`Chapter 01: Introduction about establishment:1.1: About Brandix casualwear:Brandix Lanka Limited was founded in 1972 and is based in Colombo, Sri Lanka. The company was formerly known as Lux Shirts (Pvt.) Ltd. The company has manufacturing locations in Sri Lanka, India, and Bangladesh. Vision of the Brandix casualwear is To be the inspired solution for branded clothing. Brandix has been become the pioneer in Sri Lanka's apparel sector.Brandix Lanka limited is a well-known garment manufacturing company which has South Asias largest apparel group, providing integrated solutions covering the entire value chain, from product design, development, manufacturing and raw-material supply. Because of that reason, clients are being provided best what clients can be satisfied. They are doing the best for their customers, so they have been given lot of orders from foreign branded company. Because of that reason Brandix is one of the largest exporter of apparel in Sri Lanka. As the holding company of the Brandix Group of companies, it is engaged in developing, manufacturing and marketing end-to-end apparel solutions to global fashion super brands. Brandix is supplying garments on behalf of world super brands such as Victoria's Secret, Gap, Next, Marks and Spencer, Liz Claiborne, Abercrombie and Fitch etc.Brandix Lanka Limited operates as a subsidiary of Phoenix Ventures Ltd. Although it was a single manufacturing facility in 1972 now it has 34 plants island wide and supports the Group and employs over 35,000 people directly. Brandix Lanka Ltd was founded in 2002 and pioneered the concept of holistic apparel solutions from a unique, customer-centric structure.The company specializes in casual bottoms, intimate and active wear, woven and knitted fabrics and a host of apparel industry accessories. Producing their own fabric, threads, buttons and hangers give them their most tactical edge in textiles and reinforce our core strengths of advanced research and development, outstanding design, fabric printing, washing, dyeing, wet processing, finishing, and relentless quality control services with fastest turnaround times. Embedding and integrating these services into seamless verticality is the value chain the Brandix Lanka offered to their clients.

Figure 1.1: Brandix casualwear, EkalaBrandix Casualwear forms the core of the Group, its flagship unit where 'inspired solutions' are conceptualized in a holistic service to its customers. The company is supplying woven bottoms, basic pants, cargo pants, 5-pocket jeans, shorts and skirts; the quintessence of our product portfolio, to the world's top brands. Its seven production facilities include a state-of-the-art, fully automated denim facility which is the first of its kind in Sri Lanka.Brandix casual ware adding another milestone for their successful movement, Brandix commissioned its Green Factory in April 2008. It is not only for the country but the world too, setting a new benchmark as the first one of its kind in the country. The 130,000 square foot Brandix Casualwear plant at Seeduwa exceeds stipulated Green Factory standards for energy consumption, water conservation, solid waste management and carbon emissions. The complete conversion supports initiatives for supply chains to achieve carbon neutrality, and reduces the facility's carbon footprint by as much as 64%, achieving a 46% saving in energy a 63% cut in water consumption and zero solid waste to landfill. The new, sophisticated air-conditioning systems and ducting have greatly increased efficiency with special prismatic material in skylights letting in solar light but not solar heat.

1.2: Achievements of the company:

GOTS (Global Organic Textile Standard)On-site inspection and certification of processors, manufacturers and traders performed by independent specially accredited bodies is the basis of the GOTS monitoring system in order to provide a credible assurance of the integrity of GOTS-certified textiles.( Six Casualwear facilities in Sri Lanka have received

LEED CertificationBrandix is proud to receive the recent global recognition for its Eco Centre in Seeduwa for Brandix Casualwear. The plant received Platinum rating in August 2008 under the Leadership in Energy and Environmental Design (LEED) Green Building Rating System

WRAP (Worldwide Responsible Apparel Production)WRAP (Worldwide Responsible Apparel Production) is the most recognized compliance standard in the United States for the apparel industry.

GOTS (Global Organic Textile Standard)On-site inspection and certification of processors, manufacturers and traders performed by independent specially accredited bodies is the basis of the GOTS monitoring system in order to provide a credible assurance of the integrity of GOTS-certified textiles.( Six Casualwear facilities in Sri Lanka have received)

1.3: Innovation Center at Brandix Casualware:In Ekala factory there are two main departments who are responsible for technical issues. They are Maintenance department and the innovation center. Maintenance department is responsible for all the regular maintenances of the machining and the other technical system in the company. The innovation center is the place which produce new machines to the production lines according to the. After starting innovation center there are around 450 machines it had produced. The main target of the innovation center is 40% automate the production lines. To achieve this target they are produce machine which are completely different one another. During training period, that kind of projects had to be done. Producing these machines is for minimize the time wastage and increase the production rate.

Chapter 02: Technical experiences obtained during training2.1: Experiences obtained related to workshop activities:2.1.1: Activities carried out: WeldingArc welding

Figure 2.1: Arc welderTo operate an arc welder, the earth (ground wire) must be attached to the material to be welded. The other cable runs to the hand-piece, in which the welding electrode is clamped.When the electrode touches the work, electrical current flows from the welder though the rod and work-piece back to the welding machine. If the current flow is established and then the electrode quickly pulled back a little from the work-piece, a very high temperature arc forms between the end of the rod and the work-piece. This melts the welding rod (becomes filler material)and the materials being welded.

Figure 2.3; Establishing arcFigure 2.2: Arc welding

The welding electrode (the stick or rod) has an inner core of metal similar to the material that is being welded. This core also has a diameter that is proportional to the material as the work-piece gets thicker. The inner of the rod is surrounded by a welding flux. When the molten material solidifies, the flux forms a spate layer on top that can later be knock away with the chipping hammer. The flux on welding rods serves these functions : Provides a gas shield, Gives steady arc by providing current bridge, cleans and slows the cooling of the weld, introduces appropriate alloys into the weld.

Specific electrodes available for welding : Mild steel Cast iron Stainless steel Copper, bronze, brass, etc. High tensile steels

Safety precautions: Always wear an appropriate welding visor, helmet, clothing that covers arms and legs, and gloves Wear goggles when hipping slag or wire-brushing welds Keep all electrical cables in good conditions Make sure contact cannot be made with hot items Keep inflammable items well away Ensure there is plenty ventilation

Gas welding

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals, respectively. Oxy-fuel is one of the oldest welding processes and still widely used for welding pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artworkIn oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded.The apparatus used in gas welding consists basically of an oxygen source and a fuel gas source (usually cylinders), two pressure regulators and two flexible hoses (one of each for each cylinder), and a torch. A welding torch head is used to weld metals. It can be identified by having only one or two pipes running to the nozzle and no oxygen-blast trigger and two valve knobs at the bottom of the handle letting the operator adjust the oxygen flow and fuel flow.

Figure 2.4: Welding torchesThe flame is applied to the base metal and held until a small puddle of molten metal is formed. The puddle is moved along the path where the weld bead is desired. Usually, more metal is added to the puddle as it is moved along by means of dipping metal from a welding rod or filler rod into the molten metal puddle. The metal puddle will travel towards where the metal is the hottest. This is accomplished through torch manipulation by the welder.Oxyacetylene welding/cutting is not difficult, but there are a good number of subtle safety points that should be learned such as:

More than 1/7 the capacity of the cylinder should not be used per hour. This causes the acetone inside the acetylene cylinder to come out of the cylinder and contaminate the hose and possibly the torch. Acetylene is dangerous above 1 atm pressure. It is unstable and explosively decomposes. Proper ventilation when welding will help to avoid large chemical exposure.

TIG Welding

Figure 2.5: Welding circuitGas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used.

Figure 2.6: TIG weldingGTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore, it is significantly slower than most other welding techniques.The electrode used in GTAW is made of tungsten or a tungsten alloy, because tungsten has the highest melting temperature among pure metals, at 3,422 C (6,192 F). As a result, the electrode is not consumed during welding, though some erosion (called burn-off) can occur. Manual gas tungsten arc welding is often considered the most difficult of all the welding processes commonly used in industry. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece

2.1.2: Activities carried out: Drilling and tappingDrillingDrilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary end cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the workpiece, cutting off chips from the hole as it is drilled. Drilled holes are characterized by their sharp edge on the entrance side and the presence of burrs on the exit side (unless they have been removed). Also, the inside of the hole usually has helical feed marks.Drilling may affect the mechanical properties of the workpiece by creating low residual stresses around the hole opening and a very thin layer of highly stressed and disturbed material on the newly formed surface. For fluted drill bits, any chips are removed via the flutes.

Twist drill bits:The twist drill bit is the type produced in largest quantity today. It comprises a cutting point at the tip of a cylindrical shaft with helical flutes; the flutes act as an Archimedean screw and lift swarf out of the hole.

Figure 2.7: Twist drill bitTwist drill bits range in diameter from 0.002 to 3.5in (0.051 to 88.900mm)and can be as long as 25.5in (650mm). The most common twist drill bit (sold in general hardware stores) has a point angle of 118 degrees, acceptable for use in wood, metal, plastic, and most other materials, although it does not perform as well as using the optimum angle for each material. In most materials it does not tend to wander or dig in.A more aggressive angle, such as 90 degrees, is suited for very soft plastics and other materials; it would wear rapidly in hard materials. Such a bit is generally self-starting and can cut very quickly. A shallower angle, such as 150 degrees, is suited for drilling steels and other tougher materials.Drill bits with no point angle are used in situations where a blind, flat-bottomed hole is required. These bits are very sensitive to changes in lip angle, and even a slight change can result in an inappropriately fast cutting drill bit that will suffer premature wear. Long series drill bits are unusually long twist drill bits. However, they are not the best tool for routinely drilling deep holes, as they require frequent withdrawal to clear the flutes of swarf and to prevent breakage of the bit. Instead, gun drill bits are preferred for deep hole drilling.

Drill press:A drill press (also known as a pedestal drill, pillar drill, or bench drill) is a fixed style of drill that may be mounted on a stand or bolted to the floor or workbench. Portable models with a magnetic base grip the steel workpieces they drill. A drill press consists of a base, column (or pillar), table, spindle (or quill), and drill head, usually driven by an induction motor.

Figure 2.8: Drill Press The head has a set of handles (usually 3) radiating from a central hub that, when turned, move the spindle and chuck vertically, parallel to the axis of the column. The table can be adjusted vertically and is generally moved by a rack and pinion.

A drill press has a number of advantages over a hand-held drill:

Less effort is required to apply the drill to the workpiece. The movement of the chuck and spindle is by a lever working on a rack and pinion, which gives the operator considerable mechanical advantage The table allows a vise or clamp to be used to position and restrain the work, making the operation much more secure The angle of the spindle is fixed relative to the table, allowing holes to be drilled accurately and consistently Drill presses are almost always equipped with more powerful motors compared to hand-held drills. This enables larger drill bits to be used and also speeds up drilling with smaller bits.

Taps and dies

Fig 2.9: Various tapsTaps and dies are cutting tools used to create screw threads, which is called threading. A tap is used to cut the female portion of the mating pair (e.g., a nut). A die is used to cut the male portion of the mating pair (e.g., a bolt). The process of cutting threads using a tap is called tapping, whereas the process using a die is called threading. Both tools can be used to clean up a thread, which is called chasing.

The three taps types are commonly used by most machinists:

1-Bottoming tap or plug tapThis tap has a continuous cutting edge with almost no taper .A bottoming tap is usually used to cut threads in a hole that has already been partially threaded using one of the more tapered types of tap; the tapered end of a bottoming tap is too short to successfully start into an unthreaded hole.2-Intermediate tap, second tap or plug tap :This tap has tapered cutting edges, which assist in aligning and starting the tap into an untapped hole. The number of tapered threads typically ranges from 3 to 5.Plug taps are the most commonly used type of tap.3-Taper tap :Has a more pronounced taper to the cutting edges. This has a very gradual cutting action that is less aggressive than that of the plug tap. Tapping may either be achieved by hand tapping by using a set of taps first tap, second tap & final (finish) tap or using a machine to do the tapping, such as a lathe, radial drilling machine, pillar type drill machine, vertical milling machines. Machine tapping is faster, and generally more accurate because human error is eliminated. Common reasons for tap breakage are:

Tap-related problems: Wearing of tap cannot be easily quantified (use of worn-out taps) Use of tap with improper tap geometry for a particular application. Use of non-standard or inferior quality taps. Clogging withchips. Mismatch of machines feed and tap feed may cause the tap to break in tension or compressions. Misalignment between tap and hole. Use of improper and/or insufficient cutting lubricant. Improper or zero float for use with screw machines (recommended feed .1 slower to establish float for 40 tpi or higher and .15 slower for 40 tpi or finer) Improper spindle speed.

In order to overcome these problems, special tool holders are required to minimize the chances of tap breakage during tapping. Various tool holders may be used for tapping depending on the requirements of the user.2.1.3: Activities carried out: Grinding and finishingGrinding

Grinding is considered to be a finishing process or finishing operation having many different applications in the machine tool industry. Grinding covers a wide range of finishing and machining tasks as follows. Abrade hard materials Improve surface finish Tighten the tolerance on cylindrical or flat surfaces by removing a small amount of material Reshaping cutting tools Surface grinding of mold sections

For material removal, the method used in grinding is called abrasion.in other words, in grinding, an abrasive material rubs against the metal part and clears or removes tiny pieces of material. Grinding is necessary for the following reasons: The material is too hard to be machined economically. If the surface is adequately supported, grinding can produce flatness tolerances of less than 0.0025mm on a 127 x 127 mm steel surface. Machine removes excessive material. Grinding should be used when size tolerance specifications are beyond the capability of turning. It is also applied if the requirements of surface finish are too tight for hard turning.

Grinding can be various types, like as follows: Surface grinding Centered grinding Center less grinding Contour grindingSurface grinding: This is perhaps the most fundamental of operation. Surface grinding is the process of providing precision ground surface either to a critical size or for the surface finish.Centered grinding: In this type of grinding, the grinding is performed at the center. There are two types of centered grinding. OD and ID grinding.Contour grinding: In case of contour grinding, the chopping function is used to grind the side face of a work piece.

Grinding wheels

Fig 2.10: Grinding wheelsFig 2.11: Wheel specifications

ANSI Standard Marking System1. Type of grain material an abrasive wheel uses2. The grit (or size) of the abrasive particles in the wheel.3. The overall hardness of the wheel.4. The type of bonding material used.This is the syntax for the ANSI marking system:[Grain material] [Grit] [Hardness] - [Bond Material]

Example: C24S-BF is a name for a common type os masonry grinding wheel. C - Wheels grain material is silicon Carbide 24 - Grit of the wheel on the coarse side S - Medium/Hard BR Bonding material is Resinoid ReinforcedGrain MaterialGrit Hardness

A=Aluminum Oxide 16=Very Coarse A=Extremely Soft

C=Silicon Carbide 30=Coarse P=Soft

CG=Ceramic 60=Medium S=Medium/Hard

ZA=Zirconia Aluminum 80=Fine T=Hard

ZAC=Zirconia Silicon Carbide 120=Very Fine Z=Extremely Hard

The abrasive grains in cutting and grinding wheels have to be held together by some kind of material, a bonding material. There are several varieties of bonding materials and bonding methods, including fiberglass mesh reinforcement.

2.1.4: Activities carried out: Lathe machineA lathe is a machine tool which rotates the work piece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the work piece to create an object which has symmetry about an axis of rotation.A lathe may or may not have legs which sit on the floor and elevate the lathe bed to a working height. At one end of the bed (almost always the left, as the operator faces the lathe) is a headstock. The headstock contains high-precision spinning bearings. Rotating within the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle. Spindles are powered, and impart motion to the workpiece.

In most modern lathes the spindle is driven by an integral electric motor, often either in the headstock, to the left of the headstock, or beneath the headstock, concealed in the stand.In addition to the spindle and its bearings, the headstock often contains parts to convert the motor speed into various spindle speeds.

Fig 2.12: Lathe machine parts

Metalworking lathes have a carriage (comprising a saddle and apron) topped with a cross-slide, which is a flat piece that sits crosswise on the bed, and can be cranked at right angles to the bed. Sitting atop the cross slide is usually another slide called a compound rest, which provides 2 additional axes of motion, rotary and linear. Atop that sits a toolpost, which holds a cutting tool which removes material from the workpiece. There may or may not be a lead screw, which moves the cross-slide along the bed.A workpiece may be bolted or screwed to a faceplate, a large, flat disk that mounts to the spindle. Faceplate dogs may be used to secure the work to the faceplate or the workpiece may be mounted on a mandrel, or circular work clamped in a three- or four-jaw chuck which mount directly to the spindle. In precision work cylindrical workpieces are usually held in a collet inserted into the spindle and secured either by a draw-bar, or by a collet closing cap on the spindle. Suitable collets may also be used to mount square or hexagonal workpieces.A soft dead center is used in the headstock spindle as the work rotates with the center. Because the center is soft it can be trued in place before use. The included angle is 60. Traditionally, a hard dead center is used together with suitable lubricant in the tailstock to support the workpiece.A circular metal plate with even spaced holes around the periphery, mounted to the spindle, is called an "index plate". It can be used to rotate the spindle to a precise angle, then lock it in place, facilitating repeated auxiliary operations done to the workpiece. Other accessories, including items such as taper turning attachments, knurling tools, vertical slides, fixed and traveling steadies, etc., increase the versatility of a lathe and the range of work it may perform.When a workpiece is fixed between the headstock and the tail-stock, it is said to be "between centers". When a workpiece is supported at both ends, it is more stable, and more force may be applied to the workpiece, via tools, at a right angle to the axis of rotation, without fear that the workpiece may break loose.When a workpiece is fixed only to the spindle at the headstock end, the work is said to be "face work". When a workpiece is supported in this manner, less force may be applied to the workpiece, via tools, at a right angle to the axis of rotation, lest the workpiece rip free. Thus, most work must be done axially, towards the headstock, or at right angles, but gently.

2.1.5: Activities carried out: Milling machine

Milling is the machining process of using rotary cutters to remove material from a workpiece feeding in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.The milling cutter is a rotary cutting tool, often with multiple cutting points

Fig 2.13: Milling machine

As the milling cutter enters the workpiece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the workpiece with each pass.Milling machines are basically classified as vertical or horizontal. These machines are also classified as knee-type, ram-type, manufacturing or bed type and planer-type.Milling cutters are usually made of high-speed steel and are available in a great variety of shapes and sizes for various purposes. The teeth of milling cutters may be made for right-hand or left hand rotation and with either right-hand or left-hand helix.

Fig 2.14: Milling cutterMilling types:

End milling:End mills are those tools which have cutting teeth at one end, as well as on the sides. They are usually made from high speed steel or cemented carbide, and have one or more flutes. They are the most common tool used in a vertical mill.Side-and-face cutter:The side-and-face cutter is designed with cutting teeth on its side as well as its circumference. They are made in varying diameters and widths depending on the application. The teeth on the side allow the cutter to make unbalanced cuts without deflecting the cutter as would happen with a slitting saw or slot cutter (no side teeth).Slot Mill:Slot drills are center-cutting end mills, generally two- (sometimes three- or four-) fluted cutters that are capable of drilling straight down into the material and then moving laterally to cut a slot. Slot drills are so named for their use in cutting keyway slots. The term slot drill is usually assumed to mean a two-fluted, flat-bottomed end mill if no other information is given.Ball nose cutter:Ball nose cutters are similar to slot drills, but the end of the cutters are hemispherical. They are ideal for machining 3-dimensional contoured shapes in machining centers, for example in moulds and dies. They are also used to add a radius between perpendicular faces to reduce stress concentrations.

Arbors:

Fig 2.15: Arbor

Milling machine arbors are made in various lengths and in standard diameters of 7/8, 1/2 , 1/4, 1 and1 inch. The shank is made to fit the taper hole in the spindle while the other end is threaded.Milling cutters that contain their own straight or tapered threaded portion to provide alignment and support for tool shanks are mounted to the spindle with collets, spindle adapters, and quick-change tooling which adapt the cutter shank to the spindle.

Collets:

A collet is a form of a sleeve bushing for reducing the size of the hole in the milling machine spindle so that the small shank tools can be fitted into large spindle recesses

Figure 2.16: Collets

Spindle Adapters:

A spindle adapter is a form of a collet having a standardized spindle end. They are available in a wide variety of sizes to accept cutters that cannot be mounted on arbors.

Fig 2.17: Adapters

2.2: Experiences obtained in automation field: 2.2.1: Pneumatics: Pneumatics basically is operating a machine or a tool using compressed air and the air pressure is significant. Some of the advantages of using a Pneumatic system:

High effectivenessThere is an unlimited supply of air in our atmosphere to produce compressed air.Moreover, the use of compressed air is not restricted by distance, as it can easily be transported through pipes High durability and reliabilityPneumatic components are extremely durable and can not be damaged easily. Compared toelectromotive components, pneumatic components are more durable and reliable. Simple designThe designs of pneumatic components are relatively simple. They are thus more suitable for use in simple automatic control systems. High adaptability to harsh environmentCompared to the elements of other systems, compressed air is less affected by hightemperature, dust, corrosion, etc. SafetyPneumatic systems are safer than electromotive systems because they can work in inflammable environment without causing fire or explosion. Easy selection of speed and pressureThe pressure and the volume of air can easily be adjusted by a pressure regulator. Environmental friendlyThe operation of pneumatic systems do not produce pollutants. Therefore, pneumatic systems can work in environments that demand high level of cleanliness. EconomicalAs pneumatic components are not expensive, the costs of pneumatic systems are quite low.The cost of repair is significantly lower than that of other systems.

Although pneumatic systems possess a lot of advantages, they are also subject to manylimitations. Some of them are: Relatively low accuracyAs pneumatic systems are powered by the force provided by compressed air, their operation is subject to the volume of the compressed air. As the volume of air may change when compressed or heated. Low loadingAs the cylinders of pneumatic components are not very large, a pneumatic system cannot drive loads that are too heavy. Processing required before useCompressed air must be processed before use to ensure the absence of water vapour or dust. Otherwise, the moving parts of the pneumatic components may wear out quickly due to friction. Uneven moving speedAs air can easily be compressed, the moving speeds of the pistons are relatively uneven. NoiseNoise will be produced when compressed air is released from the pneumatic components.

2.2.1.1: Main pneumatic components:

Pneumatic components can be divided into two categories:1. Components that produce and transport compressed air.2. Components that consume compressed air.

All main pneumatic components can be represented by simple pneumatic symbols. Eachsymbol shows only the function of the component it represents, but not its structure. Pneumatic symbols can be combined to form pneumatic diagrams. A pneumatic diagram describes the relations between each pneumatic component, that is, the design of the system.Components that produce and transport compressed air:

Examples of components that produce and transport compressed air include compressors and pressure regulating components.Compressor:

Fig 2.18: Pneumatic compressorCompressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. A compressor can compress air to the required pressures. It can convert the mechanical energy from motors and engines into the potential energy in compressed air. A single central compressor can supply various pneumatic components with compressed air, which is transported through pipes from the cylinder to the pneumatic components. Compressors can be divided into two classes: reciprocating and rotary.

A reciprocating compressor or piston compressor is

Fig 2.19: reciprocating compressora positive-displacement compressor that uses pistons driven by a crankshaft to deliver gases at high pressure. So it is used to provide compressed air for the automation applications. The main advantages of the reciprocating compressor are that it can achieve high pressure ratio. The intake air enters the suction manifold, and then flows into the compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a crankshaft. After that compressed air is discharged. This type of compressor are used for oil refineries, gas Dynamic Displacement pipelines, chemical plants, natural gas processing plants and refrigeration plants. The rotary vane compressor employs a series of rotating vanes or blades, which are installed equidistant around the periphery of a slotted rotor. The rotor is mounted eccentrically in a steel cylinder so that the rotor nearly touches the cylinder wall on one side, the two being separated only by an oil film at this point. Directly opposite this point the clearance between the rotor and the cylinder wall is maximum. Heads or end plates are installed on the ends of the cylinder to seal the cylinder and to secure the rotor shaft. The vanes move back and forth radially in the rotor slots as they follow the contour of the cylinder wall when the rotor is rotating. The vanes are held firmly against the cylinder wall by action of the centrifugal force developed by the rotating rotor. In some instances the blades are spring loaded to obtain a more positive seal against the cylinder wall.

The suction vapor drawn into the cylinder through suction ports in the cylinder wall is entrapped between adjacent rotating vanes. The vapor is compressed as the vanes rotate from the point of maximum rotor clearance to the point of minimum rotor clearance. The compressed vapor is discharged from the cylinder through ports located in the cylinder wall near the point of minimum rotor clearance.

Fig 2.20: vane type rotary compressor

The rotary vane compressor does not have a sump to contain the oil reserve. The oil is therefore extracted from the discharge gas by means of an oil separator (described later in the series) and continually delivered in a controlled manner to the internal surface of the rotor housing to perform essential lubrication. Some models are now constructed within a body that has an oil reservoir adjacent to the compressor to simplify oil management and to improve the security of lubrication.

Pressure regulating component:

Fig 2.21: Service unitPressure regulating components are formed by various components, each of which has its own pneumatic symbol. Individual functions are filtering, regulating and lubricating. This is achieved though the service unit or Filter Regulator Lubricating (FRL) which is connected upstream of the pneumatic systems. Filter regulator lubricator are being used in both hydraulic and pneumatic system in order to minimize dust particle, moisture, abrasive materials from the system. The air quality is measured in classes according to ISO 8573-1 standard .It considers the three types of contaminants that could affect pneumatic equipment life: Quantity of water particles dissolved in the air, Quantity of oil particles dissolved in the air, and Quantity of solid particles in the air.Basic components of FRL unit are pressure regulator, pressure gauge, dust filter, condensate drain, lubricator.

(i) Filter can remove impurities from compressed air before it is fed to the pneumaticcomponents.(ii) Pressure regulator to stabilise the pressure and regulate the operation of pneumaticcomponents(iii) Lubricator To provide lubrication for pneumatic components

Components that consume compressed air:

Examples of components that consume compressed air include cylinders (execution components), directional control valves and assistant valves.

Cylinders (execution components):Pneumatic execution components provide rectilinear or rotary movement. Examples ofpneumatic execution components include cylinder pistons, pneumatic motors, etc. Rectilinear motion is produced by cylinder pistons, while pneumatic motors provide continuous rotations. There are many kinds of cylinders, such as single acting cylinders and double acting cylinders.

Single acting cylinders:Single acting cylinder is a linear actuator which produces work in only one direction. Therefore piston is returned to the initial position by a spring. Single acting cylinders are used in applications such as clamping, stamping, ejecting, lifting, feeding etc.

Fig 2.22: Cross section of Single acting cylinder

Double acting cylinders:Double-acting cylinders are cylinders which producing work in two directions. They have two ports to allow air in, one for outstroke and one for in stroke. Stroke length for this design is not limited. However the piston rod is more vulnerable to buckling and bending. Major difference between single acting and double acting, there is not spring in double acting cylinder to return the piston. Because machine can brake under fatigue failure end cushioning are used to take a smooth movement without a shocked movement of the cylinder mounted parts.

Fig 2.23: Cross section of a double acting cylinder

Gripper:

Fig 2.24: GrippersA pneumatic gripper is a specific type of pneumatic actuator that typically involves either parallel or angular motion of surfaces. The gripper can be used as part of a "pick and place" system that will allow a component to be picked up and placed somewhere else as part of a manufacturing system. Some grippers act directly on the object they are gripping based on the force of the air pressure supplied to the gripper, while others will use a mechanism such as a gear or toggle to leverage the amount of force applied to the object being gripped. Grippers are frequently added to industrial robots in order to allow the robot to interact with other objects.

Directional control valve:

Directional control valves ensure the flow of air between air ports by opening, closing andswitching their internal connections. Their classification is determined by the number of ports, the number of switching positions, the normal position of the valve and its method of operation. Common types of directional control valves include 2/2, 3/2, 5/2, etc. The first number represents the number of ports; the second number represents the number of positions. 2/2 Directional control valve:The structure of a 2/2 directional control valve is very simple. It uses the thrust from thespring to open and close the valve. The control valve can be driven manually or mechanically, and restored to its original position by the spring. Flow Path Open Flow Path Close

Fig 2.25: 2/2 Directional control valve 3/2 Directional control valveA 3/2 directional control valve can be used to control a single acting cylinder. The open valves in the middle will close until P and A are connected together. Then another valve will open the sealed base between A and R (Ex). The valves can be driven manually, mechanically, electrically or pneumatically. 3/2 directional control valves can further be divided into two classes: Normally open type (N.O.) and normally closed type (N.C.)

Fig 2.26: 2/2 Directional control valve

5/2 Directional control valveWhen a pressure pulse is input into the pressure control port P, the spool will move to the left, connecting inlet P and work passage B. Work passage A will then make a release of air through R1 and R2. The directional valves will remain in this operational position until signals of the contrary are received. Therefore, this type of directional control valves is said to have the function of memory.

Fig 2.27: 5/2 Directional control valve

Pushing connectors in Pneumatics:

Fig 2.28: Parts of a pushing connectorIn Pneumatic systems, Pushing connectors are used to connect Pneumatic tubes together or with some another device. There are many type of them in many sizes. Normally they include lock claws to fit the tubes with the connectors, until press the release sleeve. So it shouldnt be Never touched the release sleeve of one-touch fittings when they are pressurized. It may cause tube separation, resulting in potentially dangerous situations. There are many type of pushing connectors in the industry as can be used in various purposes.

Male connector Female connector Triple Branch Branch Tee

Union straight Union straight reducer Union Elbow Union Elbow reducer

Union Tee Union Y Union Tee Reducer Union Y reducer

Fig 2.29: Types of pushing connectors2.2.2: Components used in industrial automation:2.2.2.1: PLC (Programmable logic Controller):Mechatronics is the latest trend in technology which is an integration of mechanical, electronics and computer engineering. Automation technology is the technical part of the Mechatronics.

Industrial automation consist of five basic components: Actuators (Pneumatic, Hydraulic, Electrical) Sensors (Binary, Analog.) Processors (PLC,IPC, microcontrollers, Relays) Network (Digital cables, Ethernet, profiBUS) Software (Human-Machine interface, Controller programming)

Advantages of using PLCs as processors in automated system: Greater flexibility and reliability. Easy debugging as error detection programs are available. Low power consumption and space requirement. Less maintenance due to no moving parts. No special programming skills required by maintenance personnel.

Types of PLCs: Depending on the way of connecting input and output modules to the central control unit.

Fig 2.31: Compact PLCFig 2.30: Modular PLC

The PLC operates internally in a way very similar to computers: The states of the input devices are continuously monitored and copied from the input module into input RAM memory area. The CPU then executes the control program stored in the program stored in the program memory area. Depending on the program and the states of the inputs, the output states of the relevant output devices are then written into the output RAM memory area. At the end of each execution cycle, data in output RAM area are then copied to the output RAM area are then copied to the output modules. After each execution new cycle begins.

Programming of a PLC:

Control programs must be systematically designed, well-structured and fully and fully documented in order to be as; error free, low-maintenance, cost effective as possible.Some of the Programming languages:1. Ladder diagram (LD): A graphic programming language derived from the circuit diagram of directly wired relay controls.

2. Function Block Diagram (FBD): This originates from the logic diagram for the design of electronic circuits.

3. Instruction list (IL): An assembler type language characterized by a simple machine model.

Industrial and commercial environments are being widely used PLC in present time. PLC can be found in almost any manufacturing facility. There are several manufacturers of PLCs. Each brands have unique programing method, but basically all PLCs hardware structures and programming concepts are very similar .There are lot of different PLC brands, famous brands can be mentioned as following Allen Bradley PLC GE Fanuc PLC Horner electric PLC Siemens PLC Array PLC

Every PLC consist of following component Central processing unit (CPU) Memory Inputs Output modules Power supply Programming Terminal

Connection between above mentioned components can be demonstrated using following figure.

Fig 2.32: Connection among PLC components

Central processing unit of PLC:

PLC has a central processing unit like other computerized devices. It is the brain of the PLC It is controlled by operating system software The operating system program is a supervisory programs that are loaded and stored permanently in the PLCs memory by PLC programmer .CPU does following operations Updating inputs outputs ,using inputs status it energizes or de energizes its output Performing logic and arithmetic operations Communicating with memory ,Programed data are stored in memory .So CPU can read or change the content of memory locations Scanning application program Communicating with a programing terminal

Fig 2.33: Central processing unit

Memory: Memory is the most important component that stores information, programs, and data in a PLC. There are two process that are being done using memory .The process of putting new information into a memory location is called writing. The process of retrieving information from a memory location is called reading. There two common types of memory used in PLCs: Read Only Memory (ROM) and Random Access Memory (RAM). A ROM location can be read, but it cannot be written. ROM is used to store programs and data that should not be altered. Because of that reason the PLCs operating programs are stored in ROM.A RAM location can be read or written. Therefore the information stored in a RAM location can changed. Ladder logic programs are stored in RAM, programing langue may be different with the PLC brands. When a new ladder logic program is loaded into a PLCs memory, the old program that was stored in the same locations is over-written and essentially erased. The memory capacities of PLCs can vary. Memory capacities are often expressed in terms of kilo-bytes (K). One byte is a group of 8 bits. One bit is a memory location that may store one binary number that has the value of either 1 or 0. (Binary numbers are addressed in Module 2). 1K memory means that there are 1024 bytes of RAM. 16K memory means there are 16384 bytes of RAM.

Input modules and output modules:A PLC takes information from inputs and makes decisions to energize or de-energize outputs. The decisions are made based on the statuses of inputs and outputs and the ladder logic program that is being executed. The input signal can be given to the PLC by using pushbuttons, limit switches, relay contacts, photo sensors, proximity switches, temperature sensors, and the like. These input devices can be AC (alternating current) or DC (direct current). The input voltages can be high or low. The input signals can be digital or analog. Differing inputs require different input modules. An input module provides an interface between input devices and a PLCs CPU, which uses only a low DC voltage. The input modules function is to convert the input signals to DC voltages that are acceptable to the CPU. Standard discrete input modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V DC, 220 V DC, and transistor-transistor logic (TTL) level.

The devices controlled by a PLC include relays, alarms, solenoids, fans, lights, and motor starters. These devices may require different levels of AC or DC voltages. Since the signals processed in a PLC are low DC voltages, it is the function of the output module to convert PLC control signals to the voltages required by the controlled circuits or devices. Standard discrete output modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V DC, 220 V DC, and TTL level.

Power supply: Standard commercial AC power lines are being used to power the PLC. But many PLC components are utilizing 5V or another low voltage of DC power. Those components are CPU and memory. The PLC power supply converts AC power into DC power to support those components of the PLC.

Programming Terminal:A PLC requires a programming terminal and programming software for operation. The programming terminal is used for programming the PLC and monitoring the PLCs operation. It may also download a ladder logic program (the sending of a program from the programming terminal to the PLC) or upload a ladder logic program (the sending of a program from the PLC to the programming terminal).

Programing device:Generally personal computers are used to program the PLC. Working software allows users to modify, store, troubleshoot the program. Personal computers communicate with PLC using processor via a serial or parallel data communications link Hand-held unit are often used for modifying, troubleshooting or transferring programs to multiple machines on the factory floor.

2.2.2.2: Relays:A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal, or where several circuits must be controlled by one signal. There are many functions which are being used relays, those things can be mentioned as following Relays are used where it is necessary to control a circuit by a low-power signal .Moreover it can be used to take different voltages level where several circuits must be controlled by one signal ,it is called multiple switching process Fig 2.34: RelayRelays are used to take different control path (separation of different load circuits for multi pole relays ) It is used for logic function and interlocking

Easy maintenance is main advantage of relays. Relays are mainly made for two basic operations. One is low voltage application and the other is high voltage. For low voltage applications, more preference will be given to reduce the noise of the whole circuit. For high voltage applications, they are mainly designed to reduce a phenomenon called arcing.There are many applications for relays: laboratory instrument, telecommunication systems, computer interfaces, domestic appliances, air conditioning and heating ,automotive electrics, traffic control ,light control ,electric power control ,control of motor and solenoid. Relays act considerable part in control and automation engineering field. There are only four main parts in a relay. They have been mentioned below Electromagnet Movable Armature Switch point contacts Spring

Fig 2.35: Relay working principle

When a voltage is applied to the relay coil, then it causes to create a electromagnet field .That created electromagnet field causes to attract the armature to the coil core .then armatures the relay contacts, either closing or opening them, it is depending on the design of the relay. After that return spring return the armature to the initial position when the current to the coil is interrupted .That return force is mainly provided by two factors. They are the spring and also gravity.2.2.2.3: Timers:

Fig 2.36: Multi range TimerA timer is a specialized type of clock for measuring time intervals. In automation industry timers are being used to preform different tasks, it is depending on the application. There are two types of timers, a timer which counts upwards from zero for measuring elapsed time is often called a stopwatch, a device which counts down from a specified time interval is more usually called a timer. Some timers sound an audible indication that the time interval has expired. Time switches that timing mechanisms which activate a switch, are sometimes called timers.Timers and time switches may be free-standing or incorporated into appliances and machines. Their operating mechanism may be mechanical, electromechanical or purely electronic (counting cycles of an electronic oscillator). Timing functionality can also be provided by software, typically in a computer. Basically there are four types of timers that can be found in automation industry .they are mentioned below Mechanical timers Electromechanical timers Electronic timers Computer timers Mechanical timers:

Mechanically operated timers are called Mechanical timers, they use mechanical clockwork to measure time. Mechanical timers are typically set by turning a dial to the time interval desired turning the dial stores energy in a mainspring to run the mechanism. They function similarly to a mechanical alarm clock, the energy in the mainspring causes a balance wheel to rotate back and forth. Electromechanical timers:Short-period bimetallic electromechanical timers use a thermal mechanism, with a metal finger made of strips of two metals with different rates of thermal expansion sandwiched together steel and bronze are commonly used materials. An electric current flowing through this finger causes heating of the metals, one side expands less than the other, and an electrical contact on the end of the finger moves away from or towards an electrical switch contact. Electronic timers:Electronic timers are essentially quartz clocks with special electronics, and can achieve higher precision than mechanical timers. Electronic timers have digital electronics, but may have an analog or digital display. Integrated circuits have made digital logic so inexpensive that an electronic timer is now less expensive than many mechanical and electromechanical timers, because of that reason electronic switches are being used for many application in automation industry. .Many timers are now implemented in software. Modern controllers use a programmable logic controller rather than a box full of electromechanical parts. The logic is usually designed as if it were relays, using a special computer language called ladder logic. In PLCs, timers are usually simulated by the software built into the controller. Each timer is just an entry in a table maintained by the software. So electronic timer most useful device that have been invented mainly for use of automation industry 2.2.2.4: sensors:A sensor is a converter that measures a physical quantity and converts it into a signal which can be read by an observer or by an (today mostly electronic) instrument. There are three color wires in a common sensor and the brown and blue wires are for power supply. The black wire is for the output signal. When we use sensors with normal electrical equipment, the sensor output should not connect to the equipment directly, the high current can damage to the sensor. It should be connect through a relay. But when the sensors use with the PLC the sensor output can directly connect to the PLC. Some sensors give the (+) outputs which are called PNP type and some sensors give the (-) outputs which are called NPN type.. Some are normally close and some sensors are normally open. There are some four wire sensors as normally open and close together. Relays can be used convert normally closed into normally open.

Fig 2.37: NPN and PNP outputs

There are different type of sensors those sensors are mentioned below Proximity sensor Temperature sensor IR sensor UV sensor Touch sensorA proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. There are several types of proximity sensors due to the sensing target: Capacitive, photoelectric, inductive etc.

Capacitive Sensors:Capacitive sensors detect anything (metal or non-metal) that is conductive or has a dielectric different from that of air. Capacitive sensors are constructed from many different media, such as copper, Indium tin oxide (ITO) and printed ink. Size and spacing of the capacitive sensor are both very important to the sensor's performance.

Fig 2.38: Method in Capacitive Sensors

Photoelectric Sensors:

A photoelectric sensor, or photo eye, is a device used to detect the distance, absence, or presence of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are used extensively in industrial manufacturing. There are three different functional types: opposed (through beam), retro-reflective, and proximity-sensing (diffused). There are three different functional types: opposed (through beam), retro-reflective, and proximity-sensing (diffused).

Fig 2.39: Photoelectric sensors

Inductive sensors:

Fig 2.40: An inductive sensorAn inductive sensor is an electronic proximity sensor, which detects only metallic objects without touching them. The sensor consists of an induction loop. Electric current generates a magnetic field, which collapses generating a current that falls asymptotically toward zero from its initial level when the input electricity ceases. The inductance of the loop changes according to the material inside it and since metals are much more effective inductors than other materials the presence of metal increases the current flowing through the loop. This change can be detected by sensing circuitry, which can signal to some other device whenever metal is detected.

Ultrasonic sensor:

Ultrasonic sensors (also known as transceivers when they both send and receive, but more generally called transducers) work on a principle similar to radar or sonar which evaluate attributes of a target by interpreting the echoes from radio or sound waves respectively. Ultrasonic sensors generate high frequency sound waves and evaluate the echo which is received back by the sensor. Sensors calculate the time interval between sending the signal and receiving the echo to determine the distance to an object. This technology can be used for measuring wind speed and direction (anemometer), tank or channel level, and speed through air or water. To measure tank or channel level, the sensor measures the distance to the surface of the fluid.

2.3: Air Conditioning and Ventilation System installed

Air conditioning is the process of altering the properties of air to more favorable conditions. This type of system is designed to change the air temperature and humidity within an area. The cooling is done by using a simple refrigeration cycle. Brandix Company also have Air conditioning systems to have more confortable conditions to the workers and customers also.The Air Conditioning and Ventilation System installed at Brandix casualwear (pvt) Ltd. At Ekala consist of the following:Air cooled water system serves the product development area ground and mezzanine floors and the cutting section.The Mechanical ventilation system serves the raw material stores area.The Chilled water Air Conditioning system consists of (03) Nos. Carrier Air cooled chillers, (11)Nos. Carrier Air handling units( AHU rooms) complete with spiral ducted type air distribution system. Mechanical ventilation system is completed with (10) Nos. fans for cutting section.A/C system commissioned and put to beneficial use on 11.07.2005All the system has installed by the Built Mech Services (Pvt) Ltd., Narahenpita, Colombo 05.And all the maintenance are doing by Maintenance & Service Division of that company.

Table 2.1: Temperature Maintaining at Occupancy Areas.AreaTemp.(C)

Cutting Section1) Cutting Area2) Office Cubicles3) Medical Center Product Development4) Ground level5) Mezzanine Level242324

2324

There are several types of Air Conditioning systems. Window Air conditioning Split Air Conditioning Package Air Conditioning2.3.1: Package Air Conditioning These types of Air Conditionings are used to cool more than two rooms or a large space. There are two types because of the cooling method of Condenser: Air cooled A/C system Water cooled A/C systemIn the Air cooled condenser packages, the condenser is cooled by the atmospheric air. This is the most common method used in Brandix Casualwear, Ekala. There is an outdoor unit that comprises of the important components like compressors, condenser, and in some cases the expansion valve also. The outdoor unit is kept on an open place where the free air flow is available.

Air handling Units (AHU)

An Air handling unit or an air handler is a device used to condition and circulate, air as a part of heating, ventilating and air conditioning system (HVAC). HVAC is the technology of indoor and vehicular environmental comfort. AHUs are usually large metal boxes with blowers, heating or cooling elements, filter racks or chambers, sound attenuators and dampers. AHU connects to the duct system to distribute the conditioned air through the building and returns it to the AHU. Sometime returning air was admitted from the room space. In Brandix cacualwear also used this method. A/C system at Brandix, Ekala doesnt have ducts to return air to the AHU. Air is sucked from the spaces near by the AHU room.

Figure 2.41: HVAC ducts

An Air handling unit located at cutting section at Brandix has following specifications.

Table 2.2: Air Handling UnitsLocationCutting section

DesignationAHU-1

MakeCarrier

Model No:39G1722

Serial No:MAH 05501539

Motor (K.W.)11

Rated Voltage (V)400

Rated Current (A)21.3

Running Current (A)14

Air flow rate (CFM)15,000

Supply air Temperature (0C)13

Return air Temperature (0C)26

Chiller

A chiller is a machine that removes heat from liquid (Called Chilled water). Chilled water is some type of cooled water. Chilled water is circulated through a heat exchanger. In the Brandix at Ekala some Carrier brand air cooled chillers are used.Where chiller capacities greater than 200 tons (703kW) are required, or where stand-by capability is desired, chillers may be installed in parallel. Units should be equal size to ensure balanced fluid flows.

Figure 2.42: Air cooled chillerWhere a large temperature drop (>250F) is desired, chillers may be installed in series.3m separation between units is required for air flow, and a some distance (1.8 m) is required from units to obstructions.

Carrier Air cooled chillers used for Production development and cutting section in Brandix have following specification.

Model No : 30GBN-150Serial No : MCH 05130591Entering water temp. (Deg F) : 58.7Leaving water temp. (Deg F) : 44.2Running Capacity : 66%Saturated condensing temp. (Deg F) : 95.2Discharge pressure (Psig) : 187.4Suction Pressure (Psig) : 65Total Current (A) : 111Supply Voltage (V) : 387

Water pumps used to circulate chilled water in Brandix have following specifications.

Make : Monoflo-Din MasterModel No : DMT-80-320Serial No : 326Full load amps : 21.5AInlet pressure : 0 PsiOutlet pressure : 16Ps

Figure 2.43: Chilled water pumps

2.4: Introduction about projects done:

During training period I was able to participate and handle several projects. Meanwhile I was able to help in their other projects as well. By involving their project I could understand lot of things about manufacturing. Although I was there to train about control and automation, I was able to take idea about not only automation but also machining and electronic. In here I can mention major three projects that I could involve. Mini loop cutter machine Button wrapping machine Buzzer controller Garment surface grinder

2.4.1: Mini loop cutter machine:Mini loop cutter construction was a most important project for beginner of automation engineering which given during training at Brandix innovation center. Because of that project lot of information about automation equipment could be known. Machine was designed to cut loops of the trousers after taking initial commands. There are changeable knife up time and loop length in the program. Some electronic components were also used for the construction such as relays, Winston Bridge, capacitors, resistors, transformer etc.

Figure 2.44: Mini loop cutterThis is fully automated and controlled by an Array (ACD-12MCDC). Here the output rate is greater than the human labor. So it is used as a efficient and effective machine. First the outer bodies of the loop cutters are fabricated in the workshop. I could help to made some parts also. Then we did the wiring for it. First a step down transformer was used to reduce 230V into 24V and a bridge rectifier was used to convers 24VAC into DC. A capacitor was also used to make the current smoothed.A photoelectric sensor is used to indicate whether that the loop is present and then the loop is held over by the rotating wheel which came down. The wheel which hold the loop and the cutting blade are controlled by two solenoids. During this project time lot of work shop experiences were taken such as drilling, milling, polishing, lathing etc. When wiring the machine some action about electronic devices were observed. Table 7.1 Input and output of the mini loop cutterInputOutput

I0photo electric Sensor [Detect loop lie on the bed ]Q1Solenoid 1[Wheel down]

I1Push button [Emergency stop]Q2Solenoid 2[Cutting blade up and down]

I2Proximity sensor[Detect joint in loop]Q3Stepper motor driver

Figure 2.45: Solid work design of the Mini loop cutter

Figure 2.46: Electrical wiring of the mini loop cutter machine

We used the APB software for programming the ARRAY (ACD-12MCDC) PLC. The Array plc, we used had 8 inputs and 4 transistor type outputs. This was a very challenging project since we did not have experience or knowledge about PLC programming. The simulation option within the APB software helped us a great deal.

Figure 2.47: Programming of an Array for Mini loop cutters2.4.2: Garment Surface GrinderGarment surface grinder is a machine used to have a finishing of clothes. Using these machines shining or grounded surfaces can be obtained. One of this type machines was repaired in the Innovation center at Brandix Casualwear, Ekala. Then another two machines of this type were produced. At the first a list of the amounts of all the required materials and dimensions has to be taken. Then the existing machine was designed by using Solidworks.All the parts required for these two machines were fabricated in the workshop at Innovation center and new panel board has to be designed more much suitable than existing one.

Figure 2.48: Garment surface grinderThe panel board was designed by including 2-metal detective sensors, 4-Relays (24 VDC), a 24 VDC Timer, a contractor and a power supply unit. A motor, piston and a foot paddle also added.

Figure 2.49: Panel Board Circuit design of Surface Grinder

A LC1-D series AC contactor is used for the Garment surface grinder.Contactor is a type of relay that can handle the high power required to control an electric motor or other load directly. But they are not generally called relays. A contactor is controlled by a circuit which has a much lower power level than the switched circuit. Unlike general-purpose relays, contactors are designed to be directly connected to high-current load devices. Relays tend to be of lower capacity and are usually designed for both normally closed and normally open applications. Devices switching more than 15 amperes or in circuits rated more than a few kilowatts are usually called contactors. Contactors are usually normally open. So that power to the load is shut off when the coil inside in the contactor is de energized. Contactors are normally used to control electrical motors, lighting, heating, capacitor banks and thermal evaporators also.

Figure 2.50: LC1-D series contactor

Chapter 03: Management experience obtained during training:

Brandix Lanka is an internationally popular garment manufacturing company which is having many ISO standards. Therefore they have very good management system to maintain high quality garments and control such a big amount of labors. Therefore it is also a best place to acquire management training. They always work for a plan which has been taken management of the company. 5S management technics is being used inside the company in order to achieve their goals3.1: Bill of Material (BOM):A bill of Material (BOM) is a list of raw materials, sub-assemblies, intermediate assemblies, sub-components, components, parts and the quantities of each needed to manufacture an end product. A BOM can define products as they are designed (engineering bill of material), as they are ordered (sales bill of materials). The different types of BOMs depend on the business need and use for which they are intended.BOM are hierarchical in nature with the top level representing the finished product which may be a sub-assembly or a completed item.BOMs that describe the sub-assemblies are referred to as modular BOMs.A BOM can be displayed in the following formats: A single-level BOM that displays the assembly or sub-assembly with only one level of children. Thus it displays the components directly needed to make the assembly or sub-assembly. An indented BOM that displays the highest-level item closet to the left margin and components used in that item indented more to the right. Modular (Planning) BOM

Table 3.1: Table of Bill of MaterialsNoComponentDescriptionUnitQuantity

1.MS plate6mm (thickness)nos01

2.Anti-corrosive paintMetal primer-Zinc Phosphateliters03

3.Metal fillerApologygrams50

4.Hex boltGI 6mm*15mmnos08

5Hex nutGI 6mmnos08

6.Three core wire-meters03

7Plug top13Anos01

3.2: Labor hours planning:It is important to convert resources of produced good effectively (economically and efficiently).productivity is a measure of this transformation. Increase in productivity is a basic proposition for continuous economic growth in the modern word. Among various kinds of productivity labor productivity is usually considered of the utmost importance. In manufacturing industry a criterion called efficiency is often used. Efficiency is the capacity of performing a given task within a specified standard time. Raising the efficiency depends upon two factors:I. Subjective factors Workers qualities capability: Skills, Technical ability etc. Workers quantitative capability: Working effort, Increase of working hours.II. Objective factorsFactory automation, enhancing the work environments.So for both productivity and efficiency of labor to be increased proper allocation of tasks and targets is important.Table 3.2: Table for calculate time consumptionNoComponent/ TaskQuantity(nos)Time/ unit (min)Time(min)

01

02

03

Total time

Approximate working days required of one laborer

3.3: 5S managing concepts:5S is the name of a workplace organization method that uses a list of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. Transliterated or translated into English, they all start with the letter "S". The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order. It is a better way to manage not only a company but also life.

Fig 3.1: 5S concept

Sorting (Seiri):Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things per requirements and keeping them

Straightening or setting in order (Seiton):There should be a place for everything and everything should be in its place. The place for each item should be clearly labeled or demarcated. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible.

Sweeping or shining or cleanliness / systematic cleaning (Seiso):Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. This makes it easy to know what goes where and ensures that everything is where it belongs.

Standardizing (Seiketsu):Work practices should be consistent and standardized. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station

Sustaining the discipline or self-discipline (Shitsuke):

Maintain and review standards. Once the previous 4 S's have been established, they become the new way to operate. Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways.

Fig 3.2: Brandix workshop arranged using 5S

Brandix innovation center is a place where lots of technical innovations are done therefore inside the workshop.

Fig 3.3: Safety equipment

Some guidelines for safety have been mentioned below Use the technical methods in the works. Safety shoes, gloves, goggles, have to be worn when necessary. Keeping the workshops clean in an orderly manner. Maintaining a well-equipped First aid box at workshop. Provide a better working environment to the workers. Provide warnings, notices and special instructions wherever necessary. Use necessary equipment when it is required.

When considering about fire safety In Brandix casualwear there is a very sensitive fire alarm system when any fire is occurred. When the alarms are ringed everyone has to run to their positions. There are some firemen to check if all the workers come to safe places. Most of the time they do trials to train the employs for the real situation.

Fig 3.4: Fire exhauster chart

3.4: The Human Resources Management (HRM):The Human Resources Management (HRM) function includes a variety of activities, and key among them is deciding what staffing they need or hire employees to fill these needs, recruiting and training the best employees, ensuring they are high performers, dealing with performance issues, and ensuring your personnel and management practices conform to various regulations. Activities also include managing the approach to employee benefits and compensation, employee records and personnel policies. They should always ensure that employees are aware of personnel policies which conform to current regulations. Human Resource Management is a planned approach to managing people effectively for performance. HRM planning is the process by which managers ensure that they have the right number and right kinds of people in the right places, and at the right times, who are capable of effectively and efficiently performing assigned tasks. From this we can get long time benefits. Human resource planning must be integrated within the organizations strategic plans.

3.4: Training & developmentBrandix is Sri Lankas largest apparel exporter employing over 40,000 Associates directly, while generating indirect employment to an equivalent number. The Group is supported by over 38 integrated manufacturing facilities in Sri Lanka, India and Bangladesh.. So they have understood the importance of acquiring a talent pool with the desired skill sets to keep us at the forefront of their industry. In the fast changing industry of apparel, expertise and aptitudes must necessarily be in a state of flux to stay at the cutting edge. To this end, Brandix Training and Development constantly develops its broad purview of skills and talent development programs at various levels. Most training is directed at upgrading and improving an employees abilities or skills.Developmental program is a process designed to develop skills necessary for future work activities. Newly joined staff must be told the length of their probationary period, which varies with the requirements of each grade. If there are indications that staff is not suitable for confirmation, they must be counseled and then warned in writing if the problem persists. Confirmation is the step whereby a member of staff on probation is found suitable for the job and employed on permanent and personable terms.

3.5: Water management:Water purification is the process of removing undesirable chemicals, biological contaminants, suspended solids and gases from contaminated water. There is a water management plant which supply water for each and every tasks for the factory. Three tube wells are being used to supply water. There is a specified team to serve water managing. Tube well provided water they purify using standard method of chlorination.

Fig 3.5: Water supply system in Brandix, EkalaThey send chemical added water for filtering through a bended pipe system which can decrease head of the water. It is done to minimize the water pressure for better filtering. After filtering the water it sends to a tank. They have installed firing treatment line also to the plant. In this water supply plant they have used continuously timed chemical adding units to add chlorine and other chemical, pressure meters to detect pressures in some important places, submersible water pumps to pump tube well water to the plant.

Every one of Brandix associates has grasped a sense of ownership of their comprehensive policy on waste management. Inclusive systems continuously monitor and improve compliance with the Group's numerous certifications and standards. They have a very good waste water management system. Industrial Wastewater is characterized by its large volume, high temperature, high concentration of biodegradable organic matter and suspended solids, high alkalinity or acidity and by variations of flow.

Characteristics of wastewaters are measured in terms of Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD) and volatile suspended solids (VSS).Generally, pollutants take long time, may be thousands years, to be degraded naturally. Hence, those must be treated synthetically. Therefore, Industrial Wastewater treatment is an essential process. With the rising cost of land treatment, depletion of space, and concern over contamination of ground water, advanced technologies will have to take on a more significant role in treating industrial wastewater.

Fig 3.6: Waste water management in Brandix

Chapter 04: Summary and Conclusion :4.1: Summary:I selected Brandix Casualwear LTD, Ekala as my training institute, since Brandix is a well-known garment manufacturing company which has South Asias largest apparel group. Also Ekala factory has a Maintenance department and the innovation center.During the training period of three months I was able to get experience about some fabricating methods including: Lathe machine, Milling machine, Different types of saws, and welding, grinding also.

This exposure helped in understanding how a machine should be operated and maintained and how to choose the proper way of doing a task using a machine together with the knowledge of different types of tools required.

Also at the work shop I experienced the way of handling the technicians and other workers, how they allocate other resources like materials and machines by managing the optimum minimum cost. Arrangement of machines and stores in the shop floor also was an important issue at the work shop.

4.2: Conclusion:As a mechanical and Manufacturing Engineering undergraduate of Faculty of Engineering, for the three months of industrial training I selected Brandix Casualwear LTD, Ekala as my training place. I selected this particular company as it consists of a work shop and it gives knowledge n industrial automation including pneumatics, electro pneumatics, PLC (Programmable Logic Controller) etc.

Brandix Casualwear LTD has its design center and the work shop at Ekala. During my training period of three months, I could work at the work shop where fabrication works took place of the automated systems. So I could experience the work shop activities which I believe to be an essential requirement for a Mechanical and Manufacturing Engineer, when working in the field.

So it is a pleasure to mention that I could gather a lot of information to my knowledge of which I presented a brief description in this report during a period of three months at Brandix Casualwear LTD with the appreciable assistance of engineering professionals and other staff of both work shop and head office.

ContentsChapter 01: Introduction about establishment:11.1: About Brandix casualwear:11.2: Achievements of the company:21.3: Innovation Center at Brandix Casualware:3Chapter 02: Technical experiences obtained during training42.1: Experiences obtained related to workshop activities:42.1.1: Activities carried out: Welding42.1.2: Activities carried out: Drilling and tapping72.1.3: Activities carried out: Grinding and finishing102.1.4: Activities carried out: Lathe machine132.1.5: Activities carried out: Milling machine142.2: Experiences obtained in automation field:182.2.1: Pneumatics:182.2.2: Components used in industrial automation:27Mechanical timers:35Electromechanical timers:35Electronic timers:352.3: Air Conditioning and Ventilation System installed382.3.1: Package Air Conditioning392.4: Introduction about projects done:422.4.1: Mini loop cutter machine:422.4.2: Garment Surface Grinder45Chapter 03: Management experience obtained during training:473.1: Bill of Material (BOM):473.2: Labor hours planning:48Approximate working days required of one laborer493.3: 5S managing concepts:493.4: The Human Resources Management (HRM):523.4: Training & development533.5: Water management:53Chapter 04: Summary and Conclusion :554.1: Summary:554.2: Conclusion:56

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