Prepared
By:
Vikas Sakre (PGDIE 42
Roll No-103)
INTRODUCTION
Resistor is a passive electronic component having resistivity and is used
for various applications in any electronic equipment as a part of electronic
circuit used in it. Resistors offer resistance to flow of current.
Resistor can be broadly classified into fixed resistor and variable resistor.
Again fixed resistor is grouped into carbon composition, metal composition,
oxide coated and wire wound resistors. Resistors are characterised by
resistance value, power rating (in watts) and tolerance.
Wire wound Resistors consist of a cylindrical core which
is wrapped or wound with wire. The cylindrical core is typically made from a
ceramic material. The wire is a type of resistance wire. Wire wound resistors
are a type of power resistor and are very accurate. Wire wound resistors are
available as fixed, or adjustable to be used as a rheostat or potentiometer.
Wire wound resistors, which are used in electronic equipments and
instruments where high precision and more power dissipation are specified. Wire
Wound Resistors are preferred over metal oxide resistors because of being
better temperature co-efficient and of smaller size. Again wire wound resistors
can be divided into silicon coated ceramic type, aluminium type etc., based on
chemical composition and type of application. Silicon coated resistor is
further divided into radial, axial, commercial type, fusible etc., depending on
the application. Wire Wound Resistor finds application in power equipments,
testing and measuring equipments, communication equipments, medical electronic
equipments, computer hardware, audio and video equipments, Defence and Space applications.
MARKET POTENTIAL
As mentioned earlier, Wire Wound Resistor finds applications in all
electronic equipments consisting of electronic circuits. They are widely used
in process control instruments, telecommunication equipments, testing and
measuring instruments, power equipments etc., for various functions like
current limiting, on load, overload, protection etc.
There are many units in the country manufacturing different types of Wire
Wound Resistors. Most of them are manufacturing silicon coated, ceramic encased
and aluminium wound resistors. But there is an incremental growth of electronic
industries in the country, which has created further scope of new industries in
the field of wire wound resistors.
The new entrepreneur should have knowledge and should collect data about
various types of wire wound resistors used by the electronic industry and its
different applications. Manufacturing Wire Wound Resistors with high precision,
better tolerance will increase the market share.
MACHINES
& MATERIAL HANDLING EQIPMENTS REQUIRED
¢
Toggle
Action Press ½ Ton Cap.
¢
Automatic Coil Winding Machine
¢
Lead cutting Machine Grinder
¢
Lead Straightening machine
¢
Lead Tinning machine
¢
Spot Welding machine
¢
Oven (Temp. controlled)
¢
Stirrer (Ball Mills)
¢
LCR - Q Meter
¢
Digital Temperature Indicator 4½ Digit Bench
Micro ohm Meter
¢
Dimmer Stat (4A)
¢
4 ½ Digit Digital Multimeter
¢
Load Tester and Brake Tester
¢
Fusing Tent Machine
¢
Tension
Tester
¢
Marking
Machine with accessories
¢
Resistance
oil standards
¢
Electrification
¢
Office
Equipment Furniture
¢
Jigs/Fixtures
MANUFACTURING PROCESS
Process of Manufacture
For ceramic encased type resistor (power resistor), the resistors are
manufactured by winding resistance wire on ceramic rods. Then ends are spot
welded to ceramic caps with leads on lugs followed by dipping in silicon based
resin and drying. These resistors are tented at high temperature and high power
dissipation as per the specification before packing and despatch.
The essential production machinery and
test equipment required for the project have been indicated. The unit may also
utilize common test facilities available at Electronics Test and Development
Centres (ETDCs) and Electronic Regional Test Laboratories (ERTLs) set up by the
State Governments and STQC Directorate of the Department of Information
Technology, Ministry of Communication and Information Technology, to
manufacture products conforming to BIS standards
Resistors with wire lead for through-hole
mounting
Through-hole components typically have leads leaving the
body axially. Others have leads coming off their body radially instead of
parallel to the resistor axis. Other components may be SMT (surface mount technology)
while high power resistors may have one of their leads designed into the heat sink.
IMPLEMENTATION SCHEDULE
The
major activities in the implementation of the project have been listed and the
average time for implementation of the project is estimated at 12 months.
S.No
|
NAME OF ACTIVITY
|
PERIOD IN MONTHS
(ESTIMATED)
|
1
|
Preparation
of project report
|
1
|
2
|
Registration and other
formalities
|
1
|
3
|
Sanction of loan by
financial institutions
|
3
|
4
|
Plant and Machinery
|
|
a
|
Placement of orders
|
1
|
b
|
Procurement
|
2
|
c
|
Power connection/
Electrification
|
2
|
d
|
Installation/Erection
of machinery/Test Equipment
|
2
|
5
|
Procurement
of raw materials
|
2
|
6
|
Recruitment
of Technical, personnel etc.
|
2
|
7
|
Trial
production
|
11
|
8
|
Commercial
production
|
12
|
Quality Control and Standards
Standards
Since performance of electric equipments depends on the quality of
component used, it is very essential that quality standards are followed. The
samples can be tested as per Indian Standards.
General Specification
Vitreous
enamel/
|
Ceramic coated
|
|
Silicon
coated wire
|
resistors
|
|
wound resistors
|
||
Range
: 0.1 Ohm to
|
Range : 0.025 Ohm to
|
|
100 K
Ohm
|
100 K
Ohm
|
|
Power
Ratio: 1 to 200Watts
|
Power rating: 1 to 20 watts
|
|
Tolerance:
above
|
Tolerance:
5%
|
|
1 Ohm +
1%
|
and
10%
|
|
1 Ohm +
5%
|
||
below
1 Ohm + 10%
|
||
Temp.
co-efficient:
|
Temp.co-efficient:
|
|
100
PPM to 200 PPM
|
200
PPM/deg. C
|
|
To
1500 PPM/deg.C
|
Additional Information
a) The Project
Profile may be modified/tailored to suit the individual entrepreneurship
qualities/capacity, production programme and
also to suit the locational, characteristics, wherever applicable.
(b) The Electronics
Technology is undergoing rapid strides of change and there is need for regular
monitoring of the national and international technology scenario.
The unit may, therefore, keep abreast with
the new technologies in order to keep them in pace with the developments for
global competition.
(c) Quality today is
not only confined to the product or service alone. It also extends to the
process and environment in which they are generated. The ISO 9000 defines standards
for Quality Management Systems and ISO 14001 defines standards for
Environmental Management System for acceptability at international level. The
unit may therefore adopt these standards for global competition.
(d) The margin money
recommended is 25% of the working capital requirement at an average. However,
the percentage of margin money may vary as per bank’s discretion.
Pollution Control
The
Govt. accords utmost importance to control environmental pollution. The
small-scale entrepreneurs should have an environmental friendly attitude and
adopt pollution control measures by process modification and technology
substitution. Awareness among the staff members of the industrial undertaking
should also be created for abatement of pollution.
India
having acceded to the Montreal Protocol in Sept. 1992, it has become mandatory
for India to phase out the production and use of Ozone Depleting Substances
(ODS) like Chlorofluoro Carbon (CFC), Carbon Tetrachloride, Halons and Methyl
Chloroform etc. These chemicals/solvents are to be phased out immediately with
alternative chemicals/solvents.
Government
of India has already taken a number of policy measures, both fiscal and
legislative, to encourage early adoption of non-ODS technologies. A
notification for detailed Rules to regulate ODS phase out under the Environment
Protection Act, 1986 have been put in place with effect from 19th July 2000.
The Rules give the necessary legal backing and time frame for the phase out of
ODS.
We are at the very critical stage where the
momentum generated in the past has to further strengthen. As such the following
steps may help to control pollution in electronics industry wherever applicable
i) In electronic industry fumes and gases are released
during hand soldering / wave soldering/Dip soldering, which are harmful to
people as well as environment and the end products. Alternate technologies may
be used to phase out the existing polluting technologies. Numerous new fluxes
have been developed containing 2-10% solids as opposed to the traditional
15-35% solids.
ii) Electronic industry uses CFC, Carbon Tetrachloride
and Methyl Chloroform for cleaning of printed circuit boards after assembly to
remove flux residues left after soldering, and various kinds of foams for
packaging.
Many
alternative solvents could replace CFC-113 and Methyl Chloroform in electronics
cleaning. Other Chlorinated solvents such as Trichloroethylene,
Perchloroethylene and Methylene Chloride have been used as effective cleaners
in electronics industry for many years. Other organic solvents such as Ketones
and Alcohols are effective in removing both solder fluxes and many polar
contaminants
Energy Conservation
With the growing energy need and
shortage coupled with rising energy cost, a greater thrust in energy efficiency
in industrial sector has been given by the Govt. of India since 1980s. The
Energy Conservation Act, 2001 has been enacted on 18th August 2001, which
provide for efficient use of energy, its conservation and capacity building of
Bureau of Energy Efficiency created under the Act.
The following steps may help
for conservation of electrical energy:
i) Adoption of energy conserving technologies,
production aids and testing facilities.
ii) Efficient management of process/ manufacturing
machineries and systems, QC and testing equipments for yielding maximum Energy
Conservation.
iii) Optimum use of electrical energy for heating during
soldering process can be obtained by using efficient temperature controlled
soldering and de-soldering stations.
iv) Periodical maintenance of motors etc.
References:
1) dcmsme.gov.in/publications/pmryprof
2) wikipedia.com
3) www.hotfrog.in/Products/Resistor
4) www.pridmore.com/OHMITE
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