Detailed Project Report on ELECTRIC SWITCHES PLUGS, SOCKETS, UCB CABLE, LAMP HOLDER ETC.

Electrical switches are household consumables items. A switch is an electrical component that can break an electrical circuit, interrupting the current or diverting it from one conductor to another. When the switch is open, the electrical contacts do not touch and electricity cannot flow. When the switch is closed, however, the electrical contacts touch and electricity flows throughout the circuit. In almost every application, for residential, commercial or industrial use, switches are required to be installed. Electrical switches are used to perform all the electrical functions. From a fan to bulb, every electrical equipment we use in our day to day life is useless without a switch.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




ELECTRIC SWITCHES PLUGS, SOCKETS, UCB CABLE,
LAMP HOLDER ETC.
[EIRI/EDPR/4771] J.C.: 2991INR,2991US$

Electrical switches are household consumables items. A switch is an electrical
component that can break an electrical circuit, interrupting the current or
diverting it from one conductor to another. When the switch is open, the electrical
contacts do not touch and electricity cannot flow. When the switch is closed,
however, the electrical contacts touch and electricity flows throughout the circuit.
In almost every application, for residential, commercial or industrial use, switches
are required to be installed. Electrical switches are used to perform all the
electrical functions. From a fan to bulb, every electrical equipment we use in our
day to day life is useless without a switch.
The types of electrical switches
The different types of Electrical switches which are used for household as well as
commercial purposes.
One-way (single pole) Electrical switch:
It is one of the most common use switches. Generally, they are used for light,
fans, or other devices from a single location switch. Their simple function is ON
and OFF, This is something which is not in any other switch such as in three-way
and four-way. A one-way switch generally works as a brake switch. The two
terminals of the switch are connected when it is turned ON, and the contact
between the two is broken when the switch is turned OFF.

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CONTENTS

INTRODUCTION

THE TYPES OF ELECTRICAL SWITCHES

TWO-WAY (DOUBLE-POLE) ELECTRICAL SWITCH:

MOST OF THE BAKELITE ELECTRICAL FITTINGS CONSIST ESSENTIALLY OF THREE PARTS

MINIATURE SOCKETS

SUBMINIATURE SOCKETS

SMALL AND MEDIUM SOCKETS

OCTAL SOCKETS

USES AND APPLICATION

COMPOUNDING THE RAW MATERIALS:

CONTACTS:

EARTHING:-

RAW MATERIALS

PHENOL-FORMALDEHYDE RESINS:-

RAW MATERIAL SELECTION:-

BASED ON THE ABOVE CRITERION, TWO RESINS ARE MOST COMMONLY USED:-

DETAILS OF SOCKETS

HOLES OF ELECTRICAL SOCKETS

ELECTRICAL SOCKET MATERIALS

INSTALLING ELECTRICAL SOCKETS

MULTI STANDARD ELECTRICAL SOCKETS

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ELECTRICAL SOCKETS

ELECTRICAL SOCKETS

ELECTRICAL SOCKET MATERIALS

PROCESS FLOW SHEET FOR MANUFACTURING

COMPRESSION MOLDING TECHNIQUE

POWER AND PREFORMS

INSULATION

REQUIRED PRESSURES

HEATING

SETTING UP THE NEW MOLD

TEMPERATURE AND CURE

INSTALLING ELECTRICAL SOCKETS

MULTI STANDARD ELECTRICAL SOCKETS

CERTAIN DEVICES THAT ARE BEST FIT FOR USE IN THESE SOCKETS ARE:

POWER SOCKET

TYPES OF ELECTRICAL SOCKETS

MANUFACTURING PROCESS OF PLUGS

THE COVER

MANUFACTURING OF PLUG BODY AND BASE

FIGURE 1: PRODUCTION STEPS OF THE PLUG COVER AND BASE.

FIGURE 2: MOLDING PROCESS.

THE RESULTING PRODUCTS ARE SHOWN IN FIGURE 3 BELOW.

FIGURE 3: COVER AND BASE OF 3-PIN PLUG.

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COVER AND BASE OF 3 PIN PLUG

FIGURE 4: BODY CROSS SECTION.

PLUG PINS

THE PRODUCTION PROCESS INCLUDES:

FIGURE 5: PIN MANUFACTURING MACHINE.

SCREWS

FIGURE 6: SCREW SPECIFICATIONS.

STEPS IN USB CABLE MANUFACTURING

CONNECTORS:

CABLE MANUFACTURING:

CABLE CUTTING:

SOLDERING:

INJECTION MOULDING (INTERNAL):

TESTING:

INJECTION MOULDING (EXTERNAL):

COMPLETE USB CABLE MANUFACTURING

STEP 1: CONNECTOR PRODUCTION

STEP 2: CABLE PRODUCTION

STEP 3: CABLE ASSEMBLY

STEP 4: CUTTING CABLE LENGTH

STEP 5: THERMAL STRIPPING OF THE JACKET MATERIAL AT BOTH ENDS OF THE CABLE

STEP 6: SOLDER THE CONNECTOR TO THE CABLE

STEP 7: FIRST PORT SHAPE INJECTION MOLDING

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STEP 8: FIRST ELECTRICAL TEST

STEP 9: SECOND EXTERNAL INJECTION MOLDING/INSTALLATION OF PORT HOUSING

STEP 10: SECOND ELECTRICAL PERFORMANCE TEST

STEP 11: VISUAL INSPECTION AND QUALITY TESTING

PUSH AND PULL FORCE TEST:

SALT SPRAY TEST:

SWING TENSILE TEST:

PULL AND PLUG TEST:

CONSTANT TEMPERATURE TEST:

MANUFACTURING PROCESS OF LAMP HOLDER

FIG: WORKFLOW CHART OF AUTOMATIC CONTINUOUS MANUFACTING OF LAMP HOLDER VERTICAL
INJECTION MOLDING MACHINE

SORTING

FEEDING AUTOMATICALLY

MOLDING

PROCESSING AND EQUIPMENT

COMPONENTS USED IN SPOT WELDING ARE:

QUALITY CONTROL

SCHEME OF INSPECTION AND TESTING:

MARKET OVERVIEW OF ELECTRIC SWITCHES

GROWTH OF HOME AUTOMATION IN THE UNITED STATES TO AID DEMAND

RISING RENOVATION AND CONSTRUCTION ACTIVITY PUSHING GROWTH IN THE UNITED KINGDOM

INFRASTRUCTURE DEVELOPMENT TO AUGMENT REVENUE IN CHINA

ADOPTION OF TOUCH-SENSITIVE SWITCHES FUEL SALES IN JAPAN

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SHIFT TOWARDS SMART SWITCHES TO STRENGTHEN MARKET IN SOUTH KOREA

PUSH BUTTONS IN HIGH DEMAND DUE TO SIMPLICITY AND EASE OF USE

MARKET OF PLUGS AND SOCKETS

MARKET DYNAMICS AND TRENDS:

COMPETITIVE LANDSCAPE:

MARKET POSITION OF USB CABLE

INDUSTRY OUTLOOK

APPLICATION OUTLOOK

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

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3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

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PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

MANUFACTURERS/EXPORTERS/SUPPLIERS OF ELECTRICAL SWITCH, SOCKETS, MCB ETC.

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF BAKELITE POWDER

SUPPLIERS OF PHENOL FORMALDEHYDE RESINS

SUPPLIERS OF STEEL STRIPS

MANUFACTURERS NUT AND SCREWS

MANUFACTURER SLEEVES

SUPLIERS OF PLANT AND MACHINERIES

SUPPLIERS OF HYDRAULIC PRESS

SUPPLIERS OF PLASTIC PROCESSING MACHINERY

SUPPLIERS OF BUFFING MACHINE

SUPPLIERS OF MCB

RAW MATERIAL SUPPLIERS

SUPPLIERS OF PRODUCTION LINES

STEEL PIPE & SHEET MANUFACTURERS

SUPPLIERS OF D.G. SET

SUPPLIERS OF LABORATORTY EQUIPMENTS

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SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF EXHAUST FAN

SUPPLIERS OF TESTING EQUIPMENTS

IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

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17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)


COST ESTIMATION
Plant Capacity 2000 Nos/Day
Land & Building (4000 sq.mt.) Rs. 2.63 Cr
Plant & Machinery Rs. 2.12 Cr
Working Capital for 2 Months Rs. 1.06 Cr
Total Capital Investment Rs. 6.17 Cr
Rate of Return 25%
Break Even Point 62%