FINAL

This

final

internship

INTERSHIP REPORT

Executive summary
report included brief history

of

the

company,

organizational structure, work flow, row materials, suppliers and customers,

products, Mission, vision, objectives of the company and overall sections: spinning section, weaving section and finishing section. It also included
different types of machines such as:-warping machine, sizing machine,
bleaching machine, Stenter machine, jigger machine, drying and washing
machine, printing machine, calendaring machine etc. including their
operation and function. This report also include how three phase induction
motor repaired in winding section of the company, machine starting and
control mechanisms, boiler room, air compressor and conditioning system,
waste removal system, overall control plant of the company which includes
programmable logic control & relay logic system, and some basic electrical
protective devices such as: - sensor, contactor, relay, rectifier, inverter, and
fuses. Lastly, we include our project and contributions to the company which
focuses on winding Section and an internship experience gained which helps
us to improve a lot of skills like Practical, communication and team playing
skills, also to understand some work eth

CHAPTER ONE
INTRODUCTION
1.1BACKGROUND
Bahir Dar Textile Share Company is vertically integrated textile company,
manufacturing 100% cotton products including yarns and fabrics. It was
established in 1954 E.C from the fund of Italian war reparation in the town of
Bahir Dar, north south of Addis Ababa, Ethiopia. When the company was
established, there were 563 Ethiopian employees of which 360 males and
203 females. The initial capacity of the mills was 20,000 spindles, 360 looms
together with processing plant with the total output of 10 million meter
squire fabric per year. The legal shape of the company was given in May,
1954. When the company was registered as public corporation, in the name
of Bahir Dar textile mills Share Company with a capital of Eth. Birr 9,649,600.
As of September 1990, the factory changed from a public enterprise to share
company and it was financially restructured. The name of the Company is
again Bahir Dar textile share Company and its capital amount at present was
56,808,379 Eth. Birr. After the leased period, the companys management
made viable two things: structural adjustment and expansion and renovation
project, worth of more than 500million Eth Birr. Most of the existing old
machineries such as spinning, weaving and finishing were replaced by the
integrated Draw Frame (IDF) in spinning, the automatic Drawing-in machine
and the Air-Jet looms in the Weaving Section, and the garment factory.

1.2 MISSION, VISION AND OBJECTIVE OF THE COMPANY

Mission

The business missions of BDTSC are:

Producing quality products of fabrics & yarns and being low cost
provider, to be

preferred company in domestic and export markets

and profitable.
By Satisfying customer needs, contribute foreign currency for the
country.

Vision
The Business vision of the Company is to see being competitive in the
domestic and export markets in quality & low cost providing of textile
products.
Objective of the company
The main objectives of the factory are:

To
To
To
To

manufacture yarn & all kinds of finished clothes from cotton.

produce goods for household use.
sell its products locally & abroad.
engage generally in any other trade or business conducive to the

Attainment of its objectives.

1.3 Organizational Structure of the Company

An Organizational structure of BDTSC shows the scope of acceptable
behavior within the company, its line of authority and accountability, and to
some extent the organizational relationship with its external environment.

Table 1.1 responsibility of organizational structure of BDTSC

Organizational structure

Responsibility

General manager

Leads all over the company activity.

Follow each & every activity.
Control the company overall work process.

QCQA

Check the raw materials, chemical recipe and

dye stuff as much as possible with workers.

Pain service

Control the different occupational area & over

all working process depending up on the
programs Of the plan.
Organize the management working process&
co-ordinate them.

Law service

Design about legal justification on the legal

issue question & proclamation.
Respect the general manager &practice in
meeting.

Production manager

Super vision each department i.e. spinning,

weaving,finishing& garment line of the
company.

Human resource

Study &evaluate the existing organizational

structure.
Carry out in the depth study in the realistic
personal requirements ,increasing system for
the Personal, give tracing &management
personal including in the area leadership,
motivation.

A/A coordinating agency

Planning the company management to be

increasing the domestic &export marketing
system in the company productive.

Finance Dep`t

Realization of planning, budget presentation

transfer financial issue. Show the way of

financial sources the company.

Marketing and sale Dep`t

Plan and budget to the council of general

manager.
Announcement of the product of company

Audit & inspection

Controlling the management, final applying by

selling& buy

Purchasing & matter

Sorting different type of output the transport in

selling it
Determines cost.
Respecting the customer polling to expanding

Marketing studying

Study the quality, purchasing prices, marketing

system, and sailing
Of the output.
Announce the products of the company for
marketing study place.

Technical manager

Control the technical problem, solve problem

with their sub division organs

Mechanical & related

Create the work plan, give the responsibility,

control the materials which inter work shop,

Workshop

Determines the spare parts in the company

work shop.
Electrical workshop

Made electrical maintenance

Table1.1 responsibility of organizational structure

1.4 key stakeholder of the company
Any person or entity interested in a particular business is called a
stakeholder. They are affected by the business activity, and they may be part

of the core decision making team. Internal and external stakeholders may
have different interests and priorities, possibly leading to conflicts of interest.

Internal stakeholders are owners, managers, and workers.

External stakeholders are the customers and the suppliers.

The owner of BDTSC is Ethiopian government itself and takes about 99% of
the total share; therefore the key stake holders of BDTSC are owners and
customers who are the most responsible person in the Company.
1.5Production process of the company
Products
Bed sheeting_ local and export(dyed and printed)
Abu Jedi
kuta
yarn on hank
Customer or end user of product
The company supplies its products to the local and export markets. The
company produces many products which having different quality parameters
based on the customer needs. Some of the main customers of BDTSC are:

GINAD PLC
FKM PLC
Addis Fana PLC
Sayat PLC
Ambasel Trading House

1.6 Raw Material and Accessory suppliers

1.6.1 Types of Raw material

The major inputs of production are lint cotton, chemical, and dyestuffs. Lint
cotton is found locally which 370 km away from the factory site. Chemicals &
dyestuffs are imported from abroad. The inputs are available at any time.
The main raw material used for BDTSC is 100% cotton and according to some documented
and oral information tell us the supplier of the main raw material (cotton) is as shown below :-

1) Hiwot Farm Development Company

2) Des Privatized Limited Share Company
3) Abobo Farm Development Company
4) Africa Privatized Limited Share Company
5) Abdulkadir Ahmed and Cotton Results
6) Raja farm development India
7) Alkader Ahmed Farm development
The purchased bale cotton stored to the bale room by identifying its quality parameters, these
parameters are tested by the high technology and Volume Instrument. The tester machine tests
parameters of cotton. Such as;

Maturity
Fineness
Trash content

1.6.2 Types of Accessories and their Suppliers

Accessories are materials which are used in the company in addition to raw materials to perform a
complete work Such materials are dye staff chemicals, greases, oil, spare parts and sizing
ingredients. The quality of textile purchased materials should be fulfilled the following:

Reliability
Serviceability
Durability
Conformance

A) Sizing Ingredients
Sizing ingredient materials are used for sizing process in weaving section of the company is:

PVA
Maize
Arabic gum

Major Size ingredient supplier

Asrat flour factory (Bahir Dar)

Yekunu (Bahir Dar)

B) Chemicals
BDTSC uses many chemical products for finishing process in the production section. Some of the
chemicals ingredients used for finishing process are:

Hydrogen per oxide(H2O2)

Detergent
Optical brightener
Wetting agent

Chemicals and pigments supplier:

Addis Ababa(A/A)

C) Spear parts
The factory purchases many industrial spear parts for production machinery in spinning,
weaving and finishing sections. Thus are;

Electrical materials (Belgium & Italy)

PVA & rotary screen(Indian & China)

Chapter 2
Overall Internship Experience
2.1 Objective of the Internship

2.1.1 General Objective

Debre Markos University aims that this internship program enables engineering students
under the institute to relate their theoretical knowledge to the real world. 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:

The general objective of internship program is to develop students in practical of the

students theoretical knowledge to get know the interns work environment.

Internship students will develop skills and techniques directly applicable to their careers.

Internships will provide students with an in-depth knowledge of the formal functional

activities of a Participating organization.

Internships will provide students the opportunity to develop attitudes conducive to effective
interpersonal relationships.

2.1.2 Specific Objective

The intesrns during the internship are aimed to play a great role in improving their practical,
theoretical, interpersonal communications, team playing, entrepreneurship and leader ship skills,
understanding about work ethics related issues, responsibility etc.

To develop leadership skill and interaction with co-workers.

To relate practical knowledge interacting with theoretical knowledge.

To apply what was learned during coursework (skill development and professionalism) to
the working world.

2.2 Greeting and Visiting of the Company

We were apply an internship request paper for BDTSC in JUNE 2007 E.C, after a month
through a long process we were selected among thus students who have applied from the same
purpose from different universities. Actually we do have an acceptance from different organizations
and company, but we choose BDTSC since it becomes one of the huge profitable & unlimited
customer demand in textile
industries due to the fact that it used modernized electrical as well as mechanical technologies
to make its production rate and quality easier. Thats why we had preferred
to spent our internship time at this company. We had started our internship program at
BDTSC in september; Mr. Woldea gives on work suggestion, ethics and general description
about the company. The technical manager of the Company led us to every sections of the
Company and he assigned an advisor who helps us to visit and inform the general work flow of the
factory We were motivated by what we see from different sections of the company, the company
advisor Mr. Hailemariam form us into Four groups and distribute the first group to spinning
section, second group to weaving section ,third group to finishing section &the last group in
garment section. After two weeks each group will rotates and submit a report about working
conditions, knowledge gained and recommendation from each section of the company.
2.3 Overall system Components and Operation of the Company
2.3.1 Work Sections

Bahir Dar textile Share Company has four

sections these are spinning,

weaving , finishing and Garment sections. These sections have their own
different machines which perform different tasks in the production process of
factory.

Fig: process flow work section

2.3.1.1 Spinning Section

Spinning is manufacturing process for creating polymer fiber .it is conversion

of a large quantity of individual, unordered fibers of relatively short length
into a linear, ordered product (yarn) of very great length using suitable
machine and devices.
In BDTSC Spinning section includes cotton processing machines it include
from bale store to open ending machine for short staple fiber ,and for long
staple fiber the process includes from bale store to ring machine.

Fig: process flow of short staple fiber

fig: process flow of long staple fiber

Bale Store:

is a place where bale cotton is stored, thus a packed of cotton will putted
under there sequence of coming from the supplier company.
Blow room section

Blow room is the starting of the spinning operation where the fiber is opened,
cleaned, mixed and evened. The basic blow room operations are;

Opening the bales of fibers

Cleaning the fiber removing all dirt, dust and waste materials from it
Blending and mixing
Removal of micro dust particles
Feeding to the carding machine
Waste recycling

Fig: process of blow room

1) Unifloc machine
The function of unifloc machine is to processes the fiber material gently and efficiently in to micro
tufts, from which imports can be removed especially readily in the subsequent process. It is also
used to open and feed the cotton fiber and transport in to next process.

Fig: uniflock machine

Characteristic of unifloc machine

Bale lay down over length of 7.2m to 47.2m

Take of width selectable between 1.7m to 2.3m

Processing of cotton from all sources and Machine is pneumatic

2) Heavy Particle Separator Machine

It separates the frightening the light cotton with the seed of other heavy particles
Machine is pneumatically

3) Unicleaner Machine

To remove loose trash particles, fiber fragments and dust particles

Used to separate the tidy or useful part of cotton from waste part

It feeds the clean cotton to the Unimixer machine

Fig: unicleaner machine

4) Foreign Matter Detector Machine

It detects the color of cotton other than white color, this machine detects and separates it

from the white cotton and drops it as wastage then it stored in waste accumulator.
This system is based on camera or electro-optical sensor technology.

5) Unimixer Machine

It has storage, intermediate and delivery section.

Intimate mixing of bale feed.

Mixing process is equally suitable for cotton and manmade fiber.
Remove dust from the fire filter.

6) Unistore Machine

The Unistore is used as a storage, deducting and feeder machine.

Its main purpose is to provide intermediate storage for materials in order to ensure trouble-free

blow room operation.

The integration of a mesh screen filter inside the Unistore eliminates the transport air, and creates

an efficient deducting.
It stores the mixed cotton for reserve during interruption of taking cotton b unifloc and transfer to
carding as compensation to avoid any work gap between machines.

7) Waste feeder machine

In blow room section some useful cotton removed from different machines
during mixing, opening and waste removal process. This useful cotton should
recycle in order to get high productivity in the company production process
so, removed cottons feeds to the waste feeder and it will go through to the
unifloc machine path.

8) Unicontrol machine
This machine uses the uncommand which works on an electronic basis, and is a combination of
Unicontrol machine is used to control every activity of blow room in the spinning section. PLCs
and PCS with a central controlling unit. This machine shows the statues of blow room machine, an
operator can able to control all an activity in the blow room.

9) Flocked clearer roller cleaning machine

This machine is used to clean roller of roving machine. In increasing the productivity of roving
machine the flocked roller should be cleaned with good quality.

It can operate easily with direct motor starting mechanism.

Highly efficient and fast cleaning.
Low power consumption and noiseless operation.

Carding Section
Carding is a mechanical processing that disentangles, cleans and intermixes fiber to produce a
continuous web or silver suitable for subsequent process. In carding machines laps are feed and
slivers are received as an end product in cans or boxes.

Function of carding machine

Mixing
Opening
Sliver Formation
Elimination of impurities and dust

In BDTSC carding section there are two machines for carding fiber this are draw frame machine
and integrated draw frame machines (IDF).

Function of Draw Frame Machine

a) Equalizing
b) Parallelizing

c) Blending
d) Dusting removal

Drawing Section
Drawing is a process in which different slivers are combined together to produce single sliver.
Normally 8 slivers are fed behind one drawing machine and get an end product in form of single
sliver in cans or boxes, which has the same weight as of single sliver. The purpose of doing this is
that to create uniformity and average out the weight of each sliver. This process is also called 8/8
process. Drawing section consists of two sub-sections:

i) Breaker Drawing:
During this process 8 silver produced by carding machine are parallelized to produce one silver.

ii) Finisher drawing frame

it is done to give further strength and stability to the silver. The drawn silver from breaker draw
frame is again drawn. In this process the silver drawn in the breaker draw frame further used.

Roving machine
Roving machine is an intermediate machine that is used between the draw frame and ring frame.
The main purpose of this machine is to produce the roving package for the ring frame. Roving
machine where the silver is subjected to one or more attenuated process and the attenuated sliver
receive a small amount of twist and is then wound on bobbins suitable for creeling at next process.

Objects of roving Machine

Attenuation of drawn silver to form roving of required count by drafting

To remove remaining trash from the drawn silver
To produce a suitable roving for next process or ring frame

Fig: roving machine

Ring machine

Draft the roving until the required fineness is achieved

Twist the draft strand to form yarn of required count and strength
Winding the twisted yarn on to the bobbin for suitable storage, transportation and further
processing

Winding machine
Winding is the most important operation, which is the creation of large yarn
package that can be easily unwound. The yarn unwound from package
passes through yarn tensioned and control system, and with the help of a
grooved cylinder, is wound evenly around the package; the yarn enters the
recess in the cylinder, thus rotary movement of the cylinder corresponds to
the translation of the yarn.

2.3.1.2 Weaving Section

Weaving is the interlacing of two sets of yarns, i.e. warp and weft yarns at
right angle to each other. In BDTSC weaving section includes warping up to
inspection machines.

Fig: process flow of weaving section

Warping process
purpose Warping is the parallel winding of yarn from cone or cheese package on to a warp beam.
This is the process of changing the winding yarn from small size of individual cones to the bigger
cylindrical size roller. This makes suitable for looming and sizing up.

Objective of warping

To increase the quality of yarn

To increase production

To make reusable next process

Formation of suitable package for warping
Checking and clearing the yarn from spinning

Fig: warping machine

Main Parts of Warping Machine

Creel
Pressure rollers
Beams

In warping, the yarns are withdrawn from the single-end yarn packages on the creel & directly
wound on a beam. During the warping process the yarns may broke out at this instant an electrical
sensor detects the problem and send an electrical signal to control part of the Ramallumin
Leganano Italy warping machine then operator resolve the problem.

Sizing machine
It is the process of improving the strength of the yarn by passing through hot
solution of starch. This provides suitable for looming machine.

Objectives of sizing processes

To increase the smoothness of warp yarn.

To protect the yarn from abrasion.
To decrease hairiness.
To decrease the generation of static electricity.

Looming process
After the required number of warp yarns in the fabrics wound onto the weavers beam, the warp
beam ends are then passed through the drop wires, the heddles of the harness frames and the dent
of the reed. This achieved by drawing or tying in the choice depending up on whether or not the
new warp is different and from the warp already on the loom.

Picanol (Air Jet) Machines

The Air Jet weaving machines are the weaving machines with the highest
weft insertion performance and are considered as the most productive in the
manufacturing of light to medium weight fabrics, preferably made of cotton
and certain man-made fibers.

Fig: picanol air jet weaving machine

Somet weaving Machine

This machine is greatly admired for its superior quality, durability, strength and ability to work in
harsh environment and competent. This is performed operated manually since it is oldest machine,
it does not function properly. It uses electrical system for weft movement and it controlled by
manual operating system. Basic different between somet and picanol (air jet) machine

Air jet picanol

machine

Somet weaving
machine

Wefts movement through

warp is pneumatically

For weft movement uses

electrical system

Controlled by plc. System

Controlled manually

Not continuously stop

working

Continuously break its

function

It is more economical

It less economical It is
more economical

It produces relatively good

quality

Less quality
production

Table : difference between air jet picanol & somet weaving machine

2.3.1.3 Finishing Section

Finishing is the process used in manufacturing of fiber, fabric, or cloth in order to impart the
required functional properties to the fiber or fabric, its customary to subject the material to
different type of physical and chemical treatments.

Fig :process flow of finishing section

Description of the work flow in finishing section

Inspection machine
Inspection is an important aspect followed prior to garment manufacturing to avoid rejects due to
fabric quality and facing with unexpected loss in manufacturing. Its done for fault rate, fabric
construction, fabric weight, shrinkage, color, hand feel, print defect and appearance.

Roller to Batch Machine

This machine is used to change the cloth roller that coming directly in the inspection machine,
clothes in the inspection machine cut by an operators due to a defect on it, thus cutted cloth rolled
in to batch.

Hot Washing (Desizing) Machine

Desizing refers to the removal of starches and sizes from the fabric before the fabric is set for
upcoming process. The insoluble starch is broken down to soluble product which can be washed
out. The sizing material presents on the warp yarns can act as a resist towards dyes and chemical in
textile wet processing. It must be removed before any subsequent wet processing the fabric.

Pad-roll Bleach Machine

Bleaching is a process of removing all the residual coloring matter in textiles. Bleaching with
peroxides the bleaching bath is composed of hydrogen peroxides (35% or 50% by wt.) as the
bleaching agent, an activator (usually alkali) and stabilizer.

Dyeing machine
In textile finishing processes, after pretreatment the dyeing processes is takes place it is the
processes of shading the fabric by using dyes.

Ground/Lighter Shade
This process is done by applying color, binder and soap which shades the fabric lighter.

Jigger Dyeing Machine

Jigger or dyeing machine is one of the oldest dyeing machines used for cloth dyeing operations.
Jigger machine is suitable for dyeing of woven fabrics, up to boiling temperature without any

creasing. It has two main rollers which revolve on smooth bearings and are attached to with a
suitable driving mechanism, which can be reversed when required. The fabric is wound on one of
the main rollers and fed from the other.

Fig: jigger machine

Some critical problems related to the conventional jigger dyeing machines are:

Temperature control from side to side and end to end roll

Tension control from end to end
Prevention of air and creases

Stenter Machine
A machine or apparatus for stretching or stenting fabrics. The purpose of Stenter machine is to
bringing the length and width to pre determine dimensions and also for heat setting and its used
for applying finishing chemicals and also shade variation is adjusted.

Fig: stentor machine

Function of Stenter machine

Stretch the fabric and recover the width

Width of the fabric is controlled by the Stenter

Finishing chemical apply on fabric by the Stenter

Printing Machine
In BDTSC printing machine uses a cylindrical screen that rotates in a fixed position rather than a
flat screen that is raised and lowered over the same printing location so its named Zimmer rotary
printing machine. In rotary printing, the fabric travels at a consistent speed between the screen and
a rubber impression roller immediately below the screen. The impression roller serves the same
function as the press bed on a flatbed press. As the fabric passes through the rotary unit, the screen
spins at a rate that identically matches the speed of substrate movement. The squeegee on the
rotary press is in a fixed position with its edge making contact the inside surface of the screen
precisely at the point where the screen, substrate, and impression roller come together. Ink is
automatically fed into the center of the screen and collects in a wedge-shaped well formed by the
loading side of the squeegee and the screens interior surface.

Fig: printing machine

Calendaring Machine
It is the modification of the surface of the fabric by the action of heat and pressure. It takes stem as
a source, and then this stem is connected with different cylindrical rollers. After that the rollers
become hot enough, allow the fabric to pass through these rollers.

Fig: calandering machine

2.3.2 Control Unit of the Plant

This section is brain of the plant because the overall operating system is controlled and governed
by this unit. This unit is smallest sized because its built with PLC (programmable logic control).
Every machine in the company can be controlled in two ways this are relay system and PLC
system. The relay system is a bulky and an absolute because it is a mesh manual connection of
switches. The PLC is equipment that was invented to replace the necessary sequential relay circuits
for machine control and works by looking at its input and depending up on their stating turning ON
/OFF its outputs .The user enters a program usually via software in order to give the desired result.

2.3.3 Introduction to Programmable logic controller or PLC

A programmable logic controller is a solid state control system that continuously monitors the
statues of devices connected as input. Based up on a user written program, stored in memory, it
controls the statues of devices connected as output.

A digital electronic device that uses a programmable memory to store instruction and to
implements specific functions such as logic, sequence, timing, counting and arithmetic to
control machine and process.

Its uses a programmable memory to store the instruction and specific function that include
on/off control and timing counting.

Advantage of PLC

Faster response

More flexibility

Increased reliability

Easier to troubleshooting

Major Components OF PLC

Central Processing Unit (CPU)

Input/output (I/O)

Power Supply

Programming Device

Fig: major parts of PLC

a) Input/ output module

The main purpose of the I/O interface is to condition the various signal received from or sent to
external input and output devices. It provides signal conversion and isolation between the internal
logic-level signal inside the PLC and the fields high level signal. The input module converts
signals from discrete to analog input devices to logic levels acceptable and an output module
converts signal from the processor to levels capable of driving the connected discrete or analog
output devices.

b) Power supply
Power supply unit of the PLC system provides the voltage needed to run the primary PLC
components. The power supply supplies DC power to the internal circuitry of CPU and other
modules that plug into the rack. For large PLC systems, this power supply does not normally supply

power to the field devices. With larger systems, power to field devices is provided by external
alternating current (AC) or direct current (DC) supplies

C) Processor
The processor module contains the PLC microprocessor, its supporting circuitry, and its main
memory system. The main function of the microprocessor is to analyze data coming from field
sensor through the input module, makes decisions based on the user defined control program and
return signal back through output module to field device.

d) Programming device
This device is used to provide to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.

PLC operation
A Typically PLC system operates on by reading all field devices via the input interface, execute the
user program stored in application memory, then based on whatever control scheme has been
programmed by the user, turn the field output devices on or off, or perform whatever control is
necessary for the process application. Basics of a PLC function are continual scanning of a
program. The scanning process involves three basic steps.

Step 1: Testing input status

First the PLC checks each of its input with intention to see which one has status on or off. In
other words it checks whether a switch or a sensor etc., is activated or not. The information
that the processor thus obtains through this step is stored in memory in order to be used in the
following steps.

Step 2: Programming execution

Here a PLC executes a program instruction by instruction based on the program and based on
the status of the input has obtained in the preceding step, and appropriate action is taken. The
action might be activation of certain outputs and the results can be put off and stored in
memory to be retrieved later in the following steps.

Step 3: Checking and Correction of output status

Finally, a PLC checks up output signals and adjust it has needed. Changes are performed based on
the input status that had been read during the first step and based on the result of the program
execution in step two following execution of step three PLC returns a beginning of the cycle and
continually repeats these steps.

2.3.4 Protection and Control Devices

2.3.4.1 Electrical Circuit Breaker
A circuit breaker is a protective device that interrupts current flow in a fault condition. It is
not intended for routine use to turn the load on and off. A mechanical switching device capable of
making carrying and breaking currents under normal circuit conditions. Also capable of making
and carrying for a specified time and breaking currents under specified abnormal circuit conditions,
such as those of a short circuit.

Components of Circuit breaker

The five basic components of a circuit breaker are:

Frame, or case made of metal, or some type of electrical insulation

Electrical contacts
Operating mechanism
Trip unit, containing either a thermal element, or a magnetic element or both

Operation of circuit breaker

In order to allow power to pass through the breaker, the operating lever is placed in the ON
position. This mechanically closes the contact in the breaker. When current pass through the
device; a magnetic field is developed in the bar. The intensity of this fields focuses through a large
piece of metal at the end of movable arm. When the current existed as predetermined amount, the
magnetic field will pull to the right, releasing the lever and the trip mechanism, allowing the spring
to pull contact open.

Function of Circuit breaker

1) Circuit breakers as switch
Switches (pass, but do not consume electrical energy) are considered as being control devices, thus one may
also say that a breaker is a control device, or a controller. A circuit breaker can control and protect an
electrical circuit and people operating the utilization equipment.

2) As current levels to be broken

In current quantity breaker must be able to open Overload level currents . Overloads, for our
purposes, can be understood the requirements for overload protection for motors.

3) As over current protection

Any current in excess of the rated current of the equipment or the capacity of a conductor. Over
current conditions are caused by defective conductor insulation, equipment, or an excessive
workload burden placed upon the utilization equipment and its electrical circuit. Circuit breakers
provide a level of safety against over current conditions in electrical circuits.

2.3.4.2 Contactor
Contactor is having only one position of rest, operated electromechanically and capable of making,
carrying and breaking currents under normal circuit conditions, including overload operations. A
contactor does not provide overload protection. Contactors are used to electrically turn on or off
high current, non-motor loads or in motor loads where overload protection is separately provided.
The contactor operates by applying a control voltage to the contactor coil. When the coil is
energized, the moveable contacts are closed against the stationary contacts, thus completing a
circuit (when the load is wired to Normally Open contacts), or breaking a circuit (when the load is
wired Normally Closed contacts).

Fig: contactor parts

Components of Contactor
A contactor has three components. These are: power contacts
auxiliary contacts
contact springs

Operating principle of Contactor

When current passes through the electromagnet, a magnetic field is produced; this attracts the moving core
of the contactor. The electromagnet coil draws more current initially, until its inductance increases when the
metal core enters the coil. The moving contact is propelled by the moving core; the force developed by the
electromagnet holds the moving and fixed contacts together. When the contactor coil is deenergized, gravity
or a spring returns the electromagnet core to its initial position and opens the contacts.

2.3.4.3 Overload Relay

Relays control current flow in a circuit based on signals obtained from an information source. A relay is a
simple electromechanical switch made up of an electromagnetic coil and a set of contacts. An electric signal
(Voltage) gets sent to the coil creating a magnetic field, closing the armature, which closes Normally Open
(N.O.) and opens Normally Closed (N.C.) Contacts.

Operation principle of Overload Relay

A relay is an electro-magnetically operated switch. It consists of an operating coil
wound around an electromagnet pole piece, a moving armature and one or more
sets of contacts. When a voltage of the correct value is applied across the coil
terminals, the resulting current flow through the coil produces a magnetic field
similar to a bar magnet. The armature is attracted by the magnetic field and so
moves a small distance.

2.3.4.4 Electrical Fuse

In electronics fuse is a type of low resistance resistor that acts as a sacrificial device to provide over current
protection, of either the load or source circuit. Its essential component is a metal wire or strip that melts
when too much current flows, which interrupts the circuit in which it is connected. Short circuit,
overloading, mismatched loads or device failure are the prime reasons for excessive current.

2.3.4.5 Inverter
An inverter is a motor control element that adjusts the speed of an AC induction motor. It does this by
varying the frequency of the AC power to the motor. An inverter also adjusts the voltage to the motor. Most
inverters do their job by performing two main functions: first they convert the incoming DC into AC, and
then they step up the resulting AC to mains voltage level using a transformer. The goal of the designer is to
have the inverter perform these functions as efficiently as possible, so that as much as possible of the energy
drawn from the battery or solar panel is converted into mains voltage AC, and as little as possible is wasted
as heat.

2.3.4.6 Rectifier
A Rectifier is an electrical device that converts alternating current (AC), which periodically reverses
direction, to direct current (DC), which flows in only one direction. The process is known as rectification.
Physically, rectifiers take a number of forms, including semiconductor diodes, silicon-controlled rectifiers
and other silicon-based semiconductor switches. Rectifiers have many uses, but are often found serving as
components of DC power supplies and highvoltage direct current power transmission systems. Because of
the alternating nature of the input AC sine wave, the process of rectification alone produces a DC current
that, though unidirectional, consists of pulses of current. Rectifiers are used in various devices, include:
DC power supplies
A source of power instead of generating current
High-voltage direct current power transmission systems

2.3.4.7 Electrical switch

Electrical switch controls a mechanical or electrical or electronic device for making or breaking or changing
the connections in a circuit. In electrical switch is an electrical component that can break an electrical
circuit, interrupting the current or diverting it from one conductor to another. The most familiar form of
switch is a manually operated electromechanical device with one or more sets of electrical contacts, which
are connected to external circuits. Each set of contacts can be in one of two states: either "closed" meaning
the contacts are touching and electricity can flow between them, or "open", meaning the contacts are
separated and the switch is no conducting.

2.3.4.8 Transformer
The transformer used on the control system is normally step-down transformers. They are used to step the
voltage down from the line voltage to the control circuit voltage. Used in this way, the transformer is called a
control power transformer or CPT.

2.3.4.9 Sensor
A sensor is a device that measures a particular characteristic of an object or system. It is also a device that
detects and responds to some type of input from the physical environment. The specific input could be light,
heat, motion, moisture, pressure, or any one of a great number of other environmental phenomena. The
output is generally a signal that is converted to human-readable display at the sensor
location or transmitted electronically over a network for reading or further processing. Some sensors are
purely mechanical, but most sensors are electronic, returning a voltage signal that can be converted into a
useful engineering unit. Sensors take advantage of the mechanical or electrical response of its components
to relate the response to a relevant quantity.

Some Types of Electrical sensor

1) Electrical Sensor
Electrical sensors examine the change in electrical or magnetic signals based on an
environmental input. Examples of electrical sensors are metal detectors, RADAR
systems and even simple electrical meters such as voltmeters and ohmmeters.
Magnetometers are widely used in traffic intersections to detect the presence of a
vehicle.

2) Optical Sensor
Optical sensors use principles of light to quantify object characteristics. The most
common optical sensor is the electric eye, which uses a beam of light to detect the
presence of an object. Photo detectors and motion detectors act as switches to turn
lighting systems on and off. It has advantages with regard to visual appearance of
the yarn. One dimensional sensor comes to very close to observation of human eye;
whereas, two dimensional Optical sensor offers advantages for the determination of
the roundness and the density of the Yarn.

3) Chemical Sensor
Chemical sensor measures the presence and quantity of a specific chemical in an environment. Some
chemical sensors include radon and carbon monoxide detectors, automobile oxygen sensors and pH sensors.
Some chemical sensors are designed to detect a specific compound or ion for specialized testing operations.
It is applicable in bleaching machine, printing machine for adding of dyeing chemicals.

4) Temperature Sensor
Temperature sensor simply reports the temperature of a part or environment. The most common type of
temperature sensor is the thermocouple, which relies on voltage changes based on dissimilar metal
junctions. Thermocouples are available for a wide range of temperatures, from ambient environmental
temperatures through high temperature environments, such as jet engines.

5) Mechanical Sensor
Mechanical sensor measure the change in a mechanical property of an object or system. The primary
mechanical sensor is the strain gauge, which forms the basis of several different types of mechanical sensors.
A strain gauge is a variable resistor that measures the amount of deformation that a part endures when it is
affected by a force.

6) Photoelectric sensor
Photoelectric sensor feature long sensing ranges because they detect objects using light projected over great
distances relative to other types of presence sensors. These sensors are applicable in foreign matter detector
machine, Unimixer machine, warping machine, printing machine and Inspection machine.

Fig: photo electric sensor

7) Position sensor
Position sensor measure linear or angular position in reference to a fixed point or arbitrary reference. They
can be used to measure distance or displacement (change in position) or simply to detect the presence or
absence of an object (proximity sensors). It is applicable in Stenter machine and printing machine, IDF, and
drawing machine.

8) IQ plus sensor
Which is integrated to electrical board, interconnected at the bottom side and it indicates light when there is
waste on it or the yarn is cut, the machine senses it. It is applicable in open ending machine.

9) Yarn break sensor

It indicate red light when the package is full, when sliver is cut to insert the sliver in to spinning box by
pushing yarn sensor. It is applicable in open ending machine.

2.3.5 Power Supply of the Company

The factory gets its power supply from Tisa bay hydroelectric power station. It is supply with independent 15
KV, lines one for its production machines and one its utility section (boilers and air conditioners). The
average daily consumption at full load is 38,260 kWh for production machine and 2278 kWh for utility, it
has also stand by Generator with designed capacity of 800 kWh. The main power consumption and
distribution in BDTSC is as shown in

Fig:power distribution and consumption

2.3.6 Three Phase Induction Motor Repair

2.3.6.1 Induction Motor
Induction motors are the ac motors which are employed as the prime movers in most of industries; such
motors are widely used in industrial applications from small workshops to large industries. These motors are
employed in applications such as centrifugal pumps, conveyers, compressors crushers, and drilling machines
etc. An induction motor has two main parts, a fixed external stator and an internal rotor. The
stator has windings through which AC current flows and it produces a rotating magnetic field. The rotor is
attached to the output shaft and gets a torque by the rotating magnetic field. The speed of the motor is

dependent on the frequency of the electrical source and the number of windings, or poles, in the stator.
Three-phase AC induction motor are widely used in many fields. They are classified in two
categories:
Squirrel cage motor
Wound-rotor motor

Advantages of Induction Motor

The most common advantages of AC induction motor are:
Rugged construction
Reliable operation
Low initial cost
Easy operation and simple to maintenance
Simple control gear for starting and speed control
High efficiency

Disadvantage of Induction Motor

Relatively poor starting torque

Wants to turn at constant speed (50Hz divided by half the number of poles)
Cannot turn faster than 1500rpm (4-pole motor)
Draws a massive starting current, or is inefficient, or both
Kind of big and bulky for the power it develop

Specifications of Motor
The main specifications of a three phase induction motor for designing purposes are:
1. Rated output in H.P or K.W
6. Speed
2. Frequency
7. Type
3. Voltage
8. Power factor
4. Connection
9. Torque
5. Current

2.3.6.2 Construction of Three phase Induction Motor

Three phase induction motor is robust and, because of its simplicity and trouble free
features, it is the type of motor most commonly employed for industrial use. It has
six essential main parts, namely:
1) Enclosure
4) Bearings
2) Stator
5) Conduit Box
3) Rotor
6) Eye Bolt

1) Enclosure
i. Holds parts together.
ii. Helps with heat dissipation.

iii. In some cases, protects internal components from the environment.

2) Stator (Windings)
i. Stationary part of the motor sometimes referred to as the windings.
ii. Slotted cores made of thin sections of soft iron are wound with insulated copper wire to form one or
more pairs of magnetic poles.

3) Rotor
i. Rotating part of the motor.
ii. Magnetic field from the stator induces an opposing magnetic field onto the rotor causing the
rotor to push away from the stator field.

4) Bearings

a) Sleeve Bearings

b) Ball (Roller)
Bearings

i. Standard on most motors

i. Support shaft in any position
ii. Quiet
ii. Grease lubricated
iii. Horizontal shafts only
iii. Many come sealed requiring no maintenance
iv. Oil lubricated
5) Conduit Box: Point of connection of electrical power to the motors stator windings.

6) Eye Bolt: Used to lift heavy motors with a hoist or crane to prevent motor damage.
2.3.9 Induction Motor Controller
A motor controller is the actual device that energizes and de-energizes the circuit to
the motor so that it can start and stop. Motor controllers may include some or all of
the following motor control functions:
starting, stopping, over-current protection, overload protection, reversing,
speed changing, jogging, plugging, sequence control, and pilot light
indication.
Controllers range from simple to complex and can provide control for one
motor, group of motors, or auxiliary equipment such as brakes, clutches,
solenoids, heaters, or other signals.
There are different types of three phase motor controlling methods. These are:
1. Manual motor Control: Control is considered to be manually operated when
someone must initiate an action in order for the circuit to operate. Someone might
have to flip the switch of a manual Starter to start and stop a motor.
2. Automatic motor Operation/Magnetic motor controller: While manual
operation of machines is still common practice, many machines are started and
stopped automatically.
3. Combined operation: There is a combination of manual and automatic control.
A process may have to be started manually, but may be stopped automatically.

Components of control circuit

Before going to the design of control circuits it is necessary to have an idea of the
difference type of control circuits components. The following are some of the
important components used in contactor control circuits. Some of the important
components are:
I. Push Button
II. Contactors
III. Overload Relays
2.3.10 Induction Motor Starter
A 3-phase induction motor is theoretically self-starting. The stator of an induction
motor consists of 3-phase windings, which when connected to a 3-phase supply
creates a rotating Magnetic field. This will link and cut the rotor conductors which in
turn will induce a current in the rotor conductors and create a rotor magnetic field.
The magnetic field created by the Rotor will interact with the rotating magnetic field
in the stator and produce rotation.
Therefore, 3-phase induction motors employ a starting method not to provide a
starting torque at the rotor, but because of the following reasons;
1) Reduce heavy starting currents and prevent motor from Overheating.
2) Provide overload and no-voltage protection.
There are many methods in use to start 3-phase induction motors. Some of the
common methods are:
Direct On-Line Starter (DOL)
Star-Delta Starter
Auto Transformer Starter
Rotor Impedance Starter
2.3.11 Boiler System
In BDTSC some electrical machines like printing machine, drying machine,
calendaring, and sizing machine needs boiled water for manufacturing process. A
boiler is basically a closed vessel into which water is heated until the water is
converted into steam at required pressure
Working Principle of Boiler
The basic working principle of boiler is very simple and easy to understand. The
boiler is essentially a closed vessel inside which water is stored. Fuel (generally
coal) is burnt in a furnace and hot gasses are produced. These hot gasses come in
contact with water vessel where the heat of these hot gases transfer to the water
and consequently steam is produced in the boiler. Then this steam is piped to the
turbine of thermal power plant. The boiled water pumped out through long tubes to
every section of the company. There are many different types of boiler utilized for
different purposes like running a production unit, sanitizing some area, sterilizing
equipment, to warm up the surroundings of the working sections of the company.

2.3.12 Air Compressor System

Air compression is achieved by the interaction of a fixed and orbiting scroll. Air at
inlet pressure enters the compression chamber at the exterior side of the scroll
element. Once air is drawn in, the orbiting scroll seals off the inlet port. As the scroll
continues to orbit, the air is progressively compressed into an increasingly smaller
pocket. A continuous flow of compressed air leaves the scroll element through a
discharge port in the center of the fixed scroll. This process is continuously
repeated, resulting in the delivery of pulse-free compressed air. The produced
compressed air is stored in the air storage tanker, and then pumped out to the
company sections by using high pressure valve tubes. This high pressure air
compressed to the specific electrical machinery to perform a task.
2.3.13 Air Conditioning System
Roving, ring, picanol and somet machine of the factory uses blowing apparatus to
produce a significant quantity to fly they also continually stir it up. This necessitates
a corresponding effort to keep installation clean. To relieve attendants at least partly
of this burden, traveling blowers are now increasingly being used. These consist
essentially of a powerful fan that moves back and forth on rails above the machine.
2.3.14 Waste and Dust Removal System
The company use high-pressure vacuum systems to collect waste from every area
in a textile mill. These systems use automatic valves at air-handling separators such
as filter bags, fiber separators, condensers, fine-dust filters and cyclones The valves
are controlled by a programmable controller and collect waste directly at the site of
some production equipment, including cleaning lines, cards, traveling cleaner
collection boxes and spinning frame suction boxes.
In the fiber-recovery room, various waste categories are conveyed to the waste
room by high vacuum and collected in the appropriate fiber receivers, which are
automatically emptied into waste receptacles. The fine dust passing through the
separator screen of the waste receiver is collected in the fine-dust pulse-jet filter,
from which the dust can be manually or automatically emptied. The vacuum pump
is an economically operated centrifugal exhauster, sized for specific mill
requirements. The vacuum pump is a centrifugal exhauster that uses amperage
according to air volume. Twin automatic-discharge fiber receivers (primary
separators) operate together to produce a constant vacuum or separately as single
receiver systems. Waste is separated by a self- cleaning stainless-steel separator
screen and is automatically discharged to a waste receptacle. A patented, rotating
compressed-air mechanism cleans the separator screen, which is easily removed by
way of a special lift-up top section if servicing is required. The pulse-jet filter is a
fine-dust filter that operates as a secondary separator to collect the dust enters
tangentially and drops from the air stream to a plenum for manual or automatic
collection. Compressed air Venturis clean the filtration media. These units are selfcleaning and self-emptying. The centralized dust-collection system automatically
collects dust from air-handling and vacuum dust filters throughout a mill. This dust
is conveyed to a special pulse-jet filter for automatic disposal through a valve
system to a compacting auger, plastic bag.

2.4 Major Duties of the Intern

The major responsibilities that we had done as an intern in BDTSC are:
Writing a report on each section of the company every two weeks
Assisting company operators
Respect rules and regulations of the company
Making problem solving projects in each section
Working as a motor repair man
2.5 Challenges Faced and Measures
2.5.1 Challenges
We were performing different tasks in our intern period and the following problems
are faced:
Most of company worker are uneducated and are not voluntary to answer
any questions that are related to the task they worked on.
We were unable to get information about machines manual and some useful
documents about the company.
High sound pollution in the weaving section of the company challenging us
to get information related to this section and it may cause hearing loss.
There is a high amount of dust in spinning section that causes unable to see.
2.5.2 The Measures Taken to Solve the Challenges
We take different measurement in order to solve the challenge:

For the first challenge, we were tried to communicate smoothly and stay
more time with them, through a time we create friendship with them and tell
what we want .

For the second challenge, we were tried to communicate with our advisor and
operators of each section, so we were able to solve problems and getting
information easily.

For third challenge, we used high sound protection devices like cotton and
head phones to protect us from hearing loss.

To overcome the fourth problem we tried to recorded the information's, we

trying to see all parameters and sizing conditions consciously .

Chapter 3
Benefits Gained from the Internship

3.1 Upgrading the Theoretical Knowledge

The contribution of the internship program is not only for practical but it also
upgrades our theoretical knowledge. It increases the ability to apply systematic
design procedure to open ended problem and how to analyses something
technically; so it upgrades our theoretical knowledge the same as the practical one.
Internship memorizes the important conceptual theoretical parts that we have
learned among the important ones that the internship upgrades our theoretical
parts include:

Understanding the wiring diagram of the machine

The power distribution of the company

The operation of different electric devices like transformer, cont actor, and
generator

We have seen the real practical world and understood the work flow and interaction
between different levels of the organization. We saw the procedures and ways of
experiment tests for the quality control and assurance and we are also work as an
operator in each section measures like machine setting, machine element changing,
maintenance in the power control plant, etc. are taken to correct faults according to
the quality control office report. The effects are of raw material quality, mechanical
& electrical conditions of machines, lack of skillful operators air conditioning and
cleaning on production and waste is a great impact.
3.2 Improving Interpersonal Communication skill
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;

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.

3.3 Improving Team Playing Skill

Team work is very essential to upgrade the knowledge. Really we are understood
team work is an important to strength the effort to accomplish the task. We deals
generated from different direction in group work this increase the angle of thinking
because something visible for one Person is not visible for other. The benefits that
are gained when we work by group are the following:

Develop or upgrade social interaction with factory employers

Adopt abilities to read others feeling

Create suitable condition to solve something easily and others are some of
benefits gained by working in group

3.4 Improving Leadership Skill

As we are being a trainer the tasks assigned to us are not much leadership. We are
at the bottom or near the bottom of the organizational ladder being a trainer
especially at the time when we enter to the company, But we have learnt that the
way how the planers lead the respective teams, for men leads its co-workers and
the like at work place. Generally we have noticed the following important points
from the leaders:

Ability to encourage and motivate workers to do their best

The ability to communicate with all workers without any force

The ability to listen problems and focus on its solution

As leader to have clear and defined goals missions and vision

Also learns some solve any problems developed

3.5 Developing Work Ethics

The benefit of the internship program was interesting in improving ethical work
habit. Although it is difficult to memorize all benefits that are gained about work
ethics, it is important to mention the following:

Learning and respecting of any work tasks that were important in order to do
those tasks effectively & efficiently

Be on time at work and leave work by the right time (punctuality)

Be responsible in analyzing and interpreting gathering of data

Being loyal and honest when doing judgments on work

Good work ethics often inspire others to act in similar ways. Many people consider
efficient production a hallmark of good work ethics. Productivity doesn't have to
mean a huge output; it could mean consistent quality yield as well.
3.6 Entrepreneurship
Entrepreneurship is the ability of a person to create business or an enterprise of
his/her own. This internship program develops our creativity and we detect that the
private sector is better than the public sector to get better business. To be good
entrepreneur, the following abilities or skills are needed.
a. Risk management
b. Self confidence
c. Innovative skills
d. Market understanding ability
e. Educational background

CHAPTER FOUR
PROJECT
PROJECT TITLE : IMPROVEMENT OF FORWARD REVERSE MOTOR
USING TIME DELAY RELAY

ABSTRACT
Induction motor is the most important part that makes this project success.
This motor is chosen because it simple, rugged construction, easy
maintenance. Its commonly used especially for higher-powered motors. For
this project, Induction Motor has to running in forward-reverse controlled by
limit switch. These limit switch use as a sensor that detect the thing or
object when it touched. The motor will stop at the moment before it
continue running in reverse direction. This application is same as conveyor
that use in workhorses industry. The main part of this project is to measure
the time that induction motor take when it need to change forward direction
to reverse direction. From investigation the time is influenced by the speed
of motor. When the speed of induction motor is high, the time to change
direction is long.

Keywords: Induction motor, Timer(Time delay relay),Electromechanical

relay(Contactor), Electrical motor control

4.1 INTRODUCTION
4.1.2 BACK GROUND
Power distribution systems used in large commercial and industrial applications can be complex.
Power may be distributed through switchgear, switchboards, transformers, and panel boards.
Power distributed throughout a commercial or industrial application is used for a variety of
applications such as heating, cooling, lighting, and motor-driven machinery. Unlike other types
of power distribution equipment, which are used with a variety of load types, motor control
centers primarily control the distribution of power to electric motors.
Wherever motors are used, they must be controlled. In Basics of Control Components various
control products are used to control the operation of motors. For example, the most basic type of
AC motor control, involves turning the motor on and off. This is often accomplished using a
motor starter made up of a cont actor and an overload relay. The cont actor's contacts are closed
to start the motor and opened to stop the motor. This is done electro mechanically and often
requires using start and stop pushbuttons and other devices wired to control the cont actor.
The forward reverse motor control is used where forward and backward or upward and
downward movement in the operation is needed. The clockwise (forward) and counterclockwise
(reverse) rotation of a motor can be caused by interchanging the connection of any of the two of
its three terminals
To change the direction a three phase induction machine rotation, two of its phaexchanged, thus
changing the phase sequence form, say ABC to CBA. This can be accomplished by using two
contact ors, one for the forward or CW rotation and one for the reverse or CCW rotation. The
forward and reverse cont actors are mechanically interlocked i.e., if one of them is closed the
other cannot close. This is done to avoid dead short circuit in case both the cont actors closing
simultaneously. Also electrical interlocking could be provided using the cont actors control
contacts. the instruments are three phase induction motor ,time delay relay, over load relay
,fuse,electromechanical relay
the motor circuit also uses the overload input, which will shut down the motor. The normally
closed overload contacts are programmed as normally open in the logic driving the motor starter

outputs. The forward and reverse motor commands will operate normally if no overload
condition exists because the overload contacts will provide continuity

4.1.2 PROBLEM STATEMENT

In order to become economical you must have everything must be used in
manageable or controllable way .these motor control would minimize factors
like decreasing the working age of splitting table,maximize the suitability of
labor worker by decreasing the noise in case when the roller hit the splitting
wall and when the roller is not stopped by the wall it damages the labor
worker and spent money for medical as well as it becomes dependent on
others.
4.1.3 Objective
to show the power circuit

to show control circuit

how to integrate the power circuit and control circuit

To change the direction of a three phase induction motor rotation.

4.1.4 SIGNIFICANCE
After developing this project

avoid Injured labor worker

increase the working age of the table which is used for split the
fabric

stop the roller without human interface

4.1.5 LIMITATION OF THE PROJECT

This project operates by push button forward, reverse and stop buttons .i t
works using time delay relay in order to stop the forward reverse movement
of the motor which rotates the roller .when we press the forward pushbutton
it will run up to predetermined amount of time and when we press reverse
push button it will run in reverse direction.
needs an operator.

It does not return by itself it

4.2 REVIEW LITRATURE

cranes for speed and direction, also for raising and lowering of the crane hoist. Electric Railway
systems utilize this technology for forward and reverse speed control. This specific example is
suitable to use for a Model Railway application, however there are other circuit methods which
use a single Port Pin for Picpatch [motor control] This technology is used on a much larger scale
for traverse control of Forward / Reverse Speed control. A common switch mechanism used in
these applications is the Joy-Stick control method. The hand movement control action of the
Joystick should correspond with the direction of movement and speed of the crane gantry, hoist
or locomotive engine. Moving the Joystick handle to the right would move the crane to the right,
or moving the Joystick forward will move the train forward etc
Muhammad akurzmab BM zumami[three phase motor controller] The development of induction
motor controller project is a part of three phase induction motor control system that will be
designed based on micro-controller using MC68HC908MR32 integrated circuit manufactured by
Motorola. This controller board is an integral part of embedded motion control series and will be
interface with power circuit stage, opt isolator and emulator as one system to control a three
phase induction motor speed by controlling the PWM output using microcontroller program. The
controlled PWM output then will be transfer to power circuit board that consist of power inverter
switching to control the speed of the three phase motor. This method is called V/F control
method. This control board is equipped with overcurrent circuit sensor to detect fault for safety
purpose and tachometer circuit to sense motor speed. This control board also have
forward/reverse switch, start/stop switch and speed control pot.
DC AC motor controller by Ahmed Zharif muhamedThis project is about controlling the
switching of DC and AC motors. The DCmotor has large starting torque compare to AC motors
and therefore they alwaysused as starting motor to move the electric vehicle. On the other hand
the AC motorsis consider maintenance free and suitable for electric vehicle as well. It is common
practise to put these motor in an electric vehicle
t^4 Galway educational center turning the direction of robot

4.3MATERIALS AND METHDOLOGY

4.3.1 MATERIALS

4.3.1.1 INDUCTION MOTOR

Fig 3.1: three phase induction motor

One of the most common electrical motor used in most applications which is
known as induction motor. This motor is also called as asynchronous motor
because it runs at a speed less than synchronous speed. In this, we need to
define what synchronous speed is. Synchronous speed is the speed of
rotation of the magnetic field in a rotary machine and it depends upon the
frequency and number poles of the machine. An induction motor always runs
at a speed less than synchronous speed because the rotating magnetic field
which is produced in the stator will generate flux in the rotor which will make
the rotor to rotate, but due to the lagging of flux current in the rotor with flux
current in the stator, the rotor will never reach to its rotating magnetic field
speed i.e. the synchronous speed. There are basically two types of induction
motor that depend upon the input supply - single phase induction motor and three
phase induction motor. Single phase induction motor is not a self starting motor. and
three phase induction motor is a self-starting motor. Now in general we need to
give two supply i.e. double excitation to make a machine to rotate. For
example if we consider a DC motor, we will give one supply to the stator and
another to the rotor through brush arrangement. In three phase system, there are
three single phase line with 120 phase difference. So the rotating magnetic field
is having the same phase difference which will make the rotor to move. If we
consider three phases a, b and c, when phase a is magnetized, the rotor will
move towards the phase a winding, in the next moment phase b will get
magnetized and it will attract the rotor and then phase C. So the rotor will
continue to rotate.

4.3.1.1.1 PARTS OF THREE PHASE INDUCTION MOTOR

Stator: As its name indicates stator is a stationary part of induction motor. A
three phase supply is given to the stator of induction motor. The construction
of stator for both the kind of three phase induction motor remains the same.
The stator of the three phase induction motor consists of three main parts:
1 stator frame: It is the outer most part of the three phase induction motor.
Its main function is to support the stator core and the field winding. It acts as

a covering and provide protection and mechanical strength to all the inner
parts of the machine. The frame is either made up of die cast or fabricated
steel. The frame of three phase induction motor should be very strong and
rigid as the air gap length of three phase induction motor is very small,
otherwise rotor will not remain concentric with stator which will give rise to
unbalanced magnetic pull.
2 Stator core: The main function of the stator core is to carry alternating flux. In
order to reduce the eddy current losses the stator core is laminated. This laminated
type of structure is made up of stamping which is about 0.4 to 0.5 mm thick. All the
stamping are stamped together to form stator core, which is then housed in stator
frame. The stamping are generally made up of silicon steel, which reduces the
hysteresis loss.

3 Stator winding or field winding: The slots on the periphery of stator

core of the three phase induction motor carries three phase windings. This
three phase winding is supplied by three phase ac supply. The three phases
of the winding are connected either in star or delta depending upon which
type of starting method is used. The squirrel cage motor is mostly started by
star delta stator and hence the stator of squirrel cage motor is delta
connected. The slip ring three phase induction motor are started by inserting
resistances so, the stator winding can be connected either in star or delta.
The winding wound on the stator of three phase induction motor is also
called field winding and when this winding is excited by three phase ac
supply it produces rotating magnetic field.
Rotor: The rotor is a rotating part of induction motor. The rotor is connected
to the mechanical load through the shaft.
4.3.1.1.2 TYPES OF THREE PHASE INDUCTION MOTOR
Depending upon the type of rotor used the three phase induction motor are
classified as1 Squirrel cage induction motor

2 Slip ring induction motor or wound induction motor or phase wound

induction motor

4.3.1.1.3 WORKING PRINCIPLE OF INDUCTION MOTOR

When we are giving the supply to the stator winding, flux will generate in the
coil due to flow of current in the coil. Now the rotor winding is arranged in
such a way that it becomes short circuited in the rotor itself. The flux from
the stator will cut the coil in the rotor and since the rotor coils are short
circuited, according to Faraday's law of electromagnetic induction, current
will start flowing in the coil of the rotor. When the current will flow, another
flux will get generated in the rotor. Now there will be two fluxes, one is stator
flux and another is rotor flux and the rotor flux will be lagging to the stator
flux. Due to this, the rotor will feel a torque which will make the rotor to
rotate in the direction of rotating magnetic flux. So the speed of the rotor will
be depending upon the ac supply and the speed can be controlled by varying
the input supply. This is the working principle of an induction motor of either
type.

4.3.1.2 TIME DELAY RELAY

Time Delay is defined as the controlled period between the functioning of
two events. A Time Delay relay is a combination of an electromechanical
output relay and a control circuit. The control circuit is comprised of solid
state components and timing circuits that control operation of the relay and
timing range. Typical time delay functions include On Delay, Repeat
cycle(starting off), Interval, Off-Delay, Re trigger able One Shot, Repeat cycle
(starting on), Pulse Generator, One Shot, On/Off Delay, and Memory Latch. .
Time delay relays have a broad choice of timing ranges from less than one

second to many days. There are many choices of timing adjustments from
calibrated external knobs, DIP switches, thumb wheel switches, or recessed
potentiometer. The output contacts on the electromechanical output relay
are direct wired to the output terminals. The contact load ratings are
specified for each specific type of time delay relay. Time delay relays are
simply control relays with a time delay built in. Their purpose is to control an
event based on time. The difference between relays and time delay relays is
when the output contacts open &close: on a control relay, it happens when
voltage is applied and removed from the coil; on time delay relays, the
contacts will open or close before or after a per-selected, timed interval.
Time delay is arranged to stop at 17 seconds after the motor have been
started.

Fig 3.2: time delay relay

4.3.1.3 Electromechanical relay (Cont actor)
A cont actor can stand on its own as a power control device, or as part of a
starter. Cont actors are used in applications ranging from a light switch to the
most complex, automated industrial equipment. Cont actors are used by
electrical equipment that is frequently turned off and on (opening and
closing the circuit), such as lights, heaters and motors. The function of the
contactor is always the same; to make and break all power supply lines

running to a Load or, as defined by NEMA, to repeatedly establish and

interrupt an electrical power circuit.
4.3.1.4 Over load Relay
A relay that opens a circuit when the load in the circuit exceeds a preset
value, in order to provide overload protection; usually responds to excessive
current, but may respond to excessive values of power, temperature, or
other quantities. Also known as overload release. A relay in the circuit of a
motor which causes the motor to be disconnected from its source of power if
the current to the motor exceeds a predetermined value.

4.3.1.5 Fuse
Fuses are current-sensitive devices that provide reliable protection for
discrete components or circuits b melting under current overload conditions.
Choosing the right fuse for your application can bean over whelming, time
consuming process, and even for a seasoned electronics design engineer.

4.3.1.6 Push Button

The push button consists of 3 switches. Each switch has 1 NO and 1 NC.
Green push button for forward, black push button for reverse and red push
button for stopping. Screw terminals ensure easily wiring, metal housing.
Push buttons are widely used for magnetic starters, contactor, relays and
other electrical circuits for control purposes.

Fig 3.3: push button

4.3.2 METHDOLOGY

4.3.2.1 CONTROL CIRCUIT

.

:
Fig 3.4: over all control circuit
If the motor has been running in the forward direction, both M1 and TD1 will
have been energized. This being the case, the normally-closed, timed-closed
contact of TD1 between wires 8 and 5 will have immediately opened the
moment TD1 was energized. When the stop button is pressed, contact TD1
waits for the specified amount of time before returning to its normally-closed
state, thus holding the reverse pushbutton circuit opens for the duration so
M2 cant be energized. When TD1 times out, the contact will close and the
circuit will allow M2 to be energized, if the reverse pushbutton is pressed. In
like manner, TD2 will prevent the Forward pushbutton from energizing M1
until the prescribed time delay after M2 (and TD2) have been de-energized.

4.3.2.2 Power circuit

Fig 3.6: overall power circuit

The diagram appears similar to the DOL motor controller except for an
additional reverse cont actor. The main circuit breaker is the main power
supply switch that , L2, L3 of the two cont actors, waiting for any of these
two cont actors to close to deliver the voltage to the terminal of the motor
U1, V1, and W1 in order to run the motor. The forward cont actor is
configured in such a way as to run the motor to its normal forward rotation
with L1 connected toU1, L2 to V1, andL3toW1.Whereas the configuration of
the reverse cont actor is wired in contrast to the configuration of the forward
cont actor so as to provide a reverse rotation of the motor, with L1 to W1
insteadU1, then L3 to U1 instead of W1, while maintaining L2 connected to
V1. The thermal overload relay provides motor overload protection which
detects motor overload current to shut down the control system of the
forward reverse motor controller.

4.3.2.3 FORWARD REVERSE MOTOR CONTROL

Fig3.7: over all forward reverse motor control