Internal Industrial Attachment report

Internal Industrial Attachment report

Acknowledgment

I extend my sincere and most profound appreciation to all those who helped me come up with this report beginning with Mr.Kilungu, the head of the department, all the Industrial Attachment Supervisors –whose advice, guidance and contribution made my attachment a success hence this report. I appreciate the skills and experience I gained from them. I also extend my appreciation to God and my fellows for proper and accordance cooperation.

ABSTRACT

The Internal Industrial Attachment report is a reflection of the experience during my practical training at Machakos University, which is conducted in workshops and laboratories in the departments of Electrical and Electronic Engineering, Mechanical Engineering, Computer Engineering, and also Building and Civil Engineering. During my attachment period, I acquired practical knowledge and skills in the fields of electrical installation, soldering, and fabrication of simple electronics and essential electronic components. In the ICT department, I acquired skills in the safety and maintenance of computers, troubleshooting, and other computer-related ideas. In Mechanical Engineering, I gained knowledge and skills in the operation of various machines, wielding, and operation of motor vehicle systems and also masonry, plumbing, and carpentry workshops.

This report simply discusses the technical skills obtained during the attachment period and the relevance of the scheme in equipping the needed professional competence to thrive in the real world. Its contents exhibit the skills and practical knowledge in the visits to various departments, as stated above.

TABLE OF CONTENTS

Subject

Page

Abstract…………………………………………………………………………………….. 1

Chapter 1 Introduction………………………………………………………………

4

Chapter 2 Electrical and Electronics Engineering Department…… 5

2.1. Electronics……………………………………………………………..

5

2.2. Electrical Installation………………………………………………. 13

Chapter 3: Mechanical Engineering Department………………………….

19

3.1. Manufacturing plant and production…………………………….. 22

3.2. Welding and Fabrication………………………………………….. 22

3.3. Automotive Engineering…………………………………………… 25

Chapter 4: Information and Communication Technology……………….. 31

Chapter 5: Building And Civil Engineering Department…………………… 34

5.1. Masonry……………………………………………………………………… 34

5.2. Plumbing………………………………………………………………………

37

5.3. Carpentry and Joinery………………………………………………….. 39

Chapter 6: Conclusion………………………………………………………………………..

40

Bibliography………………………………………………………………………………………. 41

CHAPTER ONE: INTRODUCTION

Workshop practice updates the practical knowledge of students, and it is aimed at bridging the gap between the theoretical knowledge acquired in the class and the practical knowledge gained from the industrial attachment. It provides students with the chance to apply their pedagogical knowledge in real work situations and to blend their theoretical knowledge to perform work in the real work industry, preparing them for a transition from students to employed individuals after completion of university education.

Included in the report are various activities we conducted in different workshops at Machakos University. They include visits to the electrical installation workshop, electronics laboratory, automotive engineering department, masonry, plumbing and carpentry, Information Technology, Mechanical, and Plant production, wielding, and fabrication. This report is subdivided into various chapters discussing all skills and activities from each of the departments above.

CHAPTER TWO: ELECTRICAL AND ELECTRONICS ENGINEERING DEPARTMENT.

2.0 ELECTRONICS

Introduction.

Electronic devices are being used in most industries for both quality control and automation in the processing and assembling industries. Electronics is an engineering branch that deals with current conduction through a vacuum, gas, or semiconductor elements. It mainly deals with electronic devices and their utilization. The following will be discussed in this chapter;

• Capacitors
• Soldering and desoldering
• Integrated circuits
• Operating a Cathode Ray Oscilloscope
• Resistance Measurement and Calculations
• Transistors

APPARATUS

• Cathode Ray Oscilloscope
• Soldering gun
• Stripboard
• Resistors
• Capacitors
• Transistors
• Digital Multimeter
• Diodes
• Solder
• Solder sucker
• Signal generator

EXPERIMENTAL PROCEDURE

1. Soldering and Desoldering

• soldering gun was plugged in the socket and switched on for heating after some time. The soldering iron was held in one hand and the solder in the other. Components to be soldered were inserted into the stripboard, flipped over, and the leads bent outwards at an angle 45. The soldering gun was turned on, and the joints were heated. The soldering gun was maintained on the joint with the copper pad as the solder was touched to the joint. The soldering gun was then removed, and the welding allowed to cool naturally. The process was continuously repeated for the capacitors, transistors, diodes, and conductors. The circuit that was soldered was tested for quantity using a multimeter.

1. Resistance Measurement
2. Color code

A resistor was picked by a left hand from the band near the end. If the resistor has four groups, a general-purpose resistor code was followed; If five bands were present, the precision resistor code was followed as indicated in the result section.

1. Digital multimeter

The digital multimeter was switched on, and the dials set to resistance mode. One probe was placed at each end of the resistor. The range was then set to suit the recognizable values.

III. Cathode Ray Oscilloscope(CRO)

The CRO was connected to the power source and turned on. The time base control was set, and also both the time-base excellent monitor and time control were calibrated in desired positions. The intensity of the CRO was adjusted, and also the trigger mode set up to AUTO to the time-base operates even if an external signal does not trigger the oscilloscope.The oscilloscope was then set to display Channel 1 and then Channel 1 input selector to GROUND. The horizontal and vertical positions were adjusted until a horizontal line across the middle of the screen was visible. Also, the focus and intensity controls were changed so that the trace was sharp. To operate in the single-channel operation, the coupling channel one input was set to DC and a signal generator connected to this input, noting that the outer connector of coaxial sockets was connected to the earth. The generator was set to produce a sine wave of certain frequency and amplitude, and then the display observed on the screen, and synchronization was done to see rush easier.

For Two Channel operation, the signal generator(1kHZ, 1V) was connected to the input of the driver box. The output of the driver box was connected to Channel 1 of the oscilloscope and output two to Channel 2. The oscilloscope was then set to display both Channel 1 and 2(DUAL display mode). The channel coupling was then set to AC, and the gain and position of channel two adjusted to display both races.

DISCUSSION

SOLDERING AND DESOLDERING

Soldering is a process of joining two or more electronics parts together by melting solder around the connection. Welding is a metal alloy, and when it cools, it creates a robust electrical bond around the junction. Soldering creates a permanent relationship, but this can be reversed through the process of desoldering. For electronics soldering, the most common type of solder is lead-free rosin core solder though it is rarely used due to health concerns. Acid core solders are also not used because it damages the circuit and its components. Proper ventilation is required during soldering to curb fumes released that are harmful to the lungs and eyes.

When soldering components are bend at an angle 45 to ensure a better connection with the copper pad and prevent it from falling out during soldering, the solder should not touch the solder gun because the joints are needed to be hot for a better connection. Also, it is recommended not to blow the solder joints instead allow it to cool down naturally.

CATHODE RAY OSCILLOSCOPE

1) The CRO is a powerful tool used for displaying and measuring electrical signals, which vary rapidly and regulated by the ammeter.Electrons are emitted by the heated filament and focused into a beam and then accelerated by a high voltage until they strike the phosphor screen where they give up their kinetic energy and emit a spot of light. The voltage applied to their metal plates can be displayed horizontally or vertically hence the moving place on the screen. An oscilloscope is used for displaying a variation of one or two signals with time. The vertical axis shows the voltage while the horizontal displays time. The scale of the two axes is set by the gain and time-based controls. To obtain a steady-state display for a repetitive signal, the time-base is synchronized to one of the input signals using trigger controls. Also, an x-y array is used in which the voltage applied to one input is displayed as a function of the voltage applied to the second input.

There are sources of errors when making measurements using an oscilloscope;

• Calibration error
• Reading error

Calibration error is related to the accuracy o the components used in the oscilloscope and can be assumed to be 5% for both voltages and times. Reading error is associated with the line width of the trace. The total failure of any reading is found by combining the calibration and reading errors.

RESISTANCE MEASUREMENT

It is done with the help of a digital multimeter or an ohmmeter. Resistors have their values and tolerances indicated through ;

• Color coding
• Typographically

Color coding is done using colored rings or bands, while typography is done using printed alphanumeric. There are two types of fixed value resistors;

Precision resistors-Have tolerances of + or – 2% or lesser.

General-purpose resistors-Have tolerances of + or -5% or higher and have four bands. For general purpose resistors, the firs band can never be black, and it’s the first digit of our number. The second band indicates the second digit of the name.The third band specifies the multiplier to be applied to the number, which ranges from *1/100 to 10000000. The fourth band describes the tolerance or deviation from the determined resistance, which is+ or -5% or greater.

For precision resistor codes, the first band is never black and is the first digit of the three-digit number. The second indicates the second digit number, and the third band represents the third number. The fourth band specifies the multiplier and the fifth band the tolerance figure of the resistor, which is + or – 2%.

USE OF CAPACITORS, DIODES, AND TRANSISTORS IN RECTIFICATION.

Full-wave rectification

Four diodes labeled D1 and D4 were arranged in series pairs with only two diodes conducting current during each half cycle. Diodes D1 and D2 are forward biased during the positive half period of the supply, while D3 and D4 are reverse biased and current flows through the loads, as shown below.

2.1 ELECTRICAL INSTALLATION WORKSHOP

Objectives

1. To learn three-phase installation and metering
2. To learn two ways,one way, and intermediate switching installation.
3. To determine safety measures to be practiced during electrical wiring.
4. To understand how to draw wiring and schematic diagrams.
5. To learn three-phase metering and installation.

EQUIPMENTS AND TOOLS

• Sockets and switches
• Bulbs and bulb holders
• Double pole and Single pole switches
• Miniature circuit breakers
• Phase testers
• Insulated wire
• Warrington hammer
• Electrician tape
• Pliers
• Wire strippers
• Short circuit detectors
• INTRODUCTION

To achieve a successful performing electrical work, one must be able to read and interpret the different types of diagrams and also be familiar with electrical wiring components and symbols. Inspection and installation of electrical types of equipment are also essential to evade any possible mischiefs during electrical installation and performance. In this section, the report is all about the knowledge and skills I acquired during the electrical installation workshop. They include

• Drawing of electrical wiring symbols.
• Drawing electrical wiring and schematic diagrams.
• One way switching installation.
• Two way switching installation.
• Intermediate switching and installation.
• Three-phase installation.
• Metering, testing, and inspection of the installation.

A.THREE-PHASE INSTALLATION.

The circuit was

RESULTS AND OBSERVATION.

1. Parallel and Series Connections.

• When the bulbs were connected in parallel, the disconnection of a single lamp did not affect the working of other lights.The lamps are independent of each other, and they are of the same brightness.
• In a series connection, a single switch controls all the bulbs and can be located anywhere in the circuit. The brightness of the lamps varies.

1. Testing and Inspection of Installation.

The following were observed.

• For the insulation resistance test, an infinite reading was observed on the merger.
• In the polarity test, a low reading of about 0.7 ohms was observed on the multimeter.
• A ring circuit test was also carried out.
• The Earth effectiveness test was conducted.

DISCUSSION.

Parallel connection

In this connection, there is an introduction of an electric gap or the failure of one bulb does not affect the operation of the other lamps since each bulb is connected directly to its voltage source. All the bulbs have equal brightness since they are connected directly to the current source, and there is no resistance that one bulb offers over the other. Adding extra or reducing the number of lamps does not affect the operation of other lamps since current obtained directly from the current source is not affected by any resistance.

Series Connection.

When one switch is open, no current flows; hence all the lamps are off. The introduction of an electric gap in the circuit affects all the bulbs since the loop is not complete in the course. Closing the switch completes the circuit hence the bulbs light. The brightness of the bulbs is affected whereby the battery pushes the currents through the lamps, and the more the number of fires, the harder it is or current to flow; hence there is more resistance in the circuit. With one bulb, it is easy for the current to flow. Thus the lamp is bright. When several lights are connected in series, they experience more resistance resulting in small current around the circuit making the lamps dimmer. The more the number of bulbs, the higher the resistance hence, the lower the current through each lamp and the darker the lights.The same current flows through all the bulbs; therefore, they have equal brightness.

Inspection and Testing.

The IEE requires that before any installation is connected to the power supply, it should be tested and inspected in the sequence below.

1. a) Polarity Test

It is done to ensure all single pole switches are connected to the non-earthed conductor. It is carried out whether the circuit is dead or alive. When the course is live, a test lamp is used. For dead circuits, a continuity tester is used under the conditions that; the channel is dead, fuses in or MCB on, all switches off, and lamps out.

1. b) Earth effectiveness

Done to ensure all parts protecting insulation are mechanically and electrically sound. The earth’s polarity conductor, consumer main and earth terminal; the earth lead, earth resistant area, and the earth rod should be firm. This is done by the help of an earth loop tester.

1. c) Insulation Resistance Test

Is carried out between;

• Main conductors{live and neutral}:Meant to prove the quality of insulation material. It conducted under the following conditions;sockets are dead, switch is on ,lamps out and fuses in. An insulation resistance tester or a megger is used. A reading approaching infinity confirms the test.
• Ring Circuit Test

Done to ensure the continuity of all ring circuit wires.It ensures conductors forming the ring circuit have the right continuity.

CHAPTER THREE

BUILDING AND CIVIL ENGINEERING DEPARTMENT

Masonry

Is the art and craft of building and fabricating in clay, brick or concrete block. This chapter basically focuses on masonry during the workshop practice period.

Tools

• Hand towel
• Mason square
• Spirit level
• Straight gauge

Materials

• Cement-Used for making mortar and concrete. Acts as a glue by binding grains of sand together when water is added to complete the process of hardening.
• Aggregates-Divided into Fine aggregates that are able to pass through the 5mm sieve and Coarse aggregates which don’t pass through the 5mm sieve and are used in concrete production.
• Lime-It acts as the connection ingredient to mortars.
• Block-Produced from concrete and clay.Examples are special, concrete, foundation and clay blocks.
• Mortar-Is a mixture of sand and cement or lime and cement.It sticks firmly to bricks and blocks to keep of external “attacks” such as rains.
• Concrete-Made from a mixture of course aggregate,sand, cement and water. We have dense,light-weight and air entrained concretes.
• Bricks- Made from clay soil that contains ingredients of silica and alumina.

PLUMBING WORKSHOP

Pipe work

Consists of supply lines that bring water into the building and drains that carry water away from the building.Plumbing system consists of ;

• A Supply
• A drain
• Vents- Allow air to enter the drain system to ensure the is proper water flow.

Tools

• Vise and stand-Pipe filters use vise and stand to temporarily support pipes or other materials being worked on.
• Spring benders-Used to bend soft copper, aluminium, other metals and plastic pipes.
• Hack saw-Used to cut metals, plastics and other synthesis.
• Framing square-Used by pipefilters to lay out guidelines for cutting steel and pipe then squaring up adjacent markings at right angles and checking squareness of the end of the pipe .

Types of pipes

Pipes are used in supply, drains and also electrical distribution. They include

Copper water pipes-Suitable for water lines. It is stiff, does not corrode easily and easy to repair. It is the most durable but also the most expensive. We

• have soft and rigid copper pipes.
• Plastic water pipes-Majority are made of Polyvinyl Chloride. They are cheap, easily repaired and joined as compared to other water pipes.
• Galvanized water pipes-Made of steel and coated with zinc to make them more resistant to rusts and mineral deposits. They are tough, heat resistant and cost-moderated . Also, again these pipes are hard to install across edges and curves of a building.

Proper engineering design puts into consideration the type and effectiveness of the techniques used for pipes. These methods are as stated below.

• Socket welded joints: Used in cases of high chances of leakage in the joints. Pipes are joined by putting one into another.
• Flange joint: Used when joining metals or to other piping materials.
• Spigot and Socket: Involves a normal pipe end, the valve, being inserted into the socket or bell of another pipe or fitting with a seal being between the two within the device.

Sheet Metal Work

Sheet metal is a metal formed by an industrial process into thin and flat pieces. Made from metals such as aluminum, brass, copper, steel, and titanium. Joints in sheet metal were learned during the workshop practice.

Tools used in sheet metal work include;

Steel Rule-Used in measuring and laying out small work with accuracy being 0.5mm.

Mallet-Are sift hammers made of saw hide, rubber, copper, brass, or wood used to strike a soft and light blow on the metal.

Pliers-Used for holding, cutting, and bending work.

Tin Snips-Cuts off thin, soft metal and should be only to cut 20 gauge lighter metal.

Scriber-Used for making marks on sheet metal along the cutting edge.

There are two types of joints in sheet metal work.

• Double Lock Welt Joint: Involves folding the edges of the sheet metal over twice to make it stiff and smooth.
• Single Lock Welt Joint: Involves folding the edges of the sheet metal once to make it stiff and smooth.

CARPENTRY WORKSHOP

Tools

Several tools, as listed below, are used in the carpentry workshop.

• Mallet-Used for striking chisels when making mortises on wood.
• Tenon Saw-Used for cutting shoulders of joints and general bench cross-cutting.
• Steel Rule-Used to mark out and check dimensions and divide the width of a board into equal parts.
• Try Square- Used to mark lines at right angles across from the face side edge of a piece of wood. It is also used to check the squareness or flatness of a piece of timber provided a condition of a good light source behind the blade.
• A Marking Gauge-Used for cutting lines on a piece of timber parallel to the edge.

Bridle Joints/Forked Mortise

Made of mortise and tenon

Used for joining heavy timber frames and roof trusses, used for light framing in joinery and cabinet work.

Procedure of making Bridle Joint

• Mark out the tenon by drawing a line around the entire piece of wood to create the tenon length, ensuring that the tenon width around a third the thickness of the timber.
• Cut the tenons by band saw or tenon saw.
• Mark the mortise and decide where you want to position the joint.
• Use your recently cut tenon as a guide for the width of your mortise
• Cut out the mortise using a mallet and a chisel or mortising machine.
• Interlock the mortise and the tenon to see if they are knit; if not, they can be fastened by a minimum amount of timber shaved using a band saw.
• Once satisfied with the joint, you can bond it together with clamp and adhesive, as shown below.

Insert pic

CONCLUSION

In conclusion, the Workshop Practice at Machakos University was a great success. This was manifested through the acquisition of knowledge and skills in several fields of engineering. Through this training, I had the opportunity to blend the theoretical knowledge acquired from my class academics into practical work. Indeed the workshop was a great success.