Electrotherm (India) Ltd.

Industrial training Report

(June’19)

Electrical Engineering
Harsh Tanwar
16BEE030
PDPU
tanwarh98@gmail.com

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 INDEX

SR. CONTENT PAGE NO.

NO.
1. Industry Overview 3
2. Training Details 13
3. Project 14
I. Introduction 14
II. Buck converter 23

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 INDUSTRY OVERVIEW

Electrotherm (India) Ltd.

Corporate office

Address: Survey No. 72, Palodia (Via Thaltej), Ahmedabad,

Gujarat 382115

Phone: 027-17 660 550

Website: http://www.electrotherm.com/

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About Electrotherm:
Electrotherm (India) Limited, an ISO 9001:2008 certified, public
limited company, was founded in 1983 to cater to the needs of all
segments of steel industry, foundries and heat treatment industry.
Today, Electrotherm is a well diversified conglomerate having
businesses in the field of Engineering & Projects catering to steel
and foundry industry; transformer manufacturing; steel making;
ductile iron pipe making; manufacturing of battery operated
vehicles; renewable energy; transmission line tower and
education.

Electrotherm (India) Ltd. Has been engineering metal melting

industry since 1983. In Electrotherm from inception, R&D has
been their core competency with a common focus on
developing and adopting technologies to customize customer
needs making it a key driver in our Multi-Divisional growth
story. Electrotherm is the only Indian company with
indigenously developed world class technologies of global scale.
The major critical customized parts are manufactured in house
under stringent quality control management and the finished
products tested to withstand laid out quality parameters . They
cater to the domestic market while exports form major
component of their turnover. They service the global markets
around the world with specific focus upon Middle East, Turkey,
Pakistan, Bangladesh & Africa while catering to 31 countries
around the world. Electrotherm commands more than 50%
market share in induction melting equipments used by the
engineering and automotive industry in India. Electrotherm has
taken the first step in committing to making a pollution free
world by introducing the YObyke electric scooters and setting
up the wind farms and solar power plants and is also working
upon to introduce electric three wheelers and hybrid bus.

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Organization chart :

Chairman

Company secretary

Director

Production Research&Development Purchasing Marketing Accounts & Finance Human Resource

Production planning Product Designing Raw materials Promotions Monetary management Recruitment

Quality check Product Modifications R&D funding Market Analysis Financial records Training

Maintenance Furniture, stationery Public Relations Expenses Analysis Health & Safety

Infrastructure
Supervision Employee support
maintenance

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Major Departments:

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 1.Production
The Production department performs the activities necessary to provide
the organisation’s products or services. Its main responsibilities are:
• production planning and scheduling
• control and supervision of the production workforce
• managing product quality (including process control and monitoring
• maintenance of plant and equipment
• control of inventory

2.Research and Development (R&D)

The Research and Development (R&D) department is concerned with
developing new products or processes and improving existing
products/processes. R&D activities are closely coordinated with the
organisation’s marketing department to make sure what its customers
want in the most efficient, effective and economical way.

3.Purchasing
The Purchasing department is concerned with acquiring goods and
services for use by the organisation. These will include, for example,
raw materials and components for manufacturing and also production
equipment.
This department is also responsible for buying goods and services for
the entire organisation , for example, office equipment, furniture,
computer equipment and stationery.

4.Marketing (including the selling function)

The main function of this department is to analyse the market for
strategically promoting the product , so that it can reach to the
maximum number of people.
This department has to identify the customer needs and it is also
responsible for providing post purchase services.

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 5.Human Resource Management
The Human Resources function is concerned with the following:
• Recruitment and selection: Ensuring that the right people are recruited
to the right jobs.
• Training and development: Enabling employees to carry out their
responsibilities effectively and make use of their potential.
• Employee relations: Including negotiations over pay and conditions.
• Grievance procedures and disciplinary matters: Dealing with
complaints from employees or from the employer.
• Health and Safety matters Making sure employees work in a healthy
and safe environment.

6. Accounting and Finance

The Accounting and Finance department is concerned with the following:
• Financial record keeping of transactions involving monetary inflows or
outflows.
• Preparing financial statements for reporting to external parties such as
shareholders. The financial statements are also the starting point for
calculating any tax due on business profits.
• Paying wages and salaries and maintaining appropriate income tax
and national insurance records.
• Preparing management accounting information and analysis to help
managers to plan, control and make decisions.

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PRODUCTS OVERVIEW:

Electrotherm mainly consists of four product divisions

Engineering Steel and

and Projects: Pipe division:

TMT bars,
Furnaces stainless
steel etc.

Electro DI
Transformers
Pipe

Electric
Renewables
Vehicles

ET Thermals Yobykes

ET
3 Wheelers
Photovoltaic

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1.Engineering and Projects:
Engineering and Projects division is the oldest business of
Electrotherm since it started operations in 1983.
• It focuses on manufacturing induction melting furnaces, heating
and hardening furnaces and other steel making and refining
equipments.
• Manufactures transformers of high and lower ratings for
distribution network.

2. Steel and Pipe division:

• It manufactures structures for Transmission Line Tower and Wind
Mill applications, Stainless Steel for Industrial application and Mild
Steel & Carbon Steel for Structural/forging applications.

Electro TMT Plus Bars

Stainless Steel
Electro TLT Angles & Structurals

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 • Electro DI Pipe
Electrotherm Ductile Iron pipes developed by Electrotherm provide
an excellent medium of transporting water keeping its quality
intact. Currently, they are one of the leading manufacturers of DI
Pipe in India.

3. Renewables:
• ET Thermals- "eleCtra" brand solar water heating systems cater
to the needs of hot water to the Domestic Segments, industrial
applications and Process Industries. These systems are designed
and manufactured to suite all geographical conditions.
• ET Photovoltaic- Electrotherm Immodo Renewables Ltd. (EIRL) is
an ambitious joint venture between Electrotherm (India) Ltd. and
ImMODO Solar S.A., Spain. EIRL has furnished comprehensive
turnkey engineering, procurement & construction (EPC) services
along with long-term operation and maintenance (O&M) solutions
for Photovoltaic (PV) solar power plants in India and abroad.

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4. Electric Vehicle Division:

• YoBykes
The expertise of the company in power electronics and R&D effort of
the company has developed and launched Electric bikes and scooters
under the brand name YoBykes with a installed capacity of 2,50,000
unit-per annum. The company has also developed an electric 3 Wheeler.
Electrotherm even manufactures the control equipments of Electronic
vehicles, highly efficient, power motor and batteries which makes the
company an independent manufacturer in manufacturing a major
proportion of its Electronic vehicle.

E-Rikshaw( ET yuvraj)

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 INDUSTRIAL TRAINING DETAILS
( Project : Designing and Introduction to Stability Analysis of DC-DC
Converter)

Electrotherm (India) Ltd. – Auto Division

➢ Industry Mentor:
Name: Mr. Arun Sagar
Designation: HOD
Department: HEV R&D Department
Contact no. : 9925190506

➢ HR Details:
Name: Mr. Keyur Patel
Designation: Manager Level
Contact no. 9712973330
Email ID: Keyur.Patel@electrotherm.com

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 ➢ Project :
Designing and Introduction to Stability Analysis of
DC-DC Converter

▪ Introduction:
The DC-Dc Converters are widely used in switched mode dc
power supplies and in electronic devices.As shown in the figure
, the input to this converter is an unregulated dc voltage,which
is obtained by rectifying line voltage and therefore it will
fluctuate due to changes in the line-voltage magnitude.
Switched mode DC-DC converters are used to convert the
unregulated dc input into a controlled dc output at a desired
voltage level.

Switched mode DC-Dc converters utilize one or more switches

to transform dc form one level to another.The average output
voltage is controlled by controlling the switch on and off
duration of the switch.

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 ▪ Switched Mode Power Supply (SMPS)
A switched-mode power supply is an electronic power
supply that incorporates a power electronic
converters to convert electrical power from one
form/on level to another form/level efficiently.
The power conversion and transformation is done using
switching devices that are turned on and off at high
frequencies, and storage components such as inductors
or capacitors to supply power when the switching device
is in its non-conduction state.

Switched-mode power supplies are classified according

to the type of input and output voltages. The four
major categories are:
• AC to DC
• DC to DC
• DC to AC
• AC to AC
Some application of switch mode power supply (SMPS) are,
o The switch mode power supply (SMPS) is used in personal
computers.
o It is used in machine tool industries.
o The SMPS is used in security system.
o It is used in railway system.
o It is also used in mobile.
o It is used in battery charger.
o The SMPS is used in vehicles.
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▪ DC-DC Converter

DC-DC converters are widely used to efficiently

produce a regulated voltage from a source that may or
may not be well controlled to a load that may or may
not be constant. DC-DC converters are high-frequency
power conversion circuits that use high-frequency
switching and inductors, transformers, and capacitors
to smooth out switching noise into regulated DC
voltages. Closed feedback loops maintain constant
voltage output even when changing input voltages and
output currents.
DC-DC converters come in non-isolated and isolated
varieties. Isolation is determined by whether or not
the input ground is connected to the output ground.

Classification of DC-DC converter

• Non-isolated
• Isolated

An isolated DC-DC converter will have a high frequency

transformer providing isolation between input and
output.
A second advantage of an isolated converter is that the
output can be configured to be either positive or
negative.

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▪ Topologies
• Non isolated:

1. Buck
A buck converter steps a voltage down, producing a
voltage lower than the input voltage. A buck converter
could be used to charge a lithium ion battery to 4.2 V,
from a 5 V USB source.

2. Boost
A boost converter steps a voltage up, producing a
voltage higher than the input voltage. A boost converter
could be used to drive a string of LEDs from a lithium
cell, or provide a 5 V USB output from a lithium cell.

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 3. Buck – Boost
A buck-boost converter steps a voltage up or down,
producing a voltage equal to or higher or lower than the
input voltage. A buck boost could be used to provide a 12 V
output from a 12 V battery. A 12V battery’s voltage can vary
between 10 V and 14.7 V. A buck boost could also power an
LED from a single cell. An LED forward drop is as high as 3 V.
A lithium battery cell can vary between 2.5 and 4.2 V. There
are buck-boosts that produce positive and negative voltages.

• Isolated:

1. Fly Back
The flyback converter is used in both
AC/DC and DC/DC conversion with galvanic isolation
between the input and any outputs. The flyback converter is
a buck-boostconverter with the inductor split to form a
transformer, so that the voltage ratios are multiplied with an
additional advantage of isolation.

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2. Half bridge
A half-bridge converter is a type of DC-DC converter that,
like flyback and forwardconverters, can supply an output
voltage either higher or lower than the input voltage and
provide electrical isolation via a transformer.

3. Full bridge
A Bridge Converter is a DC to DC converter topology
(configuration) employing four active switching components
in a bridge configuration across a power transformer.A full
bridge converter is one of the commonly used
configurations that offer isolation in addition to stepping up
or down the input voltage.

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4. Push/Pull
A push–pull converter is a type of DC-to-DC converter, a
switching converter that uses a transformer to change the
voltage of a DC power supply.

5. Forward
The forward converter is a DC/DC converter that uses
a transformer to increase or decrease the output voltage
(depending on the transformer ratio) and provide
galvanic isolation for the load. With multiple output
windings, it is possible to provide both higher and lower
voltage outputs simultaneously.

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 ▪ Buck Converter

• Circuit diagram

• Operation and Circuit analysis

Continuous conduction mode

case-1: When switch S is ON

When switch in ON for a time ton, the diode will be open circuited since
it is in reverse biased condition(the n side of diode is at higher

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voltage(Vin) compared to p side which is shorted to ground through
the switch).
During this state the inductor charges and the inductor current
increases. The current through the inductor is given as

Assume that prior to the opening of switch the inductor current is I’L,
off. Since the input voltage is constant

Assume the switch is open for ton seconds which is given by

D*Ts where D is duty cycle and Ts is switching time period. The current
through the inductor at the end of switch on state is given as
IL, on = (1/L) *(Vin-Vout)*D*Ts + I’L, on (equation 1)
Hence ΔIL,on = (1/L)*(Vin-Vout)*D*Ts.

case 2: When switch is off

When switch in OFF the diode will be forward biased (short circuited
to ground) and the buck converter circuit can be redrawn as follows
The inductor now discharges through the diode and RC combination.
Assume that prior to the closing of switch the inductor current is I’’L,
off. The current through the inductor is given as

Note the negative sign at the front end of equation signifies that the
inductor is discharging. Assume the switch is open for toff seconds
which is given by (1-D)*Ts where D is duty cycle and Ts is switching
time period. The current through the inductor at the end of switch off
state is given as
I’’’L, off = -(1/L) *Vout*(1-D)*Ts + I’’L, off (equation 2)
In steady state condition as the current through the inductor does not
change abruptly, the current at the end of switch on state and the
current at the end of switch off state should be equal. Also the
currents at the start of switch off state should be equal to current at
the end of switch on state.
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• In Continuous Conduction Mode (CCM), neglecting power losses
associated with all circuit elements, the input power Pd is equal
to output power Po

Vd I d = Vo I o
Io V 1
= d =
Id V0 D

Vo t
= on = D
Vd Ts , D is Duty Cycle
• Io is the average output current and Id is the average input current
• Hence in CCM step – down converter is equivalent to a dc
transformer (step down)

• Waveforms

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• Component Selection

Given:

1) Vin(input) & Vout(output) voltage

2) Switching Frequency (fs)

3) Maximum o/p current (Imax)

4) Ripple current (∆IL)

5) Voltage ripple (∆V)

1. Inductor :
1) L= {D*(Vin-Vout)}/{ ∆IL *fS*Vin}
2) Isaturation › Ilpk , Ilpk is peak inductor current

2. Capacitor :
1) For a capacitor:
∆V = ∆IL •(ESR + + ∆T / C + ESL / ∆T)

3. Diode :

1) Forward current rating(IF) >= Maximum o/p

current through diode
i.e. IF > Imax(1-D)
2) Peak inverse voltage(PIV) > 1.2 (Vin)

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 4. Switching Device:

1) Current rating (avg.), Isw > Imax*D

2) Voltage rating >= Vin

• Modelling of Buck converter:

Select inductor current (il) and capacitor voltage (vo) as the
state variables. In this case the output of interest (vo) is one
of the state variable so we don’t actually need an output
equation. The input voltage (Vd) is the only input variable.

Using Kirchoffs laws we can derive the following state

equations:

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Step 3

Use the time averaged state space equations to solve for the
steady state transfer ratios. In the steady state all time
derivatives are zero so

Step 4
Now introduce a small ac perturbation on the duty cycle
('G) and determine the resulting ac perturbations in the
state variables. Note that Vd is assumed to be constant

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because we are trying to determine the effect of changing
the duty cycle only.

Step 5
Now apply the Laplace transform and work out the
transfer function from duty cycle to output voltage.

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Hence, buck converter transfer function is obtained.

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• Stability Analysis:

Stability Criteria:
The stability of a system relates to its response to inputs or
disturbances. A system which remains in a constant state
unless affected by an external action and which returns to a
constant state when the external action is removed can be
considered to be stable.

A systems stability can be defined in terms of its response

to external impulse inputs..

Definition .a :
A system is stable if its impulse response approaches zero
as time approaches infinity..

The system stability can also be defined in terms of

bounded (limited) inputs..

Definition .b:
A system is stable if every bounded input produces a
bounded output.

The objectives of stability analysis is the determination of

the following

• The degree or extent of system stability

• The steady state performance
• The transient response

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 The standard method of completing a system analysis
includes the following steps..

• Determine the equations or transfer functions for each

component
• Create a model - generally a block diagram
• Formulate the system model by appropriately connecting the
blocks nodes and branches
• Determine the system characteristics

A number of methods are available for determining the

system characteristics including the following.
• Root locus analysis
• Frequency Response analysis

• Overview of control Techniques for DC-DC

converters

1. Voltage mode control of DC-DC converters

It is a type of single loop controller connected to a reference
voltage, so at first output voltage is measured and compared to a
reference voltage. It uses measured output and reference voltage to
generate the control voltage. After this the control voltage is used to
determine the switching duty ratio by comparison with a constant
frequency waveform. This duty ratio is used to maintain the average
voltage across the inductor. This will eventually bring the output
voltage to its reference value and which help in the delivery of
constant voltage without any variation.

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2.Current mode control of DC-DC converters
It is more complex than VMC as it contain dual loop
including voltage and current control loops . There are
various application of CMC for different application. After
sensing the inductor current it is used to control the duty
cycle. An error signal is produced after comparing the
output voltage Vo with fixed reference voltage Vref and
this error signal is used to generate control signal ic. The
next step is to sense inductor current and compared with
control signal ic to generate the duty cycle of particular
frequency and drive the switch of the converter.

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➢ Conclusion:

From the two weeks of training , I have learned

1. Switched mode power supplies, their types, operation
and applications.
2. Designing of Buck converter and practical aspects.
3. Stability analysis criteria and control strategies used for
dc-dc converters.

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