Professional Documents
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EMT & Solar Panel Production REIL subscribes to the belief that the path to social and economic progress of the country lies through the villages and is committed to the up liftment of the rural economy by taking technology to the villages. REIL is an ISO9001 public sector undertaking started as a joint venture between RIICO (Rajasthan State Industrial Development & Investment Corporation) and Instrumentation Limited, Kota. During my training period I have taken my training in four department of this organization. These are - Agro dairy division, Renewable energy division, Industrial electronics division and Quality a REIL aims at retaining its primacy in the area of Rural Electronics, Non-conventional Energy Systems and Information Technology by developing, manufacturing and marketing quality products and by offering quality services. The company was conferred the status of a "MINI RATNA" by the Department of Public Enterprises, Ministry of Industry, Government of India in 1997 on account of it's good all round performance and excellent products. The company has added another feather in it is cap by establishing a Quality Management system for its operations and has been certified as an ISO 9001 firm w.e.f. 31st July, 1998. The area of business extends to manufacturing and marketing of electronic products are Agro-Dairy division, Renewable energy division or Industrial Electronics division Information Technology. Recognition of REILs achievements in the field of rural electronics has come in a variety of ways- in customer satisfaction, in its prestigious establishment of the Rural Electronics Technology Center in 1990 and in an award of the Department of Electronics for excellence in Electronic- now named as department of Information Technology under Ministry of communication and Information Technology, for the year 1991 and 2001.[1] REILs remarkable performance in India and abroad has encouraged the company to its sights on international markets with are newed thrust. In more than two decades of its existence REIL has played a vital assurance department. The Company, through its market driven in-house Research & Development(R&D), (recognized by the Ministry of Science and Technology, Government of India), has developed and introduced a number of new products such as data processor Electronic Milk Tester (DPEMT), Electronic Milk Weighed System, Automatic Milk Collection Station, Data Processor Milk Collection Unit (DP-MCU),Raw Milk Reception Dock (RMRD) Automation System, PC based Society Accounting & Management System, Animal Database Management System, Smart Automatic Milk Collection Station (SAMCS), Auto Zero EMT, Solar EMT in the diary sector.
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EMT & Solar Panel Production REIL is also in the business of Renewable Energy through Solar PhotoVoltaic (SPV) Technology where It started its operations, in 1986, with manufacture of SPV Modules and Systems. Since then it has supplied and installed numerous SPV Stand alone Street Lighting System, SPV de-centralized Domestic Lighting Systems, SPV Water drinking Systems, SPV Dusk Dawn Switching Systems, SPV Lanterns, SPV powered Railway Signaling Systems, Microwave Repeater Stations, Satellite Ground Terminals and Grid Interactive Power Plants etc. In this area Company has produced SPV Modules of about 8 MW generating capacity. REIL entered the business segment of voter identity card, in 1994, with state-of-art technology i.e. digital imaging and data processing technology, for large scale production of EPIC cards. It also produced over 60 Lac cards for the state of Gujarat. It is also into development and manufacture of Electronic Energy Meters, for domestic user connection, with diversified range of futuristic products like keypad based pre-paid energy meters and smart card based pre-paid meters. It already supplied about 100000 Electronic Energy Meters to State Electricity Boards. The company has a strong in-house Govt. recognized Research & Development Division which has enabled the company to effect considerable improvements in the initial adopted technologies. Indigenisation of the Milk Testing equipment and incorporating the latest State-of-the-Art microprocessor designs over the initial and older LSI designs has enabled more features and new add-on equipment has been developed to provide integrated system solutions. A prestigious collaboration with the Department of Electronics (DoE) in 1990 for the establishment of Rural Electronics Technology Centre and an award from DoE for Excellence in Electronics in 1991, testify REIL's achievements in the field of Rural Electronics. The Consistency in Excellence is recognized with repeated award for Excellence in Electronics for the year 2001, given by the Ministry of Communication and information theory. Rajasthan Electronics & Instruments Limited (REIL), as a commercial organization, has been in operation for the past 27 years with a proven track record of profitable performance, professional management and service to the rural masses through electronic products for the dairy/milk cooperatives and renewable energy sectors. REIL commenced its foray in the Dairy sector with the manufacture of Electronic Milk Testers under the technology license from National Dairy Development Board (NDDB), by using the AIET/ECE/PTS/3
EMT & Solar Panel Production technology developed overseas by Foss, Denmark. The Company entered the area of Renewable Energy through Solar PhotoVoltaic (SPV) technology, in the year 1985. The Company started its operations with manufacture of SPV Modules and control electronics for SPV powered village Street Lights.
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EMT & Solar Panel Production It operates on AC-main as well as on battery within built battery charger & automatic switch over to battery in case of power failure .Basic objective in the dairy development program is to increase the production of milk. Milk collection depends on prompt payment of fair and correct price to encourage producers to increase milk production. The system of payment based on quality (i.e. fat content ) discourages adulteration and encourages producers to increase production of high quality milk. it is further necessary that each sample of milk should be tested of its quality and testing should be completed within 2 to 3 hours time, in order to make correct payment. Milk sample would also get spoiled if not tested immediately in the absence of facilities to preserve them, especially at village level. Old traditional GERBER method of testing milk by chemicals has many inherent drawbacks, such as human error, multistep method, handling of corrosive chemicals and different type of glassware. All these add to the cost and time to milk testing. A quicker reliable and economical method of milk fat testing has therefore become inevitable and an immediate problem to solve. In the light of some problems faced by GERBER method of testing, it was felt prudent, to involve a system which should solve these problems. The process of fat measuring by EMT has involved basic principle, diluents preparation, homonization, auto zero setting etc.
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6.5 ml/test
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Light rays from a photo lamp pass through the layer of fluid in the cuvette and are scattered according to the sample of fat globules in the sample. More is the amount of fat present in the cuvette, more is the light scattered and less light scattered and less light passes through the cuvette. The rays that do pass through the cuvette strike photocell, producing a current proportional to the light intensity. The current is fed to a digital read out unit which gives direct fat percentage read out.
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EMT & Solar Panel Production Different assemblies of EMT are as follows-
2.5.1 Photometer
The photometer consists of a lamp, lamp housing and detector assembly. The detector assembly includes the cuvette and photocell.
2.5.2 Cuvette
It is made of two hundred glass discs. One has a ground depression of 0.4 mm the other has two small holes to provide inlet and outlet to the cuvette.
2.5.3 Photocell
It is a selenium barriers / silicon detector photocell. Care should be taken not to expose this photocell to light when not in operation.
2.6.1 Procedure
Take a clean 10 liter plastic container and add one liter clean water. Add contents of EDTA sachet, containing diluents' powder for 10 liter solution add 0.5 ml of triton-X-100 and 0.5 ml antifoam. Put the lid on the container and shake it until all the chemical are dissolved, then add liter clean water to prepare 10lt of solution and shake again to mix the solution. The PH of this solution should be between 9.5 to 10.1 diluents before the antifoam becomes inactive. Diluents can be kept longer if antifoam is added to the solution from time to time (0.5ml for every 2 weeks). warm up before starting measurement. This is done by switch on the EMT half an hour to one hour before measure.
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ASSEMBLY CHECKS
BURN IN TEST
ELECTRICAL CHECKS
MECHANICAL CHECKS
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EMT & Solar Panel Production After drying and zero setting measurement can begin. First result after zero check /zero setting should not be recorded as it will be little low. Therefore measure the first sample after zero check twice and record only second result. Turn the milk sample gently upside down a few times. Place the sample under milk intake and fully pressMILK IN button. Slowly remove the sample without touching the milk intake tube. Place clean milk under milk intake so that it fills into notch on the side of EMT Press MIXOUT button in all way and diluent into mix beaker. Move mix beaker to mix intake tube and position it so that it rest in notch operator homogenizer handle up and down 3 times in a steady measurement when the handle is pressed down and the third time let it test in bottom position and result will soon appear on the display empty the mix beaker completely and in ready for the next sample.
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3.1.1 Features
Display % solid-non-fat (SNF). Result is independent of sample temperature. Simple and inexpensive method of milk analysis. Effect of air bubbles on accuracy eliminated. Performs 150 tests per hours. Quick measurement and instant digital read out on LCD. Low power consumption.
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3.2.2 Features
Performs 110-130 sample per hour. Instant measurement and display of milk fat. Instant calculation of amount payable. Facility to feed milk weight directly through keypad in the absence of weighing machine. 7 segment display. Printing facility. Instant transmission of data remote display. Runs on mains and battery both. Built in battery charger. Data storage up to 800 members for days.
3.3.3 Features
Auto intake of milk sample Auto homogenization Auto zeroing Process indication Quick and instant read-out Runs on mains Measures up to 13% fat Requires small quantity of milk Performs 150Min.-180Max. test per hour Inexpensive method of testing.
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3.4.1 Features
(a) Save timeWith FOSS Milko Scan Minor PC software, many of the time-consuming tasks related to milk analysis can be carried out by means of an external PC. The simplified procedures for data collection, calibration adjustment and data storage provides for greater efficiency and productivity in your daily work. (b) Data collectionAll results can automatically be collected, displayed and stored for calculation and adjustment of the basic calibrations. All results can be saved, printed and exported to other software programs. This ensures greater data security and reduces manual data entry. (c) Export and import of dataThe results can be exported for use in other software programs. Measured results can be imported and used in various sample sets. Results can be exported and printed on any printer via the PC. (d) EmulatorEmulator software is included in order to provide training and demonstrations and for fast and easy learning of the software. (e) CompatibilityThe Milko Scan Minor PC software is approved to run under Windows 2000 and Windows XP with service pack 2. (f) Local language optionGerman as well as English language is integrated in the PC software. AIET/ECE/PTS/23
EMT & Solar Panel Production (g) Sample IDSample ID can be entered before or after data collection.
3.4.4 APPLICATIONS
(a) Cows milk (b) Skim milk (c) Buffalo milk (d) Goats milk
3.4.5 PARAMETERS TO BE MEASURE (a) Fat (b)Protein (c) Lactose (d) Total solids (e) Solids non-fat (f) Freezing point depression (g) Simple analysis of milk composition with milko-scan minor.
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4.2 SILICON
Silicon is important part of solar cell. Solar cell is made up of silicon. It has some special chemical properties, especially in its crystalline form. An atom of silicon has 14 electrons, arranged in three different shells. The first two shells, those closest to the center, are
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EMT & Solar Panel Production completely full. The outer shell is only half full, having only four electrons. A silicon atom will always look for ways to fill up its last shell (which would like to have eight electrons). To do this it will share electrons with four of its neighbour silicon atoms. Its like every atom holds hands with its neighbours, except that in this case, each atoms has four hands joined to four neighbours. Pure silicon is poor conductor of electricity because none of its electrons are free to move about, as electrons are in good conductors such as copper. Instead, the electrons are all locked in the crystalline structure.
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EMT & Solar Panel Production silicon. The process of adding impurities on purpose is called doping and when doped with phosphorous, the resulting silicon is called N- type because of the prevalence of free electrons. N-type doped silicon is a much better conductor than pure silicon. That is only one part of solar cell is N-type the other part is doped with Boron; which has only three electrons in its outer shell instead of four, to become P-type silicon. Instead of having free electrons, P-type silicon has free holes. Holes carry the opposite (positive) charge, they move around just like electrons do.
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EMT & Solar Panel Production In most cases, an autonomous system will require batteries for storage. Such systems are particularly useful and cost- effective for summer applications, when access to a site is difficult or costly, or when maintenance needs to be minimized.
Fig4.4 Working of Solar photovoltaic cell To utilize this resource of energy, REIL use solar cells, which convert Solar Energy into Electrical Energy. A solar generates approximately 0.5 volts. Higher voltage and current are obtained by connecting these cells in series or in parallel.
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EMT & Solar Panel Production best suited for general purpose application. Float zone - efficiency is 23%CZ (commercial) efficiency is 13%.
Fig 4.4.1(b) Crystalline silicon cell (c) Multi-Crystalline Silicon Cell It is made by crystallization of Si around many crystals of silicon. It has less mechanical strength than single Crystalline Silicon material, efficiency of this cell is 12 %.
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EMT & Solar Panel Production (e) Thin Film Silicon Cell It is made by very thin film of Si p-type and n-type materials and is used for special purpose. Efficiency is 25 %.
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EMT & Solar Panel Production Thus a total of 12*6=72 cells are used. The o/p voltage, current and power of each cell is the same as that of 75-watt module. The total power obtained is approx. 150 watts.[5]
Fig4.6 Construction of solar panel Hence, we can say that two charge carriers are generated by one high-energy photon. These carriers move to opposite direction due to potential barrier at the junction and constitute a AIET/ECE/PTS/32
EMT & Solar Panel Production current. One must condition of generation of mobile charge carrier is that the incident photon must have higher energy than the band gap of the semiconductor. The induced current is directly proportional to the surface area of the cell, at which the light is incident. A bare solar cell has some conducting lines made up of Silver oxide for collection of charge carriers from all the portions of the surface. These carriers are supplied to the bus bar. This is the place, from where the external terminals are connected by using copper strips. These cells are made up in different shapes and sizes, like circular, square, suedo-square, cut shaped etc. In these, Psuedo-Square is optimized size between circular and square to utilize most of the surface area & for less wastage in the process of shaping. The maximum conversion efficiency for laboratory devices is up to 20%, but for commercial cells, it lies between 10% to 15%.
Fig 4.7 SPV Module Photovoltaic cells are connected electrically in series and/or parallel circuits to produce higher voltages, currents and power levels.. Photovoltaic panels include one or more PV
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EMT & Solar Panel Production modules assembled as a pre-wired, field-installable unit. A photo voltaic array is the complete power-generating unit, consisting of any number of P materials.
manufacturing process for Solar cell module is not much typical but requires a careful
handling since the sub-assemblies are costlier. A bare cell is expensive and hence requires a careful handling. The manufacturing process of a solar power module contains the following steps as-
OK
LAMINATION LAY UP
CURING
TRIMMING
OK
CHANNELLING
REGRADE
GOODS STORE
OK NOT OK
FINAL INSPECTION
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4.8.1 Surface texturingForming pyramid like structure on Si wafer does it. This helps in decreasing the top surface reflection of solar radiation from the cell surface.
4.8.2 P-n junction formationTo a p type base of Si wafer, an n type usually phosphorus is diffused on it.
4.8.3 Back p+ junction formationThis is done by depositing an Aluminum layer and alloying it to the wafer at about 800degreeC
4.8.4 Antireflection layer depositionIt can be deposited before or after the formation of metal contacts. Usually any dielectric material having refractive index between Silicon & glass is used with an optimum thickness of 70nm.Materials used are Titanium Oxide, Tantalum oxide, Silicon Nitride and Aluminum oxide.
4.8.5 TabblingThis is the process of making terminals of a bare cell by soldering copper strips to the bus bar.
4.8.6 Row makingA row of nine cells is made by connecting positive surface of one cell to the negative surface of another cell.
4.8.7 StringingFour rows are connected in series to give a total of 36 cells in series connection. This assembly is called a string and the process is called Stringing.
STRING MAKING JIG
74W
5W
Fig 4.8.7 Stringing Process 4.8.7(a) String checking This String is checked visually for any kind of faults, which are as follows Reverse String Dry Point Dry Soldering Loose Connection Chip(Micro Broken)
4.8.7(b) Lay Up
Lay Up is a process of placing laminating material to the either side of the string. The laminating materials are as listed Top Glass (Toughened Glass) E.V.A. (Ethylene Vinyl Acetate) sheet Crane Glass Polyester Taddler AIET/ECE/PTS/36
4.8.8 Lamination
The above laminating materials are attached to the string on both sides by the process of lamination. This process takes place at 110degree C in laminating press. The module after Lay Up is placed in the press for 11minutes, which is equivalent to one cycle of the press. First five minutes, soaking takes place. This is the process to generate true vacuum in the module. Each air particle is stored from the inner part of the module. After these five minutes, heating takes place for three minutes. And for last three minutes, the heated module is pressed to attain a one-piece assembly.
4.8.9 Curing
This process comes after the lamination to attain the full strength of laminating material. for this, the module is placed into 120degree temperature for 20 minutes.
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4.8.10 Trimming
The resultant module from curing process has some extra laminating materials. These materials are then cut and the final module is then obtained. 4.8.11 Electrical Inspection This inspection is done to check the output performance of the module 4.8.12 Channeling Now to provide structural support to the module, channels are fixed around it. These channels prevent any damage to the module. A terminal box is also fitted for external connections and for mounting safety diodes and then the final product is cleaned and sent to and sent to he finished goods store.[38]
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(c) Electrical Inspection- This is used to check the performance of the module under normal working condition. AIET/ECE/PTS/40
6.1 SPOT BILLING MACHINE The Spot Billing Machine (SBM) is a Hand Held Computer, in which the program is stored
along with all the relevant data, for issue of electricity bills, right at the customer premises, immediately after the meter reading is read and input to SBM. The storage of program and data is done through a Personal Computer (Host PC) and is called pre-journey configuration for the specific meter-reader route, user-connection record including type of connection, applicable tariff, previous reading, past payments etc. The master data pertaining to the tariff tables, type of connection, consumer profile are stored on the Host PC, and made available for uploading on to the SBM at the time of configuration. Once the pre-configuration is over the SBM is ready for field operations. The meter-reader reports at the consumer site, accesses the customers account on SBM and record the current reading. On the basis of the last reading and tariff structure, a bill would be generated instantly. Payment in non-cash mode can also be collected then and there. In such case, the receipt would also be generated.
EMT & Solar Panel Production The payment could be collected through non-cash modes. A collection report can be prepared at the end of trip. After a journey is over the transaction data files are transferred from SBM to the Host PC, over a communication cable connected to serial communication port. The SBM requires about three hours for full charging after which it can be used continuously for 7-8 hours. A pre-implementation study is a pre-requisite for such projects, to identify the system requirements and user requirements. The customization can be done as per the user requirements.
6.1.1 Specifications
(a) High Speed CPU (b) 256 KB program memory (c) 4 MB data memory (d) Real Time Clock (e) LCD display unit (4 rows x 20 character) with backlight (f) 30 Keys soft silicon rubber Keypad (g) High speed serial port / program port (115 Kbps) (h) Built-in 24 column Impact printer (i) Built in 2.2 AH Lithium-Ion or 1.7 AH Ni MH battery
6.1.2 Features
(a) The bill is immediately generated. (b) The collection of dues, through non-cash instruments, is performed in the field. (c) Variety of reports can be prepared. (d) Utility Bill with all relevant details. (e) Receipt against the Bill. (f) Day end Collection report. (g) Duplicate receipt.
EMT & Solar Panel Production conventional grid supply is either erratic or non-existent. Also SPV pumps require only one time investment with no recurring cost and have a long life.[6] 6.2.1 Applications (a) Drinking water. (b) Irrigation. (c) Agriculture related use. (d) Horticulture. (e) Animal Husbandry. (f) Poultry farming. (g) High value corps
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6.3.1 Specifications
Each system consists of the following: (a) SPV Module - 35Wp (b) Battery - 12V, 80AH (c) Signaling PCB to energies front & back bulb with automatic dusk to dawn switching (d) Charge control unit.
6.3.2 Features
(a) Automatic switching and hence unmanned operation. (b) Optimal use of grid power. (c) Energy saving up to 30%. (d) Enhancement of pole-lamp life. (e) Highly efficient, reliable and economical. (f) System design can take care of any grid load / safety precautions. (g) No seasonal time setting required. (h) Highly weather proof and totally maintenance free sensor.
EMT & Solar Panel Production The sensor is totally maintenance free and encapsulated in an environment proof housing making it more reliable even in adverse atmospheric conditions. The system has the advantage of automatic setting of switching timings irrespective of whether it is winter or summer, thus making it a totally unmanned operation. Once a setting for a particular darkness level is done, it remains unchanged throughout the year.
6.4.1 Features
(a) Automatic switching and hence unmanned (b) Optimal use of grid power. (c) Energy saving up to 30%. (d) Enhancement of pole-lamp life. (e) Highly efficient, reliable and economical. (f) System design can take care of any grid load / safety precautions. (g) No seasonal time setting required. (h) Highly weather proof and totally maintenance free sensor. (i) Protection against line to line, line to neutral & line to earth fault. (j) Manual by-pass in case of system failure.[7]
EMT & Solar Panel Production 6.5.1 Applications (a) Rural areas which have no grid supply. (b) Farm Houses (c) Urban house holds which face frequent power cutsd. (d) Out-of-the-way holiday locations. (e) Holiday cottages & caravans.
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CONCLUSION
The summer training of 4 weeks in REIL played an important role to develop myself. It was a golden opportunity for me to get the practical knowledge and hands on experience from the things about which I had theoretical knowledge from the course curriculum. Hence I can say that taking training in such an organization proved to be very beneficial for me. All those that we read in our books theoretically, by this training I observed all those practically. I learnt quite a lot about agro-electronics products such as Electronic Milk Tester and also renewable energy source as SPV module. The first phase of training has proved to be quite fruitful. It provided an opportunity to encounter with such important machines. The architecture of company has various units. They are linked and controlled working of whole plant is making the student realize that engineering is not just learning the structural description and working of various machines. But the greater part is planning proper management. I am very grateful to those persons who helped directly & indirectly in the successful completion of this practical training and this will surely be fruitful in future.
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REFERENCE TABLE
S.No
[1] [2] [3] [4] [5] [6] [7]
http://www.inelrel.com/renewable_energy.html
www.enfsolar.com/directory/panel/2559 www.reiljp.com/pdf/dpemt.pdf http://www.solarserver.com/solar-magazine/solar-news/top-solarnews.html
Page No. 02 07 38 25 32 43 45
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BIBLIOGRAPHY
SITES
http://www.solarserver.com/solar-magazine/solar-news/top-solar-news.html
www.reiljp.com/pdf/dpemt.pdf www.enfsolar.com/directory/panel/2559
www.reiljp.com
www.scribd.com
www.reilsolar.com
http://www.webstatschecker.com/stats/keyword/reil_jaipur
http://www.inelrel.com/renewable_energy.html
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