Industrial training On Eastern tubes limited: observation of manufacturing process of fluorescent tube light and machinery, which use

in production.

EASTERN TUBES LIMITED

AN ENTERPRISE OF BANGLADESH STEEL AND ENGINEERING CORPORATION

Submitted To: Engineer Md.Zoinal Abedin Additional Chief engineer (Electrical) Eastern Tubes Limited 374. Tejgoan Industrial Area, Dhaka.

Submitted By:
MD.MOSTOFA KAMAL 4TH YEAR 1ST SEMESTER REG.NO:06208007 ROLL NO: 07 & MD.HAMIDUL ISLAM 4TH YEAR 1ST SEMESTER REG.NO:06208001 ROLL NO: 01

Department of Electrical and Electronic Engineering The University of Asia Pacific

Acknowledgement
Preparing this Industrial Training report on Manufacturing process On Fluorescent tube light and the function of Machinery which used in the production of Tube lights. It is a wonderful experience for us. First of all we would like to thank the Almighty Allah for supporting us on our work. We would like to thank our honorable Teacher Dr.Yakub Hossain, professor Department of Electrical and Electronic Engineering for his constant guidance and support. we would like to acknowledgement and thank to Nizam Uddin Ahmed Additional chief personal administrative officer and Mr.Apurbo kanchan das gupta Managing Director of Eastern Tubes Limited for giving us the opportunity to work Eastern Tubes Limited. we would grateful to Mr.Zoinal Abedin Additional Chief Engineer(Electrical),Mr.Abdul Hadi Engineerof production,Mr.Sadak Ali (Executive Engineer) of Eastern Tubes Limited .we would also thank Mr.Anwarul Haque(Quality control officer) for providing us with the required information and in Clearing all the quarries. We also thank the entire employee for their support.

BACKGROUND OF THE INVENTION OF FLUORESCENT TUBE LIGHT 1. Technical Field This invention relates generally to electrodeless gas discharge lamps and more particularly to the configuration and arrangement of the induction coil and the envelope in which the discharge gas is sealed. 2. Related Prior Art Various arrangements for the induction coil and envelope of gas discharge lamps are known and generally involve locating the induction coil external of the envelope in closely adjacent relationship therewith. The envelope often has a generally cylindrical shape and is surrounded by a helically coiled induction wire. When energized, the coil excites the gas within the envelope to discharge illumination. The light which is emitted is blocked somewhat in the radial direction by the induction coil but not in the axial direction of the free end of the envelope. In many applications that employ this type of coil and envelope arrangement, the light is intended to be directed axially rather than radially and thus the blockage of light in the radial direction by the coil does not inhibit the performance of the light. In another known arrangement, a flat spiral induction coil is supported adjacent a flat envelope and the light which evolves is emitted forwardly of the envelope, but is blocked in the opposite axial direction by the presence of the coil on the backside of the envelope. In these known applications, such blockage of the light by the coil does not present a problem since the light is intended to be directed in the forward direction only. In other lighting applications, such as emergency flasher beacon lights of the type used, for example, on road construction pylons, barriers, signs and the like, the light is directed in opposite axial directions from a central incandescent light source through a pair of axially oppositely disposed lenses of the device. The incandescent lamp is often powered by a battery housed within a lamp base which mounts the incandescent lamp and lenses. Both the incandescent lamp and battery have a limited operating life, and as such the present emergency flasher beacons require periodic maintenance which adds cost and

inconvenience to their usage. It would be desirable to replace the incandescent lamp source with an electrodeless gas discharge lamp source since it would eliminate the presence of an electrode (i.e., a filament) which is the principal cause for the failure of incandescent lamps. An electrode less gas discharge lamp source would further draw far less power than a comparable incandescent lamp and its usage would prolong the operating life of the battery, minimizing or altogether eliminating the requirement for frequent maintenance associated with the known incandescent beacon flashers. There does not currently exist, however, an electrode less gas discharge light source suitable for such a double-sided lighting application. In the case of the discharge lamps described above, the induction coil in each case would interfere with the emittance of light through at least one of the lenses and as such would impair the performance of the light. The present invention is directed at providing such an electrodeless gas discharge lighting configuration suitable for double-sided lighting applications. SUMMARY OF THE INVENTION AND ADVANTAGES An electrode less gas discharge lamp assembly constructed according to the present invention includes a lamp base, a pair of light-transmitting lenses mounted on the base in axially opposed relation to one another, and is characterized by an electrode less gas discharge illumination source including a generally flat spiral induction coil disposed between the lenses having axially opposite sides, and a pair of generally flat gas discharge envelopes disposed between the lenses on the opposite sides of the coil each having sealed therein an ionizable gas inductively excitable to discharge illumination by operation of the coil. Such an axially sandwiched arrangement of the coil and the two envelopes has the advantage of exciting the gas in both envelopes with a single coil, directing the light in axially opposite directions without obstruction from the coil. While not limited in its application, the invention is particularly well suited for emergency flasher or beacon-type lights wherein the light from the central source is transmitted in a)dally opposite directions through the opposed lenses of the device. The electrode less gas discharge light source has the further advantage over conventional incandescent lamp sources of minimizing or all together eliminating the need to periodically replace the light source and prolonging the life of the battery of such assemblies by operating at a relatively lower rate of energy consumption.

ORIGIN OF THE REPORT This report titled an Analysis of Florescent tube light production process and observation of its Machinery .We have done this training program as a part over B.SC Engineering program under department of Electrical and Electronic Engineering. I have prepared this report during my course requirement and also learned many things through this report .It is mandatory requirement of the program. This report contains the outcome of a project by the Eastern Tubes Limited is presented to the concerned teacher as well as the organization.

LIMITATION OF THE REPORT: 1. The main limitation of the report is the time. 2. Another limitation the study was that the organization to disclose all type of information .They can intend to maintain their own confidentiality about producing all information. 3. Data unavailability was the constraint.

Background of the Company: Eastern Tubes Limited is located at Tejgoan Industrial Area, adjacent to the Tejgaon Railway,Tejgaon Dhaka. Eastern Tubes Limited was set up a joint Technical Collaboration with Japans famous lamp manufacturing companyToshiba who supplied, erected and commissioned all its plants and equipment .The plant was established in the year of 1970 and engaged in the production of fluorescent tube light. Reportedly reconditioned plant was originally set up by Bawani Group of Industries. After liberation it was found abandoned and was taken over by the government. The Management of Eastern tube Limited was placed under Bangladesh Steel and Engineering Corporation (BSEC)(Former Shipbuilding and Engineering Corporation),on the 15th May,1972.Since then the plant is being run, controlled and Managed by BSEC.

Department of Production: The Department of production is the main power house of the organization. The Department of production is consists of the three major part. First is production system; Second is maintenance and the Third is quality control. Production System: The production coordinates all the activities of the production process. Their work is controlled and monitored the production process. Employee monitoring, record keeping of wastage, chemical mixer, break down record, close monitoring of the employee, etc work is done by the production system. It is an engineering section and the labor group activities are directly control by this section

EASTERN TUBES LIMITED PRODUCTION PROCESS FLOW CHART

Bulbe Tube Mark Enamel Solvent for Mark Enamel Phosphor Powder

Washing & Drying

Marking

Coating Butyle Acetate Nitrocellulose Adhesive Powder Stem Tube Exh.& Support Tube Lead-in-wire Filament & Oxide Mixture Filling gas (Argon) Mercury Capping Cement Cement Mixing Meth.Spirit Base cap Solder Lead Solder Flux Corrugated Wrapper Carton Inspection & Packing Cement Filling Aging Mount Making Sealing Exhausting Basing Flare Making Neck-Cleaning Baking

Stem Making

Soldering

Curing

Lighting Machine Designed and developed to utmost perfection and precision detailing, our wide range of Lighting Machines like tube sealing machine manufacturers, automatic capping machine is a part machine of GLS Lamp Making Chain & Florescent Tube light making chain. GLS chain can manufacture Lamps of wattages ranging from 10Watt to 200watt in various shapes & sizes. The FTL Chain can make TLD, 4 feet, 2 feet & 5 feet. Functioning of these machines can be automated, to benefit your specific need.

24 Head Stem Making Machine for fluorescent lamp Description: Our 24 Head Stem Making Machines are indexing turret machines, configured with an automatic flare feed, automatic lead-n-wire feed and automatic tube feed. The automatic G-Rod feeder can be provided with these machines at extra costs. In case there is a misfeed of flare in these machines, then the other components should not be loaded therein. 9

For e.g. if the flare is not loaded, then the lead-n-wire and exhaust tube can not be loaded. The wastage of materials is greatly reduced with these machines. After loading, the components are precisely positioned relative to each other and are then sealed and pinched together. The seal for this purpose is provided by burners, using a mixture of air, gas, and oxygen. The air, gas and oxygen supplies are connected to manifolds fitted on the frame of the machine which are further distributed through mixer valves to the burner. This is done so that the flames can be correctly set. The pinch is made by automatic pinch mechanism. The exhaust hole and well are blown through the seal. The burners are automatically swung away to allow the heads on the turret to index. The machine is operated by an electrical motor fitted on the frame of the machine. The drive is transmitted to gearbox that actuates the automatic mechanism by levers and linkages. The main electrical supply is connected to a control console, which is fitted on the machine. An additional feature, i.e. the thermocouple can be fitted to the annealed for checking the temperature. We can produce Exhaust and support tube by the same machine. Process control: Length of stem =85 mm. Dia of stem =5 mm. Length of led in wire =77 mm. Dia of led in wire =0.6 mm. Now, Stem=flare+Exhaustent support tube+Led in wire Fluorescent Tube Light Sealing Machine Description: Our Fluorescent Tube Light Sealing Machines are used for sealing the FTL to the mount And for sealing the lamps on both ends. This machine requires less working space and it is provided with 2 induction motors, one for head driving and one for machine driving. The feature of automatic loading and unloading can be providing at extra cost. In this industry the sealing Machine contain 12 heads. In this section the mounted stems are sealed at the two ends of the fluorescent coated tube.

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Features of our Tube Sealing Machine are specified below: 1st Position glass Shell loading is manual. 1st Position Mount Loading is manual. 2nd position Mount Loading is Automatic with mount aligner. Stamp baking burners provided on Machine. Small and compact injectors provided for smooth and efficient operation of Burners.
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Fluorescent Tube Light Exhaust Machine Description: The featured machine is FTL Exhaust machine for evacuation of unwanted gases along With heating chamber. The FTL exhaust machine is 32 Head. Although Loading & Unloading of FTL is manual but it can be automated at extra cost. This is one of the most important section for the production system. We can vacuum 32 glass tube at the same period, then filling these tube with Argon and Hg drop.Hg acts as a conductor for producing light.

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FTL Mounting Machine Description: This Machine has been designed for providing Ring (Anode Ring) to the Mounted Filament for FTL. The stems are automatically fed into the loading turret, leaving the Annealed conveyor of the stem machine. The filaments are transferred into the stem from the filament drum using vacuum pick-ups. Then the machine automatically does the Process of Electrode Pressing, Hook Making, Hook Setting and Filament Clamping. The Machine has been provided with sensors to detect the absence of 1st, 2nd or 3rd wire (LIW) and which further does not allow the filament to be loaded and simultaneously There will be no strip welding.

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Anode strip feeding is automatic, along with cutting, welding (the process of welding is Spot welding) and bending of the anode strip, which forms a ring shape. A unique provision is provided to detect absence of filament clamping on any of the sides And denies the transferring of bad mount to the unloading conveyor. The machine Automatically pastes the emitter on to the filament and unloads it on to the unloading Conveyor. Heaters are provided before the pasting/emitter unit of the emitter to remove Any unwanted moisture. In this industry the mount making machine contain 24 heads. The stem is loaded in the machine with the help of conveyer. For this machine the active Head are given in below: 1. Stem loading unit 2. Lead in wire forming: first stage. 3. Lead in wire forming: 2nd stage. 4. Lead in wire forming: 3rd stage. 5. Lead in wire hooking: Unit. 6. Hooks annealing unit 7. Filament coated and closed 8. filament stretched 9. Oxide coating unit. 10. Coating dried unit. 11. Oxide section unit. 12. Unloading. 13. Conveyor. 14.

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EASTERN TUBES LIMITED PRODUCTION PROCESS FLOW CHART

Bulbe Tube Mark Enamel Solvent for Mark Enamel Phosphor Powder

Washing & Drying

Marking

Coating Butyle Acetate Nitrocellulose Adhesive Powder Stem Tube Exh.& Support Tube Lead-in-wire Filament & Oxide Mixture Filling gas (Argon) Mercury Capping Cement Cement Mixing Meth.Spirit Base cap Solder Lead Solder Flux Corrugated Wrapper Carton Inspection & Packing Cement Filling Aging Mount Making Sealing Exhausting Basing Flare Making Neck-Cleaning Baking

Stem Making

Soldering

Curing

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CHAPTER 3 Descriptions of Induction Motor are the most widely used Motor in the industry.

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CHAPTER 4 Efficiency of Production Input,Output & wastage finding. Start from the washing section to Aging section in every stage .The difference between input & output is known as wastage.If the overall wastage quantity is less than the overall production efficiency will be increase. Quantity of wastage on 12 April of 2010 (Time 7 a.m to 5 p.m) the production was off between 2pm to 4pm for technical problem.This report is prepared before curing .Total loss in curing section is very small it is about 1.48%(Based on previous report). Size 4Feet 40watt 12.04.10(Without curing). Process Input Wastage % number Washing 3600 51 1.41 Marking 3546 40 1.12 Output 3546 3506 Remark

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Coating Baking Neek cleaning Sealing Exhausting Inspection Basing Aging

22 25 28 150 193 4 11 180

Calculation: Total wastage =Washing input Aging output % Wastage = Total wastage /Washing input 100

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Existing Production process: Production of Eastern Tubes Limited is basically a

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Mechanical process. There is no fundamental difference between different manufacturing process excepting variation in degree of automation and mechanization .Manufacturing of tube lights involves a series operation .In one segment of operation flare is made in hot cut flare machine from imported flare glass tube. The flare so produce is then fed to stem making machine where two lead in wires and one exhaust or support tube are fused together and punch is made by automatic punch mechanism. The product called stem is annealed properly to avoid crack. In another segment of operation, imported blank tubes are washed by hot water; dried and coated the inner surface with mixer of fluorescent powder, nitrocellulose, butyl acetate etc. coated tube is backed passing through gas fired backing furnace. Afterwards the coating of both ends of the tube are wiped out to facilitate fixing the lighting length of lamp by orating brush .Then the important operation i.e. sealing is done. In this operation the mounted stems are sealed is done. In this operation the mounted stems are sealed at the two ends of the fluorescent coated tube. The sealed tubes are then transferred to exhausting machine where the tube is made vacuum, mercury is injected and the tube is filled in by argon gas and both ends of the tube are sealed, preliminary tested ,base cap are inserted and cemented by cementing and ultimately checked in ageing machine to determine the function of the lamp. The lamps are re-checked after 48 hours to determine the quality characteristic which is known as curing.

Environment of workshop: 1. Outwardly, each machine and floor is kept clean. However, for instance, under the machine table or rotational components or gear the machine table or gear box and so on have not been cleaned. Also on the corner of the floor are dusty. 2. It seems the consideration for safety is lacked. Unsafe position and unsafe operation, unsafe actions were found at various places and occasions. For example, safety covers have been removed from the machine or electrical wire is crossed on the floor or electric parts are broken. 3. Layout of the manufacturing equipment should be reviewed .present layout is so complicate and not reasonable for doing the job smoothly and effectively. However, making good layout of the manufacturing equipment will be little different due to so narrow floor space. In future, construction of new building is necessary. 4. Object that is not used or necessary should be discarded .object that seldom used should be placed in distant areas. 5. Improvement of lighting level in the factory is necessary and you should try to keep the lighting level high. Spot lighting will be useful ,if it is necessary. 6. Safety path and working area should be clearly separated.

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For improving the present total factors condition, there is not specific medicine. Accumulating of every days effort can be changed it.

Maintenance: The original life span of Eastern Tube is over .So the company faces many technical problems and its regular routine maintenance work is mainly done by the companys engineer .They can effectively do their work so the condition of plant is good. The spears parts are not available in the total market. Maximum parts are made by the local engineering shop or company. Those parts are not made by the local company are imported by the original supplier Japanese Toshiba Corporation. Toshiba Corporation gives some technical assistance and support to Eastern Tube Limited. When Eastern Tube Limited faces many major problems then they can get help from Toshiba Corporation. Quality control: Eastern Tube Limited has a very strong quality control department .The main strength of Eastern Tube Limited product is its quality. Eastern Tube Limited has a very well equipped Quality control lab. This lab is the best tube light testing lab in Bangladesh .The quality control equipment is supplied by the Eastern Tube Limited technical supports provider Toshiba Corporation. Process of quality control: In every stage of the production there are maintaining
a tide quality control. In the production process are tested the long lasting capacity of the light. Here testing the low voltage and high voltage burn capacity of the light. After packing test the capacity of the light and before the final packing test the burn capacity of the light. So there are several time test the burn capability of the tube and this ensure the good quality of the tube light.

Eastern Tube Limited. 374,Tejgaon Industrial Area, Dhaka

Date: Time: Lot No.: F0:6405

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Lamp type 4feet 40 Watt. Lamp type 2feet 20Watt.

Quality control Laboratory Testing Result on Electrical Properties at0Life hour.

SL.NO

Measured Starting voltage(VS)

Measured Lamp current(IL)

Measured Lamp voltage(VL)

Measured Lamp wattage(WL)

DC.MA Reading for testing Lamp(DS2 )

Measured Lamp Lumen(Lm) DS2F0

Overall Length

Base alignment

Pin Solde r

Remarks

1. 157 2. 3. 4. 5. AVE

0.42

112

40

0.41

2626

1198 OK.

OK

Specified Specified Specified Specified Specified

Starting voltage Lamp Current Lamp Voltage Lamp Wattage Lamp Lumen Room Temperature

: 1582 volt : 0.4150.005Amp : 1132 Volt : 401 Watt : 2610 Lumen : 251c Checked BY: Anwarul Haque.

In the quality control lab: The quality control lab tests the lowest voltage burning capacity of the light. Normally Eastern Tube Limited tube light burn at least
165 voltages. This fixed by its technical support provider Toshiba Corporation. This is lower than the other tube light in the market. The lab also test that how much light through each tube. Each and everyday the sample is collected random basis and test in the lab. The test report is regularly sent to the management of the organization.

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Induction Motor is the most widely used motor in the industry, because this motor has several kinds of advantages. Some of these are given in below: 1. It has very simple and extremely rugged, almost unbreakable construction (specially squirrel cage type). 2. Its cost is low and it is very reliable. 3. It has sufficiently high efficiency. In normal running condition, no brushes are needed, hence frictional losses are reduced. It has reasonably good power factor. 4. It requires minimum of maintenance. 5. It starts up from rest and needs no extra starting motor and has not to be synchronized. Its starting arrangement is simple especially for squirrelcage type motor. It has also very few disadvantages given below:
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1. Its speed can not be varied without sacrificing some of its efficiency. 2. Just like a d.c shunt motor, its speed decreases with increase in load. 3. Its starting torque is somewhat inferior to that of a d.c shunt motor.

Precaution: While getting training. We took some precaution measures like.. 1. We put our shoes on all the time of observing as glass made materials are used in every section. 2. We never ked with or even touched any machinery equipment without proper permission. 3. We kept ourselves away from the machines that create much heat. 4. We were always careful with the laboratory tests to measure standard value. 5. We never did anything that could hamper the works of the officers and the employees.

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Conclusion: We got practical experience about the manufacturing process of fluorescent lamp while getting training in this industry. We experienced every step of process control and quality control. We are confident enough to do the jobs relating the production of fluorescent lamp if we are given such kind of works in future. Cement Mixing and filling: Marble powder, resin solution, silicon resin are mixed with each other to produce cement mixer. Then this mixer is stored in a special chamber and with the help of air pressure the essential cement fills in the Base cap. Process Control: Length of Base cap=11mm1mm Weight of cement = 2.5m1gm Lumen Calculation: F0=Fsks/Ds1=23701/0.37=6405 Cm=F0Ds2/ks=64050.41=2626 Lumen. Where F0=Lumen calculation factor. Fs=Standard Lamp Lumen. Ks=Temperature correction factor. i.e. At 25c room temperature total Luminous flux is 100%(Unity). Ds1=D.C miliampere reading for standard Lamp. Ds2=D.C=miliampere reading for testing Lamp.

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