INDUSTRIAL TRAINING PROJECT REPORT CFL MANUFACTURING PROCESS AT PHILIPS ELECTRONICS INDIA LTD.

MOHALI

SUBMITTED TO: Mr. SK SAGGAR DEPUTY MANAGER-HR PHILIPS ELECTRONICS INDIA LTD.

SUBMITTED BY:ARSHDEEP SINGH B.E. 3RD YEAR (EIC) Roll No. 100905012 THAPAR UNIVERSITY

ACKNOWLEDGEMENT

I would like to express my gratitude to all those who have significantly contributed towards my work regarding this project report and without whom this would not have been possible. First of all I would like to express my gratefulness for Mr. SK Saggar, Deputy Manager-HR at Philips Electronics India LTD. who gave me a once in a lifetime opportunity to come to Philips and do my industrial training here. I would also like to thank my teachers at Thapar University and my parents for their moral support. Last but not the least I thank the Internet for all the images and data which I have referred to for the completion of my report.

ARSHDEEP SINGH

CONTENTS I. II. III. IV. V. VI. VII. VIII. Introduction Construction Components & Their Working Principles of Operation Electrical Aspects of Operation EMF Flicker Light Emission, UV Radiation & Blue Light

IX. CFL Manufacturing Line X. Circuit Diagram XI. Manufacturing Process

1. Introduction
Man has been aware of fluorescence for hundreds of years, but was unable to put it to practical use for lighting until Thomas Edison was granted a patent for the fluorescent lamp in 1907. The fluorescent lamp is an electric lamp consisting of a glass tube, coated on the inside with a fluorescent substance that gives off light when acted upon by electricity. Fluorescent lamps and incandescent lamps are the two major sources of electric light today. However, fluorescent lamps produce 3.5 times as much light per watt, have much longer lives and often cost less than the corresponding models of incandescent lamps. Consequently, fluorescent lamps are commonly used in offices, factories, classrooms, restaurants, and libraries, as well as a number of other public buildings. Typical fluorescent lamps consist of a long glass tube that seals the inner components from atmosphere. These inner components include two electrodes that emit a flow of electrons; mercury vapor, which is the source of ultraviolet radiation; argon gas, which helps in starting the lamp and of course fluorescent power coating on the inner surface of the tube; and compact energy saving fluorescent lamp contains ballast. Manufactures of light bulbs are constantly trying to lower the costs of production. As a leading manufacturer of fluorescent lamps, Taiwan has played an important role in helping to develop the technology and automated machinery necessary to keep those products costs down. Consequently, the manufacturers in Taiwan can help entrepreneurs by supplying them with the machinery and technology needed to produce more economical and efficient fluorescent light bulbs.

An early compact fluorescent lamp

2. Construction
There are two types of CFLs: integrated and non-integrated lamps. Integrated lamps combine a tube, an electronic ballast and either an Edison screw or a bayonet fitting in a single unit. These lamps allow consumers to replace incandescent lamps easily with CFLs. Integrated CFLs work well in many standard incandescent light fixtures, reducing the cost of converting to fluorescent. Special 3-way models and dimmable models with standard bases are available. Non-integrated CFLs have the ballast permanently installed in the luminaries, and only the lamp bulb is usually changed at its end of life. Since the ballasts are placed in the light fixture they are larger and last longer compared to the integrated ones, and they don't need to be replaced when the bulb reaches its end-of-life. Nonintegrated CFL housings can be both more expensive and sophisticated. They have two types of tubes: a bi-pin tube designed for conventional ballast, and a quad-pin tube designed for electronic ballast or conventional ballast with an external starter. A bi-pin tube contains an integrated starter which obviates the need for external heating pins but causes incompatibility with electronic ballasts. The most important technical advance has been the replacement of electromagnetic ballasts with electronic ballasts; this has removed most of the flickering and slow starting traditionally associated with fluorescent lighting.

The tubular-type compact fluorescent lamp is one of the most popular types in Europe

3. Components & Their Working

CFLs have two main components: a gas-filled tube (also called bulb or burner) and magnetic or electronic ballast.

An electronic ballast and permanently attached tube in an integrated CFL

Standard shapes of CFL tube are single-turn double helix, double-turn, triple-turn, quad-turn, circular, and butterfly.

Stitched X-ray image from three different angles (0, 45, 90) of a defective IKEA compact fluorescent lamp. The burned through filament is visible in the left image.

Electronic ballasts contain a small circuit board with rectifiers, a filter capacitor and usually two switching transistors connected as a high-frequency resonant series DC to AC inverter. The resulting high frequency, around 40 kHz or higher, is applied to the lamp tube. Since the resonant converter tends to stabilize lamp current (and light produced) over a range of input voltages, standard CFLs do not respond well in dimming applications and special lamps are required for dimming service. CFLs that flicker when they start have magnetic ballasts; CFLs with electronic ballasts are now much more common.

It is the working principle of electronic ballasts to generate a high frequency AC to feed the lamp. This technique is also applied in a steadily increasing number of socalled switch-mode power supplies, there to facilitate the use of a very much smaller transformer. This advantage comes more or less as a byproduct also to the electronic ballast because the principle of transforming at higher frequencies is the same. In most cases the complete ballast including the transformer and the conversion electronics has the same dimensions as an equivalent magnetic one but the weight is only one fifth (and thereby roughly reciprocal to the price). As for CFLs, there is a wide span of final consumer prices. European high-price manufacturers claim that the cheap far-East products often do not match the European quality level, especially as cheap models mostly dispense with filament pre-heating. Pre-heating in principle excludes immediate start this being a weak argument against pre-heating, since it takes barely one second. Dispensing with it cuts design and production costs, but it cuts lamp life heavily with increasing number of starts. Also the initial brightness reduction after cold start and the loss of luminous density at low temperatures and old age varies widely and may be more a problem of cheaper designs.

Working principle of CFL or former electronic ballast

Working principle of present electronic ballast above 25 W rating

The working principle that used to be the general one during the stone age of electronic ballasts, and that is still applied on all CFLs and on electronic ballasts with lamp ratings up to 25 W, was to rectify the incoming AC via a B2 bridge and to smooth the DC output with an electrolytic capacitor. Somewhat later an upgraded electronic ballast technique was developed to enable at least an approximate restoration of the current sine wave. The incoming alternating voltage here is superimposed by a pulse width modulation or other chopping technique so that the current base line, the interconnection of the current peaks, represents an approximate sine wave. The possible variances of design are multiple, so this generic description of the principle cannot go into detail.

4. Principles of operation
A fluorescent lamp generates light from collisions in a hot gas (plasma) of free accelerated electrons with atoms typically mercury in which electrons are bumped up to higher energy levels and then fall back while emitting at two UV emission lines (254 nm and 185 nm). The thus created UV radiation is then converted into visible light by UV excitation of a fluorescent coating on the glass envelope of the lamp. The chemical composition of this coating is selected to emit in a desired spectrum.

5. Electrical aspects of operation

A special electronic circuitry is needed to start the lamp and maintain currents at adequate levels for constant light emission. Specifically, the circuitry delivers high voltage to start the lamp and regulates the current flow through the tube. A number of different constructions are possible. In the simplest case only a resistor is used, which is relatively energy inefficient. For operation from alternating current (AC) mains voltage, the use of an inductive ballast is common and was known for failure

before the end of the lamp lifetime inducing flickering of the lamp. The different circuits developed to start and run fluorescent lamps exhibit different properties, i.e. acoustic noise (hum) emission, lifetime (of the lamp and the ballast), energy efficiency and light intensity flicker. Today mostly improved circuitry is used, most especially with compact fluorescence lamps where the circuitry cannot be replaced before the fluorescence lamps. This has reduced the occurrence of technical failures inducing effects as those listed above.

6. EMF
The part of the electromagnetic spectrum that comprises static fields, and fields up to 300 GHz is what is here referred to as electromagnetic fields (EMF). The literature on which kinds, and which strengths of EMF that are emitted from CFLs is sparse. However, there are several kinds of EMF found in the vicinity of these lamps. Like other devices that are dependent on electricity for their functions, they emit electric and magnetic fields in the low-frequency range (the distribution frequency 50 Hz and possibly also harmonics thereof, e.g. 150 Hz, 250 Hz etc. in Europe). In addition, CFLs, in contrast to the incandescent light bulbs, also emit in the high-frequency range of the EMF (30-60 kHz). These frequencies differ between different types of lamps.

7. Flicker
All lamps will vary their light intensity at twice the mains (line) frequency, since the power being delivered to the lamp peaks twice per cycle at 100 Hz or 120 Hz. For incandescent lamps this flickering is reduced compared to fluorescence lamps by the heat capacity of the filament. If the modulation of the light intensity is sufficient to be perceived by the human eye, then this is defined as flicker. Modulation at 120 Hz cannot be seen, in most cases not even at 50 Hz (Seitz et al. 2006). Fluorescent lamps including CFLs that use high-frequency (kHz) electronic ballasts are, therefore, called "flicker free".

8. Light Emission, UV radiation and blue light

There are characteristic differences between spectra emitted by fluorescent lamps and incandescent lamps because of the different principles of operation. Incandescent light bulbs are tuned in their color temperature by specific coatings of the glass and are often sold either by the attribute warm or cold or more specifically by their color temperature for professional lighting applications (photographic studios, clothing stores etc.). In the case of fluorescent lamps, the spectral emission depends on the phosphor coating. Thus, fluorescent lamps can be enriched for blue light (wavelengths 400-500 nm) in order to simulate daylight better in comparison to incandescent lamps. Like fluorescent lamps, CFL emit a higher proportion of blue light than incandescent lamps. There are internationally recognized exposure limits for the radiation (200-3000 nm) emitted from lamps and luminaries that are set to protect from photo biological hazards (International Electro technical Commission 2006). These limits also include radiation from CFLs. The UV content of the emitted spectrum depends on both the phosphor and the glass envelope of the fluorescent lamp. The UV emission of incandescent lamps is limited by the temperature of the filament and the absorption of the glass. Some single-envelope CFLs emit UV-B and traces of UV-C radiation at wavelength of 254 nm, which is not the case for incandescent lamps. Experimental data show that CFLs produce more UVA irradiance than a tungsten lamp. Furthermore, the amount of UVB irradiance produced from single-envelope CFLs, from the same distance of 20 cm, was about ten times higher than that irradiated by a tungsten lamp.

9. CFL Manufacturing Line

1. Glass Tube Cutting & Glazing Machine 2. Washing & Drying Machine 3. Tube Bending with Annealing Machine 4. Coating and Coating Drying Machine 5. End Cleaning Machine 6. Baking Machine 7. Bead Mounting Machine 8. Exhaust Tube Cutting Machine 9. Pinch Sealing Machine with Sealing Annealing Machine 10.Fusion Machine for 2U / 3U / 4U CFL 11.Exhaust Inlet Conveyor 12.Exhausting Machine 13.1st Aging Machine 14.Basing Machine 15.Auto Assembly (Head Assembly) Machine 16.Transfer of Process Technologies with Suitable material sourcing 17.Training the people to operate the machines and making qualified CFL 18.Suitable Engineering Services

10. Circuit Diagram

11. Manufacturing Process

The production of fluorescent lamps is done in four stages. Most of the work is done by automatic machinery, so only a minimal number of workers are required. The four stages of production are: (1) Mount Making Three machines are used to make mounts. This machinery can be used to make stems for many types of lamps Flare Making Machine: A specially designed machine with 12 heads located around the edge of turntable flanges tubes of glass into flares. The flare is separated from the glass / tubing by a flame which polishes the surface of the glass as it cuts it. Stem Making Machine: Exhaust tubes and lead-in wires from presorted hoppers are, along with the flares, fed into the stem making machine, which automatically forms the stems. Mounting Machine:

The stems are forwarded to the mounting machine, where oxidized, tungsten wire filaments are attached, thus completing the mount making process. (2) Glass Tube Preparation Glass tubes of the appropriate length are placed in the washing and coating machine. This machine uses hot water and hot air to wash and dry the glass tubes before the inner walls of the tubes are coated with fluorescent powder. After being coated with fluorescent powder the tubes are automatically unloaded onto a roller conveyor which transports them through an oven and the through a cooling chamber. As the tubes pass through the oven, the fluorescent coating is baked on to the tubes. As they pass through the cooling chamber, two end-cleaning machines automatically brush the fluorescent coating from the ends of the tubes. The conveyor then transports the tubes to the sealing machine for final assembly. (3) Base Preparation The required portions of the ingredients needed to make the sealing compound are mixed together in a cement-mixing machine. The sealing compound is then dispensed into the bases of the lamps by an automatic filling machine. The bases are then forwarded to the basing machine for final assembly. (4) Assembly The mounts, glass tubes, and the cement filled bases are then assembled into finished products.