Industrial Training Report on Tubelights

7/31/2019 Industrial Training Report on Tubelights

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I. HISTORY OF BAJAJ ELECTRICALS

Bajaj group of India is renowned group in the business world. This group was founded by

the remarkable contribution of those time great persons. The founders established this group with

a vision and dedication for continuous development. This dedication has greatly helped to

form a Progressive Business House and in cultivating the faith of market that result out inprofit.

Jamnalal Bajaj was the founding father of Bajaj group. He was adopted fifth

son of Mahatma Gandhi. He created truth in the people for the group. He valued

honesty over the profit, actions over the words and common good over the

individual gain.

Kamal Nayan Bajaj, elder son of Jamnalal Bajaj followed the footstep of hisfather and gave growth to Bajaj group with a characteristic foresight and

pragmatic vision. He launched a diversification programme which gave the

current name Bajaj both shape and size. His unique management style created

a working environment that can match well the sprit of nationalism.

Ramkrishna Bajaj took over the reign of Bajaj Group in 1972 afterKamalNayan Bajaj and steered the group from strength for 22 years. He had

also actively participated in the freedom struggle of the country. In post

independent India, he had led the organizationth movement. All along, he

actively strengthened the foundations of business through ethics and practices

both within the group and amongst the business community as well.

Shekhar Bajajcurrent chairman of Bajaj Electricals Ltd. Started his career

with Bajaj Sevashram after which he worked at Bajaj International, thegroup export company. Mr. Shekhar Bajaj joined the Bajaj Electricals in 1980

and became the managing director in 1987. Mr. Bajaj is the chairman of Bajaj

group companies- Bajaj International and Hercules Hoist Pvt. Ltd. And on the

Board of Directors of Bajaj Auto and IDBI Bank. He had been the president of

ASSOCHAM, former president of Indian Merchant Chambers (IMC) .


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II. BIRTH HISTORY OF HIND LAMPS LTD

In the town of Etawah, Shikohabad, where presently Hind Lamps is situated, was infact a cotton

factory which was closed that time.In 1934-35, a contractor purchased this land and building

and started work of manufacturing lamps. It was named Hindustan Lamps Works Ltd. At that

time area was 35 acre and production capacity was 1000-1200 bulbs per day. But because of

some unfavorable conditions it could not operated even for one year and was closed that time.

In 1942, A Punjabi industrialist Shri Kishanchandra Sindhi and Mr. M.L. Gava bought it

and divided it into two parts one KAYCEE INDUSTRIES LTD. which was responsible for

manufacturing electric bulbs and other was KAYCEE GLASS WORKS which was responsible

for shell of the bulbs.

But in 1947, India faced partition and due to it, RADIO LAMPS WORKS LTD. was rooted out

from Karanchi and was transferred to Shikohabad. KAYCEE GLASS WORKSand KAYCEE

INDUSTRIES was merged in RADIO WORKS LTD. But due to country conditions, economic

situation firm was not good and it became very hard to run the factory.

After some time Kamal Nayan Bajaj came and took over the firm and with the collaboration of

three Europeans and Philips setup HIND LAMPS LTD. in 1951

III. INTRODUCTION OF HIND LAMPS

Hind Lamps Ltd. is a unit of Bajaj Electricals Ltd. The factory was established in 1951.It was time of starting the Lighting industry in India. A Philanthropist, a business tycoon and

freedom fighter Shri Jamnalal Bajajs eldest son Shri KamalNayan Bajaj, himself an

eminent industrialist was at the helm of the Bajaj Group of companies. It was his

entrepreneurship that bought KAYCEE GLASS WORKS. A small flame and glass shell making

factory at Shikohabad and Bajaj Electricals together combined to establish a factory. During

1946-47 KAYCEE Glass Works amalgated with Bajaj Electricals.

In the year, 1941 the Bajaj Group took a step forward. It entered into collaboration with N.V

Phillips Glaileampen Fabrieken of Holland and three leading British Electricals firms association

Electricals Industries Ltd. Crompton, Parkinson Ltd. and G.E. Electricals formed Hind Lamps.Bajaj Electrical provided half of the capital while European brought in the other half of the end.

Phillips provided technical management. This was a time when joint venture was rare unlike

today. The agreement was signed on 23 Nov. 1951. Hind Lamps commenced operation on 1st

January 1952.


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IV. PRODUCTION HISTORY

Hind lamps started with just one chain of GLS Lamps with a production volume of 3.7million lamps per annum.

Hind Lamps Ltd. entered into Miniature lamps manufacturing in 1957 and went intomanufacturing of fluorescent lighting in the year 1961.

GLS Lamps Cap manufacturing was taken up by the company in 1954 with a capacity toproduce 4 million caps per annum.

In the year 1961, production of TL shells commenced on vertical Tube drawing processand Tube Drawing Machines (Danner Process) in the year 1984-85. It was further

enhanced in the year 1994-95 to 18 million TL Shells per annum.

Glass factory than ventured into Lead Glass Tube drawing with one line in the year 1994,added another line in the year 1996-1997 with a capacity of over 2000 MT per annum

V. CORPORATE VISION

Hind Lamps aim to bring greater happiness to its customers by improving their quality of life,

enhancing stakeholder value.

The main vision of the company is to give cost competitive product in the field of lamps.

The company mainly produces lamps for following companies such as:-

Bajaj Crompton Arya Eveready


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FLUORESCENT TUBULAR LAMP(FTL)

OR

TUBE LIGHT(TL)

OR

VACUUM LAMP


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VI. FLUORESCENT TUBULAR LAMP(FTL)

BASIC PRINCIPLE OF OPERATION:-

A fluorescent lamp is a glass tube containing some mercury vapour, with a phosphorescent

coating on the interior surface of the tube. The mercury vapour is made to glow by using a high

voltage across its electrodes that sets off an electric arc discharge in the tube. The discharge canalso be described as a conducting plasma. The resulting flow of current through the mercury

vapour is stable and well-controlled by an external ballast, or loading device, which consists of a

high-inductance choke-coil that is connected in series with the tube. The continuing dischargeglow is invisible to the human eye but it causes the phosphorescent coating on the interior

surface of the tube to emit visible light.

A fluorescent tube lamp works by using the fluorescence principle. It contains two filaments, one

at each end of the tube, which glow to heat up the gas contained inside the tube. The inner

surface of the tube is coated with compound of elements having fluorescent properties, such as

phosphorus. When it was manufactured all normal air was removed from the tube. In place of the

air just a small trace of a gas is put into the tube, such as mercury vapour (for a white color),carbon di oxide (forgreen), neon(forredcolor), etc. When the electrical supply is turned on, what

happens is that the two filaments glow and then the contacts of the starter open. This action

provides a voltage across the tube that is high enough to ionise the warmed-up gas inside thetube. This ionised gas, also called a "plasma", excites the special fluorescent coating on the

inside of the tube so that it gives out visible light.

A.C. Supply

Fig. Working of Tube Light

Ionization of Electrons

Starter

Choke


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Note about the need for a choke and a starter

Without a high inductance choke in series with the tube, the plasma in the tube would simply

short-out the service wires. That would always cause the circuit's protective fuse to blow - or itscircuit breaker to trip - to cut off the supply of current to the tube. If that happened the tube light

would never be able to perform its intended purpose, which is to continue running - and giving

out a continuous light- for long periods of time. The starter is a special kind of switch: its

contacts are made of a metal alloy which, soon after a voltage is applied, heats up and bends,

causing the switch contact stopped. So a high-inductance choke must be used in circuit with the

starter and the tube for two reasons:

firstly the choke generates a high voltage pulse across the tube when the starter's contactsopen. That pulse causes the gas in the tube to ionise and become a low-resistance plasma

and secondly, because it is wired in series with the tube, the choke greatly reduces the current

drawn by the tube once it contains the low-resistance plasma.

NOTE:- A Tube Light Is a High Vacuum and Low Pressure Device, so it is also termed as a

Vacuum Light

Figure 1. A Burning Filament Figure 2. Starters


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VII. PROCESS FLOW CHARTShell Washing

Dispatch

Shell Drying

Coating Drying

Sintering

Wiping

Sealing

Wipe Spreader

Pumping

Capping Soldering

Flashing

Good lamp Loading

Suspension Making

Direct Delivery

Of Shell

Mounting Stem

Cap Filler Cement Making

SQCRepair & Storing Scrap

Packing

Store

Flare


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VIII. RAW MATERIALFOR THE PRODUCTION OF

TUBELIGHT

Glass shell Cap Cement Cathode/Filament Lead In Wire (LIW) Flange Tube Powder Exhaust tube Binder Emitter Ammonia Allon-C

SPECIFICATIONS OF THE RAW MATERIAL USED

Glass shell

Length- For 2ft- 6542 mm For 4ft- 12642 mm

Tube Out Side diameter-

For 2 & 4 ft- 36.500.75 mm

Wall Thickness-

For TLD- 0.700.05 mm For TL - 0.650.07 mm

Bow(Bouble throw):3.0 mm over 1000mm span

Siding: 0.08 max. Ovality: 0.5 max

Glazing: Medium/Heavy Bead-0.75-1.60mm Turned Inwards

Undulation of Cutting edge(U): 1.5 mm max.

Filament/Cathode

Length: 11.5-12.5mm Leg Length- 4-4.5 mm

Body Length: 3.5-4 mm No. Of Turns: 5


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Lead In Wire (LIW)

Composed of-

Nickel Plated Steel(NPS) Dumut

Bronze

NPS : Diameter- 0.60mm Length-14 mm

Dumut: Diameter-0.35 mm Length-13 mm

Bronze: Diameter-0.40 mm Length-40 mm

Over All Length (OAL): 67 mm

Flange Tube

Diameter: 11.50-11.90 mm

Wall of Thickness: 0.8-1.0 mm

Cut Length: 1140 mm

Exhaust Tube



Cut Length-100 mm


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IX. PROCESS FLOW

1. Suspension Making2. Coating3. Sintering4. Wiping5. Branding6. Sealing

I. Flare MachineII. Feet Machine

7. Pumping8. Capping

I. SolderingII. Caphole

9. Burning frame10. Packing

Let us discuss all the processes in brief one by one-

1. SUSPENSIONIt is a process in which the coating solution is prepared with the help of various

chemicals used in the suspension room.

Suspension Solution is made up of

Liquid Ammonia Allon-C (Aluminium Oxide Powder) DM Water Fluorescent Powder Water Based Binder Adinol

In this room the suspension/Fluoresent powder is prepared and it takes approx.. 8 hours to

prepare and make it for use.


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2. COATING (300X4=1200 Shells)After the suspension/Fluorescent powder is prepared then it is filled in to the glass shell with the

help of the doser and this process is completed in approx. of 16 hours .

The coating is made on to the glass shell to convert the UV rays produced into the shell to the

Visible Light that we uses.

3. SINTERINGSintering process is lead to the drying of the chemicals used during the coating process.

As we knows , we uses Ammonia, Allon-C , DM Water, Binder and the fluorescent powder as a

suspension solution for the coating.

Here we will provide the coated glass shell to the furnace at which approx.. 600 oC of temperature

is maintained, Here we will dry all the chemicals like as Ammonia, Allon- C, DM Water, Binder

etc. At final output we get only fluorescent powder binded on to the glass shell.

4. WIPINGWiping is the brushing of the sides of the glass shell after the coating process.

It is done due to the proper capping at the ends and there is no chemicals produced at the ends

when they are mounted with the Aluminium Caps and the mounts .It is done because as the

fluorescent powder is proced at the ends they will produce defects at the packing ends of the

glass shell.

In this process the sintered glass shell is brushed at both of the ends with a fixed brush and after

that at the conveyer chain it is flushed off with the help of air pressure.

5. BRANDINGIn this process the stamp of the company or the manufacturer is imposed on the glass shell after

the coating and the wiping process.

6. SEALING (32 Heads)Sealing process is also be said to be shell and mounting and this process is done at following two

machines:-

A.Flare MachineB. Feet Machine


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First of all we will move to-

A.Flare Machine (12 Heads)Firstly, the tube is feeded and is pre heated, cut and mounted into a flare at different different

positions of the machine head as 1,2,3.

This machine has two burners named melting burner and Cutting Burners.

Gases- Oxygen+LPG+Blower.

SO2 is used for the lubrication at the reamer plate or flare tool.

Length Adjuster-Cutting Burner-Glazing Burner(For Smoothing)

Then the manufactured flare is sent to the next production line to feet machine for further

production.

B.Feet Machine (28 Heads)In this Proceess the mount is prepared for the tube light and this is prepared with the help of feet

machine. In this machine the lead in wire is feeded into the flared tube.

First of all the flare is put into the hopper, and this flare is moved to another position and at that

position the catcher puts up the Lead in wire and puts two wires into the flare and then a exhaust

tube is put into the flare and the process continues at different different burners and then the

mount is prepared .

And then it is annealed at different temperatures/gas pressures . It is done to make the mount

crack free.

And at the mount machine we will use an emitter to increase the resistivity of the filament.

Emitter: 5.3-7 mg

Filament: Tungsten(25-26 mm)

At MOUNT machine there are total 18 Heads.

7. PUMPINGIn this process the gases and the mercury is filled up into the tubelight and is to be packed at the

both of the ends.

Electric Oven-Vacuum-Mercury Dosing-Gas Filling-Tipping

These some processes are to be done at the pumping machine.


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Gas used : Argon 80% and Neon 20%.

Vacuum Pressure: 45 gm

Solder Composed of Lead & Tin.

Quantity of Mercury Filled: 45 mg/Lamp.

8. CAPPING (50 Heads)Now the tube light manufactured by the pumping machine is made up of without the caps. Now

at the Capping machine the Aluminium Caps are placed at the both of the ends of the tube light.

Here we will use cap cement to fix the cap at the ends and solder the aluminium cap pins at the

both of the ends.

After the completion of the capping process it will sent over to the Burning frame , here it will bechecked or Burned at the minimum voltage of 180V.

And after the successful completion of the production of the tube light it will sent over to

Packing Section and some of the samples from such production will sent to the Quality

Department for the Verification of the Quality Standards of the tube Light.

A CONVEYER Belt Consists of 188 Tubes at a time.


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X. QUALITY DEFECTS AND CONTROL DURINGPRODUCTION

There are some of the various defects are to be seen during the production. That will become the

challenge for the Quality department to control these defects.

There are two departments to control the quality standards, these are:-

1. PCD(Process Control Department)2. SQC(Statistical Quality Control)

PCD(IN PROCESS CHECKS)

PCD is the in process control checks in which the Quality of the products is checked during the

production line. It is the most efficient way to control the quality of the product that is being

manufactured into the industry.

In this process the quality of the material is being checked at the different-different levels of the

production line. These are as follows:-

1. At FLARE MachineWe should check the following parameters regarding to the FLARE for the betterment of the

quality:-

A. LengthB. DiameterC. Drop test For checking the Strength (Min. 30 cm)D. Poor CastingE. Poor GlazingF. Chip off

2. At FEET MachineWe should check the following parameters regarding to the FEET for the betterment of the

quality:-

A. Feet strength (Min. 6cm on scale)B. Exhaust Tube length below Flange (59-61 mm)C. Single WireD. Burnt WireE. Without HoleF. Big And Small Wire


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3. At MOUNT MachineWe should check the following parameters regarding to the MOUNT for the betterment of the

quality:-

A. Flatening Width (0.6 mm)B.

Pole Distance (11-11.5 mm)

C. Mount GeometryD. Emitter Weight(5.8-7 mg)E. Coil Punching

4. At SEALING MachineWe should check the following parameters regarding to the SEALING of the Glass Shell for the

betterment of the quality:-

A. Sealing LengthB. Tip LengthC. Sealing shapeD. Filling pressure(2.4-2.6 mg of Hg)E. Flat SealingF. Seal HoleG. Powder Heat

5. At PUMPING MachineWe should check the following parameters regarding to the PUMPING of the Gases and the

Vacuum for the betterment of the quality:-

A. Lamp Not WorkingB. Poor Vacuum

6. At CAPPING MachineWe should check the following parameters regarding to the CAPS for the betterment of thequality:

A. Cement Weight(2-2.5 gm)B. Burnt PlateC. Blister on Plate


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GENERAL LIGHTING SERVICES (GLS)

OR

INCANDESCENT LIGHT BULB

OR

BULB


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XI. GENERAL LIGHTING SERVICES(GLS)

BASIC PRINCIPLE OF OPERATION:-

The incandescent light bulb, incandescent lamp or incandescent light globe produces light by

heating a filament wire to a high temperature until it glows. The hot filament is protected fromoxidation in the air with a glass enclosure that is filled with inert gas or evacuated.

Incandescent bulbs are manufactured in a wide range of sizes, light output, and voltage ratings,

from 1.5 volts to about 300 volts. They require no external regulating equipment, have

low manufacturing costs, and work equally well on either alternating current or direct current. As

a result, the incandescent lamp is widely used in household and commercial lighting, for portable

lighting such as table lamps, carheadlamps, and flashlights, and for decorative and advertising

lighting.

Incandescent bulbs are less efficient than several other modern types of light bulbs, with most

varieties converting less than 10% of the energy they use into visible light (with the remaining

energy being converted into heat). Some applications of the incandescent bulb deliberately usethe heat generated by the filament. Such applications include incubators, brooding boxes for

poultry, heat lights for reptiletanks, infrared heating for industrial heating and drying processes,

and the Easy-Bake Oven toy. But waste heat can also significantly increase the energy required

by a building's air conditioning system.

Incandescent light bulbs are gradually being replaced in many applications by other types

ofelectric lights, such as Fluorescent Lamps, Compact Fluorescent Lamps (CFL), Cold Cathode

Fluorescent Lamps (CCFL), high-intensity discharge lamps, and Light-Emitting Diodes (LEDs).

These newer technologies improve the ratio of visible light to heat generation.

Figure 2 BC Incandescent LampFigure 1 Incandescent Lamp
http://en.wikipedia.org/wiki/Incandescencehttp://en.wikipedia.org/wiki/Incandescenthttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Manufacturing_costhttp://en.wikipedia.org/wiki/Headlamphttp://en.wikipedia.org/wiki/Flashlighthttp://en.wikipedia.org/wiki/Reptilehttp://en.wikipedia.org/wiki/Infrared_heaterhttp://en.wikipedia.org/wiki/Easy-Bake_Ovenhttp://en.wikipedia.org/wiki/Air_conditioninghttp://en.wikipedia.org/wiki/Electric_lighthttp://en.wikipedia.org/wiki/Fluorescent_lamphttp://en.wikipedia.org/wiki/Compact_fluorescent_lamphttp://en.wikipedia.org/wiki/Cold_cathode_fluorescent_lamphttp://en.wikipedia.org/wiki/Cold_cathode_fluorescent_lamphttp://en.wikipedia.org/wiki/High-intensity_discharge_lamphttp://en.wikipedia.org/wiki/Light-emitting_diodehttp://en.wikipedia.org/wiki/Light-emitting_diodehttp://en.wikipedia.org/wiki/High-intensity_discharge_lamphttp://en.wikipedia.org/wiki/Cold_cathode_fluorescent_lamphttp://en.wikipedia.org/wiki/Cold_cathode_fluorescent_lamphttp://en.wikipedia.org/wiki/Compact_fluorescent_lamphttp://en.wikipedia.org/wiki/Fluorescent_lamphttp://en.wikipedia.org/wiki/Electric_lighthttp://en.wikipedia.org/wiki/Air_conditioninghttp://en.wikipedia.org/wiki/Easy-Bake_Ovenhttp://en.wikipedia.org/wiki/Infrared_heaterhttp://en.wikipedia.org/wiki/Reptilehttp://en.wikipedia.org/wiki/Reptilehttp://en.wikipedia.org/wiki/Flashlighthttp://en.wikipedia.org/wiki/Headlamphttp://en.wikipedia.org/wiki/Manufacturing_costhttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Incandescenthttp://en.wikipedia.org/wiki/Incandescence


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XII. PROCESS FLOW CHARTShell Washing

Dispatch

Shell Drying

Shell Loading

Marking

Sealing

Pumping

Capping,Soldering

Flashing

Good lamp Loading

Electrostatic coating of shellDirect Delivery

Of Shell

Mounting Stem

Cap Filler Cement Making

SQCRepair & Storing Scrap

Packing

Store

Flare


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XIII. RAWMATERIAL FOR THE PRODUCTION OF GLS

Glass shell Cap Cement Cathode/Filament Lead In Wire (LIW) Flange Tube Powder Exhaust tube Emitter

SPECIFICATIONS OF THE RAW MATERIAL USED

Glass shell

For 60 mm For Ribbon

Bulb Diameter: 601 mm 601 mm

Neck Diameter: 330.5 mm 33.00.8 mm

Mouth Opening: 35 mm(min.) 40 mm (min.)

Length: 1313 mm 1282 mm

Neck Wall Thickness: 0.3-0.8 mm 0.36-0.68 mm

Tip Thickness: 0.5-1.8 mm 0.45-1.0 mm

Filament/Cathode

Length: For 25&40W- 27.5-28.5 mm

Leg Length: 1.5-2.5 mm

Length: For 60&100W- 33.5-34.5 mm

Leg Length- 1.5-2.5 mm


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Lead In Wire (LIW)

Composed of-

Nickel Plated Steel(NPS) Dumut

Monel

NPS : Diameter- 0.60mm Length-30 mm

Dumut: Diameter-0.30 mm Length-10 mm

Monel: Diameter-0.17 mm Length-47 mm

Over All Length (OAL): 87 mm

Flange Tube



Cut Length: 1140 mm

Exhaust Tube



Cut Length-110 mm


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XIV. PROCESS FLOW

1. Flare Machine (12 Heads)2. Stem or Feet Machine (28 Heads)3. Mount Mill (20 Heads)4. Branding5. Sealing (20 heads)6. Pump or exhaust (32 Heads)7. Cap Filler8. Capping (54 Heads)9. Burning frame

Let us discuss all the processes in brief one by one-

1. FLARE MACHINEFirstly, the tube is feeded and is pre heated, cut and mounted into a flare at different different

positions of the machine head as 1,2,3.

This machine has two burners named melting burner and Cutting Burners.

Gases- Oxygen+LPG+Blower.

SO2 is used for the lubrication at the reamer plate or flare tool.

Length Adjuster-Cutting Burner-Glazing Burner9For Smoothing)

Then the manufactured flare is sent to the next production line to feet machine for further

productions.

2. FEET MACHINEIn this Proceess the mount is prepared for the GLS and this is prepared with the help of feet

machine. In this machine the lead in wire is feeded into the flared tube.

First of all the flare is put into the hopper, and this flare is moved to another position and at that

position the catcher puts up the Lead in wire and puts two wires into the flare and then a exhaust

tube is put into the flare and the process continues at different different burners and then themount is prepared .

And then it is annealed at different temperatures/gas pressures . It is done to make the mount

crack free.And at the mount machine we will use an emitter to increase the resistivity of the

filament. Red Phosphorus & IP Soln.Filament: Tungsten

At MOUNT machine there are total 20 Heads.


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3. PUMPINGIn this process the Various Gases like Argon & Nitrogen is filled up into the glass shell and is to

be packed at the end.In this process the Flushing and filling of gases takes place with the help of

Nitrogen.

These some processes are to be done at the pumping machine.

Gas used : Argon 86% and Nitrogen 14%.

Vacuum Pressure: 62 Cm of Hg

Solder Composed of Lead & Tin.

4. CAPPING (54 Heads)Now the bulb manufactured by the pumping machine is made up of without the caps. Now at theCapping machine the Aluminium BC Caps are placed at the top of the Glass Bulb.

Here we will use cap cement to fix the cap at the end and solder the aluminium BC cap at the

end.

After the completion of the capping process it will sent over to the Burning frame , here it will be

checked or Burned at the minimum voltage of 100 to 250V.

And after the successful completion of the production of the GLS it will sent over to Packing

Section and some of the samples from such production will sent to the Quality Department for

the Verification of the Quality Standards of the GLS.


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XV. QUALITY DEFECTS AND CONTROL DURING

PRODUCTION

There are some of the various defects are to be seen during the production. That will become the

challenge for the Quality department to control these defects.

There are two departments to control the quality standards, these are:-

1. PCD(Process Control Department)2. SQC(Statistical Quality Control)

PCD(IN PROCESS CHECKS)

PCD is the in process control checks in which the Quality of the products is checked during the

production line. It is the most efficient way to control the quality of the product that is being

manufactured into the industry.

In this process the quality of the material is being checked at the different-different levels of the

production line. These are as follows:-

1. At FLARE MachineWe should check the following parameters regarding to the FLARE for the betterment of the

quality:-

A. LengthB. DiameterC. Drop test For checking the Strength (Min. 30 cm)D. Poor CastingE. Poor GlazingF. Chip off

2. At PUMPING MachineWe should check the following parameters regarding to the PUMPING of the Gases and the

Vacuum for the betterment of the quality:-

A. Lamp Not WorkingB. Poor Vacuum


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3. At FEET MachineWe should check the following parameters regarding to the FEET for the betterment of the

quality:-

A. Feet strength (Min. 6cm on scale)B.

Exhaust Tube length below Flange (77-78 mm)

C. Single WireD. Burnt WireE. Without HoleF. Big And Small Wire

4. At MOUNT MachineWe should check the following parameters regarding to the MOUNT for the betterment of the

quality:-

A. Flattening Width (0.90-0.98 mm)B. Pole Distance (25-27 mm for 60/100W)(21-23mm for 25/40W)C. Mount GeometryD. Emitter Weight(4-5 mg)E. Coil PunchingF. Getter Heat

5. At SEALING MachineWe should check the following parameters regarding to the SEALING of the Glass Shell for the

betterment of the quality:-

A. Sealing Length (872 mm)B. Tip Length (9mm max.)C. Sealing shapeD. Filling pressure(62 mg of Hg)E. Flat SealingF. Seal HoleG. Powder HeatH. LengthI. Over All Length(OAL)


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6. At CAPPING MachineWe should check the following parameters regarding to the CAPS for the betterment of the

quality:-

A. Cement Weight(1.3-1.9 gm)B.

Cap Off

C. Burnt PlateD. Blister on Plate


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XVI. CONCLUSION

As all of us are familiar with the Tube light and the Bulbs that all of us are using at our

homes, in now a days every person is using a bulb or a tube light for its use. So the Fluorescent

Tubular Lamps and the General Lighting Services are the broad used terms in the field of the

Electrical Engineering. The production of such type of the products is a challenging term for any

of the industry to organize all the things in a proper manner.

Hence the production of the tubular lamps and the Incandescent bulbs will lead to the

development in the field of Electrical. The various advancements in this technology will lead to

the development of the various CFLs (Compressed Fluorescent Lamps) using the same principle

of the Tube Light and are producing a huge amount of intensity of light for our use in Nights or

Day in various different ways and different modes like as cool day, brighter etc.


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XVII. PROBLEM OCCURS/SUGGESTIONS

PROBLEM OCCURS:

During the setup of the CNG plant for the burners at the different heads for theproduction of the Incandescent Bulb and Tubular Lamp, then it will having the problem

to , maintain the proper gas pressure for the different Burners to work properly and will

provide the efficient results in the manufacturing of the different products.


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XVIII. REFERENCES

http://en.wikipedia.org/wiki/Shikohabad#History http://en.wikipedia.org/wiki/Bajaj_Electricals http://en.wikipedia.org/wiki/Incandescent_bulb http://en.wikipedia.org/wiki/Tube_light http://en.wikipedia.org/wiki/Bajaj_Group
http://en.wikipedia.org/wiki/Shikohabad#Historyhttp://en.wikipedia.org/wiki/Shikohabad#Historyhttp://en.wikipedia.org/wiki/Bajaj_Electricalshttp://en.wikipedia.org/wiki/Bajaj_Electricalshttp://en.wikipedia.org/wiki/Incandescent_bulbhttp://en.wikipedia.org/wiki/Incandescent_bulbhttp://en.wikipedia.org/wiki/Tube_lighthttp://en.wikipedia.org/wiki/Tube_lighthttp://en.wikipedia.org/wiki/Bajaj_Grouphttp://en.wikipedia.org/wiki/Bajaj_Grouphttp://en.wikipedia.org/wiki/Bajaj_Grouphttp://en.wikipedia.org/wiki/Tube_lighthttp://en.wikipedia.org/wiki/Incandescent_bulbhttp://en.wikipedia.org/wiki/Bajaj_Electricalshttp://en.wikipedia.org/wiki/Shikohabad#History

Documents

Industrial Training Report on Tubelights