INTRODUCTION 1.

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INDUSTRY PROFILE

Figure 1.1 O/E/N India Limited, Kochi

O/E/N is a joint venture with OAK/ ELECRO/NETICS Corporation, USA. It is established in 1968 and is the market leader for Electromechanical Components. Manufacturing plants are located in the suburbs of Cochin and Bangalore with over 11,000 square meters of factory space. We offer a comprehensive range of products with applications in most segments of Electronic Industry including Communications, Automotive, Strategic Industrial Controls, Instrumentation and Consumer Electronics. The quality management systems of the company are covered by ISO 9001 and ISO/TS 16949 Certification. Factory infrastructure includes fabrication plant for pressed parts, plastic moulded parts, electroplating facilities, Research & Development Laboratory, sophisticated Tool Room and Quality Assurance & Test Labs. Apart from regular production, O/E/N offers facilities for contract manufacturing and already exports considerable volumes.

O/E/N is the customer link to the future. O/E/N help turn/transform customer concepts to product applications. O/E/N create made to order products, to customer specifications. The hard earned reputation for quality products & services has helped O/E/N enhance customer base. Clients choose O/E/N and stay with it because it provides world class technical and reliable support. Customer care and satisfaction is part and parcel of the work culture. O/E/N nurture continuous innovation, team work, employee involvement and stay focused on customer needs. O/E/N has successfully established customer loyalty by working towards establishing lesser gap between customer wants and products/services it deliver. In fact, O/E/N is the virtual supplier of Electromechanical Components. The industry is organized into the following departments HUMAN RESOURCE DEVELOPMENT (HRD)

RESEARCH AND DEVELOPMENT (R&D) DEPARTMENT ASSEMBLY DEPARTMENT

O/E/N INDIA LIMITED

MATERIALS/PURCHASE DEPARTMENT

FABRICATION DEPARTMENT

AUTOMATION DEPARTMENT

TOOL ROOM

Figure 1.2 Various Departments

CHAPTER 2

DEPARTMENTS
2.1 HUMAN RESOURCE DEVELOPMENT (HRD) DEPARTMENT Human Resource Development is a set of systematic planned activities designed by an organization to provide its members with the necessary skills to meet current and future job demands. It is a framework for helping employees, develop their personal and organizational skills, knowledge, and abilities. Human Resource Development includes such opportunities as employee training, employee career development, performance management and development, coaching, mentoring, succession planning, key employee identification, tuition assistance, and organization development. The need for HRD department is: 1. Implementing a new policy. 2. Implementing a strategy. 3. Changing an organizations culture. 4. Meeting changes in the external environment. 5. Solving particular problems. The objectives of the HRD department are: 1. Develop Human resource of the company continuously for better performance to meet objectives. 2. Provide opportunities for development of different level of employees. 3. Suitable need based training programs. 4. Prepare newly induced staff to perform their work with high level of competency and excellence. 5. Meet social obligations and industry to contribute towards the excellence of technical and management education. 6. Assist the existing and potential customers in the better use of the equipment by training the employees. 7. Promote a culture of creativity, innovation, human development, respect and dignity. 8. Achieve excellence in every aspect of working life.
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9. Create environment for the trainees conducive to their character building. The HRD department has the following functions: 1. Provide skill input to apprentices and trainees. 2. Identifying training needs and impacting training. 3. Competency mapping. 4. Organizational development activities. 5. Welfare activities. 6. Recruitment, Maintenance and separation. 7. Personal administration. 8. Security services and 9. Cleaning activities. To carry out these functions, separate sub-departments have been established with the HRD department. The HRD department is headed by the Assistant General Manager (HRD), who is responsible for the efficient working of all the departments under it. The HRD department is thus responsible for maintaining a good and sustaining relation between the management and workers and between the management and the public. The department frames various policies for the welfare and satisfaction of the employees. The policies are discussed with the management and the workers unions and if found acceptable, are put into practice. The various policies include: 1. Promotion policies. 2. Incentive schemes. 3. Environmental, Organizational health and safety policies.
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Along these policies, quality is given utmost importance. INFERENCE The HRD department at O/E/N manages the activities at various departments and ensures the welfare of the workers.

2.2 RESEARCH AND DEVELOPMENT (R&D) DEPARTMENT

The corporate R&D facility operates over a wide range of electronic research and applications. It is a self-contained center, set apart from factories, with well-equipped labs and a multi-disciplinary team of professional engineers. Designers of Science and Technology recognize the R&D section under the government of India. Today many of the companys products are the direct result of R&Ds creative application or innovative designs. The setup is also geared to absorb, adapt and assimilate technology transfers from foreign collaborations. It is also responsible for transfer of technology from the group to others. Roles & Responsibilities of R&D Section Prototyping and Batch production are the main responsibilities of the R&D Department. The design development is based on the Advanced Product Quality Planning (APQP). Advanced Product Quality Planning (APQP) There are five phases which are: 1. Plan and define the program Risk analysis and feasibility review Engineers of R&D department note all the risk faced by the company during the planning time. It consists of the comparison of the analysis of other product with the companys product. This is based on consumer specifications. Risk analysis also consist of the analysis of the different problems faced by the company in the recent days, any frequent quality rejections, any launch performance is poor, will the product requirements be difficult to achieve etc. In feasibility review they should ensure the following criteria.
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Process should be adequately defined to enable feasibility evaluation. Product specification or properties should be met as written. Product should be manufactured according to tolerance specified on the drawing.

Contract review check list Define the scope

R&D: Design the relay, issue drawing etc. Marketing: Interaction with customer. Tool room: design and make tools for fabrication. Fabrication: production of parts. Manufacturing: assembly. Quality assurance: ensure the quality of components and products. Materials

Data from marketing and QAD

Watermarks, customer plant report and rejections, field return, product analysis, customer feedback etc.

Internal quality report, supplier feedback, process capability, problem resolution reports etc.

Design goals targeting reliability, life, maintainability, timing and cost.

Preliminary bill of material Preliminary process flow chart Product assurance plan First phase review and management support

2. Product design and development Design failure mode and Effect Analysis(DFMEA)

Analysis of various parts of the relay and problems at the time of manufacturing.

Design for manufacturability and assembly Design concept, function as and sensitivity to manufacturing variations. Manufacturing and assembly process Number of components Material handling

Design verification

Different dimensions such as length, width, height, NO terminal, NC terminal, coil terminal etc. is verified

Design review checklist Prototype build Engineering drawing and specification Drawing specification changes New equipments tooling and facilities Tool design Material specification Sheet metal strip procurement Tool manufacturing
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Gauges/Testing equipment procurement Bill of materials Testing equipment requirements Team feasibility commitments Second phase review and management support

3. Process, Design and Development

Manufacturing process design output

Targets for productivity, process capability and cost. Process flow chart check list. Packing standards Flow plan check list Process FMEA and checklist Prelaunch control plan and check list Process instructions Process approval acceptance criteria Data for quality ,reliability and measurability error proofing activities Method of proofing detection and feedback Measurement of system analysis plan Preliminary process capability study plan
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Packing specifications Third phase review and management support

4. Product &Process Validation Production trial run Measurement System evaluation Preliminary process capability study Product approval process Production validation testing Packing evaluation Production control plan Quality planning and sign off Fourth phase review and management support

5. Feedback Assessment and Corrective Action

Field trials and validation Multiple batch production for confirming the result Samples with PPAP Batch production

This is one of the most important departments of the company. The starting work of a product takes place here. The customer drawing has to be converted into an O/E/N drawing
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so that it can be manufactured in the company. Samples of the product have to be made and tested before the mass production. R&D is a document supported mandatory, sequenced, design system. Products are manufactured based on customer needs design, company design, development of program design. INFERENCE In R&D department the customer requirements are converted into a technical drawing. Based on that, sample products are manufactured tested and moved for mass production.

2.3 ASSEMBLY DEPARTMENT Assembly Department is one of the important departments of the company. The piece parts which is the fabrication unit outputs and the materials which are directly purchased undergo several processes here in order to develop the final product. The company produces different types of relays and switches by the processing of these piece parts. The assembly steps of Series 73 Relay are given below: Coil terminal fixing Coil winding Coil soldering Coil assembly Yoke, Core, Coil assembly staking Resistor lead trimming Resistor bending Resistor fixing Resistor soldering
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NO contact staking to NC contact terminal Base and NO terminal assembly Pressing of the base assembly and the coil assembly Moving contact and tension spring assembly Armature and tension spring assembly Assembly of armature to base and coil Final assembly staking Printing on the yoke Cover printing Calibration and cover assembly

2.3.1 STEPS
1. COIL TERMINAL INSERTION
A. Equipments Used Nil. B. Bill of Materials Coil terminal.

C. Procedure
1. Pick the bobbin and coil terminal, check visually for any type of damage or

flash in bobbin in working area.

2. Insert the coil terminal into the bobbin slots properly. 3. Place the sub assembly in the box/tray.

4. Repeat the process for other parts.

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5. Put the rejections if any in the rejection box.

2. COIL TERMINAL FIXING

A. B.

Equipments Used Coil terminal fixing tool, Pneumatic press. Bill of Materials Bobbin coil terminal assembly. Procedure 1 1. Set the tool (if necessary) on the press and adjust the pressure between 5 to 6kg/cm square. 2. Place the sub assembly properly in the tool. 3. Operate the press. 4. Take out the sub assembly check for any damage or loose terminal and place it in the box. 5. Repeat the process for other parts. 6. Put the rejections if any in the rejection box.

C.

Procedure 2 1. Place two coil terminals in the slot provided on the tool. 2. Place the bobbin on the coil terminals with the hole just above the terminal pins. 3. Operate the press. 4. Take out the sub assembly check for any damage or loose terminal and place it in the box. 5. Repeat the process for other parts.
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6. Put the rejections if any in the rejection box.

3. COIL WINDING
A. Equipments Used Automatic coil winding machine, Mandrels, Hand tools,

Multimeter, Tension gauge,

B. Bill of Materials - Bobbin-Coil terminal assembly, Winding wire (as required).

C. Procedure
1. Switch on the power and ensure that air pressure is above 4kg/cm2.

2. Select programme for the required coil resistance as per IS-PRW-73-001. 3. Load winding wire whenever needed. 4. Load bobbin assembly to the mandrels. 5. Run the machine by switching on the push button switches. 6. Check the tension of winding wire one by one using tension gauge.
7. When winding is over, take out the wound coils and check visually for coil

shape, proper routing of coil leads, breakage of winding wire, proper wrapping of coil lead, and loose winding. 8. Arrange the accepted coils in the tray. 9. Put the rejections if any in the rejection box.

4. COIL SOLDERING
A. Equipments Used Semi automatic tinning machine. B. Bill of Materials Coil assembly, Soldering lead bar, Trays.

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C. Procedure 1 (Rotating Type) 1. Switch ON the semi automatic soldering machine in order to allow it to

reach the required temperature as per respective validation reports. 2. Select the programme for 73 coil soldering. 3. Switch ON the push button to operate indexing of the arm. 4. Continue loading of the coils in the remaining set of arms. 5. Unload the coils after sequential operation of fluxing and soldering. 6. Check the soldered coils for proper soldering and melting of bobbin against 73 coil dipping height sketch.
7. If it is right, continue the process by selecting the auto mode, otherwise

adjust the machine programme for solder dip. 8. Put the rejections if any in the rejection box.

Procedure 2: (Linear Type)

1. Switch ON the power and switches of the semiautomatic tinning machine

and allow it to reach the required temperatures as per respective validation reports. 2. When temperature reaches the set temperature green light will blink in the operating panel. 3. Select the cup cleaning button from the control panel. 4. Clean the tinning cup and tinning pot. 5. Select manual mode from the control panel. 6. Select time selection A or B.
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7. Place the bobbin in the fixture. 8. Place fixture in the rail. 9. Select the button from the control panel. 10. Pick the fixture from the end of the rail. 11. Check the soldered coils for proper soldering and melting of bobbin against 73 dipping height sketch.
12. If it is right, continue the process by selecting the auto mode from the control

panel, otherwise adjust the machine solder cup height.

13. Put the rejections if any in the rejection box.

5. COIL RESISTANCE AND VISUAL CHECKING A. Equipments Used 73 Relay coil resistance checking equipment, Illuminated

magnifier. B. Bill of Material - Coil assembly after soldering and cleaning. C. Procedure
1. Check the coil checking equipment using the master sample (done daily).

2. Check the coil resistance against internal specifications. 3. After resistance checking, check the coils under illuminated magnifier against the 73 coil dipping height. 4. Take out the rejection if any and place it in the rejection box.

6.

CORE ASSEMBLY
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A. Equipments Used - Nil B. Bill of Materials Coil assembly after resistance and visual checking, Core.

C. Procedure 1. Place the core one by one to the corresponding core holes of the coil assembly.

7. YOKE, CORE, COIL ASSEMBLY STAKING A. Equipments Used Power Press, Staking tool, Dial gauge with fixture, Zero

setting piece, Chattilon gauge, Fixture for strength checking, Vernier calliper.
B. Bill of Materials Yoke, Core and Coil assembly.

C. Procedure 1. Set the tool on the press and adjust the stroke of the press.
2. Assemble yoke, coil and core assembly together.

3. Place the assembly on the tool properly and operate the press.
4. Take out the sub assembly and check the core height using the dial gauge

(specified limit : 11.80-11.90). 5. Ensure that a. Staking impression on core is the same as the photo.
b. There is no clearance (gap) between yoke and core.

6. Check the push strength of the core (35 kg min) keeping the sub assembly on the fixture, using chattilion gauge.
7. Check the core projection height (0.3mm) and core spread diameter (3.7mm)

using vernier callipers.

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8. If all the above check points are in the specified limits, continue the process for other parts. 9. Otherwise adjust the stroke of the press or regrind the punch for proper staking.
10. Place rejections if any in the rejection box.

8. RESISTOR / DIODE LEAD TRIMMING

A. Equipments Used Pneumatic Press, Trimming tool, Tweezer. B. Bill of Materials Resistor/Diode.

C. Procedure 1. Set the tool on the press and adjust the air pressure. 2. Place the resistor/diode in the slots provided in the tool. 3. Operate the press for trimming. 4. Take out the trimmed parts from the tool and continue the process for other parts. 5. Place rejections in the rejection box.

9. RESISTOR / DIODE BENDING

A. Equipments required Pnuematic press, Bending tool, Tweezer, Automatic

resistor bending unit. B. Bill of materials Resistor/diode after lead trimming.

C. Procedure 1 - Bending tool.

1. Set the tool on the press and adjust the air pressure.

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2. Place the resistor/diode in the corresponding slots provided in the tool. 3. Operate the press for bending. 4. Take out the part and continue the process for other parts. 5. Put rejections if any in the rejection box provided.

Procedure 2 - Automatic resistor bending unit. Check the input air pressure to be 6 bar. 1. Empty and arrange the resistor collection trays in proper position.
2. Switch ON the main power. Select the mode of operation Auto/ Manual by

turning the selector switch.

3. Position the tapped resistor and gradually pull up to the feeded and then align

the resistor position on the marked area and verify that the lead of the resistor is in die centre. For viewing torch light is used.
4. Put it on the manual mode and then press the start button. The machine will

run for one cycle. Check for the resistor bending, cutting and shape. Compare it with the representative samples.
5. After about 20-25 nos of cutting, turn the selector switch from run to stop.

The machine will stop. Check the resistors. Compare with the representative samples if it is right, turn the switch to auto mode and press the start button.
6. After 600 numbers of resistors the machine will be stopped. Replace the

collection box and again start the machine.

7. Continue doing the same procedure. In case if the feeding is not parallel turn

the machine to stop mode and align the tapped resistor by pulling it on required side. Then clamp the resistors and start machine.

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8. In case if any resistor is trapped in the die, stop the machine remove the

jammed resistor in the die. Then start the machine. Use torch light to view the die. 9. In case of emergency or malfunctioning turn the switch to stop mode and turn off the power switch. 10. Put the rejected parts if any in the rejection box provided.

10.

RESISTOR FIXING
A. Equipments Used Nil B. Bill of Materials Yoke, Core, Coil assembly, Resistor after bending.

C. Procedure 1. Pick one yoke, core, coil assembly. 2. Place the resistor into the corresponding holes of the coil terminal. 3. Place the sub assembly in the tray. 4. Put the rejections if any in the rejection box.

11.

RESISTOR SOLDERING
A. Equipments Used Resistor soldering power supply, Soldering fixture,

Soldering bits and accessories.

B. Bill of Materials Yoke, Core, Coil assembly after resistor fixing, 26 SWG

60/40 Solder wire, Brush, Isopropyl alcohol. C. Procedure 1. Switch ON the power supply.
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2. Fix the sub assembly into the soldering fixture. 3. Solder the points properly using soldering equipment. 4. Take out the sub assembly from the fixture and place it in the tray. 5. Put the rejections if any in the rejection box.

12.

NO CONTACT STAKING TO NO CONTACT TERMINAL

A. Equipments Used Pneumatic press/ Kumag press, Staking tool, Vibrator,

Tweezer, Micrometer, Regulated DC power supply, Rheostat, Milli volt meter.

B. Bill of Materials NO contact terminal, NO contact. C. Procedure 1 Air Press/Power Press

1. Set the tool on the press and adjust air pressure as required. 2. Place contact head in the die set of the tool and place NO terminal over it properly. 3. Operate the press and take out the part. 4. Check the total dimension using micrometer. If it is ok (1.65+/-0.065mm), continue the process otherwise correct it by adjusting the regulator of the air press. 5. Check the contact volt drop for two pieces between the tail of the contact and terminal at 20A at 12V DC(spec. <1mV) two times per shift.

Procedure 2 Kumag Riveting tool 1. Set the Kumag Anvil and the punch if required. 2. Load the contacts in the vibrator.
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3. Switch on the Kumag press and the vibrator. 4. Pull out the contact using the hole provided for the same in the terminal and place it in the anvil. 5. Operate the Kumag to get the required staking. 6. Measure the total thickness of contact (1.65+/-0.05mm) sheet. 7. Check the contact volt drop for two pieces between the tail of contact and terminal at 20A at 12V DC ((spec. <1mV) two times per shift. after staking.

Check this periodically in every two hour interval and record in the check

13. BASE AND NO TERMINAL ASSEMBLY

A. Equipments Used Tweezer B. Bill of Materials NO contact assembly and base-1A version, NO contact

assembly, base of NC terminal assembly-1C/O version. C. Procedure

1. Take the base/base assembly and insert the NO contact terminal assembly

properly using the tweezer. 2. Repeat the process for all parts.
3. In case if any rejection, put it in the rejection box.

14.

BASE AND TERMINAL ASSEMBLY STAKING

A. Equipments Used Pneumatic Press, Staking tool, Tweezer, Dial guage, fixture,

chattelon.

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B.

Bill of Materials Base and NO terminal assembly (1A version) or Base, NC terminal and NO terminal assembly (1C/O version).

C. Procedure
1. Set the tool on the press and adjust the air pressure as 2-5 kg/cm 2 for 180

base and 4-7 kg/cm2 for 380 base. 2. Place sub assembly (base and NO terminal assembly in the case of 1A version, base, NC terminal and NO terminal in the case of 1C version) in the tool properly. 3. Operate the press and take out the part from the tool. 4. Check for proper staking. Ensure the staking strength 10 kg force using chattilon. If it is OK continue the process for other parts.
5. Measure the level of NO contact button using the dial gauge and fixture (4.4

+ 0.1mm)(4.4-0.2mm). 6. Otherwise adjust the air pressure to get firm staking. 7. Put the rejections if any in the rejection box.

15.

PRESSING OF BASE ASSEMBLY AND COIL ASSEMBLY A. Equipments required Protel Press. B. Bill of materials Base assembly, Yoke assembly, core assembly, coil assembly, resistor/diode. C. Procedure 1. Set the tool on the Protel press. 2. Place the base assembly in the tool.

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3. Place the resistor/diode properly in the slots provided in the base. 4. In the case of diode, polarity should be in such a way that anode comes to terminal 85. 5. Take yoke, core, coil assembly and place properly on the base. 6. Operate the switch to insert yoke, core, coil assembly. 7. Take out the sub assembly. Ensure locking of base and bobbin and place it in the tray.
8. For relays with resistor/diode check proper seating of resistor/diode. If it is

right, place it using hand tool. 9. Continue the process for other parts. 10. Put the rejections if any in the rejection box.

16.

MOVING CONTACT, AND TENSION SPRING STAKING, C

A. Equipments Used Pneumatic press, Staking tool, Regulated DC power supply,

Rheostat, Millivoltmeter, Micrometer, Tweezer, Vernier calliper.

B. Bill of Materials Moving contact, Tension spring.

C. Procedure 1. Set the tool on the press and adjust air pressure. 2. Place the contact head in the die set of the tool and place tension spring over it properly. 3. Operate the press and take out the part.
4. Check for proper staking and total thickness of the contact button (1.01+/-

0.03mm) using micrometer and contact spread diameter (>/=2.1mm) using

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dial calliper. If it is right, continue the process otherwise correct it by adjusting the regulator of the press. 5. Check the contact voltage drop for two pieces between the tail of contact and spring at 20A at 12V DC (spec.<5mV) two times per shift.

17.

ARMATURE AND TENSION SPRING ASSEMBLY STAKING

A. Equipments Used Pneumatic press, Staking tool. B. Bill of Materials Armature, Tension spring assembly.

C. Procedure 1. Set the tool on the press and adjust the air pressure. 2. Place armature in the die set of the tool properly. 3. Place the tension spring assembly over it. 4. Operate the press and take out the part.
5. Check the staked diameter 1.4-1.5mm. If it is right, continue the process,

otherwise correct it by adjusting the regulator of the air press. 6. Ensure no gap between armature and tension spring and maintain check sheet. 7. Place the rejected parts in the rejection box.

18.

ASSEMBLY OF ARMATURE ASSEMBLY TO BASE ASSEMBLY AND

COIL ASSEMBLY
A. Equipments Used Nil

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B. Bill of Materials Sub assembly after hot air cleaning, Armature, Tension

spring assembly. C. Procedure

1. Take one relay assembly and armature tension spring assembly and

assemble them together. 2. Ensure proper seating of armature assembly on yoke dimples. 3. Put the rejections if any in the rejection box. 19. FINAL ASSEMBLY STAKING
A. Equipments Used Pneumatic press, Staking tool, Regulated DC power supply,

Rheostat, Millivoltmeter, Vernier calliper.

B. Bill of Materials Sub assembly after armature tension spring assembly.

C. Procedure 1. Set the tool on the press and adjust the air pressure. 2. Place the relay assembly in the tool properly. 3. Operate the press and take out the part by pressing the ejected lever in the front side of the tool.
4. Check the staked diameter 1.5mm minimum using the vernier. If it is right,

continue the process for all the assemblies. 5. Check the contact voltage drop between spring and yoke dimples at 20A at 12V DC (spec.<5mV) two times , two pieces per shift.

20.

COVER PRINTING

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A. Equipments Used Pad printing machine/Laser printing machine, Printing pad,

Printing stamp, Oven, Tray.

B. Bill of Materials Cover, Printing ink, Isopropyl alcohol. C. Procedure 1 Pad printing

1. Fix required printing stamp on the printing pad. 2. Apply printing ink and operate the machine for spreading ink. 3. Fix printing pad with stamp on the machine. 4. Place the cover on the fixture properly. 5. Operate the machine for printing and take out the printed covers and check for legibility, correct orientation, neatness, clarity and correctness of printing matters, font and spacing as per the customer specification.
6. If it is right, continue printing, otherwise adjust the settings.

7. Arrange the printed covers in a tray.

8. Cure the printed covers in the oven at 1000C for 1 hour.

Procedure 2 Laser printing 1. Switch on the UPS and to ensure red light is ON in the laser control unit. 2. Rotate the key switch on anticlockwise direction (0 to 1). 3. After completing the blinking of white signal light, press the green push button. 4. Switch on the automated fixture, controlling unit. 5. Place the covers on the fixture properly. 6. Operate the switch near to the fixture to move the fixture for laser marking. Take out the printed covers and check for legibility, correct orientation,
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neatness, clarity and correctness of printing matters, font and spacing as per the customer specification. 7. If it is OK continue printing, otherwise adjust the settings. 8. Arrange the printed covers in a tray.
9. Cure the printed covers in the oven at 1000C for 1 hour.

21. CALIBRATION AND COVER ASSEMBLY

A. Equipments Used Pre-set/regulated power supply with DPM, Calibration

fixture, Feeler gauge-0.2mm, Gram gauge 30-0-30 gm, Gap gauge-0.3mm, Tweezer, Knife, Hand tools.
B. Bill of Materials Relay assembly and Cover.

C. Procedure 1. Switch on the power supply to start calibration as per the internal specifications /work standard.
2. Check the visual aspects such as damage, side shift, presence of dust, any

abnormalities against the part number etc., of the relay and place it on the socket. 3. Ensure the core projection after core-coil staking is perfect.
4. Operate the relay. If OK, check the over travel using the feeler gauge.

5. For one change over relay check, adjust the NC contact pressure and contact gap using gram gauge and gap gauge. 6. If the relay does not work within the specification value, adjust the tension of the tension spring using the hand tool.

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7. Take the cover and check the visual aspects, such as correctness, correct side, font, spacing etc., of the printing and other aspects such as short moulding, colour change etc., 8. Insert the cover and again check the operating parameters. 9. Take out the relay and check for any abnormalities and proper locking of cover and base. If it is not ok correct it using the hand tool. 10. Repeat the process for all relays. 11. Place the rejections if any in the rejection box.

2.3.2 QUALITY ASSURANCE (QA) TESTING Quality Assurance Testing deals with the planned and systematic activities implemented in a Quality Management Sytem. It undertakes the testing of electronic components and products in its Quality Assurance Lab. The QA Lab is equipped with the state of the art testing equipments required for inspection and testing of products according to Joint Services Specifications. Listed below are some of the major equipments in the Lab. 1.Environmental Chamber: 65 to +180o C 2. Altitude Chamber: Altitude up to 70,000 feet. 3. Vibration Machine: 5 to 5000 Hz Max 25 mm displacement. 4.Mass spectrometer Leak Detector, Helium detector: Sensitivity 6 x 10-11 cc/sec 5. Humidity Chamber: 1) Programmable-10 to +93o C. 98%RH 2) Steady State -40oC. 90-95% RH 6.Salt Spray Chamber

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7. X-Ray Plating Thickness Tester. 8. Bump Tester-Peak Acceleration: 40+/- 4g, Drop height: 25mm.

Figure 2.1 Major Equipments In the QA Lab.

2.3.3 FINAL INSPECTION OF RELAY Pick up random samples from the lot as per sample plan OQT-QAD-XXX-001 ensuring that samples from each tray are included in the sample lot. Inspect the samples for all parameters as per the outgoing sample test (OQT-QAD-XXX-001) for the respective product. Accept the lot if all the samples meet the specifications. If there are any rejections, return the lot for rework. Re-inspect the lot as above. Record the values of 10 samples in the OQL Report, OQL-QA-004 for each part number on a daily basis. The inspection tests can be classified into two test groups based on the possible defects in the outgoing samples - major error & minor error. Minor errors are those defects that will not affect the performance of the product and are acceptable to the customers. If there is a major error in sample lots, the lot is rejected. Numbers of minor errors accepted in the lot are given in OQT-QAD-XXX-001. Details of equipments for inspection and procedures are tabulated.

Sl. No. 1

INSPECTION PARAMETER Leak test

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CHECKING AIDS Altitude chamber, Thermometer

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Dielectric strength Insulation resistance Contact resistance/ contact voltage drop Coil resistance Operate time Release time Bounce Terminal pitch/Terminal length Visual Pick-up Drop-out Contact pressure Contact gap Over travel Diode continuity Effectiveness of resistor

High V tester Megohmmeter Milliohmmeter/ Millivoltmeter Multimeter Universal time gauge or OT/RT/meter Universal time gauge or OT/RT/meter Universal time gauge or OT/RT/meter Pitch gauge Power supply/test system Power supply/test system Gram gauge Gap gauge Feeler gauge Diode tester/ test system Power supply, Multivibrator, Neon bulb

Table 2.1 Details of equipments for inspection and procedures

2.3.4 PROCEDURE
1. Leak Test: Refer work instruction WI-QAT-ET-009 & WI-QAT-ET-010. 2. Dielectric Strength: Refer work instruction WI-QAD-EQ-013 & WI-QAO-EQ-021. If jigs

are used for checking dielectric strength, preset the test voltage and press the corresponding switches provided on the test jig.
3. Insulation Resistance: Refer work instruction WI-QAO-EQ-012. Assure that the relay has

minimum insulation resistance as specified in the specification.

4. Contact Resistance: Check the contact resistance across common and NC terminals in the

unenergized condition and across common NO terminals in the energized condition. Make sure that the contact resistance is as per specification.

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5. Contact Voltage Drop: Set the required load and apply the load across the respective

contacts. Measure the voltage drop using millivoltmeter. Make sure that the contact voltage drop is as per specifications.
6. Coil Resistance: Set the selector switches of the multimeter/coil resistance tester to the

required coil resistance range. Check the coil resistance using the probes and ensure that the coil is as per specifications. In case of coil resistance tester, rejections if any will be indicated by buzzer and LED provided in the tester.
7. Operate time/ Release time/ Bounce: Refer work instruction WI-QAO-EQ-018. Make sure

that the operate time, release time, bounce are as per specification.
8. Terminal Pitch/ Terminal Length: Insert the relay in the corresponding pitch gauge. Relay

should enter the gauge freely. Assure the terminal length if it is specified to be checked.
9. Visual: Check visually for general workmanship, printing, finish, damage, alignment,

sealing, soldering etc.

10. Pick-up: Plug the relay in the socket. Gradually apply voltage and check whether the pick-

up value is as per specification. Operate the relay two or three times and ensure that the relay operates at that voltage.
11. Drop-out: Increase the voltage to nominal value. Reduce the voltage gradually and check

whether the drop-out value is within the specification.

12. Contact Pressure: Check the NO and NC contact pressure using gram gauge by applying

its tip on the top middle of moving/stationary contact spring (whichever is applicable) as close as possible to the staked moving contact in the energized and unenergized conditions respectively. See the pressure, at which the contact breaks, which is indicated by LED, is as per specification 13. Contact Gap: If the contact gap visually appears less, check the contact gap by inserting the gap gauge in between common and NO contacts in the unenergized condition and between common and NC contacts in the relay. NO contact should make or break at this setting which is indicated by LED in the socket.
31

14. Diode Continuity: Check the diode continuity using the probes of the tester. Rejections if

any will be indicated by buzzer and LED provided in the tester. 15. Check the effectiveness of resistor, using the probes provided in the test unit. If the resistor is not effective, the neon bulb attached to the probe will glow. 16. In case of relay inspected on test system, set the selector switches of the system in the required coil voltage and contact configuration. Place the relay in the respective socket. The system will indicate the coil resistance, pick-up voltage, drop-out voltage and contact lag. Rejections if any will be indicated by an Error Indicator and the readings will stop at that point. Except for visual, appropriate test systems/ fixtures/ sockets/probes etc. are used to check the above parameters. At ambient temperature 24 degree C +/- 2 degree C, this is maintained by Engineering Service Department. INFERENCE The Assembly department at O/E/N performs the systematic procedure for processing the piece parts to produce the final product. QA testing ensures the quality of the finally assembled product with the assistance of various inspection equipments. 2.4 AUTOMATION DEPARTMENT Automation is the use of computer programs to replace human design efforts. Society in its daily endeavors has become so dependent on automation that it is difficult to imagine life without automation engineering. In addition to the industrial production with which it is popularly associated, it now covers a number of unexpected areas such as trade, environmental protection engineering, traffic engineering, agriculture, building engineering and medical engineering where automation is playing a prominent role. Automation engineering is a cross sectional discipline that requires proportional knowledge in hardware and software development and their applications. In the past, automation engineering was mainly understood as control engineering dealing with a number of electrical and electronic components. This picture has changed since computers and software have made their way into every component and element of communications and automation.
32

Industrial automation engineers carry a lot of responsibility in their profession. No other domain demands so much quality from so many perspectives of the function, yet with significant restrictions on the budget. The project managers of industrial automation projects have significant resource constraint, considering the ever changing demands of its management, trying to adopt the rapid acceleration of the technological changes and simultaneously trying to maintain the reliability and unbreakable security of the plant and its instruments. Main aims of automation are: 1. Productivity gain. 2. Cost reduction. 3. Reliability and precision. 4. Health and environment. 5. Convertibility and Turnaround time. Computer-aided technologies (or CAx) now serve the basis for mathematical and organizational tools used to create complex systems. Notable examples of CAx include Computer-aided design (CAD software) and Computer-aided manufacturing (CAM software).The improved design, analysis, and manufacture of products enabled by CAx has been beneficial for industry. The main advantages of automation are: 1. Replacing human operators in tasks that involve hard physical or monotonous work. 2. Replacing humans in tasks done in dangerous environments. 3. Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc. 4. Reduces operation time and work handling time significantly. 5. Free up workers to take on other roles

33

Automation has had a notable impact on O/E/N beyond manufacturing. One of the current aims of the automation department of O/E/N is to fully automate the continuity checking process which comes after the tinning process of the relay assembly. INFERENCE The Automation department at O/E/N manufactures the various components of relays and switches using computer programs which replace the human design effort. 2.5 MATERIALS/PURCHASE DEPARTMENT O/E/N India Ltd. attempts to acquire materials, goods and services to accomplish the goals of the company. This process is referred to as purchasing. Though there are several organizations that attempt to set standards in the purchasing process, processes can vary greatly between organizations. Purchasing managers and procurement managers guide the organizations acquisition procedures and standards. Purchasing includes activities like discussing prices, discounts, delivery load time and specifications with supplier, chase data deliveries and sanction payments to deliveries. They will seek out competitive source and maximize quantity and quality. 2.5.1 PURCHASE OF MATERIALS The purchasing of materials involves many steps as given below Purchase Requisition Processing Purchase orders are originated from purchase requisition available online. A list of purchased requisitions is taken daily for further action for any item, orders are placed calling offers from different suppliers whenever applicable. Miscellaneous hardware and electrical items are ordered telephonically and regularized by formal order is originated to raise good receipt. For customer supplied items a dummy purchase order is originated to raise good receipt notes and regularization. Purchase Order Processing

34

Purchase order contains purchase order number, supplier reference, part number quality and number drawing, description, rate, delivery schedule, terms and conditions. The purchase orders are entered and stored which will be received by executives in material department and approved by department head. Whenever the marketing department informs that the supplier products are to be verified interaction with the supplier is arranged. Checking Of Incoming Goods On receipt of materials, store enters relevant details of the incoming goods in registers. The items are kept in the space provided for checking, each item is checked against the delivery schedule of supplier and difference, if any, is proved for inspection with proper ID cards. Preparation of Received Reports Details of receipts are entered in the computer and good receipt note is printed. A printout of the summary is taken daily and copies are sent to purchase department for reference while piece parts are sent to QA for inspection with GRN and ID cards. The raw materials are inspected by QA and are stored. Storage Purchased parts which require further processing after acceptance by QA are received along with process orders and store with proper identifications. The details are entered in computer and treated as in-process. The items after processing are received in piece part store along with process orders/inter shop. Chelan and acceptance card are checked and details are entered in computer. INFERENCE The Material/Purchase department at O/E/N is responsible for the purchase of various materials that are required for manufacturing. 2.6 FABRICATION & PLATING DEPARTMENT 2.6.1 OBJECTIVES

35

1. To ensure completion of production of finished products as per monthly schedule, by timely supply of parts
2. To improve group index (actual time/standard time for production). 3. To produce acceptable parts which go first time during inspection. 4. To improve tool loading effectiveness.

5. To reduce cost of quality 2.6.2 FABRICATION SHOP This is the department where all the components are manufactured which includes making of all the minor and major components of the relays and electroplating as per customer requests. About 90% of the parts such as the armature, yoke, core etc., required to manufacture the relays, and switches at O/E/N India Ltd is made by the company itself. Fabrication refers to build metal structures, by cutting, bending and assembling. The cutting part of a fabrication is via sawing, shearing or chiseling; torching with handheld torches; and via CNC cutters. The bending is via hammering (manual or powered) or via press brakes and similar tools. The assembling (joining of the pieces) is via welding, binding with adhesives, riveting, threaded fasteners, or even yet more bending in the form of crimped seam. Structural steel and sheet metal are the usual starting materials for fabrication along with the welding wire, flux and fasteners that will join the cut pieces. As with other manufacturing process both human labour and automation are commonly used. 2.6.3 ELECTROPLATING Plating is an important step which is the final step of fabrication. Plating has different steps that includes degreasing, hot soak, water rinse, acid picking, water rinse, anodic cleaning, water rinse, cyanide bath, copper bath, water rinse and unloading.

36

For plating different metals such as copper, nickel, gold, silver, cadmium, zinc, chromium etc. are used. Plating procedures include 1. Receiving of items along with the production report 2. Items are selected according to the shortage list 3. Plating is done as required by the drawing specification The plated parts are transferred for inspection. Plating thickness is measured and entered in the plating process control sheet before transferring the parts. An important factor to be noted is that O/E/N India Limited has developed an automatic plating system which is established in the plating unit. This system was developed by the automation department of O/E/N.

DEGREASING

ALKALINE CLEANING

WATER RINSE

ACID CLEANING

WATER RINSE

WATER RINSE

ANODIC CLEANING

WATER RINSE

WATER RINSE

CYANIDE DIP

CU PLATING

WATER RINSE

WATER RINSE

ACID DIP

NICKEL PLATING

NICKEL PLATING

WATER RINSE

WATER RINSE

UNLOADING

DRYING

Figure 2.2 Automatic Plating Line

INFERENCE
37

The Fabrication department at O/E/N is responsible for the manufacturing of various components of relays and switches. About 90% of the components are manufactured by the company itself. The final step of fabrication is plating. The plated parts are the transferred for inspection. 2.7 TOOL ROOM In tool room, they are manufacturing, maintaining and repairing the progressive tools for fabrication, assembly tools for assembly section and mould for molding section. 2.7.1 MANUFACTURING PROCEDURE The drawing for a particular tool will be issued from design section with respect to the work order. After getting the drawing, the routing for the entire work will be done by the shift supervisors. After routing, the supervisor will hand over the drawing copy to the respective toolmakers for pre-machining the work pieces. Work piece are taken from raw material store by giving store request in slip. Then the work piece will undergo pre-machining. The pre-machining includes shaping, milling, and surface grinding. Work piece are then loaded in micron milling and jig boring for pre-drilling holes, boring, cavity milling, steps, slots etc. to the required dimensions as per the drawing. These work pieces will be handed over to tool makers for tapping, relive holes etc. After that work piece will undergo heat treatment. Heat treatment will help the work piece to become hard. Heat treated work piece are then taken to further operations like surface grinding, profile grinding, spark erosion, wire cut, and final EDM. After the final operation EDM the work piece will be taken for inspection. The work piece will be inspected as per the drawing. By finishing the inspection the tool makers will assemble the work piece as per the drawing. The assembled tool will be taken for a trial.

38

Five thousand parts will be produced and handed over to QA for inspection. If QA approved the part, then the tool will be moved to concern department. 2.7.2 MAINTENANCE AND REPAIR Bench workers are maintaining and repairing the tools. For each tool and mould they keep a record. In that record the tool maker will note down the actions that he took for repairing the tool. 2.7.3 TOOL ROOM PROCESS FLOWCHART The working procedure in a tool room is illustrated using the flowchart below

Assembly Requirement

Automation Requirement

R&D Requirement

Fabrication Requirement

Miscellaneous

Tool Design

Planning

Tool Room (Drawing)

Priority

Scheduling

Cost estimation

Material to be used

Tool Planning

Store requisition

Supervisors

Tool Maker (Drawing)

Pre-Machining

Final Assembly

Bench work

Heat Treatment Fail

Trial & Part Inspection With TCN

Final Machining

39 Pass
FFTN, TOOL NUM &Transferring

Inspection

Fig. 2.3 Tool Room Procedure

2.7.4 OPERATIONS IN TOOL ROOM

1. Cutting: Power hack saw are using for cutting the work piece to required dimension.

2. Shaping: Shaper machine are using for shaping process. Machining of flat work piece to the required size by keeping 0.5 allowances for further operations.
3. Milling: Vertical and horizontal

4.

milling machines are using for this process. We can do milling and drilling process on this machine.

5. Micron milling: Numerical control milling machine are used for this process. In this

machine we can do drilling, milling, boring etc with accurate dimensions.

6. Jig boring: Digital read out (DRO) is used for maintaining the accurate and perfect

output. Jig boring machine maintain 2 micron accuracy. Drilling and boring of holes to require dimensions are done with this machine.
7. Surface Grinding: Work piece are grounded to magnetic chuck for grinding. By grinding

the surface will be smooth. By this machine we can do flat, vertical, horizontal grinding. We can maintain perpendicularity.
8. Cylindrical Grinding: This machine is used to grind the cylindrical work piece like

cylinders, pillars etc. By this machine we can grind internal and external round work piece.

40

9. Profile Grinding: The image of the work piece is projected to the machine. With the help

of projected image, flat, vertical, concave and any other irregular forms can be grinded to the given dimension. The accuracy of this machine is 1 micron.
10. Spark Erosion: It is a method of drilling holes in hardened work piece by sparking.. Brass

and copper rods are using as electrodes for sparking.

11. EDM: EDM means Electro Discharge Machine. There are two types of EDM

A: Stabilized current is used for this process. Brass, copper with zinc coating wires are used. The required diagram is drawn in computer and inserts the floppy to the machine. The machine will cut the work piece as per the drawing. The work piece is dipped in chilled water to avoid over heating of piece. B: Cutting of the work pieces to the required dimension is done by sparking .Copper and tungsten are used as electrodes. The work piece is dipped in dielectric fluid to avoid short circuits. Mild steel, Orvar supreme, OHNS etc. are the metals used for tool making.

INFERENCE The Tool room department at O/E/N is responsible for the manufacturing, maintenance and repairing of various tools for fabrication, assembly section and moulds.

CHAPTER 3

PRODUCTS

41

From O/E/N India Ltd., unit at Kochi, we inferred that the following products were manufactured. They are:
1. Relays

2. Switches 3.1. RELAYS Relays are electromagnetically operated switches. An actuating current on a coil operates one or more galvanically separated contacts or load circuits. The electromechanical relay is a remote controlled switch capable of switching multiple circuits, either individually, simultaneously, or in sequence. The primary functions of a relay are:1. The galvanic separation of the primary or actuating circuit and the load circuits. 2. Single input/multiple output capability. 3. Separation of different load circuits for multi-pole relays. 4. 5. Separation of ac and dc circuits. Interface between electronic and power circuits.

6. Amplifier function. 3.1.1 APPLICATIONS OF RELAYS Typical applications of relays includes laboratory instruments, telecommunication systems, computer interfaces, domestic appliances, air conditioning and heating, automotive electrics, traffic controls, lighting controls, building control, electric power controls, business machines, control of motors and solenoids, tooling machines, production and test equipments.

3.1.2 RELAY DESIGN The most important components are:

42

CONTACT SYSTEM OR SECONDARY SIDE 1. Fixed contact.

2. Moving contact: Contacts being moved by the magnetic system to switch the low circuits. 3. Contact springs: Holding the contact but sufficiently flexible to allow the contacts to

move. MAGNETIC SYSTEM

1. Coil: The coil generates the necessary magnetic field to actuate the armature and the

contact.
2. Core: The core is made up of highly magnetic permeable material that concentrates the

magnetic field.
3. Yoke: The yoke establishes the magnetic circuit. 4. Armature: The armature is the moving part of the magnetic system that closes and opens

the magnetic circuits and acts via an actuator or the moving relay contacts.
5. Return spring: For quick return of the moving contact to normal condition on removal of

the coil power. MECHANICAL COMPONENTS

1. Case and Base: The case and base is used to protect the relay against external influences.

It protects the relay against electric shock.

2. Insulation: The insulation is provided within the relay to separate the primary circuit from

the secondary side. It provides the required isolation.

3. Actuator: The actuator is used in some relay design to translate the motion of the

magnetic system to the contact system or moving contacts. It must have insulation properties to isolate the primary circuit (coil, magnetic circuit) from the secondary side (contact system).
4. Pins or terminals: The terminals are used to connect between the contact system and the

load. 5. Mounting devices 3.1.3 RELAY CONTACTS Contact performance is influenced by contact material, voltage and current values applied
43

to the contacts, the type of load, frequency of switching, ambient atmosphere, form of contact, contact switching speed and of bounce. The contacts are practically not clean because the surfaces are covered by thin layers of low conductivity, semiconductor properties or even isolating characteristics. These layers of oxides, sulphides and other compounds will be formed on the surface of metals by absorption of gas molecules from the ambient atmosphere within a very short time. The growth of these layers will be slowed down and eventually stopped as the layer itself prevents further chemical reaction. The resistance of these layers increases with their thickness. To get a reliable electrical contact, these layers have to be destroyed. This can be done by mechanical or electro-thermal destruction. MECHANICAL CLEANING When the contacts are closing, the metal surfaces will collide and hit against each other several times, causing elastic deformation of the contact area and mechanical destruction of the thin layers. The design of most of the relays allows the contact surfaces to wipe across each other destroying the non-conductive films on the contact surfaces. This contact wipe is often enough to clean the surface and reduce resistance to an acceptable level, as well as keeping the resistance stable throughout the electrical life of the relay. ELECTRICAL CLEANING The low and non-conductive layers can be destroyed by the effects of
a) Fritting (Electrical voltage) b) High current (Heating of contact points) c) Thermal effects (High temperature due to electrical arc)

A) FRITTING The term fritting describes the electrical breakdown of oxide / foreign layer when a sufficiently high voltage is applied across a closed contact. Due to the applied voltage and very short distance between the low potentials a high electric field is generated. This electric field
44

destroys the thin non-conductive layer and establishes a metal bridge electrically linking the two surfaces. The value of fritting voltage depends on the contact material, composition and thickness of layers, conductivity and composition of the contact surface. B) HIGH CURRENT High continuous currents and increased contact resistance due to the layers, causes heating of the contact. The layers will be destroyed thermally and a larger effective contact area is created, reducing the resistance. C) ARC SPARKS Under certain circumstances, an electric spark or arc will be generated during contact making or contact breaking under load. The extremely high temperature of these arcs may destroy the contact layers and burn or disintegrate other contaminants or particles in the vicinity of the point of contact. RELAY HANDLING
1. Avoid ultrasonic type cleaning of all type of relays.

2. To obtain initial performance throughout life, avoid dropping or hitting the relay. 3. Case of the relays should not be removed. 4. Sealed relays should be used for installation where adverse environment conditions, presence of sulphides, organic chemicals etc. 5. Always apply rated voltage to relay coil. 6. Do not switch voltage and currents that exceeds the designated values. 7. Use flux resistant/sealed relays for automatic soldering. TYPES OF RELAYS The various relays that we inferred from the company include industrial relays, power relays, telecommunication / signal relays, and automotive relays.

1. INDUSTRIAL RELAYS 45

Several industrial relays manufactured by O/E/N are listed below: Series31(1R/2R) Series 31(3R/4R) Series 31H Series 33

FEATURES

Mounting Style Contact Form Rating Coil

Plug in 2C,3C 10 A at 24 VDC/230 VAC 6-220 VDC, 6-230 VAC

Solder/Plug in 1-3C 10 A at 24 VDC/230 VAC 6-220 VDC, 6-230 VAC

Table 3.1 Industrial Relays

Panel / Plug in 2C, 1Z 10 A at 220VDC 12 - 220VDC, 24 - 230 VAC

Panel / Plug in 2C, 3C 30A at 24VDC/230VAC 6-48 VDC , 115 - 230 VAC

2. TELECOMMUNICATION/SIGNAL RELAYS Several telecommunication/signal relays manufactured by O/E/N are listed below Hermetically Sealed Relay Series 30-X Signal Relays Series 42 Signal Relays Series 46 Cradle Relays Series 67

FEATURES

Mounting Style Contact Form Rating Coil

PC 2C, 4C 1A at 24 VDC Sensitive Adjusted

PC 1C 1A at 24 VDC / 230VAC 12, 24VDC

PC 2C 2A at 30 VDC /125 VAC 5 - 48 VDC

Solder/Plug in/PC 2- 8C 3, 5 and 7 A at 24 VDC/115 VAC AC: 115, 230V DC: Various

Table 3.2 Telecommunication/Signal Relays

3. POWER RELAYS
46

Several power relays manufactured by O/E/N are listed below SERIES 26 FEATURES SERIES 43 SERIES 48 SERIES 55H

Mounting Style Contact Form Rating Coil

PC 1C, 2C, 1CK Up to16A at 24VDC / 230 VAC 6 - 48 VDC

PC 1A, 1C Up to 5A at 24VDC/230 VAC 12, 24 VDC

PC 2A, 2C Up to 10A at 24VDC/230 VAC 6 - 48 VDC

PC 1A 25A at 24VDC/230 VAC 12, 24 VDC

Table 3.3 Power Relays

4. AUTOMOTIVE RELAYS Several automotive relays manufactured by O/E/N are listed below SERIES 35 FEATURES SERIES 35H SERIES 35HT SERIES 3572

Mounting Style Contact Form Rating Coil

PC 1A, 1C 20 A at 12 VDC 6-48 VDC

PC 1A 40A at 12VDC / 20 A at 24VDC 6 - 48VDC

Table 3.4 Automotive Relays

PC 1A 70A at 12 VDC (Glow Plug Load) 6 - 24VDC

PC 1A, 1C Up to 45A at 12VDC 6-24 VDC

3.2 SWITCHES

47

A switch is an electrical component that can break an optical circuit, either by 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 set of electrical contacts. Each set of contact can be in one of the two states either closed, meaning the contacts are touching and electricity can flow between them or open meaning the contacts are separated or the switch is non-conducting. Different types of switches manufactured by O/E/N include Rotary wafer switch Keyboard switch Rocker switch Push button switch Toggle switch Micro switch

The main rotary switches that are manufactured are A, J, OM series 3.2.1 APPLICATIONS OF SWITCHES A switch may be directly manipulated by a human as a control signal to a system, such as a computer keyboard button, or to a control power flow in a circuit, such as a light switch. Automatically operated switches can be used to control the motions of machines, for example, to indicate that a garage door has reached its full open position or that a machine tool is in a position to accept another work piece. Switches may be operated by process variables such as pressure, temperature, flow, current, voltage and force, acting as sensor in a process and used to automatically control a system. For example a thermostat is a temperature operated switch used to control a heating process. A switch that is operated by another electronic circuit is called a relay.

48

3.2.2. ROTARY SWITCHES Different type of rotary switches manufactured by O/E/N includes the following FEATURES Series 11 (AM) Series 12 (J /JC) Series 13(OM) Series 16(LORLIN CK)

Angle of throw No. of Positions Contact Rating Approval

30 ,45 ,60 ,90

30

10o, 11.25o,12.85o,15o, 18o, 20o,22.5o, 25.7o, 30o Up to 36 positions Up to 1A at 28VDC / 110 VAC LCSO

30o Up to 12 positions 150 mA at 250 VAC Nil

Up to 12 position Up to 1A at 28 VDC and 0.5A at 110VAC LCSO

Up to 12 position Up to 2A at 28VDC and 1A at 110 VAC LCSO

Table 3.5 Rotary Switches

3.2.3 OTHER SWITCHES Other switches manufactured by O/E/N includes FEATURES Micro Switch: Series 22 Rocker Switch: Series 25 Rocker Switch: Series 27

Contact Form Contact Rating Approval

One Form Z (momentary action) Up to 10 A at 28 VDC / 2 amps 230 VAC Nil

SPST, 2 - 8 Station 25 mA at 28 VDC LCSO

Available in Slide & Piano versions 50 mA at 24 VDC Nil

49

Table 3.6 Other Switches

3.2.4. SELECTION CRITERION O/E/N offers a comprehensive range of wafer switches to meet your ever switching requirements. This bulletin is intended to help the user select the optimum switch for his requirements on the basis of the variety of switch sizes, contact and insulation materials, switching configurations and options available. ROTARY SWITCH DESIGN CHART This chart may be used to determine the required switch type by inter-relating the switch function (number of positions and angle of throw), switch size(diameter across switch frame with standard bent terminals) and insulation. SWITCH TYPE PARAMETERS Design size of switch frame (diameter across switch frame with standard bent terminals) HM 17.5mm (0.68 inch ) Insulating materials Number of positions and throw (in degrees)
4 90 6 60 8 45
10 36 12 30 14 25.7 16 22.5 18 20 20 18 24 15 36 10

ACORN 27.0mm (1.062 inch) Diallyl Phthalate

J 40.0mm ( 1.562 inch) Phenolic

JC 40.0mm ( 1.562 inch) Ceramic

MULTIDEX 46.4mm (1.609 inch )

Diallyl Phthalate

Diallyl Phthalate

Table 3.7 Rotary Switch Design Chart

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CONTACT MATERIALS All O/E/N switches use the OAK development constant pressure, double wiping contacts. The contacts are self-cleaning and require no maintenance during life under normal operating conditions. The self-cleaning action assures a clean, positive contact capable of wiping through accumulated particles of dust, oxides and contaminants. The contacts are outstanding for long life and efficient operation with minimum contact-resistance variation throughout their lifetime. Contact Material Suggested Maximum Operating Temperature +100C Typical Life Cycles Suggested Application Comments

Silver plated brass(with protective anti tarnish coating) Silver alloy(with protective anti tarnish coating) Gold flash 0.76 micron thick on silver alloy

10000 cycles

Commercial

After plating is worn through, brass to brass contact is still made, but contact resistance may become erratic. Provide silver to silver contact in excess of 200000 cycles with relatively consistent contact resistance When initial storage is likely to be long and reliable switching is required readily when used, gold flash is recommended. Again when storage is likely in corrosive environments, gold flashing will be effective. Gold flashing facilitates soldering. When tarnish films cannot be tolerated because of low level loads or dry switching, gold plating offers an effective solution .contact resistance will remain essentially constant over life of gold to gold contact. Reliable switching is possible even when used infrequently or used in corrosive environments.

+100C

200000 cycles

Military and long life commercial application Long shelf life before initial life

+100C

Gold to gold Life : Nominal Silver to silver: :In excess of 200000 cycles

Gold flash 2.5 to 5 micron thick on silver alloy

+100C

50000 cycles gold to gold contact and 200000 cycles silver to silver thereafter.

Dry circuitry. Minimum contact resistance variation. In frequent use.

Table 3.8 Contact Materials

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INSULATING MATERIALS The table below lists the types of stator and rotor insulation now available for O/E/N switches. Insulation Material Temperature range C (NonMilitary) Diallyl Phthalate -65 to +85 This is a thermo setting moulded insulation with excellent electrical characteristics with high insulation resistance coupled with low dielectric constant. Being moulded, the material allow better contact placement This is the most economical insulation material. Not recommended for high voltage circuitry or where high insulation resistance are required. Relatively the most expensive insulation material. It is stronger and more rigid than other materials and has higher temperature rating, higher insulation resistance and higher dielectric voltage rating. It has a very low dielectric loss factor and very little change in dielectric constant with temperature or frequency making it suitable for use in critical high frequency circuits. Comments

Phenolic

-65 to +100

Ceramic

-65 to +150

Table 3.9 Insulating Materials

CONTACT RESISTANCE Contact resistance of O/E/N switches ranges from 0.003 ohms to 0.015 ohms measured from one contact to the adjacent contact. If the contacts are 1800 apart, the measured resistance will be higher than when they are closer together because of the extra length of rotor blade included in the measured circuit. Gold flashed or plated contacts will offer a somewhat higher contact resistance typically ranging from 0.010 ohms to 0.020 ohms.

52

Usually, the magnitude of the contact resistance is not important, if it remains substantially constant. For O/E/N switches, contact resistance is essentially uniform throughout the life of the switch.

53

CONCLUSION
The Industrial training provided by O/E/N India Ltd. impart an idea about the manufacturing process of relays and switches. The industrial exposure gave a sense of knowledge about the day to day activities and working of various departments at O/E/N. The R&D department provides an opportunity to visualize the research and development process that is undergoing in the design of a product. The manufacturing of the products can be done either by human labour or by the automation department. This training provide me an idea about how various components of relays and switches can be manufactured by human effort and by automation which replaces the human effort. The assembly department at O/E/N help me to understand the step by step procedure in the assembly line of their products.

54