ELECTRIC SWITCHES PLUGS SOCKETS & MCB (MINIATURE CIRCUIT BREAKER)
[EIRI/EDPR/4669] J.C.: 2886XL
Electric switches, plugs, sockets, etc. are nothing but electric fittings which are quite familiar to the people as it is found in every home. They can be manufactured using different major raw materials e.g. steel, brass, thermosetting or thermoplastic resins However this report is totally based on bakelite powder or resin which is thermosetting type. Bakelite powder is also known as phenol formaldehyde resin. also other electrical accessories e.g. plates, lamps holders, may be manufactured from phenol formaldehyde resin and same plant and machineries making the industry highly flexible and profitable. Besides electrical fittings radio cabinets, inks stands, table lamps, door and cabinets, handles, power relay components, camera shutters, textile bobbins and other accessories may also be manufactured with little or no change.
As mentioned earlier though electrical fittings may be manufactured from other materials also it may be noted that bakelite electrical fittings are best and economical. Also bakelite is bad conductor of electricity making them shock resistant which may be there is case of metal electrical fittings.
Electric fittings are manufactured in different sizes as required by the customer. They may be of two or three pin. Three pin sockets and plugs have one major advantage over two pin one's since they are earthed also. Also various combinations are practiced in the 5-15 ampere range.
These combinations are (1) 5 amp. switches, sockets, Bell push & Flush type fuses (2) 15 amp. and 5-15 amps. combination etc. can imagine the scope of this industry. To make it more clear due to the development in electric production more industries will be installed, more and more electricity, as well as industrial purposes which in turn will require more fittings.
COST ESTIMATION
Plant Capacity 2000 Nos./Day
Land & Building (500 sq.mt.) Rs. 14.00 Lac
Plant & Machinery Rs. 86.50 Lac
Working Capital for 2 Months Rs. 75.84 Lac
Total Capital Investment Rs. 1.82 Cr
Rate of Return 135%
Break Even Point 26%
CONTENTS
PRODUCT 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
B.I.S. SPECIFICATION
IS: 4949-1968
2. TERMINOLOGY
3. MATERIAL
4. CONSTRUCTION
5. TERMINALS AND SCREWS
6. ACTUATING MECHANISM
7. CREEPAGE DISTANCES AND CLEARANCES
8. MARKING
9. TESTS
1. SCOPE
1. SCOPE
2. TERMINOLOGY
PUSH-BUTTON SWITCH
MECHANICAL FEATURES
3. CATEGORIES
4. ELECTRICAL RATINGS
5. MATERIALS AND WORKMANSHIP
MATERIALS:-
MARKING
USES AND APPLICATION
COMPOUNDING THE RAW MATERIALS:
CONTACTS:
EARTHING:-
RAW MATERIALS
PHENOL-FORMALDEHYDE RESINS:-
RAW MATERIAL SELECTION:-
DETAILS OF SOCKETS
HOLES OF ELECTRICAL SOCKETS
ELECTRICAL SOCKET MATERIALS
INSTALLING ELECTRICAL SOCKETS
MULTI STANDARD 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
POWER SOCKET
TYPES OF ELECTRICAL SOCKETS
PLANT AND MACHINERY SECTION
COMPRESSION MOULDING DRESS:-
DIE OR MOULD:-
MCB (MINIATURE CIRCUIT BREAKER)
INTRODUCTION
WORKING PRINCIPLE MINIATURE CIRCUIT BREAKER
MINIATURE CIRCUIT BREAKER CONSTRUCTION
CONSTRUCTION OF MCB
FRAME OF MINIATURE CIRCUIT BREAKER
OPERATING MECHANISM OF MINIATURE CIRCUIT BREAKER
TRIP UNIT OF MINIATURE CIRCUIT BREAKER
OPERATION OF MINIATURE CIRCUIT BREAKER
TYPES OF MINIATURE CIRCUIT BREAKERS (MCB’S)
TYPE B MCB
TYPE C MCB
TYPE D MCB
(2) DISTRIBUTION BOX
TYPES OF ELECTRICAL DISTRIBUTION BOARDS
FUSE BOXES:
MAIN BREAKER PANEL:
MAIN LUG PANEL:
SUBPANELS:
TRANSFER SWITCHES:
USAGE AND APPLICATION
1. HOME ELECTRICAL PANELS
2. LIGHTS
3. INDUSTRIAL APPLICATIONS
4. HEATERS
5. GROUND FAULT TRIP MECHANISM
B.I.S. SPECIFICATION
PROCESS FLOW CHART
PROCESS FLOW CHART (MCB)
PROCESS FLOW CHART DISTRIBUTION BOX
PRODUCTION PROCESS
(A) FOR MCB
(1) SPOT WELDING:-
PROCESSING AND EQUIPMENT
THE ABOVE MENTIONED STAGES ARE BETTER EXPLAINED THROUGH FOLLOWING BLOCK DIAGRAMS:
KNOB ASSEMBLY: -
COMPONENTS USED:
STEPS OF KNOB ASSEMBLY:-
TOOLS USED:-
THE PROCESS FLOW DIAGRAM FOR KNOB ASSEMBLY IS SHOWN BELOW: -
MCB ASSEMBLY: -
THERMAL OPERATION: -
MAGNETIC OPERATION: -
QUALITY CONTROL
SCHEME OF INSPECTION AND TESTING:
MARKET POSITION
CHINA CIRCUIT BREAKER MARKET, BY RATED VOLTAGE (USD MILLION)
EUROPE CIRCUIT BREAKER MARKET, BY COUNTRY, 2024 (UNITS)
INCREASING RURAL ELECTRIFICATION, TO DRIVE THE GLOBAL MCB AND MCCB MARKET
MARKET OVERVIEW
MARKET SEGMENTATION
NORTH AMERICA DISTRIBUTION PANEL MARKET, BY END USE, 2016 & 2024 (USD BILLION)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
TOP ELECTRICAL SWITCH MANUFACTURING COMPANIES IN THE WORLD
ELECTRICAL SWITCH MANUFACTURING COMPANIES
SIEMENS
SCHNEIDER ELECTRIC
POLYCAB
PHILIPS
HPL
HONEYWELL
HAVELLS
GREAT WHITE
GOLD MEDAL
GM
CORUM
ANCHOR
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
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:
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:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
LIST OF IMPORTANT LICENSES REQUIRED TO START MANUFACTURING ELECTRICAL SWITCHES, SOCKET & MCB
MANUFACTURERS/EXPORTERS/SUPPLIERS OF ELECTRICAL SWITCH, SOCKETS, MCB ETC.
SUPPLIERS OF RAW MATERIALS
BAKELITE POWDER
PHENOL FORMALDEHYDE RESINS
STEEL STRIPS
MANUFACTURERS NUT AND SCREWS
MANUFACTURER SLEEVES
SUPLIERS OF PLANT AND MACHINERIES
HYDRAULIC PRESS
PLASTIC PROCESSING MACHINERY
BUFFING MACHINE
SUPPLIERS OF MCB
RAW MATERIAL SUPPLIERS
SUPPLIERS OF PRODUCTION LINES
STEEL PIPE & SHEET MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS
LABORATORTY EQUIPMENTS MANUFACTURERS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EXHAUST FAN
SUPPLIERS OF TESTING EQUIPMENTS
GANIZATION CHART
SWOT ANALYSIS
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
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
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
