An Industry Visit Report On

K.J.V. ALLOY CONDUCTORS PVT. LTD.

BACHELOR OF TECHNOLOGY In MECHANICAL

2011-2012

Submitted To : Rajasthan Technical University,

Submitted By :

TABLE OF CONTENTS

S.NO.

CONTENT

PAGE NO.

1. 2. 3.

Industry Overview Conducting Wire AAAC (All Aliminium Alloy Conductor)

3 5

6 7 13 14

4. 5. 6.

Manufacturing of AAAC Final Product Conclusion

AN INTRODUCTION TO K.J.V. ALLOY CONDUCTORS PVT. LTD.

COMPANY PROFILE :
We started our operations with manufacturing AAC (All Aluminium Conductor), ACSR (Aluminium Conductor Steel Reinforced), Bare Aluminum Wire & Strips, Bare Aluminum Alloy Wire, in theyear 1989. Subsequently we included AAAC (All Aluminium Alloy Conductor) & Paper Covered (Insulated) Wire & Strips to our product mix for distribution & transmission power lines .

SUPPLIES TO :
We have supplied our products to major Electricity Boards and Turnkey Contractors of India as well as overseas. Our products covers entire range of voltage & transmission lines suitable upto 765kV. We have also successfully exported our products under stiff global competition. Currently we are supplying wire rods to major cable and conductor manufacturers and steel plants.

INFRASTRUCTURE :
We have State-of-the-art, well equipped, fully integrated manufacturing facility, experienced and technically sound professionals that ensures meeting customer deadlines. Continuous training and developmentis carried out for staff at all levels.

GROWTH :
We have experience of over three decades in aluminium industry with average growth of 30% PA in financial performance. We have over 500 statisfied customers globally with customer base increasing every year.

BRANCHES:

In total we have 3 manufacturing units, Nagpur (Maharashtra), Hyderabad (AP) & Boregaon (65kms from Nagpur, in MP) with the annual production capacity of 36000MT PA.

QUALITY ASSURANCE :
We exercise rigid quality control at all the stages of the product manufacturing cycle. Our products have been approved by the Bureau of Indian Standards (IS 398 Part 1, 2 & 4), and we have been licensed to put their mark on our products. Our products have also been tested and approved by various electricity boards and 3rd party inspection agencies like RITES, TATA PROJECTS & DGSND & international firms like SGS, INTERTEK, EILetc.We are ISO 9001:2008 certified company ensuring quality end product. All our products have been Type Tested in NABL accredited Laboratories - NTH, ERDA, CPRI as well as other government laboratories - TAG, MPLUN, NSIC, CPET.

LOCATION :
(In Nagpur ) 31 , MIDC, Central MIDC road, NAGPUR (MS)

CONDUCTING WIRE

A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear mechanical loads and to carry electricity and telecommunication signals.

Wire is commonly formed by drawing the metal through a hole in a die or draw plate. Standard sizes are determined by various wire gauges. The term wire is also used more loosely to refer to a bundle of such strands, as in 'multistranded wire', which is more correctly termed a wire rope in mechanics, or a cable in electricity.

A cable is two or more wires running side by side and bonded, twisted or braided together to form a single assembly. In mechanics cables, otherwise known as wire ropes, are used for lifting, hauling and towing or conveying force through tension.

AAAC ( ALL ALUMINUM ALLOY CONDUCTOR )

Various type of conducting wires manufacture here. The conductor which I have seen manufacturing here is :

AAAC conductor is made from aluminum-magnesium-silicon alloy of high electrical conductivity containing Magnesium (0.6-0.9%) & Silicon (0.50.9%) to give it better mechanical properties after treatment.

AAAC conductors are generally made out of aluminum alloy 6201 (Minimum Conductivity is 54%). AAAC Conductor has a better corrosion resistance and better strength to weight ratio and improved electrical conductivity than ACSR Conductor on equal diameter basis.

Key Benefits :
High Tensile Strength Higher Conductivity Better Corrosion resistant.

Manufacturing of ALL ALUMINIUM ALLOY CONDUCTOR

In the series of manufacturing of conducting wire , the steps are:

ALUMINIUM DRAW : We require firstly to draw the wire rod of

alumium alloy . The drawing of rod is done by the drawing machine . There is certain decrease in diameter by pressing the wire in between two rolling dies.

TUBULAR STRANDING : There after the wire of required dia is then

passed to tubular stranding machine, so as to twist the required number of wires together.The more individual wire strands in a wire bundle, the more flexible, kink-resistant, break-resistant, and stronger the wire is. But more strands cost more.

CONDUCTOR COILER : Then after when the wire is in stranded form ,

it is required to coil the wire strands over the wire drum. This is done with the help of wire coiler machine .In this macine wire strand comes from the wire twister are send to this machine , which in turn sends the wire strands to the coiler drum placed there.

In this way complete production of wire strands and coiling on drum is to be done.Its detailed explaination with fig. is shown below.

ALUMINIUM DRAW MACHINE

The wire rod to be drawn is pointed in the Wire Pointing Machine. This pointed wire is inserted through the die of the first Wire Drawing Machine and fastened to a
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locking device on the drum. The drum is then started. As the drum rotates, the wire fastened to the drum gets pulled and coiled around the drum. Since the wire getting pulled is passed through the die having a higher inlet diameter and a lower outlet diameter, the drawn wire diameter gets reduced.

The starting end of the drawn wire is released from the lock of the first drum, is passed through the overhead loop and pulley provided, is brought down and is inserted through the die of the second drum and drawn through this die for further reduction. Thus, the wire is drawn through all the wire drawing drums of the set in a continuous manner to get the required finished diameter of the wire.

When the drum of the last wire drawing machine gets fully loaded with the drawn wire, the machine will be stopped to unload the finished material and then restarted. (If one opts for the continuous coiling machine, the drawing process will not have to be stopped for this purpose)

When the bundle of input rod finishes, the machine should be stopped. The end of this bundle is welded to the end of a new bundle of rod using the butt welding machine. Then the process is to be continued.

Lubricant in Tank 2000 lit. Outlet dia 13 mm Motor 120HP.

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Fig. : Aluminium Draw Machine

TUBULAR STRANDING

We can twist conducting wires in strand of wires with the help of this tubular stranding machine easily. The line is mainly used for the assembly of bare and insulated conductors into concentric strands or cables including steel, aluminum, copper, aluminum alloy wire, as well as control cable and optical cable. The machine has a round cage with number of cradles that helps in holding the spools. The cage rotates in both the clockwise and anti-clockwise direction together. The direction of operation is from left side to right side.The direction is easily changeable with the help of a lever that is provided in the gear box.

The lowest number of strands is 7: one in the middle, 6 surrounding it. The next level up is 19, which is another layer of 12 strands on top of the 7. After that the number varies, but 37 and 49 are common, then in the 70 to 100 range (the number is no longer exact). Even larger numbers than that are typically found only in very large wires. For application where the wire moves, 19 is the lowest that should be used (7 should only be used in applications where the wire is placed and then does not move), and 49 is much better. For applications with constant repeated movement, such as assembly robots, and headphone wires, 70 to 100 is mandatory.

Power requirement : 35 HP

The capstan diameter for variety of strands is shown in table.

S. No. No. of Bobbins (Spools)

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Capstan Dia.

1 2 3 4 5 6 7

1+6 Bobbin (Double Plate) 12 Bobbin (Double Plate) 24 Bobbin (Double Plate) 36 Bobbin (Triple Plate) 24 Bobbin (500 mm) (Triple Plate) 18 Bobbin (Anti-Torssion) (Triple Plate) 24 Bobbin (Anti-Torssion)

750 mm 750 mm 915 mm 1200 mm 1000 mm 915 mm 1000 mm

Fig. : Tubular stranding machine

CONDUCTOR COILER

Now the stranded wire is ready but is in not in form to supply. So the stranded conducting wire is coiled on drum so as to transfer easily in vast areas. This is done with the help of conductor coiler machine.
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This machine rolls the stranded wire on the drum costantly . The wire comes tightly from a machine and then through a conductor coiler machine , it transfers the same stranded wire on the drum which is rotating. So this gives the tight coiling of wire strands on drum.

Fig.: Conductor Coiler

Now , it is ready to supply.

Final Product which forms after all of this processing is the AAAC conducting
wire which is shown below :

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Fig. : Close View of AAAC Wire Strand

CONCLUSION

During this industry visit of a day , I learnt the conducting wire manufacturing process. The wire is of AAAC (All Aluminium Alloy Conductor ) type .
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I get to know about the manufacturing from a wire rod to a strand of conducting wire of uniform diameter. During this visit , I learnd the working of Alluminium Draw machine , which straightns and smooths the wire of uniform cross section.Also about the Tubular Stranding machine , which twist the wire together in variety of no. of strands. I learnd also the working of Conducting Coiler , which makes the coils of conducting wire on drum very fastly and make its finished good to sell .

Thus I have utilise a day and concentrated on the manufacturing of wires and the study of machines.

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