Workshop 13

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WORKSHOP PRACTICE

LAB MANUAL

INSTRUCTOR NAME

M-TAHIR MAHMOOD

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING


TECHNOLOGY UNIVERSITY OF TECHNOLOGY
NOWSHERA

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB SAFETY MEASUREMENTS

It is your responsibilities to ensure that at all times you work in such a way
as to ensureyour own safety and that of other persons in the laboratory.

None of the experiments in the laboratory is dangerous provided that


normal practicesare followed. However, particular care should be done
while performing experiments.

If you are uncertain about any safety matter for any of the experiments,
you MUSTconsult a demonstrator.

All accidents must be reported to a laboratory supervisor or technician


who will takethe necessary action.

You should take care of all lab equipment and do not practice any
experiment withoutinstructor permission.

Prominently show your University ID card before entering in the Lab.

Submit your ID card to lab assistant before issuing any equipment in the lab

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB LIST OF EXPERIMENT

01 STUDY OF ELECTRONIC COMPOENTS

02 ELECTRICAL WORKSHOP TOOLS

03 TO IDENTIFY THE VARIOUS ELECTRONIC COMPOENT& FORM FACTOR

04 TO USE SOME CAD PCB MAKING SOFTWARE SUCH AS PROTEUS

05 TRANSFER THE DESIGN ON COPPER LAMINATED SHEET BY DIFFERENT


METHOD

06 TO MAKE A SETUP FOR ETCHING PROCESS OF A FINISHED PCB DESIGN

07 TO UNDERSTAND &MASKING LABELING POLISHING PCB DESIGN

08 TO USE AUTOMATED & MANUAL DRILLING OF PCB DESIGN

09 TO STUDY SOLDERING & DESOLDERING

10 TO STUDY CABLES ACCORDING TO CORES

11 TO MAKE A SERIES CIRCUIT &MEASURE HOW VOLTAGE IS DIVIDE WITH


THE HELP OF MULTIMETER

12 TO MAKE A PARALLEL CIRCUIT &STUDY THE BEHAIVOUR OF CURRENT


WHEN THE LOAD IS CONNECTED IN PARALLEL.

13 TO CONSTRUCT A TEST LAMP BOARD

14 TO MAKE A FAN REGULATOR CIRCUIT

15 TO MAKE A STAIR CIRCUIT


16
IDENTIFICATION &TESTING OF TWO TERMINAL DEVICE&ICS

TO MEASURE THE ENERGY WITH THE HELP OF AN ENERGY METER &VERIFY


17 IT WITH THE HELP OF VOLTMETER ,AMMETER &STOP WATCH.

18 WELDING(A)

19 WELDING LAP JOINT

20 WELDING BUTT JOINT

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 01 STUDY OF ELECTRONIC COMPONENTS

OBJECTIVES
a. To get familiar with basic electronic components such as Resistor, capacitors, Inductor,
diodes, transistors, integrated circuits (IC), light emitter diode (LED), switches, fuses,
batteries, power plugs, connectors, wires and cables.
b. To test and understand the function of various electronic components.

RESISTORS
A resistor is a passive two-terminal electrical component that implements electrical resistance as a
circuit element. The current through a resistor is in direct proportion to the voltage across the resistor's
terminals. This relationship is represented by Ohm's law. A device used in electrical circuits to maintain
a constant relation between current flow and voltage. Resistors are used to step up or lower the voltage
at different points in a circuit and to transform a current signal into a voltage signal or vice versa, among
other uses. The electrical behavior of a resistor obeys Ohm's law for a constant resistance; however,
some resistors are sensitive to heat, light, or other variables.
Resistors are one of the most used components in a circuit. Most are color coded, but some have their
value in Ohms and their tolerance printed on them. A multimeter that can check resistance can also be
helpful, providing the resistor is already removed from the board (measuring it while still soldered in
can give inaccurate results, due to connections with the rest of the circuit). They are typically marked
with an “R” on a circuit board.

POTENTIOMETERS
Potentiometers are variable resistors. They normally have their value marked with the maximum value
in Ohms. Smaller trim pots may use a 3-digit code where the first 2 digits are significant, and the 3rd is
the multiplier (basically the number of 0′s after the first 2 digits). For example, code 104 = 10 followed
by four 0′s = 100000 Ohms = 100K Ohms. They may also have a letter code on them indicating the
taper (which is how resistance changes in relation to how far the potentiometer is turned). They are
typically marked with an “VR” on a circuit board.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CAPACITORS
A capacitor (originally known as a condenser) is a passive two-terminal electrical component used to
store energy electrostatically in an electric field. By contrast, batteries store energy via chemical
reactions. The forms of practical capacitors vary widely, but all contain at least two electrical conductors
separated by a dielectric (insulator); for example, one common construction consists of metal foils
separated by a thin layer of insulating film. Capacitors are widely used as parts of electrical circuits in
many common electrical devices.

Capacitors are also very commonly used. A lot have their values printed on them, some are marked with
3-digit codes, and a few are color coded. The same resources listed above for resistors can also help you
identify capacitor values. They are typically marked with an “C” on a circuit board.

INDUCTORS
An inductor, also called a coil or reactor, is a passive two-terminal electrical component which resists
changes in electric current passing through it. It consists of a conductor such as a wire, usually wound
into a coil. When a current flows through it, energy is stored in a magnetic field in the coil. When the
current flowing through an inductor changes, the time-varying magnetic field induces a voltage in
the conductor, according to Faraday’s, which by Lenz's law opposes the change in current that created
it. Inductors, also called coils, can be a bit harder to figure out their values. If they are color coded, the
resources listed for resistors can help, otherwise a good meter that can measure inductance will be
needed. They are typically marked with an “L” on a circuit board.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


TRANSFORMERS
A transformer is a static electrical device that transfers energy by inductive coupling between its
winding circuits. A varying current in the primary winding creates a varying magnetic flux in the
transformer's core and thus a varying magnetic flux through the secondary winding. This varying
magnetic flux induces a varying electromotive force (emf) or voltage in the secondary winding.
Transformers are normally pretty easy to identify by sight, and many have their specs printed on them.
They are typically marked with an “T” on a circuit board.

FUSES
In electronics and electrical engineering, a fuse is a type of low resistance resistor that acts as a sacrificial
device to provide overcurrent protection, of either the load or source circuit. Its essential component is
a metal wire or strip that melts when too much current flows, which interrupts the circuit in which it is
connected. Short circuit, overloading, mismatched loads or device failure are the prime reasons for
excessive current. A fuse interrupts excessive current (blows) so that further damage by overheating or
fire is prevented. Fuses can be easy to identify, and typically have their voltage and ampere rating
marked on them.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


SEMICONDUCTORS

DIODES
In electronics, a diode is a two-terminal electronic component with asymmetric conductance, it has low
(ideally zero) resistance to current flow in one direction, and high (ideally infinite) resistance in the
other.
Semiconductors, such as Diodes (typically marked with an “D” on a circuit board).

TRANSISTORS
A transistor is a semiconductor device used to amplify and switch electronic signals and electrical
power. It is composed of semiconductor material with at least three terminals for connection to an
external circuit. A voltage or current applied to one pair of the transistor's terminals changes the current
through another pair of terminals. Because the controlled (output) power can be higher than the
controlling (input) power, a transistor can amplify a signal. Today, some transistors are packaged
individually, but many more are found embedded in integrated circuits.
Transistors (typically marked with an “Q” on a circuit board).

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


BRIDGE RECTIFIERS

A diode bridge is an arrangement of four (or more) diodes in a bridge circuit configuration that provides
the same polarity of output for either polarity of input. When used in its most common application, for
conversion of an alternating current (AC) input into a direct current (DC) output, it is known as a bridge
rectifier. A bridge rectifier provides full- wave rectification from a two-wire AC input, resulting in
lower cost and weight as compared to a rectifier with a 3-wire input from a transformer with a center-
tapped secondary winding.
Bridge Rectifiers (typically marked with an “BR” on a circuit board)

INTEGRATED CIRCUITS
An integrated circuit or monolithic integrated circuit (also referred to as an IC, a chip, or a microchip)
is a set of electronic circuits on one small plate ("chip") of semiconductor material, normally silicon.
This can be made much smaller than a discrete circuit made from independent components. Integrated
circuits are used in virtually all electronic equipment today and have revolutionized the world of
electronics. Computers, mobile phones, and other digital home appliances are now inextricable parts of
the structure of modern societies, made possible by the low cost of producing integrated circuits.
Integrated Circuits (typically marked with an “U” or “IC” on a circuit board)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LED AND LED DISPLAY
A light-emitting diode (LED) is a semiconductor light source. LEDs are used as indicator lamps in many
devices and are increasingly used for other lighting. LEDs emitted low-intensity red light, but modern
versions are available across the visible, ultraviolet, and infrared wavelengths, with very high
brightness.

SWITCHES
In electrical engineering, a switch is an electrical component that can break an electrical circuit,
interrupting the current or diverting it from one conductor to another. The most familiar form of switch
is a manually operated electromechanical device with one or more sets of electrical contacts, which are
connected to external circuits. Each set of contacts can be in one of two states: either "closed" meaning
the contacts are touching and electricity can flow between them, or "open", meaning the contacts are
separated and the switch is non-conducting.

BATTERIES
In electricity, a battery is a device consisting of one or more electrochemical cells that convert stored
chemical energy into electrical energy.
Batteries are also pretty easy to identify, and are well marked with their specification.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


RELAYS
A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching
mechanism mechanically, but other operating principles are also used. Relays are used where it is
necessary to control a circuit by a low-power signal (with complete electrical isolation between control
and controlled circuits), or where several circuits must be controlled by one signal. Relays are
typically enclosed in plastic, and many have their specs printed on them. They are typically marked
With a “K” on a circuit board.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB EXERCISE
EQUIPMENT REQUIRED

Electronic components (Resistor, capacitors, diode, Transistor)

Digital multimeter

A1.Determining Resistor values

Resistor Colour Codes

1st digit
Tolerance
2nd digit
Multiplier (no. of zeros,
following 2nd digit)

Colour Band 1 Band 2 Band 3 Band 4


Black 0 0 ×1 –
Brown 1 1 ×10 1%
Red 2 2 ×100 2%
Orange 3 3 ×1000 –

Yellow 4 4 ×10000 –

Green 5 5 ×100000 0.5%


Blue 6 6 ×1000000 0.25%
Violet 7 7 ×10000000 0.1%
Grey 8 8 – –

White 9 9 – –

Gold – – ×0.1 5%
Silver – – ×0.01 10%

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Resistance measurement

Procedure
1. Connect probes: black probe to COM terminal and red probe to terminal marked with ‘
2. Set function to resistance measurement
3. Set to the appropriate range (refer to above)
4. Connect the two probes’ crocodile clips to the resistor (or to the resistor circuit via jumper wires)
to make measurement
5. Note the reading, adjust range if necessary
6. Take the more accurate reading.

Determine the value for the given data

Measured Value
No. Colour code Actual Value
(DMM)
1 Red, red, black

2 Red, black, orange

3 Blue, gray, green

A2. Determining capacitor values

Code Tolerance
C ±0.25pF
J ±5%
K ±10%
M ±20%
D ±0.5pF
Z 80% / -20%

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Determine the value of the ceramic capacitors

No. Code Number Actual


Value
1 104

2 223

3 68

DIODE TESTING
Draw the schematic symbol of a 1N4001 diode and identify the leads (Anode and Cathode) in
the box below.

a. Set the Lab DMM to Diode Testing mode.

b. Measure the forward and reverse bias voltages of the given diodes and record them
i. Forward bias voltage:
Place the RED probe on the Anode. Touch the BLACK probe to the Cathode and
record the reading
ii. Reverse bias voltage:
Place the RED probe on the Cathode. Touch the BLACK probe to the Anode and
record the reading

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


RESULT

1N4001

1N914

CONCLUTION:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 02 ELECTRICAL WORK SHOP TOOLS

ELECTRICAL FITTING ACCESSORIES:

(1) Hand Drill (7) Electric Drill

(2) Switch Button (8)Wall Socket

(3) Plug (9)Main Switch

(4) Bed Switch (10) Circuit Breaker

(5) Rewireable fuse (11) Bulb Holder

(6) Patti fitting

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


ELECTRIC CIRCUIT SYMBOLS:
Volt meter Push Button

AC Source DC Source

Motor

Ammeter

Circuit Breaker
Tube Light

Energy meter Ground

Lamp wire bypass

CONCLUTIONS:

Checked By: _ Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 03 TO IDENTITY THE VARIOUS ELECTRONICS COMPONENTS AND FORM
FACTOR.

OBJECTIVE:
a. To get familiar with basic electronic instrument and Equipment handling and usage
procedure for Digital Multimeter, DC power supply, Function Generator and CRO.
b. To study the self-test / calibration procedure of CRO.

INTRODUCTION:
MULTIMETER:
A Multimeter is an electronic device that is used to make various electrical measurements such as
AC and DC voltage, AC and DC current, and resistance. It is called a Multimeter because it combines the
functions of a voltmeter, ammeter, and ohmmeter Multimeter may also have other functions such as diode test,
continuity test, transistor test, TTL logic test and frequency test.

OSCILLOSCOPE:
An oscilloscope is a laboratory instrument commonly used to display and analyze the waveform of
electronic signals. In effect, the device draws a graph of the instantaneous signal voltage as a function of
time.

Fig 1. Cathode Ray tube Oscilloscope Fig 2. Out Line Diagram of CRO

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


FUNCTION GENEARTOR:
A function generator is a specific form of signal generator that is able to generate waveforms with
common shapes Unlike RF generators and some others that only create sine waves, the function
generator is able to create repetitive waveforms with a number of common shapes.

POWER SUPPLY:
A power supply is an electrical device that supplies electric power to an electrical load.
The primary function of a power supply is to convert electric current from a source to the
correct voltage, current, and frequency to power the load. As a result, power supplies are sometimes
referred to as electric power converters.

ELECTRONICS ELEMENTS:
RESISITOR:
In electronic circuits, resistors are used to reduce current flow, adjust signal levels, to divide voltages, bias active
elements, and terminate transmission lines, among other uses.
A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


INDUCTOR:
An inductor, also called a coil, choke, or reactor, is a passive two-terminal electrical component that stores
energy in a magnetic field when electric current flows through it. An inductor typically consists of an
insulated

PROCEDURE:
Electronic Circuit Overview. An electronic circuit is a structure that directs and controls electric current
to perform various functions including signal amplification, computation, and data transfer. It comprises
several different components such as resistor, transistor capacitor, inductors and Diodes

CONCLUTIONS:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB:04 TO USE SOME CAD PCB MAKING SOFTWARE SUCH AS PROTEUS

OBJECTIVE:
Used the Proteus Design Suite for PCB making audio amplifier TDA2030 amplifier circuit

THEORY:

The Proteus Design Suite is a proprietary software tool suite used primarily for electronic design
automation. The software is used mainly by electronic design engineers and technicians to
create schematics and electronic prints for manufacturing printed circuit boards.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


PROCEDURE:

TDA2030 Amplifier Circuit Use a pair of TDA2030 integrated. This monolithic integrated circuit is a
class AB, which comes to providing up to 15W of output power with an 8 Ohm load. The TDA
2030provides high output current and low harmonic distortion

CONCLUTION:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB:05 TO TRANSFER THE DESIGN ON COPPER LAMINATED SHEET BY DIFFERENT
METHOD.

OBJECTIVE:
 Copper laminated sheet
 Soldering Iron
 Soldering Wire
 Soldering Sucker
 AC Supply
\
THEORY:

COPPER LAMINATED SHEET:

Copper Sheet & Plate. Copper sheet and copper plate find use in a huge array of applications one of few
metals that doesn’t need to be extracted from ore (i.e., it is directly usable in its natural state).Copper
exhibits excellent thermal and electrical Conductivity, good ductility
And a natural resistance to corrosion.

SOLDERING IRON:
A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow
into the joint between two work pieces. A soldering iron is composed of a heated metal tip and an
insulated handle.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


SOLDERING WIRE:
Solder wires are wires with a low melting point which can melt along with the soldering iron. Depending
on the application and soldering temperature, many different types of soldering wires are available. Solder
wires are generally two different types - lead alloy solder wire and lead-free solder.

SOLDERING SUCKER:
A quality solder sucker is a quintessential part of any home soldering setup. These small, inexpensive
tools are used to remove unwanted solder. They’re also essential for the process of desoldering a joint.
Most solder suckers consist of a plunger or vacuum

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


AC POWER SUPPLY
A power supply is an electronic circuit that converts an ac voltage to dc voltage. It is basically consisting of the
following elements: transformer, rectifier, filter and regulator circuits. Power supply units (PSU) are used in
computers, amateur radio transmitters and receivers, and all other electronic equipment that use dc voltage as an
input.

A printed circuit board, or PCB, is used to mechanically support and electrically connect electronic
components using conductive pathways, tracks or signal traces etched from copper sheets laminated
onto a nonconductive substrate ,After prototyping a circuit on a breadboard or dot board it is always
better to make PCB for added stability and compactness

CONCLUTION:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB: 06 TO MAKE A SETUP FOR ETCHING PROCESS OF A FINISHED PCB DESIGN

OBJECTIVE:
 Ferric chloride
 Copper sheet
 CAN

ETCHING:

Etching is the process of using strong acid to cut into the unprotected parts of a metal surface to create a
design in intaglio (image is created by cutting, carving or engraving into a flat surface) in the metal. As
an intaglio method of printmaking it is, along with engraving, the most important technique for old
master prints and remains widely used today.

CAN

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


COPPER SHEET:

Copper Sheet & Plate, is widely known for its architectural applications whereas the familiar green
patina appearance is achieved when exposed to the elements. Copper sheets / plates are also noted for
their high electrical and thermal conductivity, and good corrosion resistance.

Procedure:
Place some newspaper on the bottom so the etching solution does not spoil your floor. Take a plastic box
and fill it up with some water. Dissolve 2-3 teaspoons of ferric chloride power in the water. Dip
the PCB into the etching solution (Ferric chloride solution) for approximately 30 minutes.
CONCLUSION:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB:07 TO UNDERSTAND MASKING LABELING POLISHING PCB DESIGN

OBJECTIVE:
Sand paper
Copper Sheet
Iron

THEORY:

Sand paper:
Sand paper and glass paper are names used for a type of coated abrasive that consists of sheet of paper
or cloth with abrasive material glued to one face.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


COPPER SHEET
Copper sheet is a good conductor of heat and the best conductor of electricity after
silver. Copper can be alloyed with tin, zinc and lead to form a range of brasses each with different
properties.

IRON:
Firstly, Iron the side of PCB. After 30 seconds, you will find the Matte Paper will stick to Copper firmly.
It means it is successful. Then Iron the whole PCB.

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB: 08 TO USE AUTOMATED AND MANUAL DRILLING OF PCB DESIGN.

OBJECTIVE:
To make of manual drilling on PCB for automatically maintain a constant voltage level Voltage input 12v
and output 5v, 9v CIRCUIT.

 THEORY: When using a conventional drill press, hole placement accuracy can be improved and
drill breakage minimized through the use of a "sensitive drilling" or "finger" chuck. Small formats,
precision high-speed drill presses, ideal for PCB fabrication, are also available from a number of
sources.
 Regardless of the type of drill press being used, a pressure foot should be employed if available.
 If available, position a work lamp on a flexible mount as close to the work surface as possible.
 Although more brittle than conventional high speed steel (HSS) drills, tungsten carbide bits
designed specifically for PCB drilling will yield far superior hole wall quality. Minimize burr
formation, and outlast HSS bits almost 10 to 1. The downside is that, with smaller diameters
[0.018"(0.46mm) and less], the carbide drills are easier to break and must be handled carefully.
 Always use drill bits that have been fitted with depth setting rings. This will allow you to set the
plunge depth stop on your drill press to a single value that will work for all bit diameters.

Prepare a chart that links the various diameter bits with the symbols used in the drillmaster

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


PROCEDURE:
Drilling is a slow process as each hole must be drilled individually. So depending on the drill size
we drill a stack of one to three PCB panels together. We can drill holes down to 100 microns in
diameter. To give you an idea of the size
 Step 1 – The Design.
 Step 2 – Printing the Design.
 Step 3 – Creating the Substrate.
 Step 4 – Printing the Inner Layers.
 Step 5 – Ultraviolet Light.
 Step 6 – Removing Unwanted Copper.
 Step 7 – Inspection.
 Step 8 – Laminating the Layers.

CONCLUSION:

Checked By: Date:

Marks Awarded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 09 TO STUDY SOLDERING AND DE-SOLDERING
OBJECTIVE: To Study Desoldering and Soldering Technique
APPARATUS:
1. Solder Iron
2. Solder wire
3. De-soldering pump
4. Flux
5. PCB
6. Different electronic components

THEORY:

Introduction: Soldering is the act of unifying two pieces of similar or dissimilar metals by an alloy
called Solder, the melting point of which is lower than that of the metal to be united. When two
surfaces of the metal are soldered together, the solder penetrate pores of the metal and it makes firm
grip with permanent electrical continuity and strength.

Solder: The soldering material or solder usually employed for the purpose of joining together two
or more metals at temperature below their melting point and is a fusible alloy consisting essentially
of lead and tin. Solder is an alloy (mixture) of tin and lead, typically 60% tin and 40% lead. It melts
at a temperature of about 200°C. Coating a surface with solder is called 'tinning' because of the tin
content of solder. Solder for electronics use contains tiny cores of flux, like the wires inside a mains
flex.

Flux: When a metal is heated in free air, it is immediately affected by oxygen. A layer of oxide is
formed over the surface which is a hindrance during soldering. This layer of oxide can be removed
using chemical compounds called fluxes. They are deoxidizes agents and are used to keep the
surface clean from oxide, increase the fluidity of the solder and help the joints to adhere perfectly.
The melting temperature of the flux is always less than that of the solder used.

Soldering Techniques: Soldering techniques can be broadly classified in two groups:

Iron soldering or manual soldering


Mass soldering or automatic soldering
Manual soldering requires solder iron, solder wire, flux and electronic components. Solder irons are
available in different temperature ranges, and available with ratings of 6 W, 12 W, 25 W, 35 W, 100
W, 150 W etc. Selection of the solder iron depends on the use.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


SOLDERING:
1. Take one PCB, solder iron, solder wire and electronic components and give supply to
solder iron.
2. Place the iron at the angle of 45 degree, with the tip touching as many elements of the joints
as possible. Place the solder wire near the iron and let it flow. Pass it around the joints.
3. Remove the iron and let the solder flow in the area from where the iron has been
removed.
4. When the solder has successfully flowed in the lead and track, take the solder away and then
remove the iron.

DESOLDERING:

To de-solder means to remove a joint or re-position a wire or component. There are two ways to remove
the solder:

1. With a de-soldering pump (solder sucker)

1. Set the pump by pushing the spring-loaded plunger down until it locks.
2. Apply both the pump nozzle and the tip of your soldering iron to the joint.
3. Wait a second or two for the solder to melt.
4. Then press the button on the pump to release the plunger and suck the molten solder into
the tool.
5. Repeat if necessary to remove as much solder as possible.
6. The pump will need emptying occasionally by unscrewing the nozzle.

2. with solder remover wick (copper braid)

1. Apply both the end of the wick and the tip of your soldering iron to the joint.
2. As the solder melts most of it will flow onto the wick, away from the joint.
3. Remove the wick first, then the soldering iron.
4. Cut off and discard the end of the wick coated with solder.

After removing most of the solder from the joint(s) we can remove the wire or component lead
straight away (allow a few seconds for it to cool). If the joint will not come apart easily apply
your soldering iron to melt the remaining traces of solder at the same time as pulling the joint
apart.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUSION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 10 TO STUDY CABLES ACCORDING TO CORES

Introduction:
There are four electrical cables according to its core
1-Single core cable
2-Two core cable
3-Three core cable
4-Four core cable

1. Single core cable:


In this type of cable one conductor is present and it is separated by an insulator the cables are used for
Main electric boards in Ammeter, Voltmeter etc
2. Two core cable:
In this type of cable two conductors are present which are separated by an insulator these cables are
Used in electrical machines, electrical pump and other house hold items.

3. Three core cables:


In this type of cable three conductor are present which are separated by an insulator these are used in
House wiring for three phase required in industrial factories are in commercial building.
4. Four core cable:
In this type of cable four conductors are present which are separated by an insulator .these cables are
Used for transmission line and distribution line.

Special cables:
1. R.G cable

2. Co-Axial cable

3. Telephone cable

4. Telephone intercom cable (20-105)

5. Fiber Optic Cable

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


1. R.G Cable:
It’s a common type of satellite co axial cable in single core it is used in wide variety of residential and
commercial application it is specially used for distributing signals

2. Coaxial cable:
It is used as transmission line for radio frequency signals its application includes feeds line connecting transmitter
and receiver with their antenna and for distributing signals this cable also provides the protection of the signals
from external electromagnetic interference it is also used for video distribution in home offices and restaurants it
is also used in dish antennas.

3. Telephone Cable:
It is used in in wiring of telephone lines for indoor and outdoor purposes in residential and commercial area.

4. Intercom Cable:
It is used in intercom wiring for indoor purposes in the same building or building to building.
5. Fiber Optic Cable:
The fiber optic cables are used mainly for internet and digital audio connection between devices an optical fiber
cable contains one or more optical fiber .Fiber optic lines are laying for long distance s for phone calls and for
internet .fiber optic cable consist of bundles of glass threads each of which is cable of fiber .optical fiber has a
greater signal band width than metal cable.

6. Security Alarm Cable:


Those types of wires or cables which are used in the alarms of residence, commercial, industrial and military
properties are called security alarm cables.

Other Special Types Cable:


1. Coil cable.

2. Multimedia Cable.

3. Security Alarm Cable.

4. Multimedia Communication Cable.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO: 11 TO MAKE A SERIES CIRCUIT AND MEASURE HOW VOLTAGE IS
DIVIDE WITH THE HELP OF MULTIMETER

APPARATUS:
Voltmeter, ammeter tester bulb holder tape, wires circuit board

DAIGRAM:

PROCEDURE:
1. Philled the ends of wire.

2. Connect one end of wire with one terminal of switch

3. Extend the wire from switch to the bulb holder.

4. Connect three bulb holders in series with each other.

5. Now extend the wire from last bulb holder to ammeter.

6. Connect the leading negative terminal of ammeter to negative terminal of switch.

7. Extend the wire from switch to plug

8. Carefully check all connection

9. Place bulbs in bulb holder and provide the voltage.

10. The bulbs glowed when switch is on.

RESULT:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB#12 TO MAKE A PARALLEL CIRCUIT & STUDY THE BEHAVIOR OF CURRENT
WHEN THE LOAD IS CONNECTED IN PARALLEL

APPARATUS:
Voltmeter, Ammeter, Phase tester, Screw driver, Pliers &cutter, Crimping tool ,Circuit board, Bulb holder,
Insulation tape, Wire, Single pole switch.

Circuit diagram:

Procedure:
1. Take wires according to the measurements.
2. Remove the insulation of wire from both ends.

3. Connect the wires with the positive terminals of switches.

4. Connect the negative terminals of switches with positive terminals of holder.

5. Connect the negative terminals of holder with ammeter in series.

6. Now the loads (bulbs) are in parallel way.

7. Connect a voltmeter with neutral and phase wire.

RESULT:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 13: TO CONSTRUCT A TEST LAMP BOARD

OBJECTIVE: After completing the practical’s student will be able to:


I. Draw circuit diagram according to the title of the practical.
II. Prepare the list of required wiring accessories according to the circuit diagram.
III. Prepare the list of wiring tools required to perform the practical.

REQUIRED:
WIRING TOOLS & INSTRUMENTS:-
(i) Electrician plier (ii) Side cutting plier (ii) Electrician knife (iv) Connector screw driver (v) Phase tester (vi)
Drill Machine with drill bit (vii) Bradawl / Pocker (viil) Multi meter.

WIRING MATERIAL:-
(i) Single-way switch (ii) Two pin socket (ii) Bulb holder (iv) Bulb (v) Fuse with fuse wire (vi) Wooden Board
(suitable in size) (vii) Wooden screws 1/2" 8Nos. (viii) Used sand paper (ix)Wiring cable 3/0.029" (colored) as
required (x) Ac supply source

CIRCUIT DIAGRAM

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


PROCEDURE:
1. Cut the wire into two pieces making each one a meter long.

2. Now you have two pieces of wire. Fix the bulb holder using one end of the two pieces of wires and install a
light bulb on to the holder.

3. You have other two ends of the wire free. Fix a two-pin plug on that free pairs of wires. It means you can light
up the bulb if you put two-pin plug in a live two-pin socket.

4. Check the continuity of the test lamp by an multi meter be sure that bulb turns on when the plug is inserted in a
live two-pin socket.

5. Now, pull out the plug from the socket.

6. Finally, you need to slice one of the wires in the middle and remove insulation from each of the cut-ends for
half an inch so that the bare copper is clearly visible.

7. Your test lamp is ready for experimental test. Always use a cap to cover the bare copper wire to avoid any
accidental electrification.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 14: TO MAKE A FAN REGULATOR CIRCUIT

APPRATUS:
Multi meter, Single way switch, Circuit board, Fan regulator, Peeler, Cutter, Screw driver, Wire as required,
Phase tester, Crimping tool.

CIRCUIT DIAGRAM:

PROCEDURE:
1. Take wires according the measurement.

2. Remove the insulation from wires.

3. Connect the phase wire with the one terminal of single way switch.

4. Other end of switch connects with the regulator.

5. Second end of the regulator connects with one end of fan.

6. Other end of fan connects with the negative terminal of source.

7. Switch on the circuit and regulate the speed of fan using regulator.

PRECAUTIONS:
1. Make all connection carefully.

2. Don’t touch the phase wire.

3. Avoid from reading during wring.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 15: TO MAKE A STAIR CIRCUIT

APPARATUS:
Multi meter, Phase tester, two way switch, Bulb and Bulb holders, Cutter, Plier, Screw driver, Crimping tool,
Wires as required, Circuit board.

CIRCUIT DIAGRAM:

PROCEDURE:
1. Take wires according to the measurements and a circuit board.

2. Remove the insulation of wires.

3. Connect positive terminal if AC supply to the central terminal of s/w 1.

4. Connect the upper and lower terminal of s/w 1 and s/w 2with each other.

5. Connect the central terminal of s/w 2 with positive terminal of bulb holder.

6. Connect the negative terminal bulb holder with the negative terminal of source.

7. Turn on the circuit in the bulb glowed.

PRECAUTIONS:
1. Make all connections carefully.

2. Don’t touch the main power supply.

3. Connection should not be loose.

4. Avoid from sparking during wiring.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO#16 IDENTIFICATION &TESTING OF TWO TERMINAL DEVICE &ICS

OBJECTIVE:
Identify the measure the Two terminal active devices
APPARATUS:
 SC Diode
 Zener Diode
 DIAC
 Integrated Circuit
 Multimeter

THEORY:
A-SEMI CONDUCTOR DIODE
TWO TERMINAL DIODE:
A diode is an electrical device allowing current to move through it in one direction with far greater
ease than in the other. The most common type of diode in modern circuit design is the semiconductor
diode, although other diode technologies exist. Semiconductor diodes are symbolized in schematic
diagrams as such

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


When placed in a simple battery-lamp circuit, the diode will either allow or prevent current
through the lamp, depending on the polarity of the applied voltage:

When the polarity of the battery is such that electrons are allowed to flow through the diode, the
diode is said to be forward-biased.
Conversely, when the battery is "backward" and the diode blocks current, the diode is said to be
reverse-biased. A diode may be thought of as a kind of switch: "closed" when forward-biased and
"open" when reverse-biased.
ZENER DIODE:
Zener diode is basically like an ordinary PN junction diode but normally operated in reverse
biased condition. But ordinary PN junction diode connected in reverse biased condition is not
used as Zener diode practically.

A Zener diode is a specially designed, highly doped PN junction diode. The name Zener diode
was named after the American physicist Clarence Melvin Zener who discovered the Zener effect.
Zener diodes are the basic building blocks of electronic circuits. They are widely used in all kinds
of electronic equipment. Zener diodes are mainly used to protect electronic circuits from over
voltage.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


DIAC

The term DIAC stands for the Diode for Alternating Current (DIAC), it is a bidirectional semiconductor switch
that can be turned ON in both forward and reverse direction.
The device is a member of the Thyristor family and it is mostly used in triggering TRIAC
And other Thyristor based circuits.
The DIAC starts conducting electric current if the applied voltage goes beyond its break-over voltage.

DIACs are available in different types of DIAC packages such as discrete components in small leaded
packages, surface-mount packages, large packages that are bolted to chassis and various other packages.
Most of the time the DIAC and TRIAC are used together, so they are available in integrated packages also.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


D. Meter check of a diode:

Being able to determine the polarity (cathode versus anode) and basic functionality of a diode is a
very important skill for the electronics hobbyist or technician to have

Since we know that a diode is essentially nothing more than a one-way valve for electricity, it
makes sense we should be able to verify its one-way nature using a DC (battery-powered)
ohmmeter. Connected one way across the diode, the meter should show a very low resistance.
Connected the other way across the diode, it should show a very high resistance.

In order to determine which end of the diode is the cathode and which is the anode, you must know with
certainty which test lead of the meter is positive (+) and which is negative (-) when set to the "resistance"
or "Ω" function.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


(II)INTEGRATED CIRCUIT

An integrated circuit is electronic circuit or device that has electronic components on a small
semiconductor chip. It has functionality of logic AND or amplifying of a signal. These are mainly
two types of circuits: Digital or Analog. Analog ICs handle continuous signals such as audio signals
and Digital ICs handle discrete signals such as binary values.

TYPES OF INTEGRATED CIRCUIT

ANALOG ICS DIGITAL ICS

Linear ICs (Linear Integrated Circuits) are Digital ICs (Digital Integrated
called as analog IC. Circuits) are also called as nonlinear
IC.

Linear integrated circuits inputs and


Digitals ICs contain circuits whose
outputs can take on a continuous range of
inputs and outputs voltage are
values and the outputs are generally
limited to two possible levels low or
proportional to the inputs.
high.

It is used in aircraft, space, vehicles, It’s used in microprocessor, computers,


radars, PLL, Oscilloscopes etc. clocks, digital watches, calculator etc.

The design requirements are more drastic The design requirement as less
as compared to digital ICs. drastic as compare To linear ICs.

Its commercially available as


It is commercially available as operational microprocessor chips, memory chips,
amplifiers, voltage multipliers, voltage analog to digital chips , digitals to
comparator, regulators, microwave analog chips, logic gates, flip flops,
amplifiers Etc. counters, registers etc.

Its consist of very less number of Its consist of more number of


transistor as compared to digital ICs.. transistor as compared to linear ICs.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Some IC’s numbers and pin diagram of IC

CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 17: TO MEASURE THE ENERGY WITH THE HELP OF AN ENERGY METER AND
VERIFY IT WITH THE HELP OF VOLTMETER, AMMETER, AND STOPWATCH
APPARATUS:
Voltmeter, Ammeter, Load, AC source, Wires, Energy meter
THEORY:

ENERGY METER:
An electricity or energy meter is a device that measures the amount of electric energy consume by residence,
Business, Or an electrically power device, Electricity meters are typically calibrated in billing units, The most
common one being the kilowatt hour. Periodic readings of electric meters establish billing cycles and energy used
during a cycle.

In settings when energy saving during certain periods is desired, Meters may measure demand, the maximum use
of power in sum interval. “Time of day” metering allows electric rates to be changed
During a day, to record usage during peak high-cost periods and off-peak, Lower-cost, periods. Also, in some
areas meters have relays for demand response shedding of loads during peak loads periods. The most common
unit of measurement on the electricity meter is the kilowatt hour, which is an equal to the amount of energy used
by a load one kilowatt over period of one hour, or 3,600,000 joules. Some electricity companies use the SI mega
joule instead.

S.R# Voltage Current Time Calculated Measured %Error


energy energy
1 236 2.11 1.9 0.497 0.5236 5.57
2 236 1.94 2.11 0.457 0.473 3.58
3 238 1.66 2.46 0.406 0.406 2.83
Table for manual calculations

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


CIRCIUT DIAGRAM:

CONCLUTION:

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 18: (A) WELDING

INTRODUCTION
Welding is the process of joining similar metals by the application of heat, with or without
application of pressure or filler metal, in such a way that the joint is equivalent in composition
and characteristics of the metals joined. In the beginning, welding was mainly used for
repairing all kinds of worn or damaged parts. Now, it is extensively used in manufacturing
industry, construction industry (construction of ships, tanks, locomotives and automobiles) and
maintenance work, replacing riveting and bolting, to a greater extent.
The various welding processes are:
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.

Electric arc welding


Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two
electrodes through ionized gas.

Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC or DC);
b. Welding electrode;
c. Work piece;
(d)Welding leads (electric cables) connecting the electrode and work piece to the power supply

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Fig:1 Arc welding set up

Fig: 2 parts of an electrode

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Electric arc between the electrode and work piece closes the electric circuit. The arc
temperature may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges
and joining them. When a long joint is required the arc is moved along the joint line. The front
edge of the weld pool melts the welded surfaces when the rear edge of the weld pool solidifies
forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines.
These machines supply high electric currents at low voltage and an electrode is used to
produce the necessary arc. The electrode serves as the filler rod and the arc melts the surface
so that, the metals to be joined are actually fixed together.
Sizes of welding machines are rated according to their approximate amperage capacity at 60%
duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated
current output at the working terminal.
Transformers
The transformers type of welding machine produces A.C current and is considered to be the
least expensive. It takes power directly from power supply line and transforms it to the voltage
required for welding. Transformers are available in single phase and three phases in the market.

Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce
D.C current in either straight or reversed polarity. The polarity selected for welding depend
upon the kind of electrode used and the material to be welded.
Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into
D.C by virtue of which the operator can use both types of power (A.C or D.C, but only one
at a time).In addition to the welding machine, certain accessories are needed for carrying out
the welding work.
Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the
case of using and coiling the cables. Cables are specified by their current carrying capacity, say
300 A, 400 A, etc.

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Electrodes
Filler rods are used in arc welding are called electrodes. These are made of metallic wire called
core wire, having approximately the same composition as the metal to be welded. These are
coated uniformly with a protective coating called flux. While fluxing an electrode; about 20mm
of length is left at one end for holding it with the electrode holder. It helps in transmitting full
current from electrode holder to the front end of the electrode coating. Flux acts as an insulator
of electricity. In general, electrodes are classified into five main groups; mild steel, carbon steel,
special alloy steel, cast iron and non‐ferrous. The greatest range of arc welding is done with

Electrodes in the mild steel group. Various constituents like titanium oxide, potassium oxide,
cellulose, iron or manganese, Ferro silicates, carbonates, gums, clays, asbestos, etc., are used
as coatings on electrodes. While welding, the coating or flux vaporizes and provides a gaseous
shield to prevent atmospheric attack. The size of electrode is measured and designated by the
diameter of the core wire in SWG and length, apart from the brand and code names; indicating
the purpose for which there are most suitable
Electrodes may be classified on the basis of thickness of the coated flux. As
1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded
Electrodes are also classified on the basis of materials, as
1. Metallic and
2. Non‐metallic or carbon
Metallic arc electrodes are further sub‐divided into
1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, etc.
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc. In case of non‐metallic
arc electrodes, mainly carbon and graphite are used to make the electrodes
Carbon and graphite are used to make the electrodes

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


1- ELECTRODE HOLDER 2- GROUND CLAMP

3- WIRE BRUSH 4- CHIPPING HAMMER

5- HAND GLOOVES 6- FACE SHIELD

7- WELD POSITION

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


WELDING TOOLS

Electrode holder
The electrode holder is connected to the end of the welding cable and holds the electrode. It
should be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electrode holder. The jaws of the holder are insulated, offering protection
from electric shock.

Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance
connection.

Wire brush and chipping hammer


A wire brush is used for cleaning and preparing the work for welding. A chipping hammer is
used for removing slag formation on welds. One end of the head is sharpened like a cold chisel
and the other, to a blunt, round point. It is generally made of tool steel. Molten metal dispersed
around the welding heads, in the form of small drops, is known as spatter. When a flux coated
electrode is used in welding process, then a layer of flux material is formed over the welding
bead which contains the impurities of weld material. This layer is known as slag. Removing
the spatter and slag formed on and around the welding beads on the metal surface is known as
chipping.
Welding table and cabin
It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made‐up by any suitable thermal resistance material, which can isolate
the surrounding by the heat and light emitted during the welding process. A suitable draught
should also be provided for exhausting the gas produced during welding.

Face shield
A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand type
is convenient to use wherever the work can be done with one hand. The helmet type though
not comfortable to wear, leaves both hands free for the work.
Shields are made of light weight non‐reflecting fiber and fitted with dark glasses to filter out
the Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to
protect it from spatter.

Hand gloves
These are used to protect the hands from electric shocks and hot spatters

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Techniques of Welding
Preparation of work
Penetration of the weld. Before commencing the welding process, the following must be
considered
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
c) Set the welding current, as per the size of the electrode to be used.

WELDING POSITIONS

Depending upon the location of the welding joints, appropriate position of the electrode
and hand movement is selected. The figure shows different welding positions.
Flat position welding
In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same
position is sometimes called down hand.
Horizontal position welding
In this position, welding is performed on the upper side of an approximately horizontal
surface and against an approximately vertical surface.
Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB NO 19: (B) WELDING

LAP JOINT
Aims: To make a double lap joint, using the given mild steel pieces and by arc welding.

Material used:
Two mild steel pieces of 100X40X6 mm

Tools and equipment used


1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAP JOINT

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Procedure

1. Take the two mild steel pieces of given dimensions and clean the
surfaces thoroughly from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and
prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap
joint with the required over lapping.
4. The electrode is fitted in to the electrode holder and the welding
current is set to a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding
the over lapped pieces the arc is struck and the work pieces are
tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces
are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on
both the sides.
9. Remove the slag, spatters and clean the joint.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result The lap joint is thus made, using the tools and equipment as mentioned above.

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


LAB #20 WELDING
BUTT JOINT

Material required: 2m.s flat pieces of given size.

Tools required:
1. welding transformer,
2. connecting cables,
3. electrode holder,
4. ground clamp,
5. Electrode
6. hipping hammer,
7. Welding shield etc.

Aim: preparation of butt joint as shown in figure using shielded metal arc welding process.

BUTT JOINT

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY


Procedure:
1. The given metallic pieces filled to the desired size.
2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode dia based on thickness of work piece and hold it on the
electrode holder. Select suitable range of current for selected dia.
6. Switch on the power supply and initiates the arc by either striking arc
method or touch and drag method.
7. Take welding to be done before full welding.
8. In full welding process after completion one part before going to second part.
Slag is removed from the weld bed. With the metal wire brush or chipping
hammer.
9. Then the above process will be repeated until to fill the groove with
weld bed or weld metal.
Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result: butt joint is prepared as shown in figure by using arc-welding process.

Checked by: Date:

Marks Awardeded:

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING TECHNOLOGY

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