A Training Report Presented by:- Kaushik Jain

Introduction to Organization: The LNJ Bhilwara group, pioneers in Textiles and Graphite Electrodes

for over 40 year in also very well know in the fields of Sponge Iron, Power generation, Telecommunication and financial services. The group was founded by the Veteran industrialist, Shri Laxmi Nivas Jhunjhunwala in 1961. The total assets of the end of 2005-06 stood at Rs. 3553 crores with record sales turnover of Rs. 2387 crores. In 1968-69, RSWM manufactured Indias first polyester viscose (PV) blended yarn. In 1972, the group ventured into Graphite plant, Hindusthan Electro Graphite Ltd. (now HEG Ltd.) at Mandideep in M.P., in technical and financial collaboration with Pechiney of France. Today HEG Ltd. is Indias no.1 Graphite Electro exporter and operate the largest graphite plant in South East Asia and Middle East.

An Introduction to the Rishabhdeo unit

The unit came into existence on July 12, 1989 with the purchase of the assets of erstwhile Siddha Syntex, a14,300 spindles spinning plant by the LNJ Bhilwara. Under the dynamic leadership and vision of its president, Shri Prakash Maheshwari, the unit not only stood on its own feet, but expanded 32,832 spindles having world class technology with in a short period of six years only. Now the unit is having 33,168 spindles equipped with metal detectors, Auto leveler cards and Draw frames, Auto corners, TFO, Pallet packing machines etc. besides other latest spinning machines. The total assets of the unit are around Rs. 68 crores with annual sales turnover of about Rs. 133 crores. The company is currently supplying fabrics for Maruti-Esteem and Zen, Mitsubishi- Lancer, Tata Safari, Sumo, Estate, Indica and general motors of India.

PRODUCTS
The unit mainly manufactures 100% Viscose and Polyester

viscose blended gray spun yarns in counts range NE 8s to 60s in single, double and multifold yarns. Besides plain yarns, the unit manufactures sewing threads, coarser denier, and fully viscose yarns customer needs.

Departments at Rishabhdeo Unit (RSWM)

Production department Finishing department Maintenance department Engineering department CPPC (Central Production Planning Control) Budget & MIS department Store & Purchase department IT department Finance & Account department SQC (Statistical Quality Control) Personnel & HRD department

Production &

Finishing

Process

Blow-Room :It is used for opening the cotton fibers, clearing of dust, foreign particles like metal, stones, seeds, and colored contamination. Carding :Either single or double cylinder carding machine is used for individualization/parallelization of cotton fibers, the sliver. The machine is equipped with open loop auto leveler. The carding machine auto leveler has following basic parts:Transducer:- It is used to give the voltage signal according to the thickness of output sliver to the CPU. CPU:- This unit compares the required sliver weight signal and running sliver weight signal received from Transducer and gives analog signal to the feed inverter. Feed inverter:- It is used to control the speed of the cotton feed rolls to maintain constant sliver weight at output. Display:- It is used for data feeding and to maintain operation of the auto leveler as well as machine operation.

Draw-frame:Breaker are used to give pass to the sliver received from carding. This required to make the output sliver more and more homogeneous. Draw-frame finisher:In addition to above function it has auto leveler to control wrapping of the sliver. The Revter Auto leveler has following critical parts:Distance sensor & TsG sensor:- which gives a voltage signal to the controller equal to the sliver thickness. Servo Motor:- according to the signal received from the controller to increase or decrease the sliver feeding the servo motor works. Techo-sensor:- It is installed at the servo motor gearing and gives feed back to the controller as it make the implementation as required. Sliver monitor sensor:- It is used to monitor the delivered sliver and to control it within the set limits, either by alarms or by switching off machine. CPU:- Main unit of the auto leveler is CPU, used to received the data from monitoring sensor, like distance sensor, techo sensor and gives output signal to the G-90 unit for controlling operation of servo motor. G-90:- It is type of frequency inverter gives output in the form of square wave for operation of servo motor.

Introduction to Motor Speed Control

Need for Variable speed drivers
There are many and diverse reasons for using variable speed

drives. Some applications, such as paper making machines, cannot run without them while others, such as centrifugal pumps, can benefit from energy savings.
In general, variable speed drives are used to: Match the speed of a drive to the process requirements

Match the torque of a drive to the process requirements

Save energy and improve efficiency

Variable speed drives can be classified into three main categories:

Mechanical variable speed drives Hydraulic variable speed drives Electrical variable speed drives 1. Electrical variable speed drives for DC motors (DC drives) 2. Electrical variable speed drives for AC motors (AC drives)

DC & AC Motor control using Inverter circuit

Introduction to INVERTER(Frequency Converter)

An inverter is an electrical or electro-mechanical

device that converts direct current (DC) to alternating current (AC); the resulting AC can be at any required voltage and frequency with the use of appropriate transformers, switching, and control circuits. The electrical inverter is a high-power electronic oscillator. It is so named because early mechanical AC to DC converters were made to work in reverse, and thus were "inverted", to convert DC to AC. The inverter performs the opposite function of a rectifier.

General block Diagram of an Converter

Power electronic converter or converter for short, is an assembly of power electronic components that converts one or more of the characteristics of an electric power system.

Variable Frequency Drives

First, the Converter (usually a diode rectifier) converts three-phase AC power to DC power. Next, the DC Bus stores and filters the DC power in a large bank of capacitors. Last, the Inverter (usually a set of six IGBTs) switches or inverts the DC power in a Pulse Width Modulated (PWM) AC waveform to the motor.

Why the IGBT is mostly used

Good power handling capabilities Low forward conduction voltage drop of 2 V to 3 V, which is higher than

for a BJT but lower than for a MOSFET of similar rating This voltage increases with temperature making the device easy to operate in parallel without danger of thermal instability High speed switching capability Relatively simple voltage controlled gate driver Low gate current

Some other important features of the IGBT are:

There is no secondary breakdown with the IGBT, giving a good safe
operating area and low switching losses Only small snubbers are required

Pulse-Width Modulation (PWM)

Gate commutated inverters (DC/AC converters) Most modern AC variable speed drives in the 1 kW to 500 kW range are based on gate commutated devices such as the GTO, MOSFET, BJT and IGBT, which can be turned ON and OFF by low power control circuits connected to their control gates. Here, in this textile industry, used inverter circuit based on the IGBT device. 1.Single-phase square wave inverter

Three-phase inverter A three-phase inverter could be constructed from three inverters of the type shown in Figure. However, it is more economical to use a 6-pulse (three-leg) bridge inverter as shown in Figure.

Three-phase inverter using gate controlled switches

a typical diagram of

inverters used in Carding machine

a typical diagram of inverters using in Process (Auto)corner machine

Control system for AC variable speed drivers

Main components of an AC variable speed derive

Variable speed drive control loops

Simple open-loop control, no feedback from the process Closed-loop control, feedback of a process variable Cascade closed-loop control, feedback from more than one variable

closed-loop VSD system

A closed-loop feedback control system

Cascade controller for speed and torque

INTRODUCTION TO SENSORS
1. Current measurement transducers Current Shunt
A current shunt and amplifier is the simplest form of current feedback. This well established technique is illustrated in Figure, the DC bus current is passed through a link of pre-calibrated resistance and the voltage across it is measured. The voltage is directly proportional to the current passing through the shunt.

2. Speed measurement transducers

Analog speed transducers
A tachometer generator or tacho-generator (abbreviation: tacho) is a

small electromagnetic generator that is usually fitted to the nondrive end (NDE) shaft of an electric motor. Tacho-generators can be either of the flange-mounted, solid-shaft type or the hollow-shaft type.

There are two types of techo-generator:1. DC Techo-generator 2. Ac Techo-generator

a typical diagram of Sensors(LVDT type)

 In the finishing process, the yarn cleaner machine is for the finishing of the

3.Diameter measurement Sensor (Photo diode)

sliver and it produce a sliver of fixed or constant diameter. The working of this machine is based on the photo diode, which senses any variation in the diameter of sliver and then machine removes this variation and produce a fixed diameters sliver.

symbol of Photo diode

Constructional Diagram

Kinds of Photo diodes Photodiodes come in all shapes and sizes. Some come with built-in lenses, some come with optical filters, some are designed for high-speed responses, some have large surface areas for high sensitivity, and some have small surface areas.

Introduction to PLC (Programmable Logic Control)

General block diagram of PLC system

A Typical diagram of PLC circuit used in (i) Carding & & (ii) Process corner machine

PROTECTION OF AC CONVERTERS & MOTORS

The protection of AC variable speed drives includes the protection

of the following two major components of a VSD: The AC converter The electric motor

Typical list of variable speed drive parameters

Variable speed drive diagnostics table

Electric motor protection The useful life of an electric motor is dependent on the following main components: Electrical parts, such as the stator windings & insulation, the rotor windings & insulation and their respective external connections Mechanical parts, such as the stator core with slots, the rotor core with slots, the shaft, the bearings, the frame & end shields and the cooling system.

Motor protection direct temperature sensing

1. Microtherm (thermostat) 2. Thermistor sensors and thermistor protection relays 3. Thermocouple

Typical connection of thermistor protection relays

Connections between a thermocouple sensor and its controller

SELECTION OF AC CONVERTERS
The following checklist covers most of the factors that need to be considered: The nature of the application Maximum torque and power requirements and how these change with speed Starting torque requirements The speed range - minimum and maximum speed Acceleration & deceleration requirements (Is braking necessary?) Compatibility with the mains supply voltage Environmental conditions where the converter and motor are required to operate, ambient temperature, altitude, humidity, water, chemicals, dust, etc Ventilation and cooling for the converter and motor Direction (uni- or bi-directional) Accuracy of the speed control Dynamic response (speed and torque response requirements). Speed regulation requirements with changes in load, temperature, supply voltage

CONCLUSION
We are very happy to say that our training about working principle of Inverter & Servo system in text tile industry RSWM, Rishabhdeo is successful. Here we learnt about that hows an inverter operates a dc/ac motor speed, also learnt about an servo driver unit & PLC and about the various electronic equipments used in this industry. Our training incharge Mr. H. Nayar is very well to make it successful. He gave a lot of knowledge about the industry and various equipments. Our heartfelt thanks to him and all the members of engineering department.