INDUSTRIAL TRAINING

REPORT
TRAINING INFORMATION

NAME : DEVENDRA KUMAR

YEAR : FINAL

ORGANIZATION: RAJKIYA ENGINEERING COLLEGE

AZAMGARH
PLACE OF TRAINING: DPM ENGINEERING WORKS
LUCKNOW

FIELD OF TRAINING: General

1
 TABLE OF CONTENTS

TRAINING INFORMATION 1
TABLE OF CONTENTS 2

CHAPTER 1: INTRODUCTION 3

1. SERVICES AND MAJOR FUNCTIONS 3

2. DIFFERENT SECTIONS AND CLOSE RELATIONSHIPS 5

3. SITE LAYOUT 7

4. ORGANIZATIONAL STRUCTURE 8
CHAPTER 2: MATERIALS AND CUTTING SPEEDS 10

CHAPTER 3: MACHINE TOOLS AND SPECIFICATIONS 12

1. PLANNING MACHINE 12

2. UNIVERSAL MILLING MACHINE 14

3. SHAPER 14

4. HAND DRILL 15

CHAPTER 4: CNC MACHINING CENTER 16

1. HITACHI SEIKI VA35 CNC MACHINING CENTER 16

2. MACHINE SPECIFICATIONS 18

3. G CODE AND M CODE 20

4. AN EXAMPLE PROGRAM 20

5. STEPS IN USING THE MACHINE 22

CHAPTER 5: FEASIBILITY SURVEY ON A MINI-HYDRO POWER PROJECT 24

1. INTRODUCTION 24

2. FLOW PREDICTION AND MEASUREMENT 24

3. HEAD MEASUREMENT 26

CHAPTER 6: MANUFACTURING CROSS FLOW TURBINES 28

6.1 INTRODUCTION 28

2
 2. A CROSS FLOW TURBINE 28

3. COUPLINGS 31

4. GENERATOR 31

CHAPTER 7: OTHER ACTIVITIES 32

1. MANUFACTURING A CHALK MACHINE 32

2. SELF POWERED WATER PUMP FOR RIVERS 32

3. MILLING A PRINTED CIRCUIT BOARD 33

4. AN ELECTRONIC ROTATION COUNTER 34

CONCLUSION 34

1.CONCLUSION 34

2.SUGGESTIONS FOR THE IMPROVEMENT OF THE ENGINEERING WORKSHOPS

34

3.SUGGESTIONS FOR THE IMPROVEMENT OF TRAINING PROGRAM 34

3
 INTRODUCTION
1. SERVICES AND MAJOR FUNCTIONS
The infrastructure of the Engineering Workshops could provide the following listed services to
its consumers both in academic and non-academic terms.

 Machining of metals

 Welding

 Foundry work

 Smith and fitting work

 Woodwork

 Vehicle repair

Subject to the rules established by the Faculty and the University, deploying the following
functions was expected from it.

 Provide above mentioned services to the engineering undergraduates to carry out their
academic activities such as practicals, experiments and etc.

 Provide above mentioned services to the Faculty of Engineering and the University as
a whole if requested.

 Within the feasibility limits, provide above mentioned services to the public. (Service
cost is usually expected to be charged from the service consumers).

It is important to distinctly note that the Engineering Workshops could provide related
knowledge wise services to other engineering organizations and to the public who need
assistance in their work.

2. DIFFERENT SECTIONS AND CLOSE RELATIONSHIPS

The Engineering Workshops itself is a collection of five different subsections that are
interrelated. Brief descriptions about them are given below.

5
1. DIFFERENT SECTIONS

1. Metal Workshop
The Metal Workshop is the place for machining metals. It comprises the following prominent
machine tools with other supporting machines and equipments.

 Drilling machines  Milling machines

 Engraving machines  Planers

 Gear shapers  Shaping machines

 Grinding machines  Slotting machines

 Lathe machines

* Several varieties of some of these machine tools could be found for specialized operations.

2. Welding And Foundry Shop

The Welding and Foundry shop comprised equipment to deploy following services:

 Arc welding  Oxyacetylene welding

 Metal casting  Spot welding

 Mig welding  Tig welding

3. Smithy And Fitting Shop

The Smithy And Fitting Shop mostly comprised hand tools (anvils, hammers, chisels, etc.)
and some machine tools (Electric hammer and sheet metal rollers, benders and cutters).

4. Woodwork Shop
Comprised of 10 carpenters and 2 laborers the Woodwork Shop enclosed the following
machine tools.

 Band saw  Saw and planner

 Circular saw  Thickness planner

 Disc and bobbin sander  Wood planer

 Double end tenoner  Wood turning lathe

 Drill

 Mortiser

 Pattern miller

 Router

6
 5. Vehicle Repair Unit
The Vehicle Repair Unit extends its services . It comprised the following work force:

 Electricians (1)

 Greasers (3)

 Mechanics (3)

 Welders (1)

6. Other Sections
The Tool Store and the Consumable Good Store being separate from the above supply the
tools and consumable goods to all the above five subsections.

2. CLOSE RELATIONSHIPS
The Engineering Workshops has close relationships with the other departments of the
Faculty and especially with the Department of Production Engineering through which the
academic activities are conducted. On the other hand, machine tools and equipments of the
Department of Production Engineering are also used to carry out the tasks of the Engineering
Workshops freely. Specially, the Computer Numeric Controlled (CNC) Machining Center.

3. SITE LAYOUT

Gate 1 Gate 2

Woodwork
Faculty Main Corridor

Vehicle

Tool &
Cons umable goods

Welding

Metal Smithy &

fitting

Foundry

Figure 1-1 The Engineering Workshops

7
CHAPTER 2: MATERIALS AND CUTTING SPEEDS
Production of an item with desired qualities inherently involves the knowledge of the
materials that should be used for the product and the qualities of them. A simple example is
using stainless steel for a product that should not get stained.

Furthermore the effective processing of these materials until a finished product is obtained
requires the knowledge of processing characteristics of the materials. For example consider
machining stainless steel. Some important points to be considered are:

 The tool material that should be used.

 The level of machining (i.e. rough or finish)

 The cutting speed

 Requirement of coolants

Table 2-1 gives the cutting speeds of the commonly used materials under different
conditions.

10
 Table 2-1 Cutting Speeds

Workpiece Material Cast iron Mild Steel Malleable Cast iron Bronze Aluminium Stainless Brass
iron steel

Rough cut
HSS tools

50-60 40-50 80-110 45-60 110-150 400 100-120 200-300

(ft/min)

Finish cut
80-110 65-90 110-130 70-90 150-180 700 100-120 200-300
(ft/min)

Rough cut
120-200 140-160 250-300 150-180 600 800 140-200 600-1000
(ft/min)
Carbi

tool
de

Finish cut
350-400 250-300 300-400 200-250 1000 1000 240-360 600-1000
(ft/min)

11
CHAPTER 3: MACHINE TOOLS AND SPECIFICATIONS
3.1 PLANNING MACHINE
Unlike most of other machines, the planning machine contains a sliding table which carries
the workpiece. Cutting tools do not move but the workpiece. The one in Metal Workshop was
not frequently used because of the heavy operating cost. It was only used for heavy duty
metal works.

The prime mover of the sliding table is a DC motor with the following specifications.

 Volts 115/39

 Amps 25/113

 HP 15/4.5

 rpm 1500/720/225

 Excitation Volts 110

 Rating Cont

 Insulation Class E

 Year 1965

 BSS 261 315 7

The DC supply for the above motor is obtained from a DC generator which is directly coupled
to an induction motor driven by main AC supply of the Metal Workshop. The rating of those
are as follows:

DC Generator Specifications:

 Volts 115/39

 Current 113 A

12
  Power 13 kW

 rpm 1440

 Excitation 110 V

 Winding Comp. Int.

 Rating Cont

 Insulation Class E

 Year 1965

 BSS 2613/57

Induction Motor Specifications:

 Volts 400/440 (3 Phase 50Hz)

 Current 27.5 A

 Power 21 HP

 Rpm 1440

 Rating Cont

 Stator Delta

 Insulation Class E

 Year 1965

 BSS 2613/57

13
3.2 UNIVERSAL MILLING MACHINE
The universal milling machine in the Metal Workshop has a horizontally swivel bed and can
be used in both vertical and horizontal milling arrangements. The detachable milling head is
used when vertical milling is performed and can be turned vertically to mill at any other
inclination.

Specifications of the machine are listed below.

 Manufacturer Brown and Sharp MFG Company, USA

 Spindle motor 230 V, 3 phase, 50 Hz,

9 A (full load)

 Cutter Speeds 33 to 1275 rpm

 Feed rates 3/8 to 16 7/8 inch/min

3.3 SHAPER
A shaper contains a table on which the workpiece is mounted. The linear movement of the
cutting tool wipes away the excess material. This is exactly the opposite of what happens in
the planning machine where the tool is fixed and the workpiece is linearly moved.

The Metal Workshop has two shapers, a fully mechanical one and a hydraulic operated one.
The ram moving motor of the fully mechanical shaper is of 2HP and that of the hydraulic one
is 7.5HP.

The mechanical shaper has a constant speed prime mover which turns a disk as shown in
Figure 3-1 to convert the rotational movement of the prime mover into reciprocal motion of the
cutting tool.

TOO
e

Figure 3-1 Rotational Into Reciprocal Motion Conversion

14
This arrangement allows quick return motion. Further more this allows feed rate change
without any gear arrangement or control of speed of motor. This is done by varying the
eccentricity e. The higher the e, the higher the feed rate is. A simple trade off of this feed rate
control system is that as the feed rate is reduced, the stroke of the ram also gets reduced.
The hydraulic type shaper does not have this problem and the feed rate and the stroke can
be independently controlled. Figure 3-2 shows the hydraulic arrangement. This machine has
been manufactured by Rockford Machine Tool, Rockford, Illinois, USA.

CYLINDER PISTON CONNECTED TO RAM

HYDRAULIC
SWITCH

HUDRAULIC OIL
PUMP SUMP

Figure 3-2 Hydraulic Arrangement Of The Shaper

3.4 HAND DRILL

A hand drill is a versatile equipment which can be freely used for drilling holes as well as for
some other purposes where a portable rotational prime mover is required.

The specifications of the NHP1030 hand drill manufactured by Makita Corporation, Japan are
given below.

 Supply 230 VAC, 2.0 A,

50-60 Hz

 Power 430 W

 Speed 0-2700 rpm

 Maximum drill
10 mm
bit size

15
CHAPTER 4: CNC MACHINING CENTER
4.1 HITACHI SEIKI VA35 CNC MACHINING CENTER
The Hitachi Seiki VA35 CNC (Computer Numeric Controlled) machining center that belongs
to the Department of Production Engineering is frequently used for accurate and automated
machining of metals as well as for wood, plastic and other materials. The machining accuracy
of the machine is 0.001mm. Figure 4-2 shows various parts of the machine tool.

Figure 4-1 Hitachi Seiki VA35 CNC Machining Center

16
Figure 4-2 Hitachi Seiki VA35 CNC Machining Center

17
Manufactured by Hitachi Seiki Co. Ltd., Japan, the control unit of this numerically controlled
milling machine is of Fanuc System 6M-B. The controlling is based on two Intel 8085
microprocessors.

Figure 4-3 is a block diagram which shows the controlling structure of the CNC machine.

EEPROM OR
TAPE INPUT

MICRO
CONTROL PROCESSOR ROM

SPINDLE POSITION X,Y,Z POSITION

X
S MOTOR Y
DRIVER
SPINDLE MOTOR Z

X,Y,Z MOVEMENT MOTORS

Figure 4-3 Numerical Control Of The Machine

2. MACHINE SPECIFICATIONS
1. GENERAL INFORMATION

 Manufacturer Hitachi Seiki Co. Ltd., Japan

 Model VA 35–II

 Control unit Fanuc System 6M–B

 Weight 4000 kg

18
4.2.2 TABLE

 Working area 1000*355 mm2

 Maximum carrying capacity 500 Kg

3. STROKES

 x-axis stroke in the crosswise

560 mm
direction of the table

 y-axis stroke in the longitudinal

350 mm
direction of the table

 z-axis stroke in the vertical

400 mm
direction of the spindle head

 Distance between the spindle nose

150-550 mm
and top of the table

4. SPINDLE HEAD

 Spindle nose contour NT 40

 Spindle speed 60-600 rpm

 Spindle speed change Stepless (s 4 digit)

 Spindle motor AC 5.5 kW (30 min)

5. FEED

 Least increment 0.001 mm

 Cutting feed rate 3600 mm/min

 Rapid traverse 13000 mm/min

19
6. AUTOMATIC TOOL CHANGE (ATC)

 No. of tools 30

 Shank type BT 40, CAT 40

 Maximum tool diameter 95 mm

 Maximum tool length 250 mm

 Maximum tool weight 10 kg

 Tool selection method Random shortest course

 Pull stud type MAS - 1

3. G CODE AND M CODE

The entire functioning of the machine is based on G Code and M Code specifications.

G Codes define the preparatory functions of the machine. In simple terms, they control the
movement and machining related functions of the machine tool. For example, the code "G76"
followed by some related arguments is used for fine boring. "G00" with X,Y,Z arguments
rapidly moves the bed and the spindle head to the position specified by the arguments.

M Codes are known as auxiliary functions. They control specific behaviors of the machine.
For example "M08" turns on the coolant, M05 stops the spindle.

4. AN EXAMPLE PROGRAM
The listing given below is a program which was used to bore holes in couplings of two
turbines which were manufactured in the Engineering Workshops. It is written in G and M
Codes.

Unless otherwise stated, all the dimensions are in mm.

1 G28 G91 Z0;

2 G28 X0 Y0;

3 G40 G49;

4 G90;

5 G92 X253.087 Y177.818 Z343.05;

20
 6 G00 x131.25;

7 G00 Z5.0 F10;

8 M03 S150;

9 M98 P151;

10 M05;

11 M09;

12 G28 G91 Z0;

13 G28 X0 Y0;

14 M30;

15 %

The meaning of each line is given below.

1 Return to reference point, Incremental programming, Z=0 is the reference point (Z

movement only)

2 Return to reference point, X=0 and Y=0 (X and Y movements only)

3 Tool diameter compensation cancel, Tool length offset cancel

4 Absolute programming

5 Programming of absolute zero point, X=253.087, Y=177.818, Z=343.05

6 Positioning (rapid), X=131.25, Y=0

7 Positioning (rapid), Z=5.0, Feed rate set to 10 mm/min

8 Spindle rotation CW, speed=150 rpm

9 Sub program (o0151) call-out

10 Spindle stop

11 Mist/coolant off

12 Return to reference point, Z=0, Incremental programming (Z movement only)

13 Return to reference point, X=0 and Y=0

14 End of program, Control unit reset

15 Just display the end of current listing

Line 9 in the above program calls the sub program o0151. This sub program is the actual part
of the program which bore holes and is listed below.

21
 1 G76 G98 X131.25 Y0.0 Z-52.0 Q0.5 R2.0;

2 X119.903 Y53.384;
3 (some more x and y values)

4 M99;

The meaning of each line is as follows:

1 Fine boring; Return to initial level in canned cycle after finishing; Starting X,Y
coordinate: X=131.25, Y=0.0; Final Z coordinate = -52.0; Before boring tool is taken
out, move it 0.5 away from the bored wall of the workpiece; Radius of boring = 2.0
(This value does not have any effect on boring since the tool determines the actual
radius.).

2 Repeat boring for X=119.903 and Y=53.384.

3 Repeat the same in line 2.

4 End of sub program.

5. STEPS IN USING THE MACHINE

The distinct operations involved in using the CNC machine are listed below in sequence they
are done.

1. Generating the program (in G & M Codes)

2. Sending it to the machine

3. Running the program

First a drawing of the machined workpiece is created using AutoCAD in a PC. Then using a
special routine of AutoCAD, the contours of the cutting tool are generated. This is finally
stored as a text file in the hard drive of the PC.

Next, the CNC machine is set to retrieve this file. Through the coaxial cable which links the
PC and CNC machine, it is then fed into the machine tool. A numeric name for the program is
given at the beginning of the file retrieval to figure out the starting point (or the address in the
memory) of the retrieving program from earlier read programs.

Using this numeric name of the program, it is taken to the front from other programs in the
memory and it stays waiting to run. Pressing the "Start" button sequentially executes the
listing.

Figure 4-4 shows the monitor (on the Main Control Panel) displaying a program waiting to be
executed.

If needed a program can directly be written using the Main Control Panel of the CNC machine
and executed. This is tedious and errors may occur easily.

22
Figure 4-4 A Program Waiting To Be Executed (Sub Control Panel Display)

23
CHAPTER 5: FEASIBILITY SURVEY ON A MINI-HYDRO
POWER PROJECT
1. INTRODUCTION
This chapter described the methods that were used for flow rate prediction and measurement
and head measurement of a stream called Madapiti Oya in Nuwara Eliya district as a
feasibility survey to construct a mini-hydropower plant. APPENDIX A: FEASIBILITY REPORT
ON THE PROPOSED MINI-HYDRO POWER PROJECT AT KABARAGALA ESTATE
contains full details of it.

The capacity of a hydropower scheme entirely depends on two factors being the water flow
rate and the head (the height difference between the reservoir and the power house).

2. FLOW PREDICTION AND MEASUREMENT

Two methods that were carried around the stream are described here. One is a flow
prediction method and the other one is a flow measurement method.

5.2.1 AREA-RAIN FALL METHOD

This is a flow prediction method. In simple terms, the catchment area of a water stream is
multiplied by the rainfall to find the flow.

Figure 5-1 shows an example contour map that can be used in this method to find the
catchment area of a stream. The lighter dashed lines enclose the areas. For example the
area which determines the flow at point B of the stream is enclosed by the outer light dashed
lines bounded by three mountain peaks.

Figure 5-1 Using A Contour Map To Find The Catchment Of A Stream

Figure 5-2 shows a simple representation of a hydrological cycle. It is seen that sub-surface
transfer flow, evaporation and transpiration reduce some amount of water from the value

24
calculated just by multiplying the area and the rainfall. Depending on the weather and
geographical conditions, suitable corrections for these can be applied for a more accurate
flow prediction.

Figure 5-2 The Hydrological Cycle

5.2.2 THE FLOAT METHOD

This is a flow measurement method. As shown in Figure 5-3, the time taken for a float to
travel a known distance on the surface of the stream is found and hence the mean velocity of
the stream. The mean velocity depends on the bed surface of the stream and hence a
correction factor is applied for the velocity given by the division of the float length by the time
in calculating it. The mean cross sectional area of the steam is also found.

The flow is obtained by multiplying the mean values of cross sectional area and velocity.

Figure 5-3 Float Method Of Flow Measurement

25
5.3 HEAD MEASUREMENT
5.3.1 PRESSURE GAUGE METHOD
Being not a very accurate method, pressure gauge method of head measurement employees
a calibrated pressure gauge into which a long transparent water filled open ended pipe is
fitted.

Figure 5-4 Pressure Gauge Method Of Height Measurement

Figure 5-4 shows how a pressure gauge is used in height measurement. The calibrated
pressure gauge at B directly reads the pressure at point B with reference to point A. This
reading can then be used to calculate the height difference between points A and B using the
density of water.

The open end A of the pipe is then taken to point B and the meter can then be moved down
to a point below the point B. This is done from the expected beginning to the expected end of
the penstock and the head is calculated from the sum of reading of the meter.

5.3.2 TACHEOMETRIC SURVEYING

This is an accurate method of head measurement which uses an optical theodolite as shown
in Figure 5-5.

Figure 5-5 Tacheometric Surveying

A measuring staff is kept at point X and readings at points A, B and C which can be identified
because of the cross hairs and stadia hairs of the instrument are taken. The inclination of the

26
lines of sight () is also taken. These measurement can be mathematically manipulated to
find the vertical and horizontal distances between the instrument and a given point. Thus a
vertical profile along a path can be generated.

If a compass is additionally used at the instrument position to find the direction of point X
relative to some reference direction (magnetic north), a bird’s eye view of the surveyed path
can also be drawn.

27
CHAPTER 6: MANUFACTURING CROSS FLOW
TURBINES
6.1 INTRODUCTION
During the time of training, two similar 280kW cross flow turbines were manufactured in the
Engineering Workshops. They were intended to be directly coupled to the generator as
shown in Figure 6-1.

WATER

TURBINE GENERATOR

COUPLING

WATER
Figure 6-1 Direct Coupled Turbine
The following sections describe each component of the above system.

6.2 A CROSS FLOW TURBINE

Figure 6-2 shows the cross section of a cross flow turbine that had been manufactured earlier
in the Engineering Workshops.

28
 Figure 6-2 A Cross Flow Turbine
In a cross flow turbine, the blades are arranged in a squirrel cage. Water from the penstock
hits a blade and travels across the cage, hits a second blade and leaves out. This is
illustrated in Figure 6-2.

The turbine shown in Figure 6-2 has a governor connected to it internally. The latter produced
ones do not contain governors.

Figure 6-3 shows the external dimensions of a 280kW cross flow turbine that was
manufactured in the Engineering Workshops.

29
 520mm

590mm

80mm

540mm

840mm

770mm

Figure 6-3 External Dimensions Of A 280kW Cross Flow Turbine

The squirrel cage blade structure of the turbine is kept in position by two bearings at each
end of the rotor. The especial feature is that one of them is of self aligned type. A self aligned
bearing allows the axis of the shaft which goes through it not to be the same axis of the outer
fixed frame and the inclination may vary. This is shown in Figure 6-4.

INCLINED TRUE AXIS OF

ROTATION
NOMINAL AXIS OF
ROTATION

Figure 6-4 A Self Aligned Bearing

The self aligned bearing allows the manufacturing eccentricity of the bearing mounts not to
cause vibrations or related mechanical failures.

30
6.3 COUPLINGS
The connection between the turbine and the generator is established by a set of cast iron
couplings shown in Figure 6-5. Each of these couplings contains fifteen nylon bushes. Each
bush on the turbine side coupling is connected to one bush on the generator side coupling
using a metal rod. The nylon bush arrangement reduces vibrations and related failures due to
possible eccentricities that may exist between two shafts.

one set of METAL ROD

connectors

NYLON BUSHES

TURBINE SIDE GENERATOR SIDE

Figure 6-5 Coupling Between Turbine And Generator

6.4 GENERATOR
The alternator for an above turbine is of brushless self excited type with an automatic voltage
regulator fitted into it. Figure 6-6 is a simple representation of such an alternator.

GENERATOR EXCITER

ARMATUR
3
RECT

FIELD FIELD

ARMATURE
AVR

3  OUT

Figure 6-6 Brushless, Automatic Voltage Regulated Alternator

31
CHAPTER 7: OTHER ACTIVITIES
7.1 MANUFACTURING A CHALK MACHINE
The chalk machine that was being manufactured in the Engineering Workshops used a
piston-cylinder arrangement in producing crayons. Made of brass, Figure 7-1 shows one such
piston-cylinder pair.

MOLTEN PASTEL

CYLINDER
WATER

PISTON

Figure 7-1 A Piston Cylinder Pair Of The Chalk Machine

The operation is as follows:

1. Fill the cylinders with molten pastel.

2. Pass water around the cylinders to solidify the crayons quickly.

3. Move the piston upwards to remove the crayons.

The machine contained a set of piston-cylinder pairs which worked simultaneously. Pressing
the molten pastel into the cylinders and moving the piston upwards were performed by using
two hydraulic jacks one on top and the other under the piston-cylinder structure.

7.2 SELF POWERED WATER PUMP FOR RIVERS

This is a design of Professor Sanath Ranathunga and I had no personal involvement with it.

A pipe is spiral wound inside a thrown away barrel as shown in Figure 7-2. The barrel is fitted
with blades on its surface and submerged in the river. As the barrel rotates, water and air
enter and pipe from its open end one after another. This pressurize the water inside the pipe
and naturally elevates to a higher level.

32
 AIR BARREL
SPIRALED
PIPE

WATER BLADES

Figure 7-2 The Self Powered Water Pump For Rivers

7.3 MILLING A PRINTED CIRCUIT BOARD

The conventional way of creating a printed circuit board or PCB for short involves chemical
etching of unwanted portions of copper from a copper clad board. Instead of using a
chemical, milling away the unwanted portions of the copper surface reduces time and effort
needed in creating PCBs drastically. Though some drawbacks exist, this was tried on the
small universal milling machine and satisfactory results could be obtained.

First some broken tool shanks were found and ground to the shapes shown in Figure 7-3
using the drill bit grinder.

a b

0.5mm 0.5mm

Figure 7-3 Tools To Mill A PCB

Figure 7-4 Milling A PCB

Cutter (a) in Figure 7-3 created a rough surface finish. The shape of the cutting edge of cutter
(b) was seen to force the copper chips into the board producing a smooth surface finish.

33
7.4 AN ELECTRONIC ROTATION COUNTER
On request of the Workshops Director Dr. S.D. Pathirana, an electronic rotation counter was
designed and assembled. This was intended to give a primitive idea of electronic counting to
the engineering undergraduates who were not exposed to them before. In fact, the counter
was supposed to be used as a teaching guide to teach the students automated motion
controlling of machines.

The block diagram of the four digit counter is shown in Figure 7-5.

SENSOR AMP SCHMITT

TRIGGER
PHOTO
CELL CD4026 7

LED
SSD
DRIVER 8
SSD
LM324
Interrupt point to
CLK input of next
increment count
CD4026

Figure 7-5 Electronic Rotation Counter

CD4026 is a decade counter and can drive a seven segment display (SSD) directly. The
carry out pin of one IC is fed to the clock input of the next IC so that the count of next stage is
incremented by 1 for 10 counts of this stage.

LM324 contains four general purpose operational amplifiers and used for the photo cell signal
amplification and as a Schmitt trigger.

34
CHAPTER 11: CONCLUSION
1. CONCLUSION
The profit of an organization entirely depends on the way the top chairs manage the
resources the organization has. Whatever the other aspects may be, it was seen that
managing human resource was extremely difficult. The stability or the sustainability of the
organization mostly depends on this factor.

On the other hand, it was prominently seen that thinking should precede doing. In most cases
it could be seen that there exists easier or better ways to do something.

As far as the above mentioned factor is considered, continuous knowledge mining followed
by experience in a cycle upholds the entire system in every aspect.

Earning and living a satisfactory life is the desire of all.

2. SUGGESTIONS FOR THE IMPROVEMENT OF THE

ENGINEERING WORKSHOPS
The experiences I had in the Engineering Workshops suggest me the following to be
implemented for the improvement of the place.

1. Maintain a simple booklet on materials that are used in the Engineering Workshops.
This should contain the properties and the processing aspects (cutting speeds,
coolants, etc.)

2. Maintain a booklet on each machine about the capabilities of them and the current
condition.

3. Implement a method to return the unused consumable goods to the stores.

4. Maintain a training program for the employees at least one session a month.

5. Teach the employees how to collaborate with others.

3. SUGGESTIONS FOR THE IMPROVEMENT OF TRAINING

PROGRAM
A group of 14 undergraduates including myself had the first year in-plant training at the
Faculty Workshop together and all of us did what we were supposed to do separately.
Though we discussed what we were doing among ourselves a little, I feel it would have been
better if we were explicitly encouraged by the Industrial Training Unit to had formal
discussions at least once a week. Some of the undergraduates (I feel I was one of that group)
were seen to work harder gaining more knowledge and the real taste of engineering and
some were not. If discussions of this nature were conducted, all of us could have gained a
better knowledge and improved ourselves collectively. The participation of the training
supervisor would have been a further encourage.

Furthermore I suggest that it would have been better if all the undergraduates were exposed
to some presentations on the in-plant training before we were released. Some illustrative
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aspects of practical engineering could have been discussed widening the openness of the
eyes of us. Though we new what engineering was, we were not exposed to any sort of
practical engineering when we went for the training.

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