RSWM LTD

RISHABHDEV ( RAJ.)
PROJECT REPORT

SUBMITTED BY:
RASHMI JAIN ( E. C. DEPT.)
NIRMA UNIVERSITY,
AHMEDABAD.
SUBMITTED TO:
Mr. M S Manilal
DGM( Personal &HRD)
 ACKNOWLEDGEMENT

Nothing in this world can be accomplished without the blessings of God, the Almighty.
Therefore, at the outset, I would like to thank him with the blessings of whom, this arduous work
could take its shape.

At the very outset, I would like to extend my sincere thanks to Mr. Anil Dalawat ,DGM (
Engineering) & Mr. Harish Nair (Manager Engineering) for giving me an opportunity to work
on rather unique project under his able guidance and taking some time out of his busy schedule
for giving me valuable tips on information collection and data collection for the purpose of
carrying out of my summer training in his esteemed organization

I am also thankful to Mr. M.S. Manilal DGM (Personal & HRD) who give me opportunity to get
summer training.

I am indebted to the workers, staff and officers of the RSWM - Rishabhdeo for all good gestures
that they have shown towards me.

Your sincerely,

Rashmi jain
 PREFACE
The preface is an opportunity to talk to the reader to the personal level and explain the objective
and driving forces behind writing this report.

In Rishabhdev textile the main objective of my training program was that I have to work with
electronics components. Under my training program I learnt that what is the use of electronic
components in machinery .

How can we use them? In my training program, I worked with several functions of the
Engineering department I am describing various functions of Engineering department. What is
the role of Engineering manager and lastly conclude with Engineering department at Rishabhdev
textile.

In this report I am giving information about the L.N.J.Bhilwara group. After this I am giving the
unit location of the group.

After this I am introducing about RSWM LTD. After this describing RSWM unit Rishabhdeo I
am presenting consideration of Engineering department

INDEX
S.No. Chapter No. Topics

1. Chapter 1 Present scenario of Indian Textile

industry.

2. Chapter 2 Introduction of LNJ group

3. Chapter 3 General introduction of the RSWM unit

Rishabhdev

4. Chapter 4 Departments at Rishabhdev unit

5. Chapter 5 Engineering Department

 CHAPTER –1

Present scenario of Indian textile industry:

The Indian textile industry is one of the oldest industries in the country and occupies an
important position in its economy. Its predominant presence in the Indian economy is manifest in
its significant contribution to the industrial production employment generation and foreign
exchange earning. Currently it adds about 14 percent to the industrial production and about 4%
to the GDP. It is a second largest provider of the employment after agriculture. Which provides

employment to about 35 million people including substantial segment of ST/SC and women.

Together with allied agriculture sector it provides employment to over 90 million people. The
contribution of this industry to the gross export earning of the country is over 30% while adds
only 7 to 8 % to the gross import will of the country it is the only industry which self reliant
complete in value chain, i.e. from raw material to the highest value added products viz. Garments
/ made-ups. As a consequence, the growth and development of this industry has significant
bearing on the over all development of the Indian economy.

The Indian textile industry has maintained a significant in the world textile economy by virtue of
its contribution to world textile fibers / yarns. The industry presently contributes about 21% of
the world spindle age in the world after china with the contribution of about 57% of world loom
age; this industry has also the highest loom age in the world. At about 2.7-3 million tones, India
is third largest producer of cotton in the world after China and USA, with a share of 14-15%in
the man-made fiber sector India, is synthetic fiber and filament yarns.
 CHAPTER2

Introduction of LNJ Bhilwara group: -

The ‘LNJ Bhilwara Group’, pioneers in Textiles and Graphite Electrodes for over 40 years in the
country, is

also very well known in the fields of Sponge Iron, Power generation, Telecommunications and
financial services.

The Group was founded by the Veteran industrialist, Shri Laxmi Nivas Jhunjhunwala in 1961
with the inspection of its first unit at Bhilwara, which from a small plant has over the years
grown into a big tree having 9 companies and 20 plants spread all over the country. It is a family
consisting of about 20,000 members belonging to various states with divergent cultural
background and working in unison for achieving Groups objectives and mission. The total assets
of the Group at the end of 2005-06 stood at Rs.3553crores with record sales turnover of Rs.2387
crores.

The LNJ Bhilwara Group has its origin in 1941 when the founder and chairman emeritus, Mr.
L.N.Jhunjhunwala (LNJ) were hardly 13 years old.

At the age of 31 years, in1959, Mr. LNJ was given the license to put up a medium sized Textile
mill at Bhilwara in Rajasthan at a cost of Rs 6 million. This venture, Rajasthan Spinning and
Weaving mills
Ltd.(RSWM), the first textile mill of the LNJ Bhilwara Group in Rajasthan was a big success
and continuous to be the flagship company of the group. In 1968-69, RSWM manufactured
India’s first polyester viscose (PV) blended yarn and this is where Mr. LNJ made his fortune
having consolidated his business, the group started diversification.

In1972, the group ventured into Graphite and set up a Graphite plant, Hindustan Electro Graphite
Ltd. (now HEG Ltd.) at Mandideep in M.P., in technical and financial collaboration with
pechiney of France. Today HEG Ltd. Is M.P. with a capacity to produce 60,000 MT of sponge
iron.

During 1998 the group ventured into international quality specialized automotive automatic
fabrics through a Joint Venture Company “Bhilwara Melba De Witte Ltd.”(BMD) with Melba
industrial of Australia and De Witte lie tacr of Belgium. This fully integrated world class plant at
Banswara, Rajasthan is weaving capacity to produce 1.8 million meters. of fabrics per annum the
company is currently supplying fabrics for Maruti-Esteem and Zen, Mitsubishi –Lancer, Tata
Safari, Sumo, Sierra, Estate, Indica and General Motors of India.

In its four decades long existence, the group has come to be identified with quality and
technology. Eight of the group’s companies have been awarded IS/ISO 9001:2000certification
for their exemplary quality standards.
 CHAPTER3

An Introduction to the unit:-

The unit came into existence on July 12, 1989 with the purchase of the assets of erstwhile Siddha
Syntex, a 14,300 spindles spinning plant by the LNJ Bhilwara. Under the dynamic leadership
and vision of its president, Shri Prakash Maheshwari, the unit not only stood on its own feet, but
expanded to 32,832 spindles having world class technology with in a short period of six yrs.
Only. Now the unit is having 52848 spindles equipped with latest state-of –the-art technology
machines like chute feed system with metal detectors, Autoleveller cards and Draw frames, Auto
corners, TFO, Pallet packing machines etc. besides other latest spinning machines.

The total assets of the unit are around Rs. 68 crores with annual sales turnover of about Rs.133
crores

MANAGEMENT STRUCTURE

The unit is managed by a strong management team comprising of 10 functional manager in

different cadres headed by the COO, Shri K.B. Khatod an eminent Techno craft and the CE
(GYB), Shri S.C.Garg, versatile Management Professional.
 CHAPTER4

Department at Rishabhdev Unit (RSWM):-

• Production department

• New product Department

• Finishing department

• Maintenance department

• CPPC (Central Production Planning Control)

• Budget & MIS department

• Store & Purchase department

• IT department

• Finance & Account department

• SQC (statistical quality control)

• Personnel & HRD department

• Engineering department
 CHAPTER -5

Frequency Inverter

Also called Frequency Converter, it's a power

conversion device running at mains power
(60Hz / 50Hz). The frequency inverter converts a basic fixed frequency (50Hz/60Hz), fixed
voltage (220V/380V/480V etc.) to a variable frequency (maximum frequency up to 400Hz),
variable voltage (maximum voltage equal to input voltage) to control AC motor speed.

Frequency converter takes advantage of controlling AC motor in variable speed for energy
saving. If you gain an understanding of frequency and how AC motor is wound you will find that
understanding the frequency inverter will be quite straight forward.

Nowadays, frequency converters are widely used in many variable frequency systems, such as
mechanical drive systems and control systems. It is important to improve the control strategy to
make the frequency inverter adaptable to different situations.
Frequency inverter

Fig.(a)
 Block diagram of frequency inverter

Fig.(b)

Proximity switches

Proximity switches open or close an electrical circuit when they make contact with or come
within a certain distance of an object. Proximity switches are most commonly used in
manufacturing equipment, robotics, and security systems. There are four basic types of proximity
switches: infrared, acoustic, capacitive, and inductive.

Infrared proximity switches work by sending out beams of invisible infrared light. A
photodetector on the proximity switch detects any reflections of this light. These reflections
allow infrared proximity switches to determine whether there is an object nearby. As proximity
switches with just a light source and photodiode are susceptible to false readings due to
background light, more complex switches modulate the transmitted light at a specific frequency
and have receivers which only respond to that frequency Acoustic proximity sensors are similar
in principle to infrared models, but use sound instead of light.
 They use a transducer to transmit inaudible sound waves at various frequencies in a preset
sequence, then measure the length of time the sound takes to hit a nearby object and return to a
second transducer on the switch. Essentially, acoustic proximity sensors measure the time it
takes for sound pulses to "echo" and use this measurement to calculate distance, just like sonar.

Proximity switches are used in manufacturing processes -- for example, to measure the position
of machine components. They are also used in security systems, in applications such as detecting
the opening of a door, and in robotics, where they can monitor a robot or its components'
nearness to objects and steer it accordingly.

Proximity switch
Fig.(a)

Fig.(b)

Fig.(c) Fig.(d)
 Fig.(e)

Rectifier

A rectifier is an electrical device that converts alternating current (AC) to direct current (DC), a
process known as rectification. Rectifiers have many uses including as components of power
supplies and as detectors of radio signals. Rectifiers may be made of solid state diodes, vacuum
tube diodes, mercury arc valves, and other components.

When only one diode is used to rectify AC (by blocking the negative or positive portion of the
waveform), the difference between the term diode and the term rectifier is merely one of
usage, i.e., the term rectifier describes a diode that is being used to convert AC to DC. Almost all
rectifiers comprise a number of diodes in a specific arrangement for more efficiently converting
AC to DC than is possible with only one diode. Before the development of silicon semiconductor
rectifiers, vacuum tube diodes and copper(I) oxide or selenium rectifier stacks were used.
Early radio receivers, called crystal radios, used a "cat's whisker" of fine wire pressing on a
crystal of galena (lead sulfide) to serve as a point-contact rectifier or "crystal detector". In gas
heating systems flame rectification can be used to detect a flame. Two metal electrodes in the
outer layer of the flame provide a current path and rectification of an applied alternating
voltage, but only while the flame is present.

Half-wave rectification
In half wave rectification, either the positive or negative half of the AC wave is passed, while the
other half is blocked. Because only one half of the input waveform reaches the output, it is very
inefficient if used for power transfer. Half-wave rectification can be achieved with a single
diode in a one-phase supply, or with three diodes in a three-phase supply.

Full-wave rectification

A full-wave rectifier converts the whole of the input waveform to one of constant polarity
(positive or negative) at its output. Full-wave rectification converts both polarities of the input
waveform to DC (direct current), and is more efficient. However, in a circuit with a non-center
tapped transformer, four diodes are required instead of the one needed for half-wave
rectification. (See semiconductors, diode). Four rectifiers arranged this way are called a diode
bridge or bridge rectifier:

Uninterruptible power supply

An uninterruptible power supply, also uninterruptible power
source, UPS or battery/flywheel backup, is an electrical apparatus that provides emergency
power to a load when the input power source, typically mains power, fails. A UPS differs from
an auxiliary or emergency power system or standby generator in that it will provide near-
instantaneous protection from input power interruptions, by supplying energy stored in
batteries, supercapacitors, or flywheels. The on-battery runtime of most uninterruptible power
sources is relatively short (only a few minutes) but sufficient to start a standby power source or
properly shut down the protected equipment.
A UPS is typically used to protect hardware such as computers, data
centers, telecommunication equipment or other electrical equipment where an unexpected power
disruption could cause injuries, fatalities, serious business disruption or data loss. UPS units
range in size from units designed to protect a single computer without a video monitor (around
200volt-ampere rating) to large units powering entire data centers or buildings. The world's
largest UPS, the 46-megawatt Battery Electric Storage System (BESS), in Fairbanks, Alaska,
powers the entire city and nearby rural communities during outages.

1. Common power problems

-Power failure
-voltage sag
-Voltage spike
-Under-voltage (brownout)

2. Technologies

-Line-interactive
-Double-conversion / online
-Hybrid Topology / Double Conversion on Demand
- Ferro-resonant
-DC power

3. Applications

- N+1
- Multiple redundancy
- Outdoor use
-Internal systems
 UPS POWER SUPPLY

Working of UPS system

 Servo Drive

A servo drive receives a command signal from a control system, amplifies the signal, and
transmits electric current to a servo motor in order to produce motion proportional to the
command signal. Typically the command signal represents a desired velocity, but can also
represent a desired torque or position.

A sensor attached to the servo motor reports the motor's actual status back to the servo drive.
The servo drive then compares the actual motor status with the commanded motor status. It then
alters the voltage frequency or pulse width to the motor so as to correct for any deviation from
the commanded status.

Use in Industry

Servo systems can be used in CNC machining, factory automation, and robotics, among other
uses. Their main advantage over traditional DC or AC motors is the addition of motor feedback.
This feedback can be used to detect unwanted motion, or to ensure the accuracy of the
commanded motion. The feedback is generally provided by an encoder of some sort.

Servos, in constant speed changing use, have a better life cycle than typical AC wound motors.
Servo motors can also act as a brake by shunting off generated electricity from the motor itself
 Digital AC servo drive

Programmable logic controller

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control

system that continuously monitors the state of input devices and makes decisions based upon a
custom program to control the state of output devices.

Almost any production line, machine function, or process can be greatly enhanced using this type
of control system. However, the biggest benefit in using a PLC is the ability to change and
replicate the operation or process while collecting and communicating vital information.

Another advantage of a PLC system is that it is modular. That is, you can mix and match the
types of Input and Output devices to best suit your application.
Development
Early PLCs were designed to replace relay logic systems. These PLCs were programmed in
"ladder logic", which strongly resembles a schematic diagram of relay logic. This program
notation was chosen to reduce training demands for the existing technicians. Other early PLCs
used a form of instruction list programming, based on a stack-based logic solver.

Modern PLCs can be programmed in a variety of ways, from the relay-derived ladder logic to
programming languages such as specially adapted dialects of BASIC and C. Another method
is State Logic, a very high-level programming language designed to program PLCs based
on state transition diagrams.

Surface Mount Device

Surface-mount technology (SMT) is a method for producing electronic circuits in which the
components are mounted or placed directly onto the surface of printed circuit boards (PCBs). An
electronic device so made is called a surface-mount device (SMD). In the industry it has largely
replaced the through-hole technology construction method of fitting components with wire leads
into holes in the circuit board.

Both technologies can be used on the same board for components not suited to surface mounting
such as large transformers and heat-sinked power semiconductors.

An SMT component is usually smaller than its through-hole counterpart because it has either
smaller leads or no leads at all. It may have short pins or leads of various styles, flat contacts, a
matrix of solder balls (BGAs), or terminations on the body of the component.
 Fig.(a) SMD led tube light circuit diagram

Photo cell

Functionality

The photocell transmitter sends a modulated light beam in infrared range. The receiver monitors

the light beam for disruptions. In case of a disruption of the infrared beam the receiver releases a

pulse.

For multipurpose use the photocell can be operated in three different operation modes: reflection

photocell, transmitter and receiver.

Photocell Features

• Releasing accuracy 1/10.000 second

• Diversity of types:
  Reflection photocell
 One-way photocell for large distances

• Large photocell range:

o Reflection photocell approx. 25 m

o Transmitter and receiver photocell more than 150 m

• Variable supply of the photocell:

o Battery operation

o Supply from ALGE timing device

o External supply from 4 to 18 VDC

• Battery condition indication with LED (green, yellow, red)

• Indication of the photocell alignment with LED (green, yellow, red)

• Synchronisation of two photocells (main and backup), to prevent interferences

• Setting of dead time (approx. 20 ms to 2 s /factory setting = 20 ms)

Photo cell sensor
Photo cell fig. (a)

Fig.(b)
 Relay

A relay is an electrical switch that opens and closes under the control of another electrical
circuit. In the original form, the switch is operated by an electromagnet to open or close one or
many sets of contacts. It was invented by Joseph Henry in 1835. Because a relay is able to
control an output circuit of higher power than the input circuit, it can be considered to be, in a
broad sense, a form of an electrical amplifier.

A simple electromagnetic relay, such as the one taken from a car in the first picture, is an
adaptation of an electromagnet. It consists of a coil of wire surrounding a soft iron core, an iron
yoke, which provides a low reluctance path for magnetic flux, a moveable iron armature, and a
set, or sets, of contacts; two in the relay pictured. The armature is hinged to the yoke and
mechanically linked to a moving contact or contacts. It is held in place by a spring so that when
the relay is de-energised there is an air gap in the magnetic circuit. In this condition, one of the
two sets of contacts in the relay pictured is closed, and the other set is open. Other relays may
have more or fewer sets of contacts depending on their function. The relay in the picture also
has a wire connecting the armature to the yoke. This ensures continuity of the circuit between
the moving contacts on the armature, and the circuit track on the Printed Circuit Board (PCB)
via the yoke which is soldered to PCB.