NSS COLLEGE OF ENGINEERING

INDUSTRIAL TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE AWARD OF DEGREE OF

Bachelor of Technology
in

ELECTRICAL AND ELECTRONICS ENGINEERING

of
University of Calicut
by
ATHIRA S [NSANEEE030]

NSS College of Engineering

Department of Electrical and Electronics Engineering
Palakkad - 678 008

March-2017
 NSS COLLEGE OF ENGINEERING
PALAKKAD
( Affliated To Calicut University)

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING

CERTIFICATE

This is to certify that this report is a bonafide record of the “INDUSTRIAL TRAIN-

ING” undertook by ATHIRA S in partial fulfillment of the requirements for the award of

Degree of Bachelor of Technology in Electrical and Electronics Engineering of

University of Calicut, during the academic year 2016-2017.

Head of Department Group Tutor

Dr.Anitha P
Professor(HOD) Dept. of EEE
Dept. of EEE
 ACKNOWLEDGEMENT

I wish to express my indebtedness and gratitude to all those who have

helped me for a successful completion of my industrial training at at Keltron
Component Complex Limited, (KCCL).

First and foremost, I thank God Almighty for His providence and for being
the guiding light throughout the course of this industrial training program.

I’m thankful to Dr.Sudha T, Principal and Dr.Anitha P, Head of the

Department for providing necessary facilities and giving me the opportunity to
carry out this industrial training.

I’m deeply indebted to the training instructors for their timely help and
meticulous guidance for the successful completion of the training sessions.

Finally, I would like to extend my sincere gratitude to my parents and

friends who have always been encouraging and helpful throughout the course
of this training program.

Department of Electrical & Electronics Engg. i NSSCE, PALAKKAD

 ABSTRACT

The industrial training was conducted at Keltron Component Complex Limited, (KCCL)

which is a subsidiary company of Kerala State Electronics Development Corporation Limited

(KSEDC). I undertook 10 days of training at KCCL from June 22nd, 2016 to July 1st, 2016 to

get an industrial exposure in a practical aspect of technical implemen-tation. During the

course of training, I was able to interact freely with the officials and other employees in the

plant and could fetch maximum relevant information from them. I also got an opportunity to

visit the work area and get a hands on experience on various industrial devices. The training

helped me to get an idea about the various manufacturing processes for Electrolytic

capacitors, AC motor-start capacitors and resistors and various other electrical instruments

which are used in the plant.

Department of Electrical & Electronics Engg. ii NSSCE, PALAKKAD
 Contents

ACKNOWLEDGEMENT i

ABSTRACT ii

LIST OF FIGURES iv

1 INTRODUCTION 1
1.1 KELTRON Component Complex Ltd . . . . . . . . . . . . . . . . . . . 1
1.1.1 HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Research & Development Centre . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 CAPACITORS 4

3 CAPACITOR TYPES 6
3.1 Aluminum electrolytic capacitor . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . 7
3.3 AC Motor Start Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 PRODUCTION PROCESS 10
4.1 Etching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Anodization(Formation of Dielectric Layer) . . . . . . . . . . . . . . . . 11
4.3 Slitting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Stitching and Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Impregnation Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 Encapsulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Department of Electrical & Electronics Engg. iii NSSCE, PALAKKAD
 4.8 Aging (Reforming) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.9 Process Inspection & Packaging . . . . . . . . . . . . . . . . . . . . . . 13

5 RESISTORS 14
5.1 Carbon Film Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 RESISTOR COLOR CODE 17

7 CONCLUSION 19

8 REFERENCES 20

Department of Electrical & Electronics Engg. iv NSSCE, PALAKKAD

 List of Figures

2.1 Prallel-Plate Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Aluminium Electrolytic Capacitor . . . . . . . . . . . . . . . . . . . . . 6

3.2 Design of AEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Power Factor Correction Capacitor . . . . . . . . . . . . . . . . . . . . . 7
3.4 AC Motor Start Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Process Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.1 Stator phase windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.2 Carbon film resistor with exposed carbon spiral . . . . . . . . . . . . 15
5.3 Carbon film resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.1 A typical axial-lead resistor . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.2 Resistor Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Department of Electrical & Electronics Engg. v NSSCE, PALAKKAD
 Chapter 1

INTRODUCTION

Kerala State Electronics Development Corporation, popularly known as

KELTRON,is the first state electronics Development Corporation of India, fully owned
by Government of kerala. KELTRON’s history is a saga of innovation in electronics.
From being a pioneer in 1973, to the role of a trend setter today, Keltron has been the
catalysis for the development of electronics industry in Kerala. In five years since
inception, Keltron had set up several production centres and engaged more than 5,000
people directly or indirectly for the manufacture of electronic goods.

1.1 KELTRON Component Complex Ltd

1.1.1 HISTORY
Keltron entered the electronic components industry by setting up India’s largest Alu-

minium Electrolytic Capacitor plant in technical collaboration with Spargue Electro-mag,

Belgium, in 1976 at Kannur, Kerala. KELTRON COMPONENT COMPLEX LTD (KCCL)

went into commercial production on 19th August 1978. Since then KCCL has grown and

now is the biggest manufacturer of Aluminium Electrolytic Capacitors in In-dia. Presently

the installed annual capacity is 250 million Pcs, which can go upto 275 million Pcs in 3-

shifts. It also produces other passive electronic components including Resistors and

Crystals. Company’s production capacities were enhanced during 1985-90 to enhance the

capacity to 150 million Capacitors per annum. During the year 2009-10, the three sister

concerns of KELTRON, viz. Keltron Crystals Ltd, Keltron Resistors Ltd

Department of Electrical & Electronics Engg. 1 NSSCE, PALAKKAD
and Keltron Magnetics Ltd were merged into KCCL and is working as a single entity

manufacturing Aluminium Electrolytic Capacitors, Metalized Polypropylene Capacitors,

Carbon & Metal Film Resistors and Piezo-electric Quartz Crystals. KCCL has state of the

art manufacturing facility with more than 100 automatic and semi-automatic machines,

imported from Japan,Taiwan,Italy etc. Company also have in-house developed Forming

Plant for Low Voltage and High Voltage Foils. It has a buildup area of more than 11000

sq.mtrs for machines alone, and a skilled workforce of more than 650 persons having an

average 15+ years experience. Over the years, Keltron has added on several other types

of components enlarging its range to cater to the needs of the Indian market. Today, Kel-

tron enjoys a sizable market share, and is identified as a reputed supplier of electronic

components for professional, industrial and consumer electronics applications.

1.2 Research & Development Centre

KCCL’s R & D named ‘Electronics Research & Development Centre [ERDC]’ is a
DSIR recognized R & D lab with many innovative and recognized achievements.
The R & D won : ‘ELCINA Award 1993’ for excellence in Research & Development
for the work done in the field of forming technology. KCCL is ISO 9001 certified
(now ISO 9001:2008). The products are approved by DGQA, Ministry of Defence,
Govt.of India with MS, DPP Grade 1. It also has product Approvals from C-DOT,
CACT, LCSO and Defence Dept., UL etc. It has many awards and recognitions in
hand including : ‘Na-tional Productivity Award 1988-89’ under large-scale electronic
components units from National Productivity Council, Govt. of India.

1.3 Products

KELTRON is India’s leading capacitor manufacturing company. The cur- rent

range of components manufactured by Keltron includes:
1. Aluminium DC Electrolytic Capacitors
2. Motor Start Capacitors
3. Motor Run (SH) Capacitors
4. MPP Capacitors
5. KVR Power Capacitors

Department of Electrical & Electronics Engg. 2 NSSCE, PALAKKAD

6. Carbon / Metal Film Resistors
7. Piezoelectric Crystals
8. High CV large can Capacitors
KELTRON Capacitors are widely accepted by major equipment manufacturers and
Con-sumer Electronic Industries including BEL, ITI, Crompton Greaves, V-Guard,
Tata Mo-tors, L & T, EXIDE, Onida, Railways, Water Authority, Electricity Board etc.
Keltron also offers a range of Resistors, and maintains a strong engineering team
experienced in the design and manufacture of quartz crystal. Keltron marketing
divisions are spread over the country including Delhi, Mum- bai, Kolkata, Chennai,
Ahmedabad, Hyderabad, Bangalore, Trivandrum etc.

Department of Electrical & Electronics Engg. 3 NSSCE, PALAKKAD

 Chapter 2

CAPACITORS

Figure 2.1: Prallel-Plate Capacitor

A Capacitor is identified by the type of dielectric or plate material used on it.

Some of the most common capacitors which find widespread application in electronics as

well as electrical industries are paper, plastic film (such as Polystyrene, Polypropy-lene,

Polycarbonate, etc.), Ceramic, Mica, Aluminium Electrolytic, Tantalum, and oth-ers. Fig 2.2

shows a parallel plate capacitor. A capacitor is expressed in terms of its capacitance, in

microF (micro-farads) and its working voltage in Volts (V). Other pa-rameters which specify

its quality are Leakage Current, Dissipation Factor (also referred

Department of Electrical & Electronics Engg. 4 NSSCE, PALAKKAD

to as Loss Factor). Aluminium Electrolytic Capacitors are being used extensively
for consumer electronic goods all over the world. Like any other type of capacitor
the Alu-minium Electrolytic Capacitors (AECs) too have two plates separated with
a dielectric. While most other types of capacitors are bi-polar in nature (any polarity
voltage can be connected to either of the plates) a good majority of AECs are
polar. Practical capacitors are available commercially in many different forms. The
type of internal dielectric, the structure of the plates and the device pack- aging all
strongly affect the characteristics of the capacitor, and its applications. Above
approximately 1 micro Farad electrolytic capacitors are usually used because of
their small size and low cost compared with other types.

Department of Electrical & Electronics Engg. 5 NSSCE, PALAKKAD

 Chapter 3

CAPACITOR TYPES

3.1 Aluminum electrolytic capacitor

Figure 3.1: Aluminium Electrolytic Capacitor

An aluminum electrolytic capacitor, usually simply called an electrolytic capac-itor

(e-cap), is a capacitor whose anode (+) consists of pure aluminum foil with an etched

surface, covered with a uniformly very thin barrier layer of insulating aluminium oxide,

which operates as a dielectric. The electrolyte, which covers the rough surface of the oxide

layer, operates as the second electrode, the cathode (-). E-caps have the largest ca-

pacitance values per unit volume compared to the two other main conventional capacitor

Department of Electrical & Electronics Engg. 6 NSSCE, PALAKKAD

families, ceramic and plastic film capacitors, but much smaller capacitance than
similar sized super capacitors.

Figure 3.2: Design of AEC

3.2 Power Factor Correction Capacitors

Figure 3.3: Power Factor Correction Capacitor

Power factor correction is the process of compensating for the lagging current by cre-

ating a leading current by connecting capacitors to the supply. A sufficient capacitance is

Department of Electrical & Electronics Engg. 7 NSSCE, PALAKKAD

connected so that the power factor is adjusted to be as close to unity as possible.This is

normally achieved by the addition of capacitors to the electrical network which compen-

sate for the reactive power demand of the inductive load and thus reduce the burden on

the supply. There should be no effect on the operation of the equipment. To reduce losses

in the distribution system, and to reduce the electricity bill, power factor correction, usually

in the form of capacitors, is added to neutralize as much of the magnetizing current as

possible. Capacitors contained in most power factor correction equipment draw current

that leads the voltage, thus producing a leading power factor. If capacitors are connected

to a circuit that operates at a nominally lagging power factor, the extent that the circuit lags

is reduced proportionately. Typically the corrected power factor will be 0.92 to 0.95.

3.3 AC Motor Start Capacitors

Figure 3.4: AC Motor Start Capacitors

Motor start and run capacitors are used in single-phase AC induction motors. Such

motors are used whenever a single-phase power supply is more practical than a three-

phase power supply, such as in domestic appliances. Motor start capacitors are used

during the motor startup phase and are dis- connected from the circuit once the rotor

reaches a predetermined speed, which is usually about 75% of the maximum speed for

that motor type. These capacitors usually have capacitance values of over 70 F. They

come in various voltage ratings, depending on the application they were intended for.

Some single phase AC motor designs use motor run capacitors, which are left connected

Department of Electrical & Electronics Engg. 8 NSSCE, PALAKKAD

to the auxiliary coil even after the start capacitor is disconnected by the centrifugal switch.

These designs operate by creating a rotating magnetic field. Motor run capacitors are de-

signed for continuous duty, and remain powered whenever the motor is powered, which is

why electrolytic capacitors are avoided, and low-loss polymer capacitors are used in-stead.

The capacitance value of run capacitors is usually lower than the capacitance of start

capacitors, and is often in the range of 1.5 F to 100 F.

Department of Electrical & Electronics Engg. 9 NSSCE, PALAKKAD

 Chapter 4

PRODUCTION PROCESS

Figure 4.1: Process Steps

The production process start with mother rolls. First, the etched, roughened and

pre-formed anode foil on the mother roll as well as the spacer paper and the cathode foil

are cut to the required width. The foils are fed to an automatic winder, which makes a

wound section in a consecutive operation involving three sequential steps: terminal

Department of Electrical & Electronics Engg. 10 NSSCE, PALAKKAD

welding, winding, and length cutting. In the next production step the wound section
fixed at the lead out terminals is soaked with electrolyte under vacuum impregnation.
The impregnated winding is then built into an aluminum case, provided with a rubber
sealing disc, and mechanically tightly sealed by curling. Thereafter, the capacitor is
provided with an insulating shrink sleeve film. This optically ready capacitor is then
contacted at rated voltage in a high temperature post-forming device for healing all the
dielectric defects resulting from the cutting and winding procedure. After post-forming,
a 100% final measurement of capacitance, leakage current, and impedance takes
place. Taping closes the manufacturing process; the capacitors are ready for delivery.

4.1 Etching
To obtain higher capacitance, surface area of aluminum foil for electrolytic capacitor

increases through etching process. In etching process, aluminum foil is applied with DC or

AC current in a chloride solution to preferentially dissolve the surface. Surface area is

increased by 60-150 times for low voltage foils and 10-30 times for high voltage foils.

4.2 Anodization(Formation of Dielectric Layer)

Aluminum foil for electrolytic capacitor is further formed with anodic oxide film
(Al2O3) on the surface as dielectric layer. Etched aluminum foil is immersed into a
solution including ammonium salt of boric acid or phosphoric acid and applied with
DC voltage so that the foil becomes positive and the solution becomes negative.
Then aluminum oxide film is formed on the surface in proportion to the applied
voltage. The anodic oxide film, having the thickness of 13-15 angstrom/V (1.3-1.5
nm/V), is extremely thin, compact and highly insulating.

4.3 Slitting Process

Etching and Forming are processed with wide roll of master foil. Then the master
roll is slitted into individual rolls with specified width as per the specification.

Department of Electrical & Electronics Engg. 11 NSSCE, PALAKKAD

4.4 Stitching and Winding

Slit anode and cathode foils after slitting process are stitched with lead tabs
and wound into cylindrical element together with spacer paper. Spacer paper is
to contain liquid electrolyte that works as real cathode and restores damaged
dielectric film, as well as maintaining the distance between anode and cathode
foils constant to prevent short cir-cuit.

4.5 Impregnation Assembling

Wound element is immersed into electrolyte bath under either low air pres- sure
condition or normal pressure to impregnate. Electrolyte contains one or more
polyhydric alcohols such as ethylene glycol as the major solvents and one or more
ammonium salts as solutes to restore the damaged oxide film (dielectric) and
significantly improve the performance and life of the capacitor. Rubber seal, rubber-
lined terminal plate or molded terminal plate is attached to impregnated element.

4.6 Encapsulation

Capacitor element is put into aluminum case and sealed together with rubber
seal or terminal plate. Materials to seal up capacitor are EPT or IIR, which is
selected depending on the capacitor series.

4.7 Sleeve
Sealed capacitor is covered with sleeve made of heat shrinkable PVC or PET. The

purpose of sleeve is to indicate information of the capacitor. When electric insulation of

inner element or aluminum case is required, proper materials shall be selected.

4.8 Aging (Reforming)

The oxide film as the dielectric is formed in Anodization (Forming) Process, but alu-

minum substrate is exposed during slitting process and stitching process. Oxide film

Department of Electrical & Electronics Engg. 12 NSSCE, PALAKKAD

layer is possibly damaged or cracked during winding. Restoring oxide film is
necessary for capacitor to fully function. In this process, capacitors are applied
with DC voltage in high temperature atmosphere to repair damaged oxide film.
Aging makes leakage current of capacitor stable and also debugs initial failure.

4.9 Process Inspection & Packaging

Capacitors finished with aging are packaged through electrical screening and
appearance inspection.

Department of Electrical & Electronics Engg. 13 NSSCE, PALAKKAD

 Chapter 5

RESISTORS

Figure 5.1: Stator phase windings

A resistor is a passive two-terminal electrical component that implements electrical

resistance as a circuit element. In electronic circuits, resistors are used to reduce current

ow, adjust signal levels, to divide voltages, bias active elements, and terminate trans-

mission lines, among other uses. High- power resistors that can dissipate many watts of

electrical power as heat may be used as part of motor controls, in power distribution

systems, or as test loads for generators. Fixed resistors have resistances that only change

slightly with temperature, time or operating voltage. Variable resistors can be used to ad-

just circuit elements (such as a volume control or a lamp dimmer), or as sensing devices

for heat, light, humidity, force, or chemical activity. Keltron offers a range of Resistors for

diverse applications in the consumer, industrial, professional electronic equipment and

many other applications. Our modern, fully automated plant with strict adherence

Department of Electrical & Electronics Engg. 14 NSSCE, PALAKKAD

to usage of superior raw materials and quality control measures ensure production
of Resistors with long term stability over the entire operating temperature range.

5.1 Carbon Film Resistor

Figure 5.2: Carbon film resistor with exposed carbon spiral

Carbon film resistors are a fixed form type resistor. They are con- structured out of a

ceramic carrier with a thin pure carbon film around it, that functions as resistive mate-rial.

Carbon film resistors are made with a deposition process. At high temperature and under a

high pressure, a ceramic carrier is held in hydrocarbon gas. The gas (methane or

benzene) is cracked at a temperature of 1000 degree celcius. The crystalline carbon is

pyrolytically deposited on the ceramic substrate. Because of the precise distribution of the

pure graphite without binding, these carbon resistors have a low noise. The desired

resistance value can be obtained by choosing the right layer thickness, and by cutting a

spiral shape in the carbon layer. The helical cut in the film increases the length of the cur-

rent path. By decreasing the pitch of the helix, the length of the resistive path increases,

and therewith the resistance value increases. Furthermore, by fine tuning the cutting of the

spiral the resistor can have a higher accuracy of resistance value. Typical tolerance values

for carbon film resistors are 2, 5, 10 and 20%˙

Because of the use of pure carbon, the carbon film resistor has a higher negative

temperature coefficient than carbon composition. The resistive temperature coefficient lies

between 2.5x10ˆ -4 ohm/degree celcius and -8x10ˆ -4 ohm/degree celcius. Also this type

of resistor is protected against chemical influences with a silicone coating. This type of

resistor is widely used in electronics. Therefore it is important to note that the small

resistors have a capacity of approximately 0.5 pF. Self induction is around 0.01

Department of Electrical & Electronics Engg. 15 NSSCE, PALAKKAD

 Figure 5.3: Carbon film resistor

H for uncut resistors and up to several Henry for spiral cut resistors. These resistors are

available in values between 1 to 10000 M and have a power rating of 1/16 , 1/8 , 1/4 , 1/2 ,

1 or 2 watts. Carbon film resistors are a significant improvement on carbon composition.

However, in comparison to metal film and metal oxide film, the commercially available

range steadily decreases. Metal and oxide film are not more expensive to produce, and

have overall better properties. The range includes Carbon Film Resistors for general

purpose applications where demands on stability and tolerance are moderate- Metal Film

Resistors for applications where demands on the parameters are highly stringent. Keltron

has specialized in the manufacture of Professional Grade Resistors.Different Types Of

Resistors manufactured by KCCL are given in Appendix B.

Department of Electrical & Electronics Engg. 16 NSSCE, PALAKKAD

 Chapter 6

RESISTOR COLOR CODE

Figure 6.1: A typical axial-lead resistor

Resistor values are often indicated with color codes. Practically all leaded resistors

with a power rating up to one watt are marked with color bands. The coding is defined in

the international standard IEC 60062. This standard describes the marking codes for

resistors and capacitors. It includes also numerical codes. The color code is given by

several bands. Together they specify the resistance value, the tolerance and sometimes

the reliability or failure rate. The number of bands varies from three till six. As a minimum,

two bands indicate the resistance value and one band serves as multiplier. The resistance

values are standardized, these values are called preferred value. The chart below shows

how to determine the resistance and tolerance for resistors.The table can also be used to

specify the color of the bands when the values are known.

Department of Electrical & Electronics Engg. 17 NSSCE, PALAKKAD

Figure 6.2: Resistor Color Code
Department of Electrical & Electronics Engg. 18 NSSCE, PALAKKAD
 Chapter 7

CONCLUSION

Keltron has initiated steps to create knowledge and innovations in the electronic field. It is

one of the leading capacitor manufacturing companies in Kerala. It has always been able

to provide high quality products. Keltron has also an Electronic Design Research section

that help in providing capacitors according to the need of the customers. Fur-thermore,

they have a well experienced technical experts and supporting staffs for the

accomplishment of the goals of the company. The organization study in Keltron helped me

to understand the various functions in an organization and how it is connected with the

management theories. I gathered a good idea about the history and profile of ‘KEL-TRON’

to enlarge my idea in the business world.

Department of Electrical & Electronics Engg. 19 NSSCE, PALAKKAD

 Chapter 8

REFERENCES

1. http://www.keltroncomp.org/index.php
2. http://keltron.org/electronic components.php
3. https://en.wikipedia.org/wiki/
4. www.google.co.in
Department of Electrical & Electronics Engg. 20 NSSCE, PALAKKAD