Maintenance

What is maintenance? Industrial maintenance usually refers to the repair and upkeep of the different types of equipment and machines used in an industrial setting. The basics of industrial maintenance may be broken down into the following five categories: general knowledge, mechanical knowledge, electrical knowledge, welding knowledge, and preventative maintenance. According to this wide variety of areas of expertise, industrial maintenance technicians usually are multi-skilled individuals, proficient in many tasks. Industrial maintenance also involves a great degree of problem solving skill. Identifying the problem alongside the best and safest means of resolving the difficulty typically are integral parts of the industrial maintenance process.

Why maintenance is important ?

Regular maintenance is essential to keep equipment, machines and the work environment safe and reliable. It helps to eliminate workplace hazards. Lack of maintenance or inadequate maintenance can lead to dangerous situations, accidents and health problems. Maintenance is a high risk activity. It has to be performed in a safe way!

What is the Task of Maintenance? Its Significance in Society?

In Europe every year, thousands of billions of Euros are invested in new machines, factories, roads, etc. It is the task of the maintenance people to take good care of these huge investments to be responsible for ensuring that they provide the service they were designed for, at best possible profits for the investors. The duty of maintenance is not only to repair and maintain the machines. A professional maintenance person will keep the machines running safely and reliably. He or she will also try continually to improve the efficiency of the equipment. The main task of maintenance is to make sure that the investments made will generate the best possible profit during the entire lifetime of the machine. Improving the availability, reliability, safety, and return on life cycle cost are the foundation of profitability and competitiveness. The better the Industrys competitiveness and the communitys ability to provide services, the more the assets efficiencies are optimised.

Maintenance for safety

Proper maintenance is essential for eliminating hazards and managing risks at the workplace. Lack of maintenance or inadequate maintenance can cause serious and deadly accidents.

Many accidents, such as slips, trips and falls, happen because of lack of maintenance or as a result of poor quality maintenance Lack of maintenance and regular service of construction equipment and machinery may lead to their failure and cause injuries to the operators and other workers (e.g. defective conveyors, derricks, hoists, faulty ladders, etc.) Poor standards of maintenance are a major underlying cause of accidents in the catering industry. Most accidents resulting from poor maintenance involve equipment (e.g. faults in plugs or cables, poorly maintained gas appliances) or happen due to leaks and spillages. Safety critical equipment can fail due to lack of maintenance causing serious accidents

The general knowledge usually required in industrial maintenance

The general knowledge usually required in industrial maintenance is an understanding of tools, blueprint reading, and safety. The correct tools and the comprehension of how to use them can be crucial for fixing potential machinery problems. Blueprint reading enables the industrial maintenance technician to understand how a particular machine works. Safety is also a pivotal aspect of maintenance, as most industrial machines can be considered dangerous. It usually is important for the technician to maintain his or her own safety, as well as those of the workers using the machinery.

Mechanical knowledge of how machines function may include a familiarity with concepts such as mechanical power transmission, fluid power, piping systems, pumps, and compressors. Since any number of mechanical parts can make up a piece of machinery, industrial maintenance typically requires the knowledge of how machines function in general. A familiarity with wiring, transformers and basic industrial electronics allows for the repairing of machines experiencing problems with power supplies. The knowledge of welding techniques, such as arc welding and gas welding, also can be necessary to solve a mechanical problem.

Instruments used in industrial maintenance A. Technical 1. Temperature controlled soldering Iron 2. Oscilloscope 3. Multimeter 4. Universal programmer 5. variable Power supply AC and DC 6. LCR meter 7. Clamp meter 8. De-soldering Gun 9. Hot air gun 10.Cleaning gun B. Mechanical 1. Hand tools 2. Pliers 3. L-keys (.5 to 15 ) 4. Set of tweezers 5. Screwdrivers 6. Cutters 7. Puller 8. Ruler 9. Hammer

C. Other essentials 1. Selves 2. Shockproof Tape 3. Soldering wire 4. Flux (liquid & solid) 5. Wires D. Self made Testing zig according to the chip you are using.

Stoll CMS-402

General Description of Stoll CMS-402

Serial no 1 2 3 4 5 6 7 8 9 10 11 12

Part Machine stand Needle carrier Racking unit Knitting unit Fabric take down Yarn delivery unit Maintenance unit Protecting unit Machine control Cable Guidance Electric Electronic system

Stepper Motor Driver Card

The image shows the stepper motors used in machines. These motors control the yarn feeder of the machines. These also control the tension of thread. There are total eight motors in machine and an individual driver card is used for Rotation of motor. These are placed in the left cabinet of the machine. The testing base for these shows the testing of card

This image shows the initial state of motor driver card when it is not triggered or ypu can say it is in low position now.

This shows the image of card when it is triggered and the card is in working position or you can say in high position in right position

This shows the image of card when it is triggered and the card is in working position or you can say in high position in left position

Linear scale encoder

An infra-red LED emits light onto the scale, which is a plane reflective metal grating of 20 m period. It is important that this scale is uniform and strongly periodic, but it does not need to be a good diffraction grating. As with RG2 and RG4 readheads, the SiGNUM readhead optics average the contributions from many scale periods and effectively filters out non-periodic features such as dirt. The nominally square-wave scale pattern is also filtered to leave a pure sinusoidal fringe field at the detector. Here, a multiple finger structure is employed, fine enough to produce photocurrents in the form of four symmetrically phased signals. These are combined to remove DC components and produce sine and cosine signal outputs with high spectral purity and low offset, while maintaining bandwidth to beyond 500 kHz. The balance and level control of these signals is further enhanced by active adjustment of individual channel gains, offsets and also control of the LED light source within the SiGNUM readhead. As a result, the inherent cyclic error (sub-divisional error, SDE) is 30 nm, i.e. 0.15% of scale period. Interpolation is by CORDIC algorithm, within the SiGNUM Si interface The IN-TRAC reference mark is embedded in the incremental scale in the form of a dark line. This feature is rejected by the filtering incremental optics, but detected by a split photodetector within the readhead. With appropriate level sensing and gating circuitry this yields a reference mark output that is bi-directionally repeatable to unit of resolution at all speeds. Calibration of phase with respect to the analogue channel is performed automatically on installation by the logic within the interface, which also provides comprehensive system monitoring and set-up assistance.

This is the I.R emitter side of the linear scale. It emits I.R rays on the photo diode on the other side. There is also a concave lens between IR emitter and IR receivers to read the coding on the linear scale.

Receiver side of the linear scale encoder. The recivers are on the other side of the PCB.

Total view of the linear scale encoder

The digital encoded scale inside the encoder. We can say it as the heart of the encoder.

PCB DESIGN STEPS IN OrCad 10.5

Entry of Schematic Diagram Schematic diagram provides the functional flow and the graphical representation of an electronic circuit. The entry of schematic diagram is the first step in PCB design using OrCad. A schematic diagram consists of: Electrical connections(nets) Junctions Integrated circuits symbols Discrete components symbols like resistors, capacitors etc. Input / output connectors Power and ground symbols Buses No connection symbols Components reference names Text

The Schematic Page Editor: The schematic page editor is used to display and edit schematic pages. So that one can parts; wires; buses and draw graphics. The schematic page editor has a tool palette that you can use to draw and place everything you need to create

a schematic page. One can print from within the schematic page editor, or from the project window.

The Part editor: The part editor is used to create and edit parts. From the view menu of the part editor you can choose either part or package. In part view one can: Create and edit parts and symbols, then store in new or existing libraries. Create and edit power and ground symbols, off-page connector symbols, and title block

 Use the tool palettes electrical tools to place pins on parts, and its drawing tools to draw parts and symbols.

The Session Log: The session log lists the events that have occurred during the current Capture session, includes message resulting from using captures tools. To display context-sensitive help for an error message, put the cursor in the error message line in the session log press F1. The ruler along the top appears in either inches or mill meters, depending on which measurement system is selected in the window panel. Your tab setting are saved and used each time you start capture.

One can search for information in the session log using the find command on the Edit menu. You can also save the contents of the of the session log to a file, which is useful when working with Orcads technical support to solve technical problems. The default filename is SESSION.TXT.

The Toolbar: Captures toolbar is dock able (that means you can select and drag the toolbar to new location) as well as resizable, and displays tool tips for each tool; by choosing a tool button you can quickly perform a task. If tool button is dimmed, you cant perform that task in the current situation.

Some of the tools operate only on what you have selected, while others give you a choice of either operating on what is selected or expanding the scope to entire project.

You can hide the toolbar, then display it again when u need it. For hiding select from the schematic page editors view menu, choose TOOLBAR.

The Tool Palette:

Capture has two tool palettes: one for the schematic page editor and one for the part editor. Both tool palettes are dock able and resizable. They can also display tool tips that identify each tool. The drawing tools on the two tool palettes are identical, however, each tool palette has different electrical tools after you choose a tool, and you press the right mouse button to display a context- sensitive pop-up menu.

The schematic page editor tool palette:

The first group of tools on the tool palette is electrical tools, used to place electrical connectivity objects. The second group of tools is Drawing tools, used to create graphical objects without electrical connectivity.

The part editor tool palette:

The first group of tools on the part palette is electrical tools, used to place pins and symbols. They have been already explained above within the schematic page editor tools. The second group of tools is drawing tools, used to create graphical objects without objects any electrical connectivity and is described:

Pin Tools: Place pins on part Pin Array: Place multiple pins on part

Selecting and deselecting of objects Once one selects an object, one can perform operations on it, include moving, copying, cutting, mirroring, rotating, resizing, or editing. One can also select multiple, objects and edit them, or group them in to a single object. Grouping objects maintain relation ship among them while one moves them to another location.

Creating Net list File

Net-list file is a document file which contains information about the logical interconnections between signals and pins. Before one create a net list file, be sure ones project is completed, annotated and it is free from electrical rule violations.

A net list file consists of nets, components, connectors, junctions, no connection symbol, power and ground symbols.

Creation of net list in capture: Select your design in the project manager. From the tools, choose create net list. The net list dialog box displays. Choose a net list format tab. If necessary, set the part value and PCB foot print combined property strings to reflect the information you want in the net list. Click ok to create the net list. In the net list file text box, enter a name for the output file. If the selected format creates an additional file, enter its file name in the second text box.

PLACEMENT OF LAYOUT PLUS What is Layout Plus? Layout plus is one part for the PCB design in which we place as well as route the components an set unit of measurement, grids, and spacing in OrCad. Within other soft wares you also have to place and route the components in similar way. For the placement and routing of the components we normally use auto-placement and auto-routing. Unfortunately, in a lot of soft wares

some critical signals have to be routed manually before auto-routing. In layout plus we also define the layer stacks, pad stacks and via's.

Steps for board design: At first, we have created a net list from our schematic diagram by using capture. Layout plus includes design rules in order to guide logical placement and routing. That means, load the net list into layout to create the board. At the same time you have to specify the board parameters. Specify board parameters: Specifying global setting for the board, including nits of measurements, grid, and spacing Place components: Use the components tool in order to place manually the components which are fixed by the system designer on the board or otherwise use auto-placement. Route the board: Use different routing technologies to route the board and take advantage of push and shove (a routing technology), which moves track you are currently routing as well as you can also auto route the board. Provide finishing of the board: Layout supplies an ordered progression of commands on the auto menu for finishing your design. These commands include design rule check, cleanup design, rename components, back annotate, run post processor, and create reports.

The design window:

The design window provides a graphical display of printed circuit board, it is primary window you use when designing your board. It also provides tools to facilitate the design process such as to update components and design rule violation.

Main window

Method to create a board with Layout Plus:

Ensure that net list with all footprints and necessary information has been created.

 Create a directory in which the schematic design, net list, and boar will co-exit and put the schematic design and net list. OrCad provides a directory for this purpose. From the layout session frames file menu, choose New. The load template file in the dialog box displayed.

Design window

Select the technology template (.TCH), then choose the open button and load the net list in other box.

 Then apply the auto ECO. If necessary, respond to link footprints to component dialog. Draw the board outline by using the obstacle tool in the tool bar.

Setting board parameters: There is some parameter which should be set before placing the components on board. They are as follows:-

Set Datum Create a board outline Set units of measurements Set system grid Add mount holes

Creating of board outline: Board outline is the graphical representation of the size of the actual PCB board. So it is the main step in layout, to draw the board outline of the actual size of PCB board.

Placement of components: Placement of components means that to place the components in designed box. A designer should follow the following steps before going for it:-

 Optimize the board for component placement. Load the placement strategy file. Place components on the board. Optimize placement using various placements

Components can be placed by using two techniques:1) Manual placement of components 2) Auto placement of components

Choose the components tool bar button. From the pop up men, choose the queue for placement. The components selection criteria dialog box appears. Enter the reference designator of the components that you want to place in the appropriate text box, and click ok. Drag the components to desired location, place it there.

Conductor Routing in Layout:After placing all the components the other main step is to route the board from the electrical connections between the components. One may route board manually or automatically by auto router. 100% auto routing can be achieved only when components are placed in the order of functional flow of electronic circuit. The main routing tool available in OrCad is as flow:-

 Add/edit route mode Edit segment mode Shove track mode Auto path route mode

Design Rule Check:In manual designs every thing was checked as a possible source of error. Components sizes, hole sizes, conductor widths and clearance, land-to-holeratio, board areas to be free of components, clearance to the edges, positional accuracy and of course electrical interconnections had tad to be personally reviewed with a great deal of care. After completing the design of printed circuit board with the help of an EDA-Tool, a designer has again to verify the PCB in order to find out errors. Such type of verifications/design rule check contains beside the general verifications commonly two types: Physical verification Electrical verification

Post processing:Post processing can be done once the design is completed in all aspects. The common way is still a process to generate GERBER data and NCD files which can be used for photo plotting and for steps of CNC manufacturing and PCBdrilling.

POWER SYSTEM DESIGN First part of electronics ckts. is power. The main power supply is in AC but mostly electronic ckts. work with DC. So a system is required to convert ac to dc and these sources should able to produce stable supplies. Power supplies may be used in. may be of different types such as regulated, unregulated, smps etc. Unregulated power supplies These are the power supplies in which the out put is not constant. That it is varies with input voltage, load, and also effected by the environment conditions such as temperature, etc. so these are the variable supplies. Commonly these supplies are not employed as there efficiency is very less. The unregulated power can be obtained using rectifying circuit after AC supply. Regulated power supplies These are the power supplies in which the output voltage is constant, i.e. the out put voltage is independent of the input voltage, load and other external conditions. So to obtain the regulated voltage using different regulators. The regulator voltage is mainly the DC voltage, it may AC to or DC to DC voltage. A better approach to power supply design is to use enough capacitance to reduce ripple to low level, then use an active feedback circuit to eliminate the remaining ripple and dependence of output voltage on input, load and environment conditions. These active devices are known as Regulators. These regulators can be used to produce negative and positive voltage of required value.

The voltage regulators are of three types:1) Constant positive voltage regulators 2) Constant negative voltage regulators 3) Variable voltage regulators

Constant positive voltage regulators:- These are the regulators which are able to produce positive and constant voltage. Some of them are given below:S. no. 1 2 3 4 Name of regulator LM 7805 LM 7810 LM 7812 LM 7815 Output voltage 5v 10v 12v 15v

These regulators are used according to the required voltage need.

Constant negative voltage regulators:- These are also the constant output voltage regulator but there output is negative in polarity. These regulators are also employed according to voltage requirements. Some of them are given below with there outputs:S. no 1 Name of regulator LM7905 Output voltage -5v

2 3 4

LM7910 LM7912 LM7915

-10v -12v -15v

Variable voltage regulators:- These are the regulator whose output voltage can be varied according to the desired need. These regulators again of two types i.e.: Positive Negative

The output of these regulators can be varied by varying the resistance of the variable resistance which is connected to the adjustable pin the regulators. So these are the most commonly used regulators in the electronic industry as wide range of stable voltage can be obtained from single chip by varying the resistance connected to the adjustable pin of the regulators. The most commonly variable regulators are:-

LM317 (it is positive regulator) LM 337(it is negative regulator)

There description is given below:-

LM317 3-Terminal Adjustable Regulator:-

General Description: The LM317 series of adjustable 3-terminal positive voltage regulators is capable of supplying in excess of 1.5A over a 1.2V to 37V output range. They are exceptionally easy to use and require only two external resistors to set the output voltage. Further, both line and load regulation is better than standard fixed regulators. Also, the LM117 is packaged in standard transistor packages which are easily mounted and handled. In addition to higher performance than fixed regulators, theLM317 series offers full overload protection available only in ICs. Included on the chip are current limit, thermal overload protection and safe area protection. All overload protection circuitry remains fully functional even if the adjustment terminal is disconnected. Normally, no capacitors are needed unless the device is situated more than 6 inches from the input filter capacitors in which case an input bypass is needed. An optional output capacitor can be added to improve transient response. The adjustment terminal can be bypassed to achieve very high ripple rejection ratios which are difficult to achieve with standard voltage, supplies of several hundred volts can be regulated as long as the maximum input to output differential is not exceeded, i.e., avoid short-circuiting the output. Also, it makes an especially simple adjustable switching regulator, a programmable output regulator, or by connecting a fixed resistor between the adjustment pin and output, theLM317 can be used as a precision current regulator. Supplies with electronic shutdown can be achieved by clamping the

adjustment terminal to ground which programs the output to 1.2V where most loads draw little current.

Typical application:

LM317/CYL U1 3 VIN VIN

ADJ

VOUT

2 VOUT R1 220E C2 .1uF

C1 .1uF R2 5k

Features 1. Guaranteed 1% output voltage tolerance (LM317A) 2. Guaranteed max. 0.01%/V line regulation (LM317A) 3. Guaranteed max. 0.3% load regulation (LM317)

4. Guaranteed 1.5A output current 5. Adjustable output down to 1.2V 6. Current limit constant with temperature 7. P+ Product Enhancement tested 8. 80 dB ripple rejection 9. Output is short-circuit protected

Packages of LM317

Application Hints:

In operation, the LM317 develops a nominal 1.25V reference voltage, VREF, between the output and adjustment terminal. The reference voltage is impressed across program resistor R1 and, since the voltage is constant, constant current I1 then flows through the output set resistor R2, giving an

output voltage of

Since the 100A current from the adjustment terminal represents an error term, the LM317 was designed to minimize IADJ and make it very constant with line and load changes. To do this, all quiescent operating current is

returned to the output establishing a minimum load current requirement. If there is insufficient load on the output, the output will rise.

PROTECTION DIODES:-

When external capacitors are used with any IC regulator it is sometimes necessary to add protection diodes to prevent the capacitors from discharging through low current points into the regulator. Most 10F capacitors have low enough internal series resistance to deliver 20A spikes when shorted. Although the surge is short, there is enough energy to damage parts of the IC. When an output capacitor is connected to a regulator and the input is shorted, the output capacitor will discharge into the output of the regulator. The discharge current depends on the value of the capacitor, the output voltage of the regulator, and the rate of decrease of VIN. In the LM317, this discharge path is through a large junction that is able to sustain 15A surge with no problem. This is not true of other types of positive regulators. For output capacitors of 25F

or

less,

there

is

no

need

to

use

diodes.

The bypass capacitor on the adjustment terminal can discharge through a low current junction. Discharge occurs when either the input or output is shorted.

No protection is needed for output voltages of 25V or less and 10F capacitance. Figure 3 shows an LM317 with protection diodes included for use with outputs greater than 25V and high values of output capacitance.

LM337

3-Terminal Adjustable Regulator:-

General Description: The LM337 is adjustable 3-terminal negative voltage regulators capable of supplying in excess of 1.5A over an output voltage range of 1.2V to 37V. These regulators are exceptionally easy to apply, requiring only 2 external resistors to set the output voltage and 1 output capacitor for frequency compensation. The circuit design has been optimized for excellent regulation and low thermal transients. Further, the LM337 series features internal current limiting, thermal shutdown and safe-area compensation, making them virtually blowout-proof against overloads. The LM337 serves a wide variety of applications including local on-card regulation, programmable-output voltage regulation or precision current regulation. The LM337 are ideal complements to the LM317 adjustable positive regulators.

Pin diagram

Features:

1) Output voltage adjustable from 1.2V to 37V 2) 1.5A output current guaranteed, 55C to +150C 3) Line regulation typically 0.01%/V 4) Load regulation typically 0.3% 5) Excellent thermal regulation, 0.002%/W 6) 77 dB ripple rejection 7) Excellent rejection of thermal transients 8) Temperature-independent current limit

9) Internal thermal overload protection 10) Standard 3-lead transistor package 11) Output is short circuit protected. These two Ic's i.e. LM337and LM317are mainly used in the regulated power supplies because using these regulator a wide range of output can be obtain which can be varied from 0v to 30v, which is much sufficient to drive any electronic circuit.

Superpro 5000
The SUPERPRO includes ultra high speed programming via 32bit RISC MCU device. This is especially suitable for programming high capacity NAND Flash devices A 144 pindriver support is builtin to provide efficient programming of large pin count devices, an additional pin expander module is not necessary to program large pincount devices. The SUPERPRO operates with a PC for engineering purpose or in standalone mode, without a PC, for repeat production mode programming. This provides seamless migration from engineering to production The SUPERPRO communicates through a USB 2.0 port and operates on most Pentiumbased, IBM compatible desktop/notebook computers. The SUPERPRO comes with a standard 48pin DIP ZIF socket and supports optional socket adapters to accommodate PLCC, TSOP, SOIC, SOP, QFP, TSSOP and BGA package types. The programmer and software supports Windows XP and Windows Vista. The programmer is scheduled to support 43,000+ IC devices by the end of 2008.

Using Superpro 5000 The main SUPERPRO screen is illustrated below. Each part of the user interface is labeled with a number and described below.

1. The Main Menu provides access to the File, Buffer, Device, Option, Project, and Help menus 2. The Toolbar includes icons for quick access to common functions. 3. Select Device to open the Device Selection dialog box. 4. Select Buffer to open the Buffer Edit window. 5. The system displays information about the selected device. 6. The system displays information about the file currently loaded in the buffer. 7. The Operation Option toolbar facilitates setting the operation options properly. The items correspond to the items in the Option Menu 8. The left side of the screen lists device operation functions. 9. The Operation Message Window displays the operation process, the operation result and the historical records of information. 10. The Status bar displays the menu item info, the progress of operation, and a Cancel button 10. The Statistical Window displays statistical information

File Menu
The File menu provides access to the Load, Save, Recent Projects, and Exit functions. Each function is described in the following sections. Load File There may be one or more data buffers in the device. If several data buffers are displayed after you have selected the device, refer to the name and the data

manual for the meanings of the buffers. The two data types of the device are Data (HEX/ASCII) and Fuse. For most EPROM and SCM, the data type is Data (HEX/ASCII). The data type for PLD device is Fuse. After you select the device, the software automatically identifies the data buffer type. You can review the buffer data types if you open the Edit dialog box for the data buffer When some file data are loaded into the data buffer, the following rules apply: With a HEX/ASCII data buffer (EPROM, MCU etc.), the system assumes that 8 bits of the data are valid. With a JEDEC buffer (PLD/PAL), the system considers the lowest bit (1 bit) of the file data valid. Select Load from the File menu to open the Load File dialog box, illustrated below. The red labels refer to the numbered explanations below.

1. Select the data Buffer name from the drop down list, as illustrated below.

The default option is considered the programming zone of the device as described in the data manual. To choose between several buffers, determine the corresponding programming zones according to the names and the data manual. The system loads the file data into the data buffers according to the data buffer names.

2. Enter the name of the data file to load in the File Name field.

First select the file type from the Files of type drop down list. Data (HEX/ASCII data) file types can be further divided into many different types according to their storage forms. You must select the appropriate file type to ensure the data loads correctly. The file type for Fuse data files is JEDEC and the file extension is jed. After selecting the file, you do not need to select the data file type. 3. Select the File Type from the drop down list. 4. Select one of the following File Modes from the drop down list: Normal to load the whole file Even to load the first byte and discard the second byte out of every two bytes Odd to discard the first byte and load the second byte out of every two bytes 1st byte of 4 to load first byte and discard the other three bytes out of every four bytes 2nd byte of 4 to load the second byte and discard the other three bytes out of every four bytes 3rd byte of 4 to load the third byte and discard the other three bytes out of every four bytes 4th byte of 4 to load the fourth byte and discard the other three bytes out of every four bytes 1st 2_byte of 4 to load the first two bytes and discard the other two bytes out of every four bytes 2nd 2_byte of 4 to load the last two bytes and discard the other two bytes out of every four bytes

Edit Select Edit from the Buffer menu to open either the Fuse Buffer Edit window or the Data Buffer (HEX/ASCII) Edit window. Use the following keys to edit the buffer data: Press the Page Up key to Page up in the data window. Press the Page Down key to Page down in the data window. Press the Home key to move the cursor to the beginning of the line. Press the End key to move cursor to the end of the line. The following sample illustrates an example with two data buffers. The red labels refer to the numbered explanations below.