ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

College of Engineering
Department of Electromechanical Engineering

Program title:

Top Beverage Industry and Trading

Project title:
Motor Controlling with Cam changeover

Name of the student ID. No:

1, Abraham Chala-----------------------------------------------------ETS0069/13
2, Obsinet Merga------------------------------------------------------ETS1072/13

Supervisors:
University supervisor name: - Mr Ephrem Niguse
Industry supervisor name: -Mr Biniam
Submitted to Addis Ababa Science and technology University
Department of Electromechanical Engineering
September, 30
Addis Ababa, Ethiopia
 Abstract
The purpose of theses report is to give general insight to what we have done during the
internship period and what we have gained during the real time practical works. As a conformity
assignment enterprise the major work we do is installing electric and also maintenance. From the
first day the staff are happy to welcome and give an introduction about the company, the work
they do daily. Throughout the internship period we have learned new skills like how to operate
different machines and also gained knowledge about single and three phase electrical
installation. We also have identified a problem and suggested possible solutions. The internship
also helps understand the value of teamwork and develops our interpersonal communication.
Most importantly we have familiarized ourselves with professional work ethics like punctuality,
reliability, accountability, transparency, Tolerance. Generally, the internship experience is
equipped with better practical knowledge and professional work ethics.
 Acknowledgment

First and for most, we would like to give our glory and praise to the Almighty GOD for his
invaluable cares and supports throughout the course of our life and helped us since the
inception of our education and enabled us to achieve our internship.
Next, we are grateful to appreciate our company Advisor Mr Biniyam for his patience,
motivation and valuable support while conducted this internship. And also we are grateful to
appreciate our campus advisor Mr Ephrem Niguse his prompt advice, tolerance guidance and
useful criticisms throughout the internship in preparing the project.
Our sincere and heartfelt gratitude goes to top beverage industry and trading for their voluble
help and cooperation in to the internship.
 List of figure
Fig 1 ………………………. Water production
Fig 2………………………… Label production
Fig 3 …………………...……. Installing electrical part(circuit) of Nail Production
Fig 4 ………………………......Bottle blower machine

Fig 5 …………………………Transformer

Fig 6………………………….Cam changeover

Fig 7 …………………………Installing cam changeover to Motor

Table of Content
s
Chapter 1................................................................................................................................................1
1.1 Introduction.....................................................................................................................................1
1.2 Objective...........................................................................................................................................1
1.3 Company overview..........................................................................................................................2
1.3.1 Water production.........................................................................................................................3
1.3.2 Nail production.............................................................................................................................4
1.3.3 Plastic production.........................................................................................................................4

Chapter 2................................................................................................................................................6
Overall Internship Experience and responsibility..............................................................................6
2.1 Overall Internship Experience....................................................................................................6
2.2 Responsibilities.............................................................................................................................6
2.3 Key Takeaways............................................................................................................................9

Chapter 3..............................................................................................................................................10
3.1 Problem Statement....................................................................................................................10
3.2 Objectives...................................................................................................................................10
3.3 Literature Review..........................................................................................................................10
Three-Phase Induction Motors.......................................................................................................10
Motor Control Methods..................................................................................................................11
Cam Changeover Switch.................................................................................................................11
3.4 Design and Methodology...............................................................................................................11
3.5 Results and Discussion..................................................................................................................14
Testing Results.................................................................................................................................14
Performance Evaluation.................................................................................................................14
Conclusion............................................................................................................................................15

Chapter 4..............................................................................................................................................16
Over all internship Skills Acquired and Challenge Faced................................................................16

Chapter 5..............................................................................................................................................19
Conclusion and Recommendation......................................................................................................19
5.1 Conclusion:.....................................................................................................................................19
5.2 Recommendation...........................................................................................................................19
 Chapter 1

1.1 Introduction

For 4 years we have been learning theoretical knowledge. These internships have been given us
an opportunity to practice in a real world of work. The objection of the internship is to produce
qualified, motivated and practice oriented students. In order to get good practical knowledge,
Top beverage and Trading company is good choice for us. During our three-month internship,
we embarked on a transformative journey that enhanced both our technical skills and
professional growth. In the first month, we immersed our self in the company’s culture, learning
the fundamentals of our role and collaborating with team members on projects. As we gained
confidence, we took on more responsibilities, contributing to meaningful tasks and applying
theoretical knowledge in real-world scenarios. By the second month, we were actively involved
in problem-solving sessions and presentations, which sharpened our communication and
analytical skills. The final month saw us leading a small project, where we utilized feedback
from our mentors to refine our approach and deliver results. This experience not only deepened
our understanding of the industry but also fostered invaluable connections that we will carry
forward in our career.
This report summarizes our three-month internship at Top beverage and Trading company,
where we worked on various electromechanical systems across water production, nail
production, plastic production, transformer maintenance and installation, and electrical
installations (both single and three-phase systems). Our responsibilities included preventive and
corrective maintenance, troubleshooting, and participation in automation projects, such as
forward and reverse motor control systems.

1.2 Objective
 To gain hands-on experience with electromechanical systems in industrial environments,
including single and three-phase electrical installations.
 To understand and implement transformer installation, maintenance, and automated
motor control systems in nail production.
 To acquire skills in troubleshooting, repairing, and maintaining systems across water,
nail, and plastic production facilities.
 To develop expertise in automation, electrical distribution systems, and industrial control
systems.

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1.3 Company overview
TOP operates in water production, nail manufacturing, plastic processing, and power system
management. It also conducts electrical installations to support its production facilities, including
the installation of single and three-phase systems for different industrial applications. The
electromechanical maintenance team ensures that all electrical and mechanical systems function
efficiently to avoid costly downtime.

TOP has established itself as a leader in [industry], known for its high-quality products/services
and commitment to customer satisfaction. The company consistently delivers reliable solutions
that meet industry standards, earning the trust of its customers. With a strong market presence
and a focus on innovation, the company continues to set the benchmark for excellence in its
field.

One of the key strengths of the company is its dedication to product/service quality. Rigorous
quality control processes ensure that customers receive consistent, dependable offerings.
Moreover, TOP stays ahead of market trends by continuously innovating and introducing new
products or features, allowing them to meet evolving customer needs and stay competitive in an
ever-changing landscape.

Despite its success, there are a few areas where the company could improve. For instance, its
pricing strategy could be more competitive, especially for price-sensitive customers.
Additionally, although the company has a strong presence in its current markets, expanding its
brand awareness through enhanced marketing efforts particularly in the digital space could
attract new customers and solidify its position with younger demographics.

TOP is a well-established and highly regarded player in [industry]. With its commitment to
quality, innovation, and customer service, the company is well-positioned for continued growth.
However, addressing areas like pricing and marketing could open new opportunities for
expansion and further strengthen its competitive edge.

Top have different production branch let see one by one:-

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1.3.1 Water production
TOP, a key player in the water production industry, has earned a strong reputation for delivering
high-quality drinking water to a wide range of consumers. With a focus on purity and safety, the
company employs state-of-the-art filtration and purification technologies to ensure its products
meet the highest health and safety standards. Their commitment to providing safe and clean
water has made them a trusted name in the market.

One of the major strengths of the company lies in its advanced water treatment processes. By
utilizing modern purification methods like reverse osmosis, UV disinfection, and multi-stage
filtration, they ensure that all harmful impurities and contaminants are removed. Additionally,
their quality control measures, including regular testing and monitoring, guarantee that their
water consistently meets or exceeds regulatory standards.

Fig 1 water production

Despite the company’s solid reputation, there are areas where it could further improve. For
instance, while the company excels in producing clean and safe water, its pricing could be more
competitive, especially in comparison to other brands offering similar products. Additionally,
expanding their product offerings to include premium or flavored water could help them tap into
niche markets and appeal to a broader customer base.

Overall, TOP stands as a reliable and respected brand in the water production industry. Their
focus on quality and safety is commendable, and they have successfully positioned themselves as
a leader in providing clean drinking water. By enhancing their pricing strategies and exploring

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new product options, the company could further strengthen its market position and continue to
grow in an increasingly competitive industry.

1.3.2 Nail production

TOP is a leading manufacturer in the nail production industry, known for producing high-quality
nails for various industrial and construction applications. The company has built a solid
reputation for its commitment to durability, precision, and consistency in its products. With state-
of-the-art production facilities and a focus on meeting customer needs, TOP has become a
trusted supplier for construction firms, hardware retailers, and manufacturers.

One of the company’s core strengths is its ability to produce a wide variety of nails, including
common, finishing, and specialty nails, with consistent quality and strength. Their advanced
manufacturing technology allows for precise shaping and finishing, ensuring that each nail meets
rigorous standards for performance. Additionally, the company places a strong emphasis on
using high-quality raw materials, resulting in nails that offer excellent durability and reliability in
various conditions.

While TOP excels in product quality, there are some areas where the company could expand its
offerings. For instance, it could benefit from diversifying its product range to include eco-
friendlier or corrosion-resistant nails, catering to emerging market demands for sustainable
building materials. Additionally, enhancing its distribution channels and expanding into
international markets would increase brand visibility and open new revenue streams.

Overall, TOP is a well-regarded player in the nail production industry, known for delivering
strong, high-quality nails that meet the needs of both large-scale and smaller construction
projects. With continued focus on innovation, sustainability, and market expansion, the company
is well-positioned for long-term growth and continued success in an evolving market.

1.3.3 Plastic production

TOP is a leading manufacturer in the plastic production industry, specializing in producing high-
quality plastic bottles for water production companies. The company has gained a strong
reputation for delivering durable, lightweight, and cost-effective bottles that meet the needs of
the bottled water market. With a focus on innovation and sustainability, TOP is a trusted partner
for water producers seeking reliable packaging solutions.

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Fig 2 label production

One of the key strengths of TOP is its use of advanced manufacturing technologies to produce
plastic bottles that are not only sturdy but also lightweight, reducing material costs and
environmental impact. The company employs efficient blow-molding processes that allow for
the creation of bottles in various sizes and designs, offering flexibility to meet the specific needs
of its clients. Additionally, the bottles are designed to maintain structural integrity, ensuring they
can withstand transport and handling while keeping water fresh and secure.

However, like many companies in the plastic production sector, TOP faces increasing pressure to
adopt eco-friendlier practices. While the company has made strides in producing recyclable
bottles, there is room to expand its efforts in using more sustainable materials, such as
biodegradable plastics or recycled content. This shift could help the company align with the
growing demand for environmentally responsible packaging solutions in the bottled water
industry.

Overall, TOP is a reliable and innovative plastic bottle manufacturer, well-regarded for its
quality and cost-efficiency in the water production market. By further investing in sustainable
practices and materials, the company has the potential to not only maintain its strong position in
the industry but also lead the way in creating greener packaging solutions for the future.

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 Chapter 2

Overall Internship Experience and responsibility

2.1 Overall Internship Experience

During our internship at TOP Beverage and Trading Company, we had the unique opportunity to
collaborate across several divisions, including TOP 4 Nail and Metal Plate Production, TOP 5
Plastic Manufacturing, and TOP 1 Bottled Water Production. Additionally, we developed and
implemented an automated bottle cap failure detection system and participated in a transformer
installation project. This diverse experience allowed us to gain valuable insights into various
aspects of manufacturing, quality control, and supply chain management within the beverage
industry.

Our work not only enhanced our technical skills but also provided us with a comprehensive
understanding of the interconnections between different manufacturing processes. Through
collaboration with various technicians, we learned the importance of quality assurance and
operational efficiency in delivering high-quality products to consumers. Overall, this internship
was instrumental in shaping our professional growth and preparing us for future careers in the
manufacturing and engineering sectors.

2.2 Responsibilities

TOP 4 Nail and Metal Plate Production

 Quality Control: Assisted in the inspection and testing of metal products to ensure they
met industry standards and specifications.
 Process Improvement: Collaborated with the engineering team to identify inefficiencies
in the production line, leading to the implementation of streamlined processes.
 Inventory Management: Helped maintain accurate inventory records and supported the
supply chain team in managing raw materials and finished goods.

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 Fig 3 installing electrical part of nail production

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TOP 5 Plastic Manufacturing

 Production Oversight: Gained hands-on experience in monitoring the plastic molding

process, ensuring consistency and quality in the production of beverage containers.
 Data Analysis: Collected and analyzed production data to identify trends and inform
management decisions, contributing to improved operational efficiency.
 Safety Protocols: Participated in safety training sessions and ensured compliance with
safety regulations, fostering a safe working environment for all employees.

TOP 1 Bottled Water Production

 Automated Inspection Systems: Assisted in the implementation and testing of

automated bottle cap inspection systems, focusing on quality assurance and product
integrity.
 Operational Support: Supported the production team in daily operations, from
monitoring the bottling process to troubleshooting minor equipment issues.
 Customer Feedback Analysis: Helped gather and analyze customer feedback regarding
product quality, which was used to inform future improvements in production and
packaging.

Fig 4 bottle blower machine

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Transformer Installation

 Installation Support: Assisted in the installation of transformers, ensuring that all

connections were secure and compliant with safety standards.
 Testing and Commissioning: Participated in testing the transformers post-
installation to verify functionality and performance, documenting results for quality
assurance.
 Safety Protocols: Followed strict safety protocols during installation to prevent
hazards, ensuring a safe working environment for all team members.

Fig 5 Transformer

2.3 Key Takeaways

 Interdisciplinary Knowledge: Our internship provided us with a comprehensive

understanding of different manufacturing processes and the interplay between them,
including electrical systems and their impact on production.
 Team Collaboration: We learned the importance of cross-functional collaboration,
working closely with engineers, production managers, and quality control teams to
achieve common goals.
 Problem-Solving Skills: Engaging in real-world challenges improved our analytical and
problem-solving skills, particularly in identifying inefficiencies and proposing practical
solutions.

Overall, our internship experience at TOP Beverage and Trading Company was instrumental
in shaping our understanding of the beverage production industry and equipped us with the skills
necessary for successful careers in manufacturing, quality assurance, and electrical systems.

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 Chapter 3

Three-Phase Motor Control System with Cam Changeover

Switch
Three-Phase Motor Control System Cam Changeover Switch

3.1 Problem Statement

In many industrial environments, the ability to control the direction of three-phase motors is
essential for various applications, such as conveyor systems and machinery operation. However,
existing solutions often rely on complex and expensive control systems that require significant
space, maintenance, and technical expertise. This creates challenges in both operational
efficiency and cost-effectiveness.

The primary challenge is to develop a reliable and safe control mechanism that simplifies the
operation of three-phase motors, enabling users to easily switch between forward, stop, and
reverse functions without the need for extensive training or complex installations. The solution
should minimize the number of components required and ensure long-term reliability and ease of
maintenance, making it suitable for diverse industrial applications.

3.2 Objectives

The primary objectives of this project are:

 To design a three-phase motor control system using One of Cam Changeover Switch.
 To ensure the system provides reliable forward, stop, and reverse control functions.
 To create a system that is easy to operate, safe, and suitable for industrial applications.

3.3 Literature Review

Three-Phase Induction Motors

Three-phase induction motors are widely used in industrial applications due to their robustness,
efficiency, and simplicity. The operation of these motors depends on the sequence of the three-
phase power supply. Reversing the sequence of the phases changes the direction of rotation of
the motor.

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Motor Control Methods

Traditional motor control methods involve the use of contactors and relays Or direct Online
or others, which can be complex and require significant space and maintenance. The use of a
cam changeover switch offers a simplified alternative, particularly in applications where only
basic forward and reverse control is needed.

Cam Changeover Switch

The Selected Cam changeover is a manual cam switch designed for controlling the direction of
three-phase motors. It allows the operator to switch between forward, stop, and reverse positions,
effectively controlling the motor's operation without the need for additional components like
contactors.

3.4 Design and Methodology

System Overview

Our system is designed to control the direction of a three-phase induction motor using the
selected cam changeover switch. The design focuses on enabling simple operation for forward,
stop, and reverse control while ensuring safety and reliability in industrial applications.

Components Required

 Cam Changeover Switch (Suitable to our System): Manual switch for controlling
motor direction.
 Three-Phase Induction Motor: Main motor to be controlled.
 Three-Phase Power Supply: Typically, 380V DC (induction motor which is
synchronised)
 Wiring and Connectors: For electrical connections.
 Jumper Cable

Fig 6 Cam changeover(two directional)

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System Design

A. Functional Design (work flow)

 Switch Positions:

 Forward Position: Connects the power supply to the motor in a specific phase
sequence (L1, L2, L3).(written on Cam changeover)
 Stop Position: Disconnects all phases from the motor, halting operation.
 Reverse Position: Reverses two phases to change the motor's rotation direction.

B. Circuit Design

 Wiring Diagram:

 Connect the three-phase power supply lines (L1, L2, L3) to the input terminals of
the switch.
 Connect the motor terminals (U, V, W) to the output terminals of the switch.

Implementation Steps

A. Safety Precautions

 Ensure the power supply is turned off before installation. (TURN OFF THE POWER
SUPPLY)
 Use appropriate personal protective equipment (PPE). (Like glove, suitable material)

B. Wiring Procedure

 Connect the three-phase power supply to the input terminals of the Our switch.
 Connect the motor terminals to the output terminals of the switch. (Nail producing raw
material)
 Secure all connections, ensuring proper insulation to prevent electrical hazards. (plastic
coat is possible)

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Fig 7 installing cam changeover to motor

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C. Testing and Calibration

 After wiring, power on the system.

 Test each switch position (Forward, Stop, Reverse) to ensure the motor operates
correctly.
 Verify that the motor smoothly transitions between forward and reverse and completely
stops in the stop position.

Expected Outcomes

 The system should allow for easy and reliable control of the motor's direction.
 All functions (forward, stop, reverse) should operate smoothly with minimal wear and
tear.
 The design should minimize complexity, making it easy to maintain and operate.

3.5 Results and Discussion

Testing Results

The system was tested under various conditions to ensure it operates as expected. The motor
successfully operated in both forward and reverse directions, and the stop function worked
reliably, cutting off power to the motor.

Performance Evaluation

The system was found to be effective for controlling the direction of the motor. The simplicity of
the design reduced potential failure points and made the system easy to operate and maintain.

Advantages and Limitations

Advantages:

 Simple and cost-effective.

 Reliable operation with minimal components.
 Easy to install and maintain.

Limitations:

 Manual operation may not be suitable for automated systems.

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Conclusion
The project successfully the design and implementation of a three-phase motor control system
using the Cam Changeover Switch. The system met all objectives, providing a reliable and
straightforward solution for motor direction control in industrial settings.

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 Chapter 4

Over all internship Skills Acquired and Challenge Faced

4.1 Over all internship Skills Acquired

The internship also helps understand the value of teamwork and develops our interpersonal
communication. Most importantly we have familiarized ourselves with professional work ethics
like punctuality, reliability, accountability, transparency, Tolerance. Generally, the internship
experience is equipped with better practical knowledge and professional work ethics.

 Technical Skills:

 Practical experience with single and three-phase electrical installations in

industrial environments.
 Knowledge of transformer maintenance, installation, and integration with
single/three-phase power systems.
 Understanding of automated motor control systems and troubleshooting PLCs.
 Experience using diagnostic tools such as mustimeters, insulation testers, and
phase testers.

 Problem-Solving:

 Gained skills in diagnosing and resolving electrical faults in single and three-
phase systems and automated controllers.
 Developed solutions to electrical and mechanical issues across various production
processes.

 Teamwork and Communication:

 Collaborated with engineers and technicians to install and maintain

electromechanical systems.
 Communicated effectively to plan and execute electrical installations and
maintenance tasks.

 Time Management:

 Balanced multiple projects, including electrical installations and transformer

maintenance, meeting deadlines while ensuring system reliability.

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Our internship experience played a great role in many aspects. The one is that this internship
experience developed my both theoretical and practical knowledge. It played role to observe my
environment and identify a problem and to become a problem solver. The other benefit is to
create a suitable situation for the choice of my carrier after graduation. In addition to this I have
developed different skills like punctuality, communication skill and others that have a greater
impact for our future carrier. In terms of
Theoretical Knowledge
Our enthusiasm and ongoing interest in training have allowed me to significantly enhance not
only our practical knowledge but also our theoretical understanding of control and power
systems. After observing practical systems, we would revisit their theoretical backgrounds to
gain a deeper understanding of their characteristics and operating principles, often achieving
insights beyond what was covered in class. We read various books, articles, and other literature,
which helped us connect theoretical concepts with real-world applications. By effectively
utilizing documentation, searching online resources, and consulting experienced professionals in
the company, we were able to continually update and deepen our theoretical knowledge
Interpersonal Skills
In the company, we were working with all the staff members and any individual peacefully,
by the experience we have gained from my internship program. Individuals often learn
different things from colleagues through communication. For any individual, communications an
important way of learning, which can be defined formally as the act, process, or experience of
gaining knowledge or skills.
Improving our leadership skills
Leading a team or an organization holds the most basic and key place of profession, hence
requires well trained person. we have learned a good leading skill from our supervisor and all be
responsible and trusted. The engineers that we work together some of the leader ship skills that
we have performed are:
 To recognize, tell and solve mistakes and problem
 Respecting differences
 Have good communication ability.
 Being passionate serve as a role model.
 Motivate others to greatness.

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Understanding about work ethics
Work ethic is a value based on hard work and diligence. During our internship period, we have
learnt about work ethics. Through the last three months we hardly able to know the following
things: -
 Possess a positive attitude at our working place.
 Responsibility and able to respond appropriately to any given situation
without having to be constantly monitored.
 Putting on work clothes, safety shoes and helmet before entering in to the
construction site or the substation.
 we also try to adapt hard things at construction sites, like sun and dust

Entrepreneurship skill

Entrepreneur means undertake the risk of new enterprises. This creation called entrepreneurship.
Being an intern student built an individual’s knowledgeable in Selection of the effective way of
doing work and develops entrepreneurship skills. Some of these includes: -
 Risk taking ability.
 Increasing efficiency of work.
 Able to invent new ideas.
 Creative mind in solving the problem of company.
 Work discipline.
 Invent short methods

4.2 Challenges Faced

 Complexity of Electrical Installations:
Working with three-phase systems required careful attention to detail, especially in
ensuring phase balance and load distribution across heavy machinery.
 High Production Demands:
The nail and plastic production facilities required continuous power, making quick
repairs and installations crucial to prevent extended downtime.
 Transformer and Motor Integration:
Ensuring proper coordination between transformer outputs and three-phase motor
systems was critical in maintaining stable power for production equipment.

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 Chapter 5

Conclusion and Recommendation

5.1 Conclusion:
In conclusion, our internship at Top beverage industries and trading have been an invaluable
experience that have deepened our understanding of the water industry and its critical role in
sustainable development. Throughout our time there, we gained hands-on experience in projects,
which enhanced our technical skills and allowed us to apply our academic knowledge in a real-
world setting.

Working alongside dedicated professionals, we learned the importance of teamwork and

communication in addressing complex challenges related to water quality and conservation. This
experience has not only solidified our passion for environmental sustainability but also equipped
us with the tools to contribute meaningfully to future projects in the field.

We are grateful for the mentorship and support we received, which have inspired us to continue
pursuing a career dedicated to ensuring access to clean and safe water for all. Overall, this
internship has been a pivotal step in our professional journey, and we look forward to applying
what we’ve learned as we move forward in our career.

5.2 Recommendation
 Water Production:
Enhance monitoring of three-phase motors to improve system reliability and prevent
unexpected breakdowns.
 Nail Production:
Further automate motor control systems to reduce manual interventions and optimize
production.
 Plastic Production:
Implement advanced monitoring systems for hydraulic and electrical systems in three-phase
machines.
 Transformer Maintenance:
Increase the frequency of preventive maintenance checks for transformers connected to
three-phase installations to ensure long-term reliability

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