INTERNSHIP ON

BASICS OF ELECTRICAL AND ELECTRONICS DEVICES

Submitted in Partial fulfillment of the Requirements for the Award of

Bachelor of Engineering in Electronics and Instrumentation

By

MEENA P E (38180004)

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

SCHOOL OF ELECTRICAL AND ELECTRONICS

SATHYABAMA
INSTITUTE OF SCIENCE AND TECHNOLOGY

(DEEMED TO BE UNIVERSITY)

Accredited with Grade “A” by NAAC

JEPPIAAR NAGAR, RAJIV GANDHI SALAI, CHENNAI - 600 119

DECEMBER - 2019

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 CONTENT

CHAPTER TOPICS PAGE

NO NO
A ABSTRACT 4
1 INTRODUCTION TO WORKSHOP 5
1.1 COACH OVERHAULING 5
2 TRAIN LIGHTNING WORKSHOP 5
2.1 ALTERNATOR SECTION 6
2.1.1 STATOR 7
2.1.2 ROTOR 7
3 RRU 9
3.1. MAGNTIC AMPLIFIER 10
3.2. CURRENT AND VOLTAGE 10
CONTROL
3.3. OVER VOLTAGE PROTECTION 10
4 BATTERIES 11
4.1. ELECTROLYTIC PREPARATIONS 11
4.2. VRLA BATTERY 12
5 BLDC FAN 14

6 DELUXE WORKSHOP 16
6.1. ALTERNATORS AND REGULATOR 16
6.2. TESTING 17

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7 INVERTER 18
7.1. IGBT 19
7.2. FEATURES 19

8 BATTERIES IN TRAINS 20
8.1. NEED FOR BATTERY 21
8.2. BATTERY OVERHAULING 21
9 REGULATED BATTERY CHARGER 22
10 ELECTRICAL MAINTANANCE 23
10.1. TRANSFORMER 23
10.2. MAIN BUS CONDUCTOR 24
10.3. CIRCUIT BREAKER 24
10.4. SAFETY DEVICES 25
10.5. METERING DEVICES 25
11 COMPUTER NUMERICAL 26
CONTROL(CNC)
12 ELECTRICAL WORKSHOP 28
12.1. COIL WINDING 29
13 CONCLUSION 30
14 CERTIFICATE 31

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 ABSTRACT
Basics of electrical and electronics devices is training on
carriage works. It is located in Perambur, Chennai.
I have completed course on Basics of electrical and electronics
devices for 8 days at electrical workshop. The topics included are
LED, Fan, VRLA batteries, super deluxe, regulator, resistance,
capacitor, voltage, current, Inverter, train attachment, any repair
removes, types of coaches, ac coach, ICF coaches, LHB coaches,
Bipolar transistor also used, safety devices, transformer, metering
devices, computer work, coach metal irons are used in computer it’s
already programming, Ac coaches, non-ac coaches, first class, second
class, farmers market coach. It was taught with ease and fun to learn.
Many applications were built using the basic concept taught. An
overview of what carriage works is and how it working is learnt from
this course. Apart from that, a brief introduction about this course was
taught.

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 1. INTRODUCTION TO WORKSHOPS
1.1. COACH OVERHAULING:
➢ Taking the survey of the coach
➢ Unloading: Equipments are removed from the coach and
moved to the respective sections
➢ Dismantle the equipment and all the internal components are
individually checked for his healthiness by both electrically
and dimensionally
➢ After servicing, the equipments has to be tested
➢ Loading all the equipments in the coaches
➢ Final testing- Again cross /checked by the neutral team of
engineers
2. TRAIN LIGHTING WORKSHOP
➢ Alternator
➢ Regulator
➢ Battery
➢ Fan and light

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2.1. ALTERNATOR SECTION
Alternator is nothing but an ac generator. It converts
mechanical energy in to electrical Light energy in the form of
alternating current. In non AC coaches, 4.5 KW alternators are used.
Excitation is produced by residual magnetism.

Fig 2.1.AlTERNATOR

PRINCIPLE:
It works on the principle of “FARADAY’S LAW
OFELECTROMAGNETIC INDUCTION”(i.e.).whenever a
conductor is placed in a magnetic field, the EMF is induced.
CONSTRUCTION:
It has two main parts namely,
1. Stator
2. Rotor

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2.1.1. STATOR:
Stator is a stationary part of an alternator. It has two windings ac winding
or armature winding (R, Y and B) and dc winding or field winding (F+, F-).

Fig 2.2.STATOR

The propulsion technology of long stator linear

synchronous motors is used to drive high speed maglev trains

2.1.2. ROTOR:
Rotor is a rotating part, it has laminated steel plates which is used
to reduced eddy current loss. It has 8 teeth and 8 slots. It has two
bearings.
1. Ball bearing: Fixed at the non- driving end.
2. Roller bearing: Fixed at the driving end.

WORKING:
When the engine starts moving, the alternator which is coupled
with the wheel starts rotating. Due to the residual magnetism the field
coil will get magnetized. Whenever the rotor starts rotating it cuts the
magnetic flux lines and hence EMF gets induced at 400 rpm speed of

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the engine. This is known as 3 phase alternating current. The one
rotation of the wheel is equal to 2.7 rotations of the alternator. The
output of the alternator is given to the regulator cum rectifier unit.

Fig 1.3.ROTOR

Rotor machines change the interconnecting wiring with

each key stroke. The wiring is placed inside a rotor and then rotated
with a gear every time a letter is pressed.

Every letter pressed on the keyboard increments the rotor

position and Get a new substitution, Implementing a polyalphabetic
substitution cipher.

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 3. REGULATOR CUM RECTIFIER UNIT (RRU)

Fig 3.1.RMTD
➢ RRU converts 3 phase alternating current in to direct current.
REGULATOR PARTS:
➢ Magnetic amplifier
➢ Excitation transformer
➢ Power diodes
➢ Current transformer
➢ Voltage detector DT1
➢ Current detector DT2
➢ Over voltage protection(OVP)
➢ RT1
➢ RT2
➢ Field diode assembly

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3.1. MAGNETIC AMPLIFIER:
It is the main part of a regulator. It works on the principle of
“SATURATION OF THE CORE” Like transformer, it has two
windings,
1. Control winding and
2. Main winding.
When there is no supply to the control winding, main winding
impedance will be Minimum and it will carry maximum impedance. It
is a basic RL circuit it is very rudder and reliable.
3.2. CURRENT AND VOLTAGE CONTROL:
It is used to control voltage and current in the circuit by use of
some power diode and current transformer, in some case, Zenor diode
is used to control the voltage and current.
3.3. OVER VOLTAGE PROTECTION:
It is a small circuit, which is connected to the rectifier, the
normal voltage IS 110 V and it can bare up to 130.If it goes beyond
140v the OVP will protect the equipment.(i.e.)., OVP has relays,
whenever the voltage increases beyond 140v the relay will open
(NO) so that the alternator and regulator will cut off and thereby it
protect the circuit.
WORKING OF RRU:
The three phase ac output from the alternator is given to the
rectifier circuit. Basically magnetic amplifier generates ac excitation
voltage but we need dc excitation voltage for that we are using diodes
D1 and D2.The rectifier circuit produces the dc output dc output of
128 ±0.5 v. If it exceeds 140 v, then the OPV used to protect and
trips the circuit.

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 4. BATTERIES:
➢ It is for charging and discharging purpose. It stores energy in
the form of dc current. This is given to the load when the
power supply cuts.
➢ Battery has four cells which are connected in series .Each
cell has two volts. While charging the electrons move from
anode to cathode and vice versa.

Fig 3.2.BATTERY
4.1. ELECTROLYTE PREPARATION:
➢ Conc. sulfuric acid is used as an electrolyte. It is diluted with
water in the ratio of 1:3.
➢ Do not disturb it 24 hrs, because it needs to take some chemical
reaction.
➢ After that we should charge anode and cathode at 72V in 3 days.
While charging bubbles will come out.
➢ Hydrometer is used to check the charging condition.

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4.2. VRLA BATTERY:

Fig 4.1.VRLA Battery

➢ A valve-regulated lead-acid battery (VRLA battery) sometimes
called sealed lead-acid (SLA) or maintenance free battery.
➢ There are three primary types of VRLA batteries, sealed VR
wet cell, and absorbent glass mat (AGM) and gel cell.
➢ Gel cells add silica dust to the electrolyte, forming a thick
putty-like gel. These are sometimes referred to as "silicone
batteries".
➢ AGM (absorbent glass mat) batteries feature fiber glass mesh
between the battery plates which serves to contain the
electrolyte.
➢ Both designs offer advantages and disadvantages compared to
conventional batteries and sealed VR wet cells, as well as each
other.
➢ Due to their construction, the gel cell and AGM types of VRLA
can be mounted in any orientation, and do not require constant
maintenance.
➢ The term "maintenance free" is a misnomer as VRLA batteries
still require cleaning and regular functional testing.

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➢ They are widely used in large portable electrical devices, off-
grid power systems and similar roles, where large amounts of
storage are needed at a lower cost than other low-maintenance
technologies like lithium-ion.
➢ A VRLA battery utilizes a one-way, pressure-relief valve
system to achieve a “recombinant” technology.
➢ This means that the oxygen normally produced on the positive
plate is absorbed by the negative plate.
➢ Water (H2O) is produced instead, retaining the moisture within
the battery.
➢ The Lead Monoxide in turns reacts with Sulfuric Acid (H2SO4)
in the electrolyte and forms Lead Sulphate (PbSO4), thus
allowing the negative plate to be discharge.
➢ In other words,O2 from the positive plate is absorbed by the
negative plate without being expelled to the outside.

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 5. BLDC FAN
5.1. TECHNICAL SPECIFICATIONS:
Nominal input: 110vdc
Input variation: 90 to 140 v
Input power : <32 W
Allowable input ripple: < 15%
Minimum on voltage: 75v
Maximum on voltage: 155v
Speed: 1300 rpm ±2.5v
5.2. FAN COMPONENTS:
➢ Fan ground (front + back): Each one
➢ Fan blade
➢ Guard monitoring ring
➢ Fan housing (bottom and top)
➢ Stator with winding
➢ Fan rotor shaft
➢ Pin for fan blade
➢ Fan bearing
➢ Rotor with magnet
➢ Fan motor control (PCB)
➢ Protection cover

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 Fig 5.1.Inside of BLDC Fan
➢ Solar power can be used to supply brushless DC fans in coaches
of Indian railways traction system.
➢ These fans are supplied from 110V DC and their operating
voltage is from 90V to 140v.
➢ There are 27 BLDC motor fans installed in each coach.

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 6. DELUX WORKSHOP
6.1. ALTERNATORS AND REGULATORS:
Construction and working principle is same as of non-ac coach. It has
two alternators and regulators. Coach full load is 193Amps; half load
is 96.5Amps.Power is constant.
CONSTRUCTION:
Rotor is brushless. It looks like pit and fall. It consists of 6V groove
pulley for smooth rotation.
6.1.2. TESTING:
➢ Insulation value should be greater than 2M ohm.
➢ 500V MEGGER is used to check insulation.
Phase-earth
Field –earth
Phase –field all should be greater than or equal to 2M
ohm. In rainy condition it should be > 1M ohm.
➢ Phase resistance is 0.053ohm.
➢ Field resistance is10ohm.
➢ Bearing condition is tested with the help of shock pulse meter
(SPM).
➢ Earth is tested with the help of 110V testing lamp.
➢ Temperature is tested with the help of thermometer. It should
be ambient temp +room temp.
➢ Cut in speed should be < 400 rpm.
➢ Minimum speed for full o/p should be < 800 rpm.

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Fig 6.1.Alternator

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 7. INVERTOR

Fig 6.2.Inverter
7.1. INTRODUCTION:
In all self-generating AC coaches, the system voltage is
110V DC. AC plant works on 415 V 3Ф AC. It has
24KVAcapacitor.

Fig 7.1.Inverter circuit

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7.2. IGBT
An insulated gate bipolar transistor is a three terminal
power semiconductor device primarily used as an electronic switch. It
has four alternating layers (P-N-P-N).It acts like MOSFET. It uses
PWM technique.
IGBT are state of the art power electronics for the traction
system of electric and diesel electric rail vehicles.
The main benefit of IGBT is that it reduces the requirement
for current, minimizing heat and traction noise while also making the
acceleration process efficient.
7.2.1. FEATURES:
➢ High efficiency.
➢ Fast switching.
➢ High voltage capacity.
➢ Low resistance.
➢ Voltage rating high >1kV.
➢ Current rating >500Amps.
➢ Lower voltage drop=0.2Ω.

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 8. BATTERIES IN TRAINS:
8.1. NEED FOR BATTERY
When the train stops rotating, the alternator stops producing
EMF. The need of power in coaches is supplied by battery. Battery
starts supplying to load
.

Fig 8.1.Batteries
8.2. BATTERY OVERHAULING:
➢ Discharge the battery bank at 12A and bypass each cell
reaches ECV of 1.75V.
➢ Charge the cells at 6A(5% of rated capacity) constant current
for 24 hours,
➢ Every cell must be physically checked for any abnormal heat.
If observed, cell to be removed or connections tightened.
Individual cell readings must be measure and recorded once
in every hour.
➢ It takes rest for 6 to 8 hours.

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➢ If any cell reaching 1.75V before 8.5hrs, repeat
charge/discharge for 1 more time.
➢ If after recycle cell reaching 1.75V before 8.5hrs, cells shall
not be put in service, else cells can be put back is service after
charging till 3 constant consecutive voltages reaching.

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 9. REGULATED BATTEREY CHARGER:

Fig 8.2.Regulated Battery Charger

9.1. NAME PLATE DETAILS:
INPUT: 415±15%, 50 Hz
OUTPUT: 110V-135V DC, 35A
WATTAGE: 4.5KW
BATTERY CHARGING CURRENT: 20Amps
MAXIMUM OUTPUT CURRENT: 50Amps
MAXIMUM LOAD CURRENT: 50Amps
RIPPLE CURRENT: V< 3V, I<2Amp
➢ The input ac supply is converted into dc by converter. This is
fed to inverter, which converts dc voltage to ac voltage.
➢ The output transformer steps down the inverted ac voltage to
require voltage level. Abridge rectifier at the secondary side of
the transformer rectifies the ac to dc, used for battery charging
as well as load also.

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 10. ELECTRICAL MAINTANANCE
10.1. SUBSTATION:
➢ In substation high voltage is converted into low voltage, and
then it will be distributed.
➢ Substations are electricity lines which are used to step down the
voltage using the transformer.
MAIN AREAS:
10.1. TRANSFORMER:
Transformer is the one which rise or lower the voltage to serve
transmission lines in substation.

Fig 10.1.TRANSFORMER

NAME PLATE DETAILS:

KVA RATINGS: 1000
NO LOAD VOLTS:
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HV (V):11000
LV (V): 433
AMPERES:
HV (A): 52.49
LV (A): 1333.37
AMBIENT FRECUENCY: 50
TYPE OF COOLING: ONAN
NO OF PHASES: 3
FREQUENCY (Hz); 50
WIRING MATERIALS: COPPER
Kg: (640)
CORE & WINDING (kg): 1450
TOTAL MASS (kg):3280
IMPEDANCE (normal) %:5.02

10.2. MAIN BUS CONDUCTOR

In electrical power distribution a bus bar is a metallic strip. It is used
for high current distribution.

10.3. CIRCUIT BREAKER:

➢ These breakers are designed for isolation of power to a traction
vehicle in the event of faults.
➢ It is used to open and close the circuit either automatically or
manually. Circuit breakers are used to terminate all current very
quickly.

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 10.4. SAFETY DEVICE:
➢ A device which is used to protect equipment machinery and
components in electrical and electronic circuits, against short
circuit over current.
➢ Relay is a circuit which will sense the fault current and it will
not trip. It will give the information to the breaker through the
master trip relay.
➢ For example, MCB (Miniature Circuit Breaker)it is a switch
which automatically turns off when the current flowing
through it passes the maximum limit. It protects the electrical
circuit from over current (i.e.).the circuit may get shorted due
to overflow. It is a better alternative to a fuse since it doesn’t
need any replacement. It can be easily reset.
10.5. METERINGDEVICES:
➢ A device that measures the amount of electrical energy
functioned by an electrically powered device.
➢ Meters are operated by continuously measuring the
instantaneous voltage and current to give energy.
Best example >>>>> CLAMP METER.

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 11. CNC (COMPUTER NUMERICAL CONTROL)
CNC is a Computer Numerical Control machine is a high precision
tool. It collects the digitalized data such as size, width, breath and
height. It uses software called CAD (Computer Aided Design).It
follows the instruction given to the CAD software.

Fig 11.1.COMPUTER NUMERICAL CONTROL

FUNCTIONS:
➢ Numerical control (CNC) (also computer numerical control
(CNC)) is the automated control of machining tools (drills,
boring tools, lathes) and 3D printers by means of a computer.
➢ A CNC machine processes a piece of material (metal, plastic,
wood, ceramic, or composite) to meet specifications by
following a coded programmed instruction and without a
manual operator.
➢ A CNC machine is a motorized maneuverable tool and often a
motorized maneuverable platform, which are both controlled by
a computer core, according to specific input instructions.
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➢ Instructions are delivered to a CNC machine in the form of
graphical computer-aided design (CAD) files, which are
transformed into a sequential program of machine control
instructions such as G-code, and then executed. In the case of
3D Printers, the part to be printed is "sliced", before the
instructions (or the program) are generated.
➢ CNC is an advance machine, and is a vast improvement over
non-computer type machining that requires manual control, by
hand wheels or levers, or mechanical control by fabricated
pattern guides (cams).
➢ In modern CNC systems, the design of a mechanical part and
its manufacturing program is highly automated.
➢ The part's mechanical dimensions are defined using CAD
software, and then translated into manufacturing directives by
computer-aided manufacturing (CAM) software.
➢ The resulting directives are transformed (by "post processor"
software) into the specific commands necessary for a particular
machine to produce the component, and then are loaded into the
CNC machine.
➢ Since any particular component might require the use of a
number of different tools – drills, saws, etc. – modern machines
often combine multiple tools into a single "cell".
➢ In other installations, a number of different machines are used
with an external controller and human or robotic operators that
move the component from machine to machine.
➢ In either case, the series of steps needed to produce any part is
highly automated and produces a part that closely matches the
original CAD.

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 12. ELECTRICAL WORKSHOP
12.1. COIL WINDING:
FOR 4.5KW ALTERNATOR,
NO OF SLOTS: 36
PITCH: 1 to 4
NO OF COILS: 6
NO OF PARALLEL WIRES: 3
NO OF TURNS: 8
TOTALLY 24 TURNS
FIELD COIL: 2(DC COILS)
NO OF COIL: 6 SETS
NO OF TURNS: 200
FOR 25KW ALTERNATOR,
NO OF SLOTS: 60
PITCH: 1 TO 4
NO OF PRALLEL WIRES: 5
NO OF TURNS: 7
TOTALLY 35 TURNS
FIELD COIL: 2(DC COILS)
SWG: 17
NO OF TURNS: 250

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12.2. CONSTRUCTION AND WORKING:
➢ Coil winding is the manufacture of electromagnetic coils. Coils
are used as components of circuits and to provide the magnetic
field of electrical machines such as motors and generators, and
in the manufacture of loudspeakers and microphones.

Fig 12.1 COIL WINDING

➢ The shape and dimensions of a winding are designed to fulfill

the particular purpose.
➢ Parameters such as inductance, Q factor, insulation strength, and
strength of the desired magnetic field greatly influence the
design of coil windings.
➢ Coil winding can be structured into several groups regarding the
type and geometry of the wound coil. Mass production of
electromagnetic coils relies on automated machinery.
➢ Because of the higher performance density, brushless EC drives
(electronically commutated motors) with permanent magnet
rotors are increasingly used instead of the asynchronous
technology.
➢ Owing to the compact design, the copper content can be cut in
half in the best-case scenario.

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 ➢ The manufacturers of electric motors also demand more
flexibility of the production technology. For producing
asynchronous motors, drawing-in systems are usually used that
are initially winding air-core coils only to draw them later into
the stator with a tool.
➢ In contrast, the concentrated winding of EC stators is more
flexible in the manufacturing process, energy saving when
implemented, better adjustable during operation and it requires
less space.

CONCLUSION
Throughout the training I have learned about the workshop electrical
and electronic services. Thus I have gained knowledge in the field of
basics of electrical and electronics in railways.

THANK YOU

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