CHAPTER -1

INTRODUCTION

Fig 1.1: Hanger 101

With a legacy of 100 years, BOSCH India is a leading supplier of technology and services in
the areas of Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and
Building Technology. Additionally, BOSCH has, in India, the largest development center
outside Germany, for end-to-end engineering and technology solutions. Jaipur Plant is the
fourth location of BOSCH Ltd. in India, commissioned in 1999 with a state-of-the-art
manufacturing facility to produce FIP's. A IATF 16949, ISO 45001 and ISO 14001 certified
company, it is a technological oasis in the developing state of Rajasthan.
JaP is the lead plant for VE pump and NHA. JaP is the second location of Injector
Manufacturing in PS-IN. Manufacturing of Nozzle Holder Assembly (NHA) started in JaP
from Sept’16. A young team of enthusiastic & resolute professionals work single-mindedly to
make Bosch, Jaipur world class.

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BOSCH Jaipur manufactures two products namely:

1. VE (Verteiler Einspritzpumpe) Pump

2. NHA (Nozzle Holder Assembly)

1.1 VE (Verteiler Einspritzpumpe) Pump

The VE injection pump is a mechanically controlled, axial-piston rotary pump. It uses a vane-
type supply pump to generate an internal pump pressure that increases with engine speed. It
has a single pumping plunger, called a distributor plunger. This plunging and rotating shaft
generates injection pressure and controls injection timing. Six individual delivery valves,
located in the pump body, connect the pump to the injectors.

The customers of Bosch include like Volkswagen and many other automobile manufacturing
industries.

Figure 1.2: Manufacturing of VE pump

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 Figure 1.3: VE Pump

1.2 NHA (Nozzle Holder Assembly)

The nozzle-and-holder assembly is made up of nozzle holder and nozzle. The compression
spring inside the nozzle holder acts on the nozzle needle via the pressure pin. During the
injection process, the nozzle needle is lifted upwards by the pressure of the fuel. The fuel
passes through the injection orifices into the combustion chamber. The injection process
comes to an end when the fuel pressure drops to a point where the compression spring can
push the nozzle needle back against its seat. Start of injection is thus controlled by fuel
pressure. The injected fuel quantity depends essentially on how long the nozzle remains open.

The customers of Bosch include like Mahindra&Mahindra, Cummins, Kirloskar and many
others.

The below figure shows the exploded view of injector and one can observe each and every
component clearly and when these components are assembled it makes an injector.

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 Figure 1.4: Exploded view of Injector

Function of Nozzle Holder Components:

1) Fuel Inlet: Diesel Fuel inlet.

2) Nozzle Holder Body: Connects fuel from high pressure pipe to nozzle.

3) Leak Off: Fuel back leak taken out to the tank.

4) Bar Filter: Fuel gets filtered as it travels through bar filter.

5) Shims: Used to get pre – compression.

6) Spring: Compression of spring gives initial force to get opening pressure.

7) Pressure Bolt: Transmits the force coming from needle to spring, needle lifts when
force on the needle is overcome by counteracting force created by hydraulic pressure.

8) Distance Piece: Connects fuel from nozzle holder body to nozzle, locates the nozzle
in correct position and gives the desired tightness against leakage.

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9) NR Nut: Holds the nozzle tight in position with NHB.

10) Sealing Washer: Seats NH with cylinder head to avoid combustion gas leakage.

11) Nozzle: Fuel come out of seat, sac hole, spay hole and get atomized.

Figure 1.5: Manufacturing of NHA

1.3 Projects
1. Temperature and humidity monitoring of electric panel.
2. Variable Frequency Drive (VFD) installation and operation.

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 CHAPTER-2

LITERATURE REVIEW

2.1 Temperature and humidity monitoring of electric panel

In the past, when regular monitoring procedures were not in place, the occurrence of
problems was highly likely. Without proper monitoring, potential issues within the system or
process could go unnoticed, leading to unanticipated breakdowns, malfunctions, or
inefficiencies. These problems might have escalated and caused more significant disruptions,
impacting productivity, safety and overall performance.

If temperature and humidity monitoring of electric panels in an industry is not present, several
potential consequences can arise:
 Equipment failure
 Increased fire hazards
 Reduced equipment lifespan
 Inefficient energy usage
 Moisture related issues
 Lack of preventive maintenance

Implementing a comprehensive monitoring system allows for real-time data collection and
analysis, enabling early detection of anomalies and deviations from the normal condition. By
promptly identifying and addressing these issues, proactive measures can be taken to prevent
their escalation into critical failures. Additionally, monitoring provides valuable insights into
the system's behavior and performance trends, facilitating informed decision-making and
strategic planning for optimized operations.

Temperature and humidity control within electrical panels are crucial for maintaining optimal
operating conditions and ensuring the longevity and reliability of electrical components. The
Testo Saveris 2 sensor has gained prominence as a widely used solution for monitoring
environmental parameters in various industrial settings.

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2.1.1 Testo Saveris 2 :
The testo Saveris 2 WiFi data logger system is the modern solution for monitoring temperature
and humidity values in storerooms and work rooms.
The system consists of WiFi data loggers and a Cloud data storage system. The testo Saveris
2 WiFi data loggers record temperature and humidity reliably at adjustable intervals and
transmit the readings directly to the Testo Cloud via WLAN. The readings stored in the
Cloud can be analyzed at any time anywhere, using an internet-enabled smartphone, tablet or
PC. Limit value violations are immediately reported via e-mail, or optionally via SMS.
Similarly, WiFi data loggers can be programmed via the Testo Cloud and analyses set up.

Technical Details
1 Measuring 0 – 100 % rH
Range -30 - +50 ℃
2 Accuracy ±0.5 ℃ / ±2 % rH
3 Resolution 0.1 ℃ / 0.1% rH
4 Measuring cycle 60 s….24 h
5 Protection class IP30

Figure 2.1: Testo Saveris 2

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Several studies have highlighted the effectiveness of the Testo Saveris 2 sensor in accurately
measuring and logging temperature and humidity levels. Its wireless connectivity and remote
monitoring capabilities make it a convenient choice for real-time data acquisition and
analysis. The sensor's compact design and ease of installation further contribute to its
practicality in industrial applications.

Research has shown that continuous monitoring of temperature and humidity using sensors
like Testo Saveris 2 helps identify potential issues before they escalate into critical failures.
Timely detection of deviations from optimal conditions enables proactive maintenance and
prevents damage to sensitive electrical equipment.

While the Testo Saveris 2 sensor has proven to be a reliable and versatile tool for temperature
and humidity monitoring, it is essential to consider factors such as sensor placement,
calibration, and data interpretation. Research suggests that proper positioning of sensors
within the electrical panel and periodic calibration are critical to obtaining accurate
measurements.

2.2 Variable Frequency Drive (VFD) installation and operation

Before the installation of Variable Frequency Drive (VFD), the MFV area of the plant faced
an issue with the "Gehring Honing Machine (DRV Short)." The problem arose from motor
shifting, causing the displacement of the table mounted on the motor during the auto cycle.
This issue was attributed to running the motor at its rated RPM and frequency without an
adequate speed control mechanism. Relying solely on the contactor logic proved insufficient
in regulating the motor's speed.

To overcome this challenge and minimize the motor's RPM or speed, the decision was made
to incorporate a Variable Frequency Drive (VFD) into the machine's setup. The VFD offered
a versatile and efficient solution to control the motor's rotational speed, thereby addressing
the problem of shifting and ensuring stable operation during the auto cycle.

2.2.1 Variable Frequency Drive (VFD)

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A Variable Frequency Drive (VFD), also known as an Adjustable Frequency Drive (AFD) or
Variable Speed Drive (VSD), is an advanced electronic device used to control the speed and

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torque of an electric motor. It achieves this by varying the frequency and voltage supplied to
the motor, allowing precise control over its rotational speed. VFDs are widely utilized in
various industrial, commercial, and residential applications to improve energy efficiency,
optimize motor performance, and enhance process control.
Moreover, VFD installations lead to significant energy savings due to reduced motor starting
currents and better speed control. This energy efficiency not only positively impacts the
overall operation cost but also aligns with sustainability and environmental initiatives.

Key components and features of a Variable Frequency Drive:

1. Inverter: The heart of a VFD is the inverter, which converts the incoming AC power into
DC power through a rectifier, and then inverts it back to AC at variable frequencies and
voltages. This enables the control of motor speed and torque.
2. Control Panel: VFDs come with a user-friendly control panel that allows operators to set
and adjust various parameters such as motor speed, acceleration, deceleration, and other
performance settings.
3. Keypad/Display: VFDs may include a keypad or display screen to facilitate programming
and real-time monitoring of motor performance.
4. Built-in Protections: VFDs incorporate safety features to protect the motor and the VFD
itself from various faults, such as overcurrent, overvoltage, undervoltage, and overheating.

Figure 2.2: Variable Frequency Drive (VFD)

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Benefits of using a Variable Frequency Drive:
 Energy Efficiency
 Soft Starting
 Process Control
 Space Savings
 Reduced Maintenance Costs:

In conclusion, Variable Frequency Drives are critical components in modern industrial

automation and process control systems. Their ability to regulate motor speed, increase
energy efficiency, and improve system performance makes them an essential tool for
industries striving to optimize operations and reduce energy consumption.

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 CHAPTER-3

WORK CONDUCTED

3.1 Temperature and humidity monitoring of electric panel

The temperature and humidity monitoring used to be done through a digital meter, but it was
only activated when a machine malfunctioned due to some fault. As a result, we decided to
implement a device called "Testo Saveris 2" for monitoring the electric panel's temperature
and humidity.
By adopting the "Testo Saveris 2," we can now ensure continuous and real-time monitoring
of the crucial environmental conditions in the electric panel. This not only helps in
identifying potential issues before they escalate into costly breakdowns but also allows us to
take preventive measures in a timely manner. The device's accuracy and reliability provide us
with valuable data insights, allowing us to optimize the panel's performance and enhance its
overall lifespan.
The implementation of the "Testo Saveris 2" device has significantly enhanced our
monitoring practices, promoting a proactive approach to maintenance and minimizing the risk
of costly breakdowns

As of now, we have successfully installed the advanced "Testo Saveris 2" devices on 8
machines, ensuring continuous and reliable temperature and humidity monitoring for these
units. However, we are facing a challenge with the remaining 12 devices, as they are
encountering an "E26" error, which is associated with issues in establishing a stable Wi-Fi
connectivity.
To address this matter effectively, our technical team is actively investigating the root cause
of the "E26" error. We understand the criticality of having these devices fully functional to
maintain a comprehensive monitoring system across all machines. Our team is meticulously
examining the Wi-Fi setup, checking for any interference, and conducting signal strength
tests to pinpoint the exact cause of the connectivity issue

Initially, we set the temperature and humidity alert limits at 25-40°C and 40-80% relative
humidity, respectively. However, we realized that these fixed limits may not be suitable for
all machines, as they are situated in different areas of the plant with varying surroundings.
To
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address this concern, we are customizing the temperature and humidity thresholds for each
device, considering their specific locations and operating conditions within the plant.

Figure 3.1: Manual Readings

After carefully analyzing the readings for over 15 days, we utilized the data to individually
set the temperature and humidity ranges for each machine through the device portal. The
objective was to establish optimal and customized thresholds that align with the specific
needs of each machine.

S no. Machine Panel AC Set Before After

Temperature
1 Machine 1 26℃ 20 - 50 ℃ 25 – 30 ℃
40 – 80 % rH 40 – 80 % rH
2 Machine 2 35℃ 20 - 50 ℃ 21 - 35 ℃
40 – 80 % rH 40 – 60 % rH
3 Machine 3 26℃ 20 - 50 ℃ 21 – 35 ℃
40 – 80 % rH 40 – 60 % rH
4 Machine 4 26℃ 20 - 50 ℃ 25 - 40 ℃
40 – 80 % rH 30 – 70 % rH
5 Machine 5 29℃ 20 - 50 ℃ 25 - 35 ℃
40 – 80 % rH 40 – 60 % rH
6 Machine 6 26℃ 20 - 50 ℃ 25 - 35 ℃
40 – 80 % rH 30 – 70 % rH
7 Machine 7 26℃ 20 - 50 ℃ 25 - 35 ℃
40 – 80 % rH 40 – 70 % rH
8 Machine 8 30℃ 20 - 50 ℃ 24 - 35 ℃
40 – 80 % rH 40 – 75 % rH

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In this process, we ensured that the set ranges do not reach the extremes of the components'
operating limits within the electric panel. By doing so, we can prevent any potential damage
or adverse effects on the components caused by temperature or humidity fluctuations.
The utilization of the device portal allowed us to easily implement these personalized settings
for each machine, providing us with a comprehensive and adaptable monitoring system.

Despite the thorough analysis and individual customization of temperature and humidity
ranges for each machine's electric panel, we encountered situations where the humidity
exceeded the set limits for specific panel, and we got warning from device. This unexpected
challenge prompted us to further investigate the root causes of these occurrences.

After conducting a thorough analysis of the machines' electric panels, we have identified
several potential reasons that could be contributing to the high humidity levels.

These reasons include:

 Holes inside the electric panel: The presence of holes or gaps in the electric panel
enclosure may allow moisture to seep into the panel from the surrounding
environment.
 Improperly fixed door lock: A poorly fixed or malfunctioning door lock on the
electric panel can result in inadequate sealing, allowing humidity from the ambient
air to infiltrate the panel's interior.
 Inefficient functioning of the AC system: If the air conditioning system within the
electric panel is not operating efficiently, it may struggle to regulate the internal
temperature and humidity effectively.
 Machine-Specific Factors: Some machines may naturally generate more heat or
humidity during their operations, which could challenge the established humidity
limits.
 Environmental Changes: Changes in the overall plant environment, such as seasonal
weather variations or alterations in nearby operations, might influence the humidity
levels in specific areas

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To address these potential causes and reduce the humidity levels in the electric panels, we were
implementing the following steps:

 Sealing and Repair: Any identified holes or gaps in the electric panel enclosure will
be promptly sealed and repaired. This will prevent moisture from entering the panel
and maintain a controlled internal environment.

 Door Lock Maintenance: The door locks of all panels will be thoroughly inspected
and fixed as necessary to ensure a proper and secure seal. This will help in
minimizing the entry of external humidity into the panels.

 A.C. System Check: The air conditioning systems within the electric panels will
undergo comprehensive checks and maintenance. This will ensure that they are
functioning optimally and efficiently in maintaining the desired temperature and
humidity levels.

 Regular Monitoring: We will continue to closely monitor the humidity levels in all
panels, utilizing the "Testo Saveris 2" monitoring system. This ongoing monitoring
will allow us to detect any deviations and promptly address potential issues.

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3.2 Variable Frequency Drive (VFD) installation and operation

To Install a Variable Frequency Drive (VFD) on a machine, the first step was to obtain the
motor rating information. This was done by removing the cover from the motor, which
required the assistance of a member from the TEF 3 department and the machine operator.

Motor Specification:
S no. Specifications Values
1. Input Voltage 415 V
2. Frequency 50 Hz
3. Power 0.37 KW / 0.5 HP
4. Speed 1385 RPM
5. Input Current 0.9 A
6. Power factor 0.72 PF
7. Winding Connection 3 ph. Star-connected

Once the motor rating was determined, the next step was to carefully select the appropriate
Variable Frequency Drive (VFD) that matched the motor rating. This ensured that the VFD
could facilitate a smooth and efficient operation of the motor.

By installing the VFD in this manner, the machine's motor could be controlled more
effectively, leading to improved performance and energy efficiency. Properly matched VFDs
can extend the lifespan of the motor and reduce unnecessary wear and tear, ultimately leading
to cost savings and enhanced productivity.

After careful consideration, we selected the “Siemens Sinamics V20” VFD for this operation
and configured its parameters.

3.2.1 Siemens Sinamics V20

the Siemens SINAMICS V20 is a compact and cost-effective frequency converter designed
for controlling the speed of three-phase AC induction motors. It falls under the category of
low- voltage variable frequency drives (VFDs) and is used in various industrial and
commercial applications.

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 Mains
Terminals

Motor
Terminals

Figure 3.2: Siemens Sinamics V20

Figure 3.3: User terminals

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Setting Parameters

Parameter Function

P0010 Commissioning Partner

= 1, quick commissioning
= 0, End of quick commissioning
P0970 Factory reset
= 1, resets all parameters (not user defaults) to their default values.
= 21, resets all parameters and all user defaults to Factory Reset state.
P0100 50 / 60 Hz selection
=0: Europe [kW], 50 Hz (factory default)
=1: North America [hp], 60 Hz
=2: North America [kW], 60 Hz
P0304 Rated motor voltage [V]
P0305 Rated motor current [A]
P0307 Rated motor power [kW / hp]
P0308 Rated motor power factor (cosφ)
P0310 Rated motor frequency [Hz]
P0311 Rated motor speed [RPM]
P0700 Selection of command source
= 0: Factory default setting
= 1: Operator panel (factory default)
= 2: Terminal
= 5: USS / MODBUS on RS485
P1000 Selection of frequency setpoint
= 0: No main setpoint
= 1: MOP setpoint
= 2: Analog setpoint
= 3: Fixed frequency
= 5: USS/MODBUS on RS485
= 7: Analog setpoint 2

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 Connection macros

Cn001 BOP as the only control source

Cn002 Control from terminals (PNP/NPN)
Cn003 Fixed speeds
Cn004 Fixed speed binary mode
Cn005 Analog input and fixed frequency
Cn006 External push button control
Cn007 External push button with analog setpoint

Connection macro Cn003 - Fixed speeds

Figure 3.4: Fixed speed connection

After carefully setting its parameters, we installed and mounted the Variable Frequency Drive
(VFD) in the electric panel of the machine. We made its connections in a manner that it
allows it to run on a fixed frequency as set by the machine’s operator.

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 Chapter-4

CONCLUSION AND LEARNING

Target State
 To maintain humidity and temperature of electric panel.
 To install and operate Variable Frequency Drive (VFD) on machine.

Benefits
 Reliable, efficient and sustainable operation of the machine.
 Enhance equipment performance, prevent failures, improve safety and lead to
significant cost saving over time.
 Precise speed control of motor.
 Significant power saving and overall efficiency increases.

Learnings
During my internship at Bosch Jaipur Plant, I learnt a lot of different things some of them are:
 Basic product knowledge (Product Overview)

 Understood the functioning of VFD’s and their parameters

 Obtained basic knowledge of components of electric panel that is about contactors,
different relays, Motor Protection Circuit Breaker (MPCB), Programmable Logic
Controller (PLC), CPU, Variable Frequency Drive (VFD), Switched Mode Power
Supply (SMPS), Human Machine Interface (HMI), NO and NC switches,
Computerized Numerical Control (CNC), lugs, etc

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 Fig 4.1: Electric panel Fig 4.2: SLD of Plant

 Power supply at plant.

 Understood ability to read the Electrical Drawing.
 Understood their control wiring and performed Direct On-line (DOL) starter, Star-
Delta starter and Reverse Forward starter.
 Understood about PLC and performed operations (like motor pump, blinking lights,
traffic light, Conveyor Belt, etc.) using ladder logic in siemens TIA portal V13.

Tank problem logic Motor pump logic

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 Traffic Light Logic

Conveyor Belt logic

Fig 4.3: Ladder Logic Programs

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 Covered all shop floor machines and stations, gained basic knowledge of their
workings and drew block diagram of hanger plant.

Fig 4.4: Calibration Line

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Additionally, I gained insights in:

 Collaboration and Teamwork: I had the chance to collaborate with professionals from
various departments. This experience taught me the value of effective teamwork,
communication, and coordination to achieve common goals and maintain a smooth
workflow.
 Problem-Solving and Troubleshooting Skills: Automation systems can encounter
technical issues and malfunctions which provided me with opportunities to develop
problem-solving and troubleshooting skills, analyze problems, identify root causes,
and propose effective solutions.
 Safety Protocols and Procedures: Safety is of paramount importance in manufacturing
environments I learned about safety protocols and procedures.
 Kaizen and 5’s.
 Time Management and Efficiency.
 Understanding Industry Trends.

Fig 4.5: Bosch Jap Campus

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