Beruflich Dokumente
Kultur Dokumente
Bachelor of Technology
in
March-2017
NSS COLLEGE OF ENGINEERING
PALAKKAD
( Affliated To Calicut University)
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
Dr.Anitha P
Professor(HOD) Dept. of EEE
Dept. of EEE
ACKNOWLEDGEMENT
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 deeply indebted to the training instructors for their timely help and
meticulous guidance for the successful completion of the training sessions.
The industrial training was conducted at Keltron Component Complex Limited, (KCCL)
(KSEDC). I undertook 10 days of training at KCCL from June 22nd, 2016 to July 1st, 2016 to
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
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
7 CONCLUSION 19
8 REFERENCES 20
INTRODUCTION
1.1.1 HISTORY
Keltron entered the electronic components industry by setting up India’s largest Alu-
went into commercial production on 19th August 1978. Since then KCCL has grown and
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
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
1.3 Products
CAPACITORS
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
microF (micro-farads) and its working voltage in Volts (V). Other pa-rameters which specify
CAPACITOR TYPES
(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
Power factor correction is the process of compensating for the lagging current by cre-
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
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.
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
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
PRODUCTION PROCESS
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
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
increased by 60-150 times for low voltage foils and 10-30 times for high voltage foils.
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.
4.6 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
minum substrate is exposed during slitting process and stitching process. Oxide film
Capacitors finished with aging are packaged through electrical screening and
appearance inspection.
RESISTORS
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
many other applications. Our modern, fully automated plant with strict adherence
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
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
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
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 ,
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
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.
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’
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