Manufacturing of CFL & Tube Light

By:- Raj Kumar Gupta B.tech(EEE) 8th Sem Roll no-100210722457

Under the Supervision of SK Sagar (Manager ,HR)

SIX MONTH INDUSTRIAL TRAINING

CONTENTS

Introduction.Products.

A. CFL ( GENUINE,ESSENTIAL )B. TUBE LIGHT (DOMESTIC, INDUSTRIAL )

Filament. A. How to made filament ?

PHILIPS ELECTRONICS INDIA LTD (MOHALI )

Mohali Light Factory (MLF) was incorporated as Punjab Anand Lamps Industries Limited (PALI) in 1983 as a Joint Venture Company in Mohali, a town situated near Chandigarh by Koninklijke Philips Electronics N.V. Holland, Anand Group of Industries & Punjab State Industrial Development Corporation for manufacturing of fluorescent & incandescent lamps. Although it is a manufacturing center for Lamps for Philips India, yet it was run as a profit center having its separate entity till Dec. 2002. The company was managed by a team of Managers headed by the Managing Director who used to report functionally to Director & Sr. Vice President, Lighting, Philips India and administratively to the Board of Directors. However, over the years the Philips increased its share holding to 93%. It has now been merged with Philips India & renamed as Mohali Light Factory (MLF). It continues to be supply center for Philips India, Lighting and is now run as a cost center.

PRODUCTS

CFL

GENUINE

ESSENTIAL

Functional non-covered Energy saving lamp, with money saving high quality light and compact design. This lamp is small enough to fit neatly wherever you need extra bright light at home, enables easy replacement of most incandescent lamp all the way.

CFL - GENUINE

Compact energy saving lamp enables fitting neatly wherever extra brightness is needed.

Save your money with long life-time and high energy efficiency compare to incandescent lamp.

Flicker-free start & Fast run up.

BENEFITS

Long-Life and Energy saving alternative to Incandescent lamps.

Fast run-up.

Recommended ambient temperature range to ensure almost constant light output (>90%): between 0 and +50° C.

FEATURES

APPLICATIONDesigned for incandescent lamp replacement in consumer applications where the lamp is not directly visible, specially suitable for indoor applications in functional areas.

Enclosed fixtures required for outdoor applications.

Not suitable for use with dimmers or electronic gear.

CFL- ESSENTIAL The Essential range is a standard stick-shape compact fluorescent lamp, with the lowest purchase price. It is available in 8W, 14W, 18W and 23W, with lumen equivalence of 40W, 75W, 100W and 125W incandescent light bulb. It is available in both 220-240V and 120-127V and able to operate under a wide voltage range. It consumes up to 80% less energy than the incandescent light bulb and lasts for 3 years.

BENEFITS

Energy saving.

Fewer lamp replacements.

FEATURES U-shaped energy saving lamp.

High energy efficiency.

Long-life alternative to incandescent lamps.

APPLICATION The Essential range is widely used to replace incandescent light bulb at all kinds of general lighting applications.

It is not suitable for dimming and electronic devices.

LINEAR FLUORESCENT TUBE LIGHT

Philips T5s Model

fluorescent tube is a low pressure mercury vapour gas discharge lamp that uses fluorescence to produce visible light. An electric current in the gas excites mercury vapour which produces short-wave ultraviolet light that then causes a phosphor  coating on the inside of the bulb to glow. A fluorescent lamp converts electrical energy into useful light much more efficiently than incandescent lamp. The luminous efficiency of a fluorescent light bulb can exceed 100 lumens per watt.

USES OF L .F . T . L

Linear Fluorescent Lamps are widely used in hospitality and office spaces .

Shopping malls .

Industries.

WHAT IS FILAMENT ?

A tungsten filament in a low pressure mercury gas discharge lamp which emits electrons. To increase electron emission a white thermionic emission mix coating is applied, visible on the central portion of the coil. Typically made of a mixture of barium, strontium  and calcium oxides and other name is electromagnetic powder .

HOW TO MADE FILAMENT ? TMD (TUNGSTEN MATERIAL DROWING MACHINE) Parts of TMD Machine

1. Main Heater.2. Drum.3. Lubricant.4. Dies.

Per day 60 lacks filament wire drawing . DIES DIES

SIZES OF DIES

990µ–345µ (800° temp)345µ–164µ (800° temp)164µ–54µ (775° temp)54µ–23µ (720° temp)23µ–17µ (690° temp) 17µ–15µ (690° temp)

STEPS OF PROCESS OF MAKING A CFL

CUTTING

GLASS TUBE CUTTING MACHINEFirst starting is two typesof tubes used to make d/t. One is 11.4 diameter (mm)tube other is 9.00 diameter (mm) tube. Small diametertube is used to make genie lamps and big diameter One used to make essential lamps.

PROCESS

Manual loading of full length lead free tube.

Glass tube rising on conveyor.

Glass tube loading on horizontal cutting.Heating through burner.First cutting into 3 pieces with wet cutting wheel.

Heating through burner and then cut the glass tube.

BENDING

GLASS TUBE BENDING MACHINE This process uses bending machine to bend the tubes of required length. The input is straight tube and output is U shaped tubes

PROCESS

Manual loading of cut glass into hopper. Transfer to bed by drum.Preheating of glass tube with burner in two stages.Heating of glass tube with burners in four stages.Strengthening of glass tube with sodium dioxide by burner .Folding of glass tube and loading to turret head by jaws.Glass blow molding in u shape mould.Annealing of bent glass tube with burner.Cooling of bent tube with air

COATING

COATING MACHINECoating machine is used for coating process. In this process the tubes are coated with fluorescent powder .The fluorescent powder is a combination of phosphor (calcium phosphate aluminum oxide) and polyethylene oxide and dispersion agent.

PROCESSManual loading of bent glass.Automatic transfer of glass tubes to heads.Suspension dosing into bent glass tubes.Controlled drying at suspension in coated shell across 10 positional with hot air.Drying at suspension in coated shell across 32 positions with hot air.Drying of coated bent tubes at brushing and wiping area using burner.Automatic unloading of coated bent tubes with pneumatic across two pass.Powder weight, hot air temp, suspension viscosity check every 2 hrs.Suspension gravity checks each shift.Transfer of shell to brushing machine.

FUSION PROCESS

Fusion machine is used to fuse the two tubes in such a manner that they should be leak proof.

PROCESS

Manual bending of 4w in sealed tube towards upper side.Manual loading on chute provided on machine.Automatic loading of sealed glass tube on outer side.Height alignment from top of both glass tubes loaded previously.Preheating of fusion ends carried out with burner.Heating of concentrated area carried out.Blasting with nitrogen to produce holes at fusion end.Glazing at fusion holes.Kissing and stretching of both the tubes, to make hollow bridge.Cooling in ambient air.Leak checking.Unloading.