Electric Switches Plugs Sockets & MCB (Miniature Circuit Breaker) (Cap: 2000 Numbers per day)

ELECTRIC SWITCHES PLUGS SOCKETS & MCB (MINIATURE CIRCUIT BREAKER)

[EIRI/EDPR/4669] J.C.: 2886XL

PRODUCT INTRODUCTION

Electrical switches are household consumables items. A switch is an electrical component that can break an electrical circuit, interrupting the current or diverting it from one conductor to another. When the switch is open, the electrical contacts do not touch and electricity cannot flow. When the switch is closed, however, the electrical contacts touch and electricity flows throughout the circuit. In almost every application, for residential, commercial or industrial use, switches are required to be installed. Electrical switches are used to perform all the electrical functions. From a fan to bulb, every electrical equipment we use in our day to day life is useless without a switch. 

The types of electrical switches

the different types of Electrical switches which are used for household as well as commercial purposes.  

One-way (single pole) Electrical switch: 

It is one of the most common use switches. Generally, they are used for light, fans, or other devices from a single location switch. Their simple function is ON and OFF, This is something which is not in any other switch such as in three-way and four-way. A one-way switch generally works as a brake switch. The two terminals of the switch are connected when it is turned ON, and the contact between the two is broken when the switch is turned OFF. 

Two-way (Double-pole) Electrical Switch: 

This type of Switch is generally used in Industrial applications but it can also be used in some home wiring systems. These switches also have ON and OFF markings on them. A double pole switch has four brass terminals instead of two like one-way. This type of switch has a ground terminal that allows you to connect two pairs of hot wires. These are generally used for 30 amps so that they can able to control higher-demand appliances such as motors, geysers, and machinery.

Bell Push Switch: It is generally used in doorbell switches. It can be used at homes, offices guest houses, or at any other place wherever needed. A bell push switch always maintains a broken circuit, even if the button is pressed.

Switch is an electrical component which can make or break electrical circuit automatically or manually. Switch is mainly works with ON (open) and OFF (closed) mechanism. Numerous circuits hold switches that control how the circuit works or actuate different characteristics of the circuit. The classification of switches depends on the connection they make. SPST (Single Pole Single throw), SPDT (single pole double throw), DPST (double pole, single throw), DPDT (double pole double throw). There are different types of electrical switches are available for different types of applications.

Electric switches, plugs, sockets, etc.  are nothing but electric fittings which are quite familiar to the people as it is found in every home.  They can be manufactured using  different major   raw  materials  e.g.  steel,  brass,   thermosetting   or thermoplastic  resins  However this report is  totally  based  on bakelite  powder or resin which is thermosetting type.   Bakelite powder  is also known as phenol formaldehyde resin.   also  other electrical  accessories  e.g.  plates,  lamps  holders,  may   be manufactured  from phenol formaldehyde resin and same  plant  and machineries  making the industry highly flexible and  profitable.  Besides  electrical fittings radio cabinets, inks  stands,  table lamps, door and cabinets, handles, power relay components, camera shutters,  textile  bobbins  and other accessories  may  also  be manufactured with little or no change.

As  mentioned  earlier  though electrical  fittings  may  be manufactured  from  other  materials also it may  be  noted  that bakelite  electrical  fittings  are best  and  economical.   Also bakelite  is  bad  conductor of  electricity  making  them  shock resistant  which  may  be  there  is  case  of  metal  electrical fittings.

Electric  fittings  are manufactured in different  sizes  as required  by  the  customer.  They may be of two  or  three  pin.  Three pin sockets and plugs have one major advantage over two pin one's since they are earthed also.  Also various combinations are practiced in the 5-15 ampere range.

These combinations are (1) 5 amp. switches, sockets, Bell push & Flush type fuses (2) 15  amp. and  5-15  amps. combination etc. can imagine the scope  of  this industry.   To  make  it more clear due  to  the  development  in electric  production more industries will be installed, more  and more  electricity, as well as industrial purposes which  in  turn will require more fittings.

COST ESTIMATION

Plant Capacity            2000 Nos./Day  

Land & Building (500 sq.mt.)    Rs. 14.00 Lac    

Plant & Machinery                    Rs. 86.50 Lac 

Working Capital for 2 Months    Rs. 75.84 Lac 

Total Capital Investment          Rs. 1.82 Cr 

Rate of Return                          135%

Break Even Point                      26%

CONTENTS

PRODUCT INTRODUCTION

THE TYPES OF ELECTRICAL SWITCHES

TWO-WAY (DOUBLE-POLE) ELECTRICAL SWITCH:

MOST OF THE BAKELITE ELECTRICAL FITTINGS CONSIST ESSENTIALLY OF THREE PARTS

MINIATURE SOCKETS

SUBMINIATURE SOCKETS

SMALL AND MEDIUM SOCKETS

OCTAL SOCKETS

B.I.S. SPECIFICATION

IS: 4949-1968

2. TERMINOLOGY

3. MATERIAL

4. CONSTRUCTION

5. TERMINALS AND SCREWS

6. ACTUATING MECHANISM

7. CREEPAGE DISTANCES AND CLEARANCES

8. MARKING

9. TESTS

1. SCOPE

1.   SCOPE

2. TERMINOLOGY

PUSH-BUTTON SWITCH

MECHANICAL FEATURES

3. CATEGORIES

4. ELECTRICAL RATINGS

5. MATERIALS AND WORKMANSHIP

MATERIALS:-  

MARKING

USES AND APPLICATION

COMPOUNDING THE RAW MATERIALS:

CONTACTS:

EARTHING:-

RAW MATERIALS

PHENOL-FORMALDEHYDE RESINS:-

RAW MATERIAL SELECTION:-      

DETAILS OF SOCKETS

HOLES OF ELECTRICAL SOCKETS

ELECTRICAL SOCKET MATERIALS

INSTALLING ELECTRICAL SOCKETS

MULTI STANDARD ELECTRICAL SOCKETS

ELECTRICAL SOCKETS

ELECTRICAL SOCKET MATERIALS

PROCESS FLOW SHEET FOR MANUFACTURING

COMPRESSION MOLDING TECHNIQUE

POWER AND PREFORMS

INSULATION

REQUIRED PRESSURES

HEATING

SETTING UP THE NEW MOLD

TEMPERATURE AND CURE

INSTALLING ELECTRICAL SOCKETS

MULTI STANDARD ELECTRICAL SOCKETS

POWER SOCKET

TYPES OF ELECTRICAL SOCKETS

PLANT AND MACHINERY SECTION

COMPRESSION MOULDING DRESS:-   

DIE OR MOULD:-  

MCB (MINIATURE CIRCUIT BREAKER) 

INTRODUCTION

WORKING PRINCIPLE MINIATURE CIRCUIT BREAKER

MINIATURE CIRCUIT BREAKER CONSTRUCTION

CONSTRUCTION OF MCB

FRAME OF MINIATURE CIRCUIT BREAKER

OPERATING MECHANISM OF MINIATURE CIRCUIT BREAKER

TRIP UNIT OF MINIATURE CIRCUIT BREAKER

OPERATION OF MINIATURE CIRCUIT BREAKER

TYPES OF MINIATURE CIRCUIT BREAKERS (MCB’S)

TYPE B MCB

TYPE C MCB

TYPE D MCB

(2) DISTRIBUTION BOX

TYPES OF ELECTRICAL DISTRIBUTION BOARDS

FUSE BOXES:

MAIN BREAKER PANEL:

MAIN LUG PANEL:

SUBPANELS:

TRANSFER SWITCHES:

USAGE AND APPLICATION

1. HOME ELECTRICAL PANELS

2. LIGHTS

3. INDUSTRIAL APPLICATIONS

4. HEATERS

5. GROUND FAULT TRIP MECHANISM

B.I.S. SPECIFICATION

PROCESS FLOW CHART

PROCESS FLOW CHART (MCB)

PROCESS FLOW CHART DISTRIBUTION BOX

PRODUCTION PROCESS

(A) FOR MCB

(1) SPOT WELDING:-

PROCESSING AND EQUIPMENT

THE ABOVE MENTIONED STAGES ARE BETTER EXPLAINED THROUGH FOLLOWING BLOCK DIAGRAMS:

KNOB ASSEMBLY: - 

COMPONENTS USED:

STEPS OF KNOB ASSEMBLY:-

TOOLS USED:-

THE PROCESS FLOW DIAGRAM FOR KNOB ASSEMBLY IS SHOWN BELOW: -

MCB ASSEMBLY: -

THERMAL OPERATION: -

MAGNETIC OPERATION: -

QUALITY CONTROL

SCHEME OF INSPECTION AND TESTING: 

MARKET POSITION

CHINA CIRCUIT BREAKER MARKET, BY RATED VOLTAGE (USD MILLION)

EUROPE CIRCUIT BREAKER MARKET, BY COUNTRY, 2024 (UNITS) 

INCREASING RURAL ELECTRIFICATION, TO DRIVE THE GLOBAL MCB AND MCCB MARKET

MARKET OVERVIEW

MARKET SEGMENTATION

NORTH AMERICA DISTRIBUTION PANEL MARKET, BY END USE, 2016 & 2024 (USD BILLION)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

TOP ELECTRICAL SWITCH MANUFACTURING COMPANIES IN THE WORLD

ELECTRICAL SWITCH MANUFACTURING COMPANIES

SIEMENS

SCHNEIDER ELECTRIC

POLYCAB

PHILIPS

HPL

HONEYWELL

HAVELLS

GREAT WHITE

GOLD MEDAL

GM

CORUM

ANCHOR

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

LIST OF IMPORTANT LICENSES REQUIRED TO START MANUFACTURING ELECTRICAL SWITCHES, SOCKET & MCB

MANUFACTURERS/EXPORTERS/SUPPLIERS OF ELECTRICAL SWITCH, SOCKETS, MCB ETC.

SUPPLIERS OF RAW MATERIALS

BAKELITE POWDER

PHENOL FORMALDEHYDE RESINS

STEEL STRIPS

MANUFACTURERS NUT AND SCREWS

MANUFACTURER SLEEVES

SUPLIERS OF PLANT AND MACHINERIES

HYDRAULIC PRESS

PLASTIC PROCESSING MACHINERY

BUFFING MACHINE

SUPPLIERS OF MCB

RAW MATERIAL SUPPLIERS

SUPPLIERS OF PRODUCTION LINES

STEEL PIPE & SHEET MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

LABORATORTY EQUIPMENTS MANUFACTURERS

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF EXHAUST FAN

SUPPLIERS OF TESTING EQUIPMENTS

GANIZATION CHART

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)