma torch through different cable lines, then the torch lights starts to comes out after the
proximity switch sensors identified the material going to be cut down. Most of the body of the truck
is being cut by this machine and next forwarded it to the intended machine. CNC machine has
different components in which each of the components has their own crucial role on functioning the
machine. These are Compressor, Filter, max pro power supply and torch height control (THC).
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Figure 10 CNC cutting machine
 Compressor
The role of compressor in functioning plasma CNC machine is so significant. The cutting
laser medium is mainly generated from this device. Due to the high pressure and
temperature generated in this device the CNC machine uses as its own driving force to
cut down very strong sheet metal according to the drawing provided.
Figure 11 Compressor
 Filter
Filter is a device which used to prevent a moisturized air coming from the compressor
due to the high temperature generated. Before the compressed air going to the power
supply the water particles are extracted by this device.
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Figure 12 Filter
 THC
This device is mainly used to control the plasma torch in managing the arc voltage, the up
and down of the torch and the minimum height between the plate and the torch. This
allows the system to maintain proper torch height regardless of variations in the material,
or flatness of the cutting bed. It sends different information to the relays then to the
plasma torch. When an error occurred to the CNC machine, alarms are screen out in this
device in which the operators can easily identify the problems that leads to maintain it in
appropriate and accurate way.
Figure 13 Torch Height Control
 Max PRO Power supply

The power supply is a 200A, 165 VDC constant-current supply. It contains the circuitry
to ignite a torch, plus a heat exchanger and a water coolant which is intended for cooling
of the chopper and torch. It has a discrete machine interface to provide communication
with a CNC. The maximum production cutting capacity of the MAXPRO200 torch is
32mm (1-1/4inches) for mild steel using the 200-amp O2/Air process, 22mm (7/8 inch)
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for stainless steel, and 19 mm (5/8 inch) for aluminum using the 200-amp Air/Air
process.
Figure 14 Max PRO Power supply
Shearing machine
The first step in fabricating a sheet metal component is cutting to size. Shearing machines
perform this function. Shearing operations are performed by the action of two blades, one fixed
in the shear bed and the other moving vertically with little or no clearance. The typical shears
consist of a fixed bed to which one blade is mounted, a vertically advancing crosshead and a
series of hold down pins or feet that hold the material in place while the cutting occurs
Figure 15 Shearing machine
Bending machine
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This type of machine is mainly used to bend a metal sheet which is already cut down by the CNC
machine or shearing machine, using a high pressurized hydraulic lifting system. This machine
has also a relay which sends the drawing specifications from the screen to the bending plate.
Mostly this machine is used in this shop for bending the trailer of the dry cargo and bending the
wave and chancy of the truck that the trailer putted on it later. It is a computerized machine in
which one can adjust the bending angle of the sheet metal from the screen after the drawing has
been inserted.
Figure 16 Bending machine
Drilling machine
Drilling machine is a machine that used to make a hole by changing the driller with diameter
arranged. It works with principles of hydraulic system that an operator manages the speed of
drilling manually whether to clockwise or anticlockwise. An oil is added to the machine for the
purpose of lubrication.
Figure 17 Drilling machine
Pressing machine
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Pressing machine is a machine that used in the manufacturing industry to deform a work piece
under high pressure to change the shape of a work piece. It works by pressing a plate or die onto
a work piece. They are controlled by one or more workers known as tool setters who position the
work piece and control the machine press. Once the work piece is positioned underneath the
machine press’s plate, the tool setter activates the machine press. Using hydraulic pressure, the
machine press pushes the plate against the surface of the work piece, which causes the work
piece’s shape to deform.
Figure 18 Pressing machine
Band sew Machine

Band sew machine is one of the very common manufacturing processes used in machinery shops
and industries to manufacture high precision products and parts in different shapes and sizes.
With the help of the Band sew machine one can perform operations and functions starting from
small objects to large size (20-65mm Band sew machine is machine that used cut different
thickness of metal in different shape. Due to it is hydraulic machine it use heroic for cooling part
of machine and make pressure while cutting machine. Band sew machine is different from other
machine by many ways.it can cut different shape like circle, rectangular, triangular and it can
rotate any directional.
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Figure 19 Band sew Machine
The Band sew machine has got the cutter installed up on it which helps in removing the material
from the surface of the work piece. The cutters are made from highly resistant materials that are
durable and produce less friction. There are two types of milling machine named, vertical and
horizontal knee Band sew machine. A Bad sew machine which is found in this shop is a
horizontal knee type in which the cutters are placed on a horizontal arbor.
Rolling machine
Rolling machine is a machine that will roll different kinds of metal sheets in to a round, semi
round or conical shape. The rolling machine boasts a working mechanism that allows it to bend
flat sheet metal in to a large arc or cylinder or even an ellipse shape. Utilizing a series of precise
and strong hardened rolls powered by either hydraulic or mechanical methods, the rolls are
brought into a pitching position with the material desired to be shaped. Once the material is
firmly held between two of the rolls, a third roll is brought into position pushing the material
causing the initial bend, or what is referred to as the pre-bend. The rolls then begin to rotate
pulling material through the pinched rolls and past the pushing rolls forcing an arc in to the
material. The machine which is used in this workshop is mainly works with the principle of
mechanical gearing system. Its work in the shop is only limited to roll a fuel tanker trailer
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Figure 20 Rolling machine
Lathe machine
A lathe is a multi-functional machine tool that rotates a work piece about an axis of rotation to
perform various operation such as cutting, knurling, sanding, facing, polishing, grooving, tapping
reaming and turning with tools that are applied to the work piece to create an object with
symmetry about that axis.
Figure 21 Lathe machine
The procedures we followed while performing our task

To achieve our goal of internship we have been following the best approach that leads us to
dedicated destination. Procedures we have been used during our internship period in BKMEC
are:
 Maintaining a good communication with our supervisor and all workers.
 Identifying the task we working on or in other word listening the information, instruction
and suggestion of our supervisor carefully by taking a note.
 Report the weekly report as scheduled for us.
 Analyze each project and works which assigned to our group.
 Work three days per week
 Inquiring unclear parts from anyone in the organization with a positive approach.
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The main support we have got from the supervisor

Our supervisor tells us the whole things that he knows, which concerned us with related hosting
organization.
 He showed us each and every things what we want to see, also by communicating
Professionals With us for more description.
 He answered the question that we raised during the internship period.
 He told technical operation of the work shop equipment and their maintenance system.
 He showed us the function, application and purpose of the different Movable and Non-
movable equipment found in the organization.
 He also shared us his experiences or the updated part that he had during his work life.
2.6 Our performance in the work shop
During our stay in the company we were performing different tasks with the fellow employees of
the company. Since we was not that much familiar before with such kinds of practical world, it
was difficult for us, at first to easily introduce to the different computerized machines in the
shop. On our first week of internship we had acquainted different machines available in the
company with their respective working principles. Then in the next week, we was able to operate
different machines and also do maintenance with the rest workers when failures have happened.
Most of the failures are happened on the plasma CNC machine since, it is computerized and
sensitive. Some workers tried to operate the machine without having enough knowledge about
the machine, at that time failures might happen. Whenever failure happens on CNC machine, an
alarm would be screen out on the THC which tells that on which part of the machine is the
failure happened. For example, if an alarm E5 screen out on the THC, we have abled to
understand from the manual that, there is a problem on the proximity switch which unable the
torch plasma to detect the material to be cut and which also has an effect on the arc voltage that
manage the voltage going to the torch plasma according to the material size to be cut. So, after
identifying the problem we can able to maintain it whether by changing the proximity switches
or by checking the proximity switch set properly on the torch plasma. The other most important
thing that we have achieved during our internship period was that designing a mobile fume
extractor device which used to suck the fumes and different particles that comes out of the CNC
KIOT 2015 Page 21

machine and welding machine that enables to prevent the operators from different respiratory
diseases and cancer.
2.7 Problems that we have faced in the company
The main problem that we have faced during our internship period was the safety problem. In the
shop we have been working, there are a lot of difficulties which makes us to be susceptible to the
injury. The fume which comes out of the CNC machine and the high noise that comes from
shearing machine at the time of cutting were among the problem we encountered. We have tried
to overcome those problems by wearing our own mask but which is less efficient to prevent us
from the fume and putting some softs into our ear to prevent the high noise at minimal amount.
2.8 Some measures that we were taken to overcome the challenges
During our stay at BKMEC we were faced different challenges as we have tried to express
above. Also we were tried to give solution for that problem as much as possible for us.
 We have identified problem in material preparation shop which can affect workers.
 We have designed project of removing that problem and can care health of workers.
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Chapter Three
3 The Overall Benefit that We Gained From the Internship
Primarily when the fourth month duration they have got knowledge about different things and
also they developed the theoretical knowledge in to practical knowledge by understanding the
science parallel with it. In general the following skills are some of the skills that every intern will
be obtain with duration of the internship program.
3.1 Improving Practical Skills
 Investigate organizational cultures and work habit of a factory.

 Understanding methods of laying raw material in factory workshop.
 Identifying different parameters specification while buying raw material.
 We have seen different way of raw material mixing in workshop room.
 Knowing reason of mixing and its advantage.
 We have also consolidated knowledge to distinguish and analyzed raw material quality
control before starting the process.
 We have also knowledge about working principle and sequence of operation of material
preparation, machining, component assembly & finishing and painting.
 Understanding machine maintenance requirement and working procedures.
 Having knowledge about each sample checking in finishing department before starting
mass production.
 We have also got the knowledge how to change customer order in to manufacturing
process.
 Knowing methods of car quality checking.
3.2 Up Grading Theoretical Knowledge
Our theoretical knowledge is up grading with the intern through;

 Safety rule of each operation.
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 Methods of problem identification and way of response.

 Referring different manual of machine.
 Working mechanism of different machinery.
 Passage of raw material in different section.
 Identifying parts of a machine which are mainly need series maintenance in different
department.
3.3 Improving Inter Personnel Communication Skills
The internship allow as to meet people who may help us land a job later on and give us the
contacts in the industry. Really, we have seen that without effective communication skills, an
employee cannot succeed in the workplace. If communication can fail or if a message can be
understood in different ways, it will be understood in the way which does the most harm.
Generally we have gained the following interpersonal communication skills .We have been
developed:
 Listening skill,
 Forwarding precise messages or instructions,
 Providing positive reinforcement to subordinates.
 We do not dictate or criticize a person's work in front of others and understanding about
their needs.
 We are interested in the people communicating with us.
 We learn from one another interactions by correcting our faults.
 Communicate effectively
 Practice personnel and social responsibility
 Demonstrate social and global competence
 Help us understand the intensions, motivation and deserve of other people.
 Allow us to work effectively with others and generally the inter personnel
communication skill used to strengthen employ moral and loyalty.
 Improve meeting productivity resolve work place conflicts effectively.
 Reduce office stress and absenteeism.
 Maximize the potential of all employs.
 Prompt employs personnel growth.
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 Building positive group spirit.

 Improve work place moral with none violent.
3.4 Improving Team Playing Skill
 Sharing and being open mind for others idea & preferring working by group is better than
a work done a single.
 It is adopted by following idea with my friend.
3.5 Understanding about Work Ethics Related Issue
 As an engineer we have seen that the decisions made will cost too much if they are not
appropriate.
 Awarding principle of being ethical.
 Our work habit must be change always being eager to know something new should be
our habits. We are developing the work habit.
 Give respect and love for our job, love our discipline when we have seen on the practical
world and being punctual.
 Develop importance of unity in working place.
 Consolidate the behavior of being diligent.
3.6 Improving Leadership Skills
Leadership, a critical management skill, is the ability to motivate a group of people toward a
common goal. These items will help us to develop our skills as a leader;
A. Getting and giving information
B. Understanding group needs and characteristics
C. Knowing and understanding group resources
D. Managing the group
3.7 Improving Entrepreneurship Skills
We have also learned from the internship skills. There are many entrepreneurs in the company
that they improve to identifying the problems, designing problem solution and interfacing
devices with software controller. In general we strongly recommended maintaining, designing
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problem that seen, preparatory process and finishing work about different machines in factory
are some of major area for entrepreneur. Because of needs lower costs and less energy
consumption.
A person being entrepreneur they should have the following characteristics.

 Risk taker
 Creativity
 Innovative
 Self confidence
 Commitment
 Hard work
Advantages of entrepreneurship;
 To improve backwardness of the people.
 To properly utilize the resource.
 Proper utilization of human potential.
 To achieve economic development of the region.
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Chapter Four
4 Project Contributed to Company
Title: Design and Simulate Automatic Fume Extraction System for CNC
Plasma Cutting Table
4.1 Problems Observed
 Difficult to supplying heavy steels for cutting and bending, to shearing and bending
machine respectively uses many workers, time loss and much energy losses.
 Difficult for forklift to entering heavy steels in to workshop; for example 25ton steel.
 Noisy sound is reflected from different working machine that disturbs the workers,
operators and also others who enters in to workshop.
 The fumes that are generated from CNC plasma cutting machine, soldering and welding
machines (the selected one).
4.2 Proposed Solutions
 Design movable table in wheel which will drive and lift up with motor to supply steels
for bending machine, shearing machine and also for entering heavy steels in to workshop.
 They may design a sound absorption system for the workshop and pulls up through the
upper part of the house.
 Design fume extraction system for the machines that produces fume at their operating
time
4.3 Abstract
In BKMEC there was not fume extractor for CNC plasma cutting table and also for welding and
soldering machines. They use cutting underwater for plasma cutting to reduce the radiation and
fume, but it was not sufficient to remove toxic on the working place. The fume generated during
plasma cutting contains metals and compounds that are dangerous when inhaled by machine
operators. During the plasma cutting process, the fume that is transmitted may include nitrogen,
argon, hydrogen, and mixtures with oxygen. Plasma cutting processes generate fume that can
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contain a variety of harmful oxides, it will be dangerous to machine operator even for others near
to cutting place. The particle size in plasma fume impacts the overall toxicity level. Fume made
up of smaller particles create higher, and more severe, exposure risks when fume extraction
systems are not implemented. Plasma cutting utilizes high-temperatures to split metals like
aluminum, stainless steel, and copper. When metals coated with materials like hexavalent
chromium (to avoid corrosion) are being cutting, they release particulate that can result in eye,
skin, and respiratory system issues. These contaminants must be extracted at the source to protect
workers from severe health and safety risks. For CNC plasma cutting table fume extraction
systems are designed to deliver high-quality standards and long-lasting performance to ensure
100% customer satisfaction.
4.4 Introduction
There has been a considerable expansion in the use of plasma cutting and this can be expected to
continue. This has particularly been the case with hand held systems which will be found in use
in a range of industries from heavy fabrication to motor vehicle repair.
CNC plasma cutting systems use gas, generate fumes and also generate gases. Plasma cutting
system is also likely to produce harmful levels of noise.
Our project advises on fume and gas produced during plasma cutting and on methods of
reduction and control. Our project may be issued to users of plasma cutting equipment in
industries, especially in BKMEC industry and also in everywhere they used on.
4.5 Problem Statement
Plasma cutting creates a brand of smoke which is highly hazardous. This is called hexavalent
chromium (Hex Chrome). This element is recognized to be cancer causing agent. Inhaling of this
increases the probability of lung cancer, damages to kidneys and intestines. Exposure to this
element creates throat and nose irritations, rashes, eye damages [8]. Because of these hazards, it
is mandatory that the workers get proper protection from hex chrome.
4.6 Goal
There are some goals of our project that as follows: -

 To remove the fume that was released from the CNC plasma cutting machine.
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 To improve the accuracy and precision in working.

 To smooth the work for effective production.
 To reduce the risk that will bring from those cause.
4.7 Objective
4.7.1 General Objective

 Design the fume extraction system for CNC plasma cutting table using ARDUINO UNO
ARDUINO UNOARDUINO UNO
4.7.2 Specific Objective

 Design ac motor for fan rotation
 Design sensor to detect fume release from plasma cutting table
 Design fan type or fan load
 Design tube for absorption
 Design fume storage and filtration system
 Simulate with ARDUINO software
 Integrate the overall system and implement it
4.8 Scope
Our project is only done for removing fume by using fume extractor which was released from
CNC plasma cutting table.
4.9 Literature Review
Related Works
Hypertherm, (2018) defines any table smaller than 5 by 10 feet; a water based fume control
system can consist of a simple tray or pan, about 4 to 10 inches deep that holds water. You can
choose to have your water level high so it touches the bottom of the plate being cut, or you can
lower the level to leave a few inches between the water and your plate. This is the cheapest,
easiest way to trap particulates from the cutting process. However, if you own a larger table,
you’ll likely want to opt for a more complex water table design with deeper tanks, removable slat
assemblies, and pneumatically controlled mechanisms to help control the water level [1].
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C.B. Solnordal, P.J. Witt, A. Manzoori, H. Namavari, E. Niknejad, M. Davari, the operative
engineering measures during the implementation of welding fumes in the automotive industries
by recording different level of efficiency of Local exhaust ventilation either in construction field
or in different manufacturing industries [2].
Witt, P. J., Solnordal, C. B., Mittoni, L. J., Finn, S., & Pluta, J. (2006), indicated that the
open nature of the ducting led to only very low flow rates and velocities in individual extraction
lines. The model also quantified the maximum flows that could be expected through the existing
hoods using the existing plant equipment. These flow rates were used to determine the
appropriate conditions under which CFD analysis of the hood should be performed [3].
Controlling Plasma Cutting Fumes with LEV indicated that Local Exhaust Ventilation
(LEV) should be installed in environments where plasma cutting takes place and a risk has been
identified. It is most appropriate for use at lower powered mechanised systems or hand-held
cutting systems. Whilst mechanised systems are available, the majority of plasma cutting
equipment is operated manually; thought should be given to the type of cutting being used when
determining LEV requirements [4].
Rapid welding and industrial supplies says that only with at-source extraction is the welder
protected and accumulation of welding fumes in the work shop prevented. Source capture
methods are preferably integrated in the workspace such as a downdraft and backdraft
workbench which is a combination of workbench and fume extractor. Other methods are
extraction arms that can be easily positioned close to the source or welding guns with integrated
fume extraction [5].
4.10 Methods and Methodology
Our first work is to identify the problem statement method and define the objectives of this
project which is followed by the literature review where all the different theoretical information
about the project had seen. Then design the system followed by system design and simulation
result. The final stage is the conclusion and recommendation.
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General block diagram of the system is follows;
AC Power
Sensor
Level Motor
Detecti
Relay
Fume
Released
From
LED
Cutting
ARDUINO UNO
Figure 23 General Block Diagram
4.11 Significance
 Smooth the work for fast and effective production.

 The health of the workers is saved.
 Effective time consumption for work.
 Increase the precision of worker on working.
4.12 Materials Used
4.12.1 ARDUINO UNO

ARDUINO Uno is an open-source microcontroller board based on the processor ATmega328P.
There are 14 digital I/O pins, 6 analog inputs, a USB connection, a power jack, an ICSP header,
and a reset button. It contains all the necessary modules needed to support the microcontroller.
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The board is equipped with sets of digital and analog input/output (I/O) pins that may be
interfaced to various expansion boards (shields) and other circuits. The board has 14 digital I/O
pins (six capable of PWM output), 6 analog I/O pins, and is programmable with the ARDUINO
IDE (Integrated Development Environment), via a type B USB cable. And in this project over all
automatic detection and extraction system was controlled by it (ARDUINO UNO).
Figure 24 ARDUINO UNO Controllers
4.12.2 AC Power Supply

A power supply is an electrical device that supplies electric power to an electrical load. The main
purpose of a power supply is to convert electric current from a source to the correct voltage,
current, and frequency to power the load. As a result, power supplies are sometimes referred to
as electric power converters.
Figure 25 AC Power Supply
4.12.3 Gas Sensor

Gas sensors (also known as gas detectors) are electronic devices that detect and identify different
types of gasses. They are commonly used to detect toxic or explosive gasses and measure gas
concentration. Gas sensors are employed in factories and manufacturing facilities to identify gas
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leaks, and to detect smoke and carbon monoxide in homes. Gas sensors vary widely in size
(portable and fixed), range, and sensing ability.
Figure 26 Gas Sensor
4.12.4 Exhaust and Fan Motor

A device which utilizes a fan using negative draft to pull fume and dust particles in to contained
filtration system. This process removes hazardous particles from the air. Exhaust fans draw the
hot or humid air from within and push this air out from the shaft window while replacing it with
fresh air from outside. It attracts warm air and expels it out through a duct. Different Types of
Exhaust Fan Motor usually have single phase induction motors, like that of ceiling fans. They are
designed according to the functions they need to serve.
Figure 27 Exhaust and Fan motor
4.12.5 Overload Relay

An overload relay is an electrical device used to protect an electric motor from overheating. So it
is essential to have sufficient motor protection. An electrical motor can be operated safely with
the help of overload relays. The relay protects the motor that intended to detect overheat if an
electric motor gets heated.
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Figure 28 Overload Relay
4.12.6 Transistor
A transistor is a miniature semiconductor that regulates or controls current or voltage flow in
addition amplifying and generating these electrical signals and acting as a switch/gate for them.
Typically, transistors consist of three layers, or terminals, of a semiconductor material, each of
which can carry a current.
Figure 29 Transistor
4.12.7 Filter Unit

A device which is used to filter the fume released from plasma cutting and collected in filtration
system. Fume is collected in her when a motor alternates fan after utilized, so it extracts fume
inhaled and again exhaled out through the pipe in to filtration system.
They have four layers for filter system;
First layer: - cotton primary, PM10 filter, replace per 14-30 days
Second layer: - cotton primary, PM10 filter, replace per 14-30 days
Third layer: - Activated cotton filter, traps harmful gases, replace per 3-6 days
Fourth layer: - HEPA H13, PM0.3 filter, replace per 6-12 days
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Figure 30 Filter Unit
4.12.8 LED
A light emitting diode (LED) is a semiconductor device that emits light when an electric current
is passed through it. Light is produced when the particles that carry the current (known as
electrons and holes) combine together within the semiconductor material.
Figure 31 LED
4.12.9 Pot HG
Potentiometer is a manually adjustable variable resistor with 3 terminals. Two of the terminals
are connected to the opposite ends of a resistive element, and the third terminal connects to a
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sliding contact, called a wiper, moving over the resistive element. Used with Gas sensor in this
project to detect the fume.
Figure 32 Pot HG
4.13 Flow Chart
The flow chart of the project is as follows;
Is Sensor Relay1 Filtration

ON Fresh Air
Detects Yes System
Motor1 Released
Fume?
N
o
No Operation
(No Fume)
Figure 33 process Flow Chart
4.14 Implementation
Implementing the flow of this project is simple and clear. There is assumption for the sensor and
extracting system. Firstly, there is the fume generated and detected by sensor which is starting
motor to suck the fume by relay is closed and stopping motor not to suck the fume by relay is
opened, since the fume can be detected or not detected by sensor. The sensor has been
programmed to detect the correct character of their state to on or off the extracting system.
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4.15 Extracting System
Those extracting indicates the system is supplied, this means when the system will supplied, the
LED red will light up or the power supply utilizes the system, meaning the fume was not
detected at the sensor or sensor does not detect the fume from the cutting place.
Figure 34 Extracting System Supplied
Those extracting indicates the system starts to extract the fume, this means a relay closed and
motor runs, and LED yellow will light up, and meaning fume was detected at the sensor or the
sensor detect the fume from the cutting place.
Figure 35 Extracting System Start to Suck the Fume
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4.16 Result and Discussion
When the system or the extracting system is utilized, the LED red was lighted up; this indicates
the power supply was putted to system. When a sensor was toggled or it would be high, LED
yellow lighted up and the relay closed; this indicates the motor starts to run and fume was sucked
automatically to the filter system and the filter system filters the fume within it and releases fresh
air to the surrounding. But a sensor was not toggled or it would be low, LED yellow disappeared
and the relay opened; this indicates the motor stops to run and has not fume at cutting place.
4.17 Limitation
The limitation of a project is costly in price but effective in work satisfaction for workers. The
CNC plasma cutting table is about 20m x 2m size and when we use one low capacity motor
cannot able to extract fume at all size of the table. Then we can use a high capacity motor or very
high fume absorption motor; that means the motor is very costly. The project limitation is the
motor we will use is costly in price for our effective work.
4.18 Conclusion
Cutting steels comes with its fume or smoke often called the cutting fume. This is not good for
health if a worker or a person exposed to it for too much time. This fume contains carbon
monoxide CO, carbon dioxide CO2, Trioxide O3, and Methane CH4 which can damage the
functions of the human lungs, liver, and kidneys. To absorb or extract this toxic fume we needed
to have good automatic fume extractor for cutting plasma releasing fume in the workshop. This
can be cutting plasma fume extraction unit.
4.19 Recommendation or Future Work
We would recommend that a company be uses those fume extraction system for this CNC
plasma cutting machine releasing fume to prevent toxic and also for Soldering machine or
welding machine. Because of we see there have no fume extraction system for different fume
releasing machines in the company. This may causes toxic to workers. We would recommend
that the company they use this effective fume extraction system. If a company will be invite me,
I will have design the fume extractor for different fume generating machines to remove toxic for
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effective production and workers satisfaction. And I want to use four low in price motors for
20m x 2m table size which one motor extract fume at each 5m.
Chapter Five
5 Conclusion and Recommendation
5.1 Conclusion
During this internship we met many kinds of people. Some were really voluntary they teach us
things we do not know, welcome us with great spatiality, and take care like we were work there
for a long time. We gain a lot of experience from those people. While staying for four months in
the factory, we have seen different three phase motors with their internal parts and how to
operate them, different machines with their operations and how to maintain them based on their
problems using wiring diagram from the manual when complex problem arises. Consequently,
we are lucky to be in BKMEC, because we have gathered much knowledge about what we have
studied in class. And there are things that we have to apply what we learn in order to achieve the
goal. Overall we are very happy with our internship period to gain many valuable experiences
from this internship.
5.2 Recommendation
5.2.1 Recommendation for the Company

Concerning on whole internship program we recommended the following in Host Company.
 Medical facilities are not given in all. So the company should give the medical facilities.
 We recommended that the company has a library which will help the interns to have
sufficient knowledge and better skills.
 We recommended that the cleaners who clean the workshop clean outside of working
hours. Because when the workers come in to work and the shop is on cleaning, the dust
causes the workers to irritated, so we say that this need to be improved.
 The company should plant good air conditioning system for worker in order to get
refreshed air during working time. It should help workers to fulfill their responsibilities
effectively.
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 They should write their vision, mission and values of company in front of entrance,
instead of put document in the training office.
 Provide enough manuals for interns including 3D view for the example sometimes they
place formworks in appropriate area.
 They should provide office for interns and pay pocket money.
 Some machines do not have sufficient manuals and have no manuals for inters; they
should provide manuals for practitioners in order to increase experience and to get more
knowledge.
 There are also problems in workers regarding to respecting of work time or on
punctuality. Therefore, it should be proper.
 In the time of production the workers some workers are not do well, so supervisors
should manage the activity of workers continuously as well as fulfill his responsibility.
5.2.2 Recommendation for the University

Universities are providing good opportunities for students in this internship program. But we
would like to recommend our University to do the following during the whole academic session.
 So that our University itself can arrange for students to do an internship at a company that
is close to them according to their needs. Because of some students are unable to afford
their foster parents to support them, the student faces a lot of problems.
 The university should have striven more on quality of education by preparing good
facilities like laboratory, library, work shop and others.
 The teaching learning method shall be more practical other than theoretical, for that to
make the students full confidential and good professional in the field of study.
 Our department is not successful reedy to internship for our, so we recommend to not
contend by this position to the next generation.
 Our University’s intern students who go for internships are not paid enough money in
their time allotted, so we recommended that the University look into this and improve it.
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References
1. Hypertherm, (2018), Retrieved from
https://www.hypertherm.com/en-US/resources/spark-the-blog/fume-%20control/?
region=NART
2. Witt, P. J., Solnordal, C. B., Manzoori, A., Finn, S., Pluta, J., Namavari, H. ... & Davari,
M. (2005). Reducing fume emission from smelting vessels using combined CFD and
engineering modeling. In John Floyd International Symposium on Sustainable
Developments in Metals Processing, NCS Associates (pp. 381-392).
3. Witt, P. J., Solnordal, C. B., Mittoni, L. J., Finn, S., & Pluta, J. (2006). Optimizing the
design of fume extraction hoods using a combination of engineering and CFD
modeling. Applied mathematical modeling, 30(11), 1167-1179.
4. Controlling Plasma Cutting Fumes with LEV Retrieved from https://www.vent-
tech.co.uk/dust-and-fume-extraction/
5. Rapid welding and industrial supplies” Fume extraction easy solutions guide for source
extraction” retrieved on April 5, 2023
6. https://microcontrollerslab.com/pic16f877a-introduction-features/
7. https://en.wikipedia.org/wiki/Power_supply
8. Gibson, H. Plasma Cutting Using a Hand Held Machine. Plasma Cutting Dangers 2013 retrieved
on April 1, 2023
9. Website of BKMEC (Belayneh Kindie Metal Engineering Complex)
10. Daily reports from the company
11. Electrical machines textbook
KIOT 2015 Page A

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WOLLO UNIVERSITY

KOMBOLCHA INSTITUTE OF TECHNOLOGY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTEMENT OF ELECTRICAL AND COMPUTER ENGINERING

5TH YEAR INDUSTRIAL CONTROL STREAM

HOSTING COMPANY: BELAYNEH KINDIE METAL

ENGINEEING COMPLEX (BKMEC)

DURATION TIME: Two Months

INTERNSHIP REPORT AND PROJECT DONE BY:

1. FIKIRU HORDOFA WOUR/1421/11

APRIL, 2015 E.C

Name of Students Signature Date

Advisor Name Signature Date

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1.3.3 Values of the Company.................................................................................................................2

1.4 product of the company.......................................................................................................................3

1.5 Overall Organization and Work Flow..................................................................................................4

2.3.2. Fabrication Shop..........................................................................................................................7

2.3.3. Heavy Truck Assembly Work Shop............................................................................................7

2.3.4. Painting shop................................................................................................................................8

2.4 Working Sections.................................................................................................................................9

2.4.2 Control Unit of the Industry........................................................................................................10

2.5 The Shop that I have been working...................................................................................................12

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2.8 Some measures that we were taken to overcome the challenges.......................................................20

4.7.2 Specific Objective.......................................................................................................................27

4.12.2 AC Power Supply.....................................................................................................................31

4.12.3 Gas Sensor................................................................................................................................31

4.12.4 Exhaust and Fan Motor.............................................................................................................31

4.12.5 Overload Relay.........................................................................................................................32

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4.12.7 Filter Unit..................................................................................................................................33

4.12.9 Pot HG......................................................................................................................................34

4.13 Flow Chart.......................................................................................................................................34

5.2.2 Recommendation for the University...........................................................................................37

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Figure 1 History of the Company..................................................................................................................1

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CEO – Chief Executive Office

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1 Back Ground of Belayneh Kindie Metal Engineering Complex

1.2 History of the Company

Figure 1 History of the Company

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1.3 Vision, Mission and Objective of the company

 Increase users coverage

 Improve workers' capacity

1.3.3 Values of the Company

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 To contribute to the socio-economic development of the nation at large and to the

1.4 product of the company

 Truck mounted dry cargo body (18 ton)

 Iveco truck (380th)

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Figure 2 Assembled trucks

1.5 Overall Organization and Work Flow

Internal Quality control and Legal

Production Design, Logistic Human

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KIOT 2015 Page 6

2.2 Getting and Visiting the Company

2.3 Shops in the company