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INTRODUCTION
Rajasthan Electronics & Instruments Ltd. (REIL) is a public sector unit and it has a prominent place amongst the electronics industry of Rajasthan. It was established in 1981. REIL has joint venture between the Government of India & the Government of Rajasthan, through their respective institutions. REIL is an ISO 9001 public sector undertaking started as a joint venture between RIICO ( Rajasthan State Industrial Development & Investment Corporation) and Instrumentation Limited, Kota. The company was conferred the status of a MINI RATNA by the Department of Public Enterprises, Ministry of Industry, Government of India in 1997 on account of its good all round performance and excellent products. The company has added another feather in it is cap by establishing a Quality Management system for its operations and has been certified as an ISO 9001 firm w.e.f. 31st july, 1998. The area of business extends to manufacturing and marketing of electronic products are:
Agro-Dairy Sector Renewable energy Sector Industrial Electronics Sector Information Technology
In all these sectors, the manufacturing facility is complemented by the departments for the function of Materials management, Quality Assurance, Research & Development, Planning & Finance Management along with infrastructure and country wide network of offices of marketing and after sales support. The company is self-reliant as far as development activity is concerned, to enable modification and improvement in existing products and also introduce new products, in tune with customer requirement. REIL aims at retaining its primacy in the area of rural electronics, Non- conventional Energy Systems and Information Technology by developing, manufacturing and marketing quality services. REIL has played a vital role in the field of rural development in India- bringing appropriate rural electronics technology to thousands of villages all over the country. REILs
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products range from Electronic Milk Testers and allied dairy equipment to Solar Photovoltaic modules systems. The company, though its market of Science and Technology, Government of India, has developed and introduced a number of new products such as Data Processor Electronic Milk Tester (DPEMT), Electronic Milk Weighed System, Raw Milk Reception Dock (RMRD) Automation Database Management System, Smart Automatic Milk Collection Station (SAMCS), Auto Zero EMT, Solar EMT in the diary sector. REIL is also in the business of Renewable Energy through Solar Photo Voltaic (SPV) Technology where it started its operations in 1986, with manufacture of SPV Modules and Systems. Since then it has supplied and installed numerous SPV Stand alone Street Lighting System, SPV de-centralized Domestic Lightening System, SPV drinking Systems, SPV dusk dawn Switching Systems, Microwave Repeate4r Stations, Satellite Ground Terminals and Grid Interactive Power Plants etc. In this area company has produced SPV modules of about 8 MW generating capacity. The company entered the area of Renewable Energy through Solar Photo Voltaic (SPV) technology, in the year 1985. The company started its operations with manufacture of SPV Modules and control electronics for SPV powered village Street Lights. During my training I have gone through the four department of REIL these are Renewable energy division, agro dairy division, industrial electronics division and quality assurance department.
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Photovoltaic are solid-state semiconductor devices that convert light directly into electricity. They are usually made of silicon with traces of other elements and are similar to transistors, light emitting diodes (LEDs), and other electronic devices. The photovoltaic device (usually called a solar cell) consists of layers of semiconductor materials with different electronic properties. Most of the material is silicon. A thin layer on the front of the cell is treated with phosphorous to give it a negative character. The interface between two layers contains an electric field and is called a junction. Light consists of particles called photons. As shown in fig 1: we can easily understand when light hits the solar cell, some of the photons are absorbed in the region of the junction, freeing electrons in the silicon. If the photons have enough energy, the electrons will be able to overcome the electric field at the junction and are free to move through the silicon and into an external circuit. Some of the more commonly available units generate 5W to 10W per square foot of the collector surface. The direct current (DC) from the solar panel is converted to alternating current (AC) through an inverter.
Silicon:
Silicon is important past of solar cell. Solar cell is made up of silicon. It has some special chemical properties, especially in its crystalline form. An atom of silicon has 14 electrons, arranged in three different shells. The first two shells, those closest to the center, are completely full. The outer shell is only half full having only four electrons. A silicon atom will always look for ways to fill up its last shell would like to have eight electrons. To do this it will share electrons with four of its neighbor silicon atoms. Its like every atom holds hands with its neighbors, except that in this case each atoms has four hands joined to four neighbors. Pure silicon is poor conductor of electricity because none of its electrons are free to move about as electrons are in good conductor such as copper. Instead the electrons are all locked in the crystalline structure. The silicon in a solar cell is modified slightly so that it will work as a solar cell.
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extra electrons were balanced out by the extra protons in the phosphorous and the missing electrons (holes) were balanced out by the missing protons in the Boron. At the junction electrons and protons are mixed and form a barrier, making it harder and harder for electrons on the N side to cross to the P side. Eventually, equilibrium is reached and we have electric field separating the two sides.
Fig. 1 Solar Cell Photovoltaic (PV) is the field of technology and research related to the application of solar cells for energy by converting solar energy (sunlight, including ultra violet radiation) directly into electricity. Due to the growing demand for clear sources of energy, the manufacture of solar cells and photovoltaic arrays has expanded dramatically in recent years. Photovoltaic is the direct conversion of light into electricity at the atomic level. Some materials exhibit a property known
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as the photoelectric effect that causes them to absorb photons of light and release electrons. When these free electrons are captured an electric current results that can be used as electricity. Photovoltaic cells are connected electrically in series or parallel circuits to produce higher voltages, currents and power levels. Photovoltaic modules consist of PV cell circuits sealed in an environmentally protective laminate, and are the fundamental building blocks of PV systems. Photovoltaic panels include one or more PV modules assembled as a pre-wired, field-installable unit. A photovoltaic array is the complete power-generating unit, consisting of any number of PV modules and panels.
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It is made by very thin film of Si P-type and N-type materials and is used for special purpose. Efficiency is 25%. (e) High Efficiency Silicon Cell The purification of Si in this type of cell is very high. Hence its efficiency is high. It is used for laboratory devices having efficiency up to 30%. Example:Cadmium Telluride Efficiency is 28%.
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(c) 150 Watt Module: These are also designed by Suido-Square cells. A total number of 72 cells are connected in series. The module has 6 rows and each row contain 12 cells. Thus a total of 12*6=72 cells are used. The output voltage, current and power of each cell is the same as that of 75-watt module. The total power obtained is approximately 150 watts.
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shifted towards the n-side. Hence the light is always made to incident at the n-side so that the photons can reach the junction. When the high-energy photons reach the depletion region, they impart sufficient energy to an electron to break its covalent bond. This electron comes in conduction band and begins to behave free electron. At the same instant, a hole is also generated due to broken covalent bond. Hence, we can say that two charge carriers are generated by one high-energy photon. These carriers move to opposite direction due to potential barrier at the junction and constitute a current. One must condition of generation of mobile charge carrier is that the incident photon must have higher energy than the band gap of the semiconductor. The induced current is directly proportional to the surface area of the cell at which the light is incident. A bare solar cell has some conducting lines made of Silver Oxide for collection of charge carriers from all the portions of the surface. These carriers are supplied to the bus bar. This is the place, from where the external terminals are connected by using copper strips. These cells are made up in different shapes and sizes like circular, square, pseudo-square, cut shaped etc. In these, pseudo-square is optimized size between circular and square to utilize most of the surface area & for less wastage in the process of shaping. The maximum conversion efficiency for laboratory devices is up to 20% but for commercial cells, it lies between 10% and 15%.
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(c) Row making- A row of nine cells is made by connecting positive surfaces of one cell to the negative surface of another cell. (d) Stringing- Four rows are connected in series to give a total of 36 cells in series connection. This assembly is called a string and the process is called Stringing. (e) String Checking- This String is checked visually for any kind of faults, which are as follows1. Reverse String 2. Dry point 3. Dry Soldering 4. Loose Connection 5. Chip ( Micro Broken ) (f) Lay Up- It is a process laminating material to the either side of the string. The laminating materials are as listed: 1. Polyester Tedlar 2. EVA (ethylene vinyl acetate) 3. String 4. EVA (ethylene vinyl acetate) 5. Top glass (Toughened glass) (g) Lamination- the above laminating materials are attached to the string on both sides by the process of lamination. This process takes place at 105 degree Celsius in laminating press. The module after Lay Up is placed in the press for 11 minutes, which is equivalent to one cycle of the press. First five minutes, soaking takes place. This is the process to generate true vacuum in the module. Each air particle is stored from the inner part of the module. After these five minutes, heating takes place for three minutes and for last three minutes, the heated module is pressed to attain a one-piece assembly. (h) Curing- This process comes after the lamination to attain the full strength of laminating materials. For this the module is placed into 140 degree Celsius temperature for 20 minutes. (i) Trimming- The resultant module from curing process has some extra laminating materials. These materials are then cut and the final module is then obtained.
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(j) Electrical Inspection- This inspection is done to check the output performance of the module. (k) Channeling- Now to provide structural support to the module, channels are fixed around it. These channels prevent any damage to the module. (l) Terminal box fitting and soldering- A terminal box is also fitted for external connections and for mounting safety diodes and then the final product is cleaned and sent to the finished goods store.
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PRODUCTION STAGE
INSPECTION STAGE
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(c) Some electric lighting systems provide sufficient current for up to 10 hours of lightening each evening. (d) Locally produced car batteries can provide up to 5 nights of energy for 8 watt DC fluorescent light. (e) The Mazda 929 uses solar cells to activate a fan to ventilate the car when the car is idle and parked during a sunny hot day. (f) Space Age technology: Solar cells, also known as Photo Voltaic cells were rapidly developed to provide electrical energy for space missions. (g) In Domestic lightening system, street lightening system, portable lantern, water pumping, railway signaling and lightening, etc.
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accurate milk fat testing instrument. It measures the fat content instantaneously on a digital read out. It does not involve the use of corrosive chemicals. It works on light scattering principle with manual homogenization. It operates on AC-mains as well as on battery with inbuilt battery charger and automatic switch over to battery in case of power failure. Several thousand small/large dairies and village Milk Collection Centers are being benefited with its use. Basic objective in the dairy development program is to increase the production of milk. Milk collection depends on prompt payment of fair and correct price to encourage producers to increase milk production. The system of payment based on quality (i.e. fat content) discourages adulteration and encourages producers to increase production of high quality milk. It is further very necessary that each sample of milk should be tested of its quality and testing should be completed within 2 to 3 hours time in order to make correct payment. Milk sample would also get spoiled if not tested immediately in the absence of facility to preserve them, especially at village level. Age old traditional GERBER method of testing milk by chemicals has many inherent drawbacks, such as human error, multistep method, handing of corrosive chemical and different types of glassware. All these add to the cost and time of milk testing. A quicker, reliable and economical method of milk has therefore become inevitable and an immediate problem to solve. In the light of some problems faced by GERBER method of testing, it was felt prudent, to evolve a system which should solve these problems. The process of fat measuring by EMT has evolved basic principle, diluents, preparation, homogenization, auto zero setting etc.
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120-150 samples/hour Capacity Accuracy (Sd) 0.06% for 0-5% fat 0.10% for 5-8% fat 0.20% for 8-13% fat
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Repeatability (Sd)
0.03% for 0-5% fat 0.04% for 5-8% fat 0.08% for 8-13% fat
Sample Volume
0.5ml/test
Diluent Volume
6.5 ml/test
Table 1
Installation Requirements:
Power Supply AC: 220-240 V (Max =10%, Min -15%) DC: 12V, 6A (Max 16V, Min 10.5V) Ambient temperature Dimensions (HxWxD) 5-45 oC 23x31x53 cm
Table 2
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Sub assemblies:
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(b) Charging Regulator: It has two functions when battery has been discharged it limits charging current to 5 amps, and other is when battery has been fully charged and reaches 14.1D charging regulator turns off charging current entirely.
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Preparation of Diluent:
(a) Diluent is used to dilute the milk sample and dissolve the proteins. (b) Chemicals required to prepare 10 litres of diluent are as follows: 1. EDTA Sachet: 52.6 gms Containing EDTA Powder 45.0 gms Di-sodium hydroxide-7.6 gms 2. Triton-x-100 (Emulsifier): 0.5 ml (10 drops) 3. Antifoam: 0.5 ml (10 drops) (c) Procedure: take a clean 10 litre plastic container and add 1 litre clean water. Add contents of EDTA sachet, containing diluents powder for 10 litres solution. Add 0.5 ml of Triton-x-100 and 0.5 ml antifoam. Put the lid on the container and shake it until all the chemicals are dissolved, then add 9 litres clean water to prepare 10 litres solution and shake again to mix the solution.
Installation of EMT:
(a) Place of installation should be such that there should be sufficient space for diluents container and battery also. Handle of EMT must be easy to reach. (b) Check 1 amp fuse in mains fuse holder and 10 amp fuse in the battery holder. (c) Connect power cables to mains. (d) Use only 12V motor car battery connect red lead of battery to + pole of battery and black lead to -pole. (e) Set selector switch at line 1, battery will now be supplied to EMT from battery. As long as main switch is at on operation, current from mains will keep the battery charged. If the power fails battery will still be able to supply enough current for several hours of operation. Set the selector switch at line, if for any reason the EMT is to be operated on mains current without a battery. (f) Prepare the diluents as described earlier.
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(g) Connect one end of plastic thick pipe to INLET stub at back of EMT and attach the filter unit to other end which is placed in the diluents container. (h) Connect one end of plastic thin pipe to OUTLET stub and place the other end in waste container. (i) Place empty beaker under milk intake tube and push milk in & milk out buttons alternatively until no bubbles are seen in syringes, end by pushing milk out button.
Process of measurement:
(a) Set power switch at ON. (b) Set battery switch at LINE/BATTERY (c) Fill bottle with diluents. (d) Empty bucket for waste. (e) Do not start procedure until EMT has been switched ON half an hour to one hour. (f) Setting display at 0.00 (g) Place milk beaker under milk intake (h) Push milk in, milk out. (i) Move mix beaker to mix intake. (j) Raise and lower handle 6 times. (k) Push repeat button so that display blinks. (l) Push zero buttons so that display reads 0.00 (m)Push repeat so that display doesnt blink ( one decimal ).
After deairing and zero setting, measurement can begin. First result after zero check/ zero setting should not be recorded as it will be little low. Therefore, measure the first sample after zero check twice and record only second result. Turn the milk sample gently upside down a few times. Place the sample under milk intake and fully press MILK IN button. Slowly remove the sample without touching the milk intake tube. Place clean milk under milk intake so that it fills into notch on the side of EMT. Press MIXOUT button in all the way to
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dispense milk and diluents into mix beaker. Move the mix beaker to mix intake tube and position it so, that it rests in the notch. Operate the homogenizer handle up and down 3 times in a steady measurement. When the handle is pressed down the third time, let it test in bottom position and result will soon appear on the display. Empty the mix beaker completely and it is ready for the next sample.
End of measurement:
Place a clean, empty mix beaker under milk intake tube and press MILK IN and MIXOUT buttons twice alternately to fill mix beaker with diluents. Place the mix beaker under mix take and operate the handle up and down six times to flush the cuvette. Switch off the EMT.
Features of EMT:
(a) Auto zero facility (b) Performs 120-150 samples per hour. (c) Instant measurement and display of milk fat. (d) Accepts small sample volume
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(e) Inexpensive method of milk testing (f) Measures upto 13% fat (g) Easy to read digital LED display. (h) Automatic switch-over to battery in case of power failure (i) Built in battery charger. (j) Runs on mains and battery both.
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Final Goods Inspection: After the final product is obtained; it is again checked for quality control.
SPV Checking:
It has three major phases(a) Inward Goods checking: First of all, the bare cells are checked for required quality. (b) String Checking: After making string, it is checked visually, if there are any faults or not. The main faults in a string are1. Reverse String 2. Dry point 3. Dry Soldering 4. Loose Connection 5. Chip (Micro broken) (c) Electrical Inspection: This is used to check the performance of output of the module under normal working condition. This is checked using a device called sun simulator. A sun simulator generates the light of same intensity and frequencies as that of SUN and check the module under the following parameters1. Open circuit voltage. 2. Short Circuit current. 3. Maximum power. 4. Peak voltage 5. Peak Current.
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(h) Dispenser test: Leakage of the milk and diluents chambers is checked. If found, dispensers are send back for repairing.
Application
Power conversion (Sunlight to electricity) Village Street Lighting Village drinking water supply & land irrigation
SPV Lantern
For providing a portable neat and clean illumination system for use in village huts, farms, work place, etc. For providing illumination at villages huts
Table 3
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Technical specification:
Measuring Range 0-13%
Table 4
Features:
(a) Society management 1. Society/ member Registration 2. Member Shares 3. Milk Rates/ charts (b) Milk management 1. milk collection/local sales /dairy sale 2. milk received at dairy 3. milk payments/ daily register 4. member/shift/month/yearly/bonus reports (c) Inventory management 1. Stock register 2. Material purchase 3. Material sales (d) Accounts management 1. Trial balance 2. Day/cash/bank book
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Technical specification:
Measuring Range Sample Volume : 0-13% : 110-130 samples per hour
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: :
0.5ml/test 6.5ml/test
Table 5
Features:
(a) Milk testing, weighing, data processing and automation (b) Auto zero facility (c) Performs 110-130 samples per hour (d) Instant measurement and display of milk fat (e) Instant calculation of amount payable (f) Facility to feed milk weight directly through keypad in absence of weighing machine. (g) Printing facility (h) Instant transmission of datas on remote display (i) 7 segment Green LED display of 25mm height (j) Data storage upto 700 members for 30 days (k) Built in battery charger (l) Runs on mains battery both (m)Instant transmission of data ( member code, fat, weight and amount)
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Working Principle:
Automatic EMT works on the photometric measurement of light scattered by the fat globules present in the milk sample. The measuring procedure follows the automated system of dilution, mixing, homogenization and photometric measurement.
Technical Specifications:
Measuring range. Capacity 0-13% fat 150-180 samples/hour
0.5ml/test 6.5ml/test
Accuracy (Sd)
Repeatability
Table 6
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(e) Quick and instant read out (f) Requires small quantity of milk (g) Measures up to 13% fat (h) Performs 150Min- 180Max test per hour (i) Inexpensive method of testing (j) Process indication (k) Close correlation to accepted standard methods or measurement of milk parameters.
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With MilkoScan Minor you get a simple analysis of whole range of parameters all from one sample in only one operation. It is possible to prepare a sample set on the PC before collecting results and prepare a manual sample. MlikoScan Minor is based on well known IR technology used in other Foss MilkoScans and complies with IDF standards and AOAC official methods. This makes it easy for non-skilled users to operate the instrument. Analysis of your milk and cream can take place instantly. There is no need for special sample treatment and no use of hazardous chemicals, making MilkoScan Minor very safe and inexpensive to use. Analysis of milk and cream can take place instantly. There is no need for special sample treatment and no use of hazardous chemicals is there.
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simplified procedures for data collection, calibration adjustment and data storage provides for greater efficiency and productivity in your daily work. (b) Data Collection- All results can automatically be collected, displayed and stored for calculation and adjustment of the basic calibrations. All results can be saved, printed and exported to other software programs. This ensures greater data security and reduces manual data entry. (c) Export and import of data- The results can be exported for use in other software programs. Measured results can be imported and used in various sample sets. Results can be exported and printed on any printer via PC. (d) Emulator- Emulator software is included in order to provide training and demonstration and for easy and fast learning of the software. (e) Compatibility- The milkoScan Minor PC software is approved to run under Windows 2000 and Windows XP with service pack 2. (f) Local Language options- German as well as English language is implemented in the PC software. (g) Sample ID-Sample ID can be entered before or after data collection. (h) Product program names- Customized product program names can be typed in. (i) Calibration Adjustment- The password protected adjustment section provide editing of referenced data, calculation of basic calibration using slope and intercept and statistic plots helping to evaluate the adjustment of calibration.
Analyzer Features:
(a) Pre-calibrated for milk and cream (b) Automatic cleaning and zero setting (c) Unique Foss standard sample (d) Non-hazardous chemicals (e) Easy and cost effective. (f) Analysis of cold samples.
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PC software features:
(a) Automatic data collection (b) Calibration adjustment (c) Import/export of result
Parameters to be measured:
(a) Fat (b) Proteins (c) Lactose (d) Total solids (e) Solids-non-fats (f) Freezing point depression (g) Simple analysis of milk composition with MilkoScan Minor.
Installation Requirements:
(a) Dimensions (H x W x D) (b) Power supply (c) Performance data measuring speed (d) Measuring range (e) Protein (f) Lactose (g) Solids non-fats (h) Total solids (i) FPD (j) Repeatability (k) Purging efficiency (l) Sample volume (m) Sample temperature : 285 x 500 x 360 mm :100-240 VAC, 50-60 Hz : 40 samples per hour : Fat 0- 40% : 0 8% : 0 7% : 0 15% : 0 50% : 0.45 0.55 oC : F,P,L, TS, SnF < 0.50% rel. : >99% : < 8ml : 5 40 oC
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: 5 38 oC : 0-95% RH
BACTOSCAN FC
The BactoscanTM FC is the Ideal solution for laboratories requiring reliable, instant and accurate bacteria count in raw milk with minimum sample handling. The unique combination of technology and biochemistry combined with optimum data processing and a software platform second to none, make Bactoscan Fc a winner. The Bactoscan Fc is a true member of the Foss integrator family. The same conveyors bar code readers etc. can be used throughout the laboratory. This eases training of laboratory staff and facilities data transfer and handling. The Bactoscan FC consists of the analyzer, the PC and the basic Foss integrator software package. A number of options are available. The 100% automated Bactoscan FC employs flow cell cytometry to provide a system that counts individual bacteria cells-IBC. This gives a high accuracy compared to methods that are strongly influenced by bacterial growth requirements and by the number of single bacteria in a bacteria cluster. Analytical quality assurance a complete range of control samples and quality assurance application software offers a system for monitoring and documenting correct analyzer performance, and helps trouble shooting if need.
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Fig.10 Bactoscan FC
Installation Requirements:
(a) Dimensions: 85 x 260 cm (b) Space Requirements: 2 x 4.5 meters (c) Weight: 197 Kg (d) Power supply: 110-240V AC (e) Power Consumption: 50VA stop, Max 2000VA (f) Water Supply for preparation: Purified water (<5 uS/cm3 ) (g) Air: 0.2 N liters/min at 4.0 7.2 bar (h) Waste: 8 liters per hour (i) Ambient temperature: 15-33oC.
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Bactoscan FC semiautomatic is only available with high sensitivity at 50 samples per hour (50H). This version does not include conveyor and stirrer system. (a) Analysis time (b) Sample intake (c) Sample temperature (d) Sample quality : 8.5 minutes : 4.5 ml : 2 - 42 oC : Raw milk of normal quality composition and good quality.
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7. 2 year warranty on instrument. 8. Software troubleshooting tools and remote support. 9. Preventive maintenance contracts.
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Features :
(a) Automatic switching and hence unmanned (b) Optical use of grid power (c) Energy saving up to 30% (d) Highly efficient, reliable and economical (e) Solid-state electronic controllers, free from mechanical wear & tear prevalent in mechanical timers. (f) Relief from seasonal time setting, unlike the seasonal setting required in mechanical timers (g) Hermetically sealed weather proof and totally maintenance free sensor. (h) Protection against faults like line to line, line to neutral and line to earth fault (i) On line service facility
Specifications :
(a) Housing: kiosk type, weather proof pole mounting panel of required size. (b) Sensor: SPV sensor of suitable capacity encapsulated in an environment-proof housing (c) Electronic Controller: Electronic controller of rugged design for automatic switching of public street lights. (d) Protection: Against line to line, line to neutral and line to earth fault. (e) Electrical Switch gear unit of rated power capacity. (f) Special features (i) Manual by-pass in case of exigency (ii) pole mounting facility. (g) Rated load model 1-100A/ph (h) Model 2-60 A/ph (i) Model 3-30 A/ph
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CONCLUSION
The summer training of 30 days in REIL played an important role to develop myself. It was a golden opportunity for me to get the practical knowledge and hands-on experience from the things about which I had theoretical knowledge from the course curriculum. Finally I conclude that this training of 30 days has given me a good knowledge about the production and quality aspects of solar photovoltaic modules, EMT, and other products. As the organization follows the ISO 9001 standards, everything is done in a particular way following the documents. In addition I gained knowledge about the working principle of solar cells and the various applications in which they are used. This training has been for small period but was valuable enough giving me insight about solar photovoltaic, E.M.T. It will be helpful in enhancing the existing technology and to market the range of product.
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BIBLIOGRAPHY
Company booklet and manual Journals news related to solar energy. www.reiljp.com www.wikipedia.com
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