Training Report
Training Report
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Abstract
Industrial training is one of the compulsory courses an undergraduate following the BSc. Course in
Mechanical engineering (Mechatronics) should undergo. One of the focuses of this course is
understanding the application of theoretical knowledge in real life engineering problems and applying
them in solving the problem in the most efficient way. According to the curriculum undertaken by Sri
Lanka Institute of Information Technology situated in Malabe, this industrial training period has been
broken down into 2 training period to be accomplished at the end of second semester of 2nd and 3rd year
of study. Accordingly, this report consists of the tasks that have been undertaken and completed as an
engineering undergraduate trainee at the Department of Research and Development of Orel Cooperation
located in Meegoda from 21st December 2020 to 19th March 2021.
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Acknowledgement
It is with great pleasure I acknowledge the contribution and assistance that was provided to myself during
the training period at Orel cooperation under R&D department. The assistance they had provided during
this period and the dedicated support they provided in aiding myself in having a successful training is
immeasurable.
I would like to give my special thanks to the Head of Innovations Research and Development Department
Mr. Dashan Rathnasinghe for all the support and guidance provided during the training process. I would
also like to thank our direct coordinator Mr. Sachithra Gayashan who supported, guided and gave the
necessary industrial training required to be gained during our time period at R&D department. I would
also like to thank all the employees present under the department of R&D who assisted us throughout
our training process.
I would also like to thank the Head of building infrastructure of R&D Mr. Rajitha Wickramasinghe who
aided in recruiting me as a trainee to work under the Research and Development department and Mr.
Sanjaya, Mr. Roshan, Mr. Risira and Mr. Isuru with whom I was also able to work with who was also
able to guided us throughout our time period at R&D department. The knowledge and industrial exposure
given to us during different designing and testing operations was immense. Therefore, I am duty bound
to thank all who aided in my training at R&D by providing and guidance when required.
Finally, I would like to thank every individual those whom I had not been able to thank by name for even
the slightest support they had provided me in order to make my industrial training at R&D department
more fruitful.
Thank you.
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List of Figures
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Figure 34 dual spot light ......................................................................................................................... 17
List of Tables
Table 1 Issues and resolution methods related to ION switch project ................................................... 14
List of Abbreviations
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Table of Contents
Abstract ..................................................................................................................................................... i
Acknowledgement .................................................................................................................................... ii
1. Introduction. ..................................................................................................................................... 1
Vision ............................................................................................................................................... 2
Mission ............................................................................................................................................. 2
Objectives ......................................................................................................................................... 2
2.2.3 Toggle switch with metallic front face (1-4 gang and 13A) ................................................... 6
3. Conclusion ...................................................................................................................................... 19
References .............................................................................................................................................. 20
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1. Introduction.
During the industrial training period at Orel Corporation the training was provided by the department of
Research and Development From 21st December 2020 to 19th of March 2021.
The main task of R&D department was to design and develop new equipments and models based on the
client’s request. based on these tasks the R&D Department consist of different teams to undertake
different components of these projects.
With the focus of having a successful training at Orel Corporation in order to achieve success as a
mechatronics engineer in the future, the training for myself was to learn the process involved in
developing a new or current model based on requests provided. This was achieved through a process of
understanding, researching and when necessary modifying present models in order to meet the set
standards.
These tasks provided the opportunity to understand the process through which a new equipment is
manufactured while at the same time showing the ways and means through which these said processes
can be further optimized and developed. Though the training at Orel Corporation did not expose myself
to the study of electrical or electronic circuitry on a wide scale, the exposure provided to these field help
in having and understanding about the fields of engineering where mechatronics engineering can be
used.
A company’s future is determined to be a successful based on the idea it has, the vision it looks for to
be in the future and the mission it is willing to follow in order to achieve its vision.
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1.1 Vision, Mission and Objectives of the company
Vision
To become a billion dollar in revenue, adaptive manufacturing, e-commerce led, global enterprise in
industry 4.0.
Mission
To reimagine business through industry 4.0.
Objectives
• Connecting people, products, and technologies through innovation, by empowering humanity to
make our world a better place.
• Achieve success through inspiring and empowering our leaders to achieve excellence beyond
what they believe is possible.
• Setting world class benchmarks, caring for their development and building relationships.
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1.2 Company background and history.
The company came into existence by the founder Somapala Kodituwakku in the year of 1920 at the age
of 21 as a company which was in charge of transporting orange fruits to the capital at that time. Later
the company ventured into another business prospect by establishing Somapala & Co which was a British
Automotive spare parts establishment, in the year 1940. The second generation of the company leader
Sugath Kodituwakku came into existence in the year 1960 by becoming the chairman who in turns led
the company to become orient with introducing Japanese spare parts and changing it into Orient
Commercial Company. In the year 1975 Phillips Distribution was acquired by Orient Commercial and
in the year 1983 a manufacturing joint venture was established with the Clipsal Australia establishing
Orient Holdings. In the year 1995 the third generation of the company came into place with Kushan
Kodituwakku who in turns expanded the company to consist of manufacturing with Research and
Development capabilities. In the year 2004 with the acquisition of Clipsal by Schneider, the company
finally became independent with the brand name switching to Orange Electric. In the year 2017 the
company was relocated the manufacturing to Orel Park which was a greenfield Project.
Currently the company is spread over 28 different countries with more than 4300 employees working
worldwide.
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1.3 Management
Tim Sherman
President, Signamax
Experienced executive business leader, with a
strong track record of top and bottom-line
revenue growth over a 20yr career in IT
Networking. Professionally trained in
Marketing and has served in senior leadership
roles with leading Fortune 500 Companies.
Sanath Wijethunge
COO, Sri Lanka
More than twenty-five years of experience in
Sales and Marketing at Senior Management
level, Marketing Graduate from the CIM – UK
and Certified Professional Marketer status
conferred by APMF in Singapore. Currently
holds a M.B.A. from University of Southern
Queensland – Australia
Saurabh Sagar
CEO, South Asia
Over 12 years of experience in Healthcare and
Electrical Markets of Asia, holding a Bachelor
of Commerce Degree from Deakin University,
Australia and Higher Certificate in
Business/Marketing and Diploma in Business
Admin & Marketing from University of
Cambridge, Singapore. Possess skills in
breaking new avenues & driving revenue
growth.
Sooraj Sivaprasad
CEO, Middle East & Africa
Business Management specializes in
Marketing, Sustained track record in business
development
and delivering strong business and operational
results in Middle East and Africa. More than
14+
years of extensive experience in the field of
Sales, Marketing and Product Support. (Orel Corporation, 2021)
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2. Training experience
The training at Orel Corporation can be differentiated according to the following tasks undertaken
Examining and evaluating different models in order to observe and document errors if present
During the industrial training at Orel Corporation under R&D department, as a trainee opportunity was
provided to partake in the following design and development projects.
Other than the above-mentioned projects the task of recreating virtual 3D models of present physical
models. These included different lighting equipment such as step lights, spotlights, lawn lights and
cabinet lights.
Also, the task of modifying a present model so as to rectify errors in present model- X5 mechanism
model.
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2.2.1 AKOYA Twin 13 Multi +USB+IND
The project was of a switch design with 2 sockets designs for 13A plugs and 2 USB charging ports.
This project was the first task that was given. The project was to produce dimensional report by creating
a drawing file of the different components using the Solidworks software. For this task the designed 3D
models were provided. In order to complete this task, firstly, it was necessary to understand which
dimensions to be displayed in this report for this purpose different drawing files which were created
previously were used as reference.
In order to complete this task first the company’s standard drawing was used as the base format.
Next the options were changed to the necessary set standards. These included,
Through undertaking this task, the ability to understand the critical dimensions while at the same time
was able to understand the method through which dimensions should be usually displayed for to be
measured later when tests are done to observe for nay manufacturing errors.
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2.2.2 Vintage toggle switch
This project involved in developing the present 3d model in order to avoid the present errors and to
optimize the manufacturing process while at the same time maintaining the cost of production to not
increase.
Here the main tasks were to modify the intermediate of the switch design while at the same time to
optimize the Dolly aperture such that the modified intermediate is capable of operating while at the same
time maintaining the visual aesthetics of a vintage switch.
The process involved in modifying the intermediate, dolly aperture and brass switch ring was to be
such that the component used in the mechanisms and other components present which consisted of
standard parts were to be present without any restrictions.
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In order to achieve this the intermediate was to be modified as follows.
Figure 6 Bottom view of intermediate prior to modification Figure 8 Bottom view of intermediate post modification
Figure 7 Top view of intermediate prior to modification Figure 9 Top view of intermediate post modification
The bottom of the intermediate was modified as shown in figure 8 was done in order to collision that
occurs between the intermediate and shifting plate. For this purpose, cut extrude tool was used.
The top of the intermediate was modified as shown in the figure 9 in order to place the standard metal
plate in charge of shifting the shifting plate from on and off position in the mechanism.
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In order to accommodate the modified intermediate, the dolly aperture was modified as shown below.
While most of the modification here were done by the supervision the modifications shown in figure 11
that is the addition of the extruded part which covers the all inner components while at the same time
retains enough space for the intermediate movement, while the other two cut extrusions were done in
order to avoid the undercut placement that occurs due to the fixing point of the mechanism to the dolly
aperture.
Furthermore, the brass switch ring was to be made through the process of pressing. Therefore, the model
was modified as follows to avoid unnecessary complexity in production and material wastage.
Figure 12 Brass switch ring before modification Figure 13 Brass switch ring after modification
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2.2.3 Toggle switch with metallic front face (1-4 gang and 13A)
This project was to design a new front face design such that the intermediate that was designed and
modified under vintage switch design can be used. For this purpose, new components such as front
metallic face, Dolly aperture had to be developed.
In order to undertake this task, firstly the stand measurements were taken and set such that further into
the modification these won’t be changed. For the development of dolly aperture, the dolly aperture of
the vintage switch design was used as the base and further modified as follows.
Figure 14 Dolly aperture before modification for 1 gang switch Figure 15Dolly aperture after modification for 1 gang switch
The part of the component used for holding the mechanism in place was cut extrude and the position of
the main screw holding the metal front plate and all other components in place were used as base for the
model. The diameter and chamfers shown in figure were standard values used, as the dolly aperture and
the metal front place were to be riveted together.
The front face was made with the use of the same said standards being
the base and the design was made with the main screw points which
connects the front case to the switch box being modeled with the aid of
another predesigned 1 gang switch as base, while the point which covers
the dolly aperture extruded point being designed such that it can be later
manufactured through pressing process.
Finally, the edge was designed with a curved edge, in order to add
visual effect as well as safety to user.
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The task of designing the 2 gang, 3 gang and 4 gang were done through process of copying and shifting
the mechanism holding position of the dolly aperture such that at the end the placement would be
symmetric.
Figure 17 Dolly aperture after modification for 2 gang switch Figure 18Dolly aperture after modification for 3 gang switch
In order to observe the feasibility and producibility of the model different virtual test such as undercut
analysis, thickness analysis, sink mark analysis and bending analysis were carried out.
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By understanding undercut analysis, it is possible to observe positions where material filling should be
or not carried out.
Figure 20 4 gang dolly aperture undercut analysis Figure 21 4 gang dolly aperture thickness analysis for 1mm
Through understanding the thickness analaysis, it is possible to identify places where material filling is
insuffient. This allows to identify positions which have to remodeled and to understand positions to
which less amount of force should be supplied.
Bending analysis helps in identifying positions that should be strengthened, in the case the 3gang and 4
gang models, ribs had to be added in order to strengthen the model in order to decrease bending. The
above figure displays such a model with rib of thickness 1mm addition.
Sink mark analysis allows to observe the visual output of the model after filling of material is done. In
the below shown figure shows the sink mark that can be observed with a depth ranging around 0.075mm
to 0.097mm. The sink mark standard for this model was to be less than 0.1mm, which has been achieved.
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Figure 23 4 gang dolly aperture sink mark analysis
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The present set standard of 13A socket designs were such that the point of insertion of 13A plug is off
center.
In order to observe the feasibility of designing a new 13A socket design under the same conditions as
the above gang switches a model for the purpose of observing was to be developed.
Firstly, the base design was modeled such that it will fit the necessary parameters of the set components.
Figure 25 Base model of the present 13A socket Figure 26 Modified 13A socket to set parameters
Finally, the front metal face was designed as shown below, which was later again modified to get an
aesthetically pleasing final design.
Figure 27 Final 13A socket with toggle switch design with adjustment for aesthetics
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2.2.4 ION switch (1-4 gang)
For this project, the main task was to observe errors that are present in the design that has been made
into a physical model (prototype). The task allocated was to observe the physical model and compare it
with the virtual 3D model designed through the Solidworks software.
As this project was carried out near the end of the training the task of identifying and resolving errors
was not completed. Therefore, the below mentioned table displays the solutions taken through
discussion with project in charge Mr. Roshan.
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In order to solve some of the above-mentioned issues following steps and actions were taken.
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Sink marks present on 1 gang Addition of pattern
dolly as first phase
change
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Modified pattern for support Changed the split
in 3 and 2 gang models line point of the
collide when being turned on model such that
with the surround interference does
not occur
The main action requested in this project was the finding of solutions for the errors observed. The main
errors such as the wobbly nature of gang switch, warping of gang switches and rectifying switch action
failure needed more in-depth workings to be done, as they come in to contact with critical measurement
points.
Therefore, these tasks the project in charge aided by providing a base design to be followed and teaching
the process through which these changes should be carried out.
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The task of rectifying the wobbly nature of gang switch, the point of fixing of the gang switch to the
surround was reduced in diameter on the switch. This in turns remedied the wobbling of switch and
provided a smooth movement for the switch.
Figure 28 Reduced inner diameter to 2.52mm by reducing 0.18mm from 2.7mm (Red colored area).
Carrying out the above task was simply done through moving circular cylindrical face by 0.02mm.
In order to facilitate proper switch action part were added as shown below which accommodate in
movement of the gang switch respective to the intermediate.
Figure 29 Modified part as shown in model to avoid switch action failure. (Yellow colored area).
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The process of avoiding a bit complex as both the physical model as well as the document related to the
molding process had to be referenced as added ribs had to avoid collision with the points that come into
contact with the pushers of the molding process. Also, another issue related to addition of ribs was that
it should not obstruct the movement of the gang switches.
Therefore, the following actions as shown below were taken into consideration.
Figure 30 Gang switches (3-left top, 2-right top, 1-bottom) with the addition of rib pattern to aid in strengthening the switch
In order to avoid collision between gang switch and surround, 2 separate split lines were added to the
model sch that above the top split line the model face is rotated by 3° and below the bottom split line the
pattern face is rotated inwards by 3°. This allowed for smooth movement of gang switch without any
conflict with the surround.
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2.3 Problems encountered
Friendly competitions and collisions between departments is one of the most common occurrences.
Presence of a healthy rivalry as such would lead to the improvement of personal and the company as a
whole. But sometimes due to this, certain tasks may not be carried out on time. The tasks where
communication between the department of tooling, Quality assurance and department of R&D in the
ION switch project was greatly hindered due to this. Therefore, presence of proper communication was
shown to be a must in a company through this incident.
Though such problems were present, the pros which were observed and absorbed during the industrial
training period at Orel Corporation outweighed the cons ending in providing a successful training for the
trainees.
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3. Conclusion
The main task or objective of an industrial training session is to provide exposure for undergraduates to
the industrial environment to which they will be entering. Through this they gain an understanding of
application of theoretical knowledge learned at the university and an appreciation to learning them. As
an undergraduate, they learn different theories on different equipment and machines used in industry and
observe them mostly as images with less or no experience on operating them and have only little or no
experience in using them in practical situations. At Orel Corporation under R&D department trainees
had the freedom to applying these gained knowledges in designing and developing new equipment and
components as necessary, where the only limiting factor being the frameworks being followed by the
company.
The employees themselves were quite friendly in being approached for gaining knowledge from and
usually were willing to help in aiding in solving problems faced even prior to being approached. This
factor itself showed the friendly nature of the company and its employees to others and displayed their
professionalism.
This became a plus point for trainees as no blockage of communication was present between trainees
and employees. The training at Orel Corporation did not only focus on technical knowledge but also
aided in improving skills such as management, interpersonal relationships, communication and conflict
resolution.
The training at Orel Corporation as an undergraduate of SLLIT was quite immense and would
recommend R&D department for any undergraduate, who is having a drive to learn while correcting
mistakes while at the same time keen on gaining knowledge on designing and developing process
involved in manufacturing process.
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References
Anderson, D. M., 2014. Design For Manufacturability. Boka Rotan, FL: CRC Press.
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