What is aluminium wiring? Aluminum wire is a type of wiring used in houses, power grids, and airplanes.

Aluminum provides a much better conductivity to weight ratio than copper, and therefore is used in power wiring of some aircraft..
Indroduction to aluminium wiring.

Since the early 1900s, utility companies have been using aluminum wire for transmission of electricity within their power grids. It has advantages over the older copper wire in that it is lighter, more flexible, and less expensive. Aluminium wire in power grid applications was very successful and is still used today. The latest market to embrace aluminium is building wire due to the rapidly rising price of copper. Electrical contractors have switched from copper to aluminium alloy. Building wire now uses the new 8000 alloy of aluminium as specified by the National Electrical Code (NEC). Contractors are also using larger sizes of aluminum building wire for low voltage feeders where the savings over copper is significant due the lower weight. Aluminium building wire will have half the weight of copper even though the aluminium conductor must have 50% greater area than copper to carry the same current. The aluminium conductors used for building wire may be compacted in such a way that the overall diameter of the aluminium wire is approximately the same as copper. . In the mid 1960s when the price of copper spiked, aluminium wire was manufactured in sizes small enough to be used in homes. When first used in branch circuit wiring, aluminium wire was not installed any differently than copper. In the late 1960s, a device specification known as CU/AL was created that specified standards for devices intended for use with aluminium

wire. Because of more rigorous testing, larger screw terminals were designed to hold the wire more suitably.

Problems with aluminium wires Aluminium wires have been implicated in house fires in which people have been killed. There were several possible reasons why these connections failed. The two main reasons were improper installation and the differences in coefficient of expansion between aluminium wire and the terminations used in the 1960s. Many terminations of aluminium wire installed in the 1960s and 1970s continue to operate with no problems. However, many connections were not made properly when installed.

Benefits of aluminium wires.

Aluminium is know to have good corrosion resistance, which is important to secure a longer life of our customers applications. Aluminium wire provides a cost efficient and effective solution, as conductivity per ton of wire is higher than in other wire material used today. Furthermore, the choice of Aluminium provides our customer with the advantage of being able to use less polyamide isolation around

the core wire. For all the mentioned reasons, aluminium is today widely used in the market of underground and underwater power and signal transfer.

History of the factory The R.S. company located at Ulhasnagar 3 is engaged in the production of aluminium wires. This industry is one of the oldest in Maharashtra ,thane district. This factory is been working for the past 21yrs . It has been established in the year 1991 , during that period the area as well as the numbers of labours were limited. In the year 2002 the factory started progressing at a uniform speed.

During the time of its establishment the factory carried on their process in a 20*20 sq ft. Now the factory has been developed both in the terms of area as well as capital. It has a wide area covering 2 buildings . manufacturing of process 1 takes place in the ground floor of one building and the 2 nd and 3rd process is been carried on the 1st and 2nd floor. The company earlier had only 7- 10 machines with limited number of workers. The company started progressing each and every year. Earlier the factory had only 10- 15 workers now they have a 45-50 labours. The labours are highly skilled with with a good team work. The company brings the product delhi and the sales is all over Maharashtra.

The Production Process

Aluminium rod, bar, and wire products can be produced by several different processes. One method of making these products is similar to rolling sheet. A long, square ingot is heated, progressively reduced in cross-section by passing it through a series of rolls, and then coiled. The coils are heated for softening and, if they are slated to become wire, the rod is pulled through smaller and smaller dies on a wire-drawing machine. Electrical conductor is made by stranding several wires into a single length.

Bar, rod, and tube can also be made by the drawing method directly from stock produced by hot extrusion. This process is also completed by the progressive thinning of the aluminium material through the use of dies. The production is been carried on with the following process . Process 1 The process 1 is the preparation of pvc . Products used are scrap, sipi oil, chemical 505, colour( green, yellow,red,blue) and janjira powder. Step 1 First the waste materials is been put into the machine so that the srap material is crushed. Here the scrap material mainly include pieces of plastic bottles . wrappers and plastic bags.

Step2 After the crushing of scrap materials the next step is to mix the scrap materials with chemical known as sunlight 505 , sipi oil, and colour

in the machine with the degree of 110 c. we can choose the colour as per our choice it can be red, green,or yellow

Step 3 After mixing of the above things a thick layer of the mixture is been formed which is a sticky substance , to avoid the stickeness it is been put in the cold water and again heated in the machine. ,this avoids elasticity and the substance so formed is in the solid form.

Step 4 The solid material formed after the process is been transformed in another machine . This machine is used to cut the formed substance into pices . This pieces are called pvc, the is used for the oating purpose

Process2: This process is based on the production of aluminium wire. Step1 The aluminum which is imported from delhi & state near by goa is in a hard & thick form. To make into thin form firstly it needs heat. It is put into the machine for the heating process. The hard & thick aluminium of bundle then keep into heater for 7 to 8hrs for slight melt then will take wire of aluminium & put into drawing machine & doing Dai

As the process running the thick wire of aluminium will convert into 6,7 thin wire of aluminium as seen in figure.

Step 2 The second step is the mixture of 1 & 2. In this the role of thin aluminium which we prepare we will hang in the one stand. Say for 7 roles of aluminium which will cross through Core Machine along with there is jar attached with core machine in that we used to put pvc as the all aluminium wires are cross through the machine inside the pvc coated over them. Between this process when the aluminium is crossing through machine one another chemical is shrinked over aluminium is Janjira powder as it doesnt stick with pvc during the process. Step 3 In the third step the coating of pvc takes place. Then pvc coated over the wire & it comes from machine it immediately put into water then the aluminium wire is ready with different colours as shown in the figure

Process 3 Process 3 is engaged in the production of 3 core wire. What do you mean by THREE CORE? It is three wire of aluminium of green, red & blue together coated with black pvc is knwn as Three core.

In this process the wires so formed is coated with black pvc together with all the wires

conclusion visit to rs factory located in Ulhasnagar made us to know the manufacturing process of aluminium wires in detail. There was detail study regarding the machines . It was a new experience for every group member to learn the process of manufacturing of aluminium wires. We got a detail information regarding each and every steps which is been carried out for the production of wires as well as learning practically how the raw materials get converted into finished goods. Each and every step or process were told by them as well as their need and reasons behind it.Basically there were 3 process and each and every process were explained by them . The respected workers gave us the information regarding each and every machine as well as the process which is been carried out from the production of pvc till the final aluminium wires. We came to know about the each and every raw materials as well as chemicals that are been used in the manufacturing process, we also came to know the reasons behind heating the chemicals and the use of janjira powder in the production process. After visiting the factory we got a knowledge about the production of aluminium wires.

Overall it was a tour of knowledge and enjoyment

Questionare 1. How many labours are there in the factory? Ans 45-50 2. Number of process carried on this factory ? Ans 3 process 3. which are the rawmaterials used in the production of pvc? Ans plastic scrap, sipi oil, sunlight 505 and janjira powder.

4. How many machines are there in the factory? Ans overall 15 machines

5. How much rawmaterials is used ? Ans 6. Ans 7. Ans 8. Ans 9. 2oo kilo of pvc, 4 kilo of colour and other chemicals. what is the estimated life of the machines? 10yrs Does machines require any repairs? yes. How many times and after how many years ? 2-3 times after 3 or 4 years From where do you bring the aluminium wires?

Ans 10 .

delhi How many labours work on a single machine?

Ans 1-2 labours 11. what are the pay scale of labours? Ans 12. Are the raw materials or co products used is investigated? Ans yes, it is done by the respected factory members. 13 How much srap or wastage is generated ? Ans 1-1.5% per day. 14. Are the scrap material been used ? Ans It is send to other factory for recycling. 15 How the chemical used in factory is released? Ans special araangements are made and it is released in the drainage system.

Name of the members Sapna khetwani Priya patil Sangeeta biswas sonali borate sonam ahuja Anjali talreja

Roll no 30 53 22 28

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