UTM SHILLONG

1. A Summer Internship Project Report on
WORKING STUDY OF PHILIPS LED AND OTHER TESTING
PRODUCTS
Submitted in partial fulfillment of the requirement for the degree of
B.Tech(ECE)3rd
year
University of Technology and Management,Shillong
By
Chakresh Tiwari
Roll No.R020113004
Under the guidance of
Mr. Himanshu Semwal
A study conducted at
PHILIPS LIGHTING LIMITED, NOIDA
University of technology and Management
Shillong (mentored by UPES Dehradun)
2013-2017

2. 1
Acknowledgement
It is indeed of great moment of pleasure to express my senses of per found gratitude to all
the people who have been instrumental in making my training a rich experience. For this, I
would like to thank Mr. Himanshu Semwal who talked to the concerned person and without
whom an internship with the company would not have been possible. I express my gratitude to
Mr. Amit Jain (Director), for giving me an opportunity to work and make the best out of my
internship.
I thank my college University of Technology and Management Shillong, for having
given me this opportunity to put to practice, the theoretical knowledge that I imparted from the
program.

3. 2
Introduction
Here,I got opportunity to have hands on experience on the real Devices. Testing of products,
Enhancement in the manufacturing, Neat Soldering and desoldering hands on practice.
Specially, to work and help the Employees in their work and their projects. Got to learn how AC to AC
converter AC to DC converter works. Dimming Effect , Flyback converter which is used in making
Dimming Products.
Tests Performed
1. Strife test
2. Surge test
3. Thermal test
4. Reliability test

4. 3
1. Surge Test
Why Do Motors Fail?
Motors fail both mechanically and electrically. Electrical failure occurs due to shorting which is caused
by a breakdown of winding insulation. There are three types of insulation failure that can occur:
• Ground wall insulation (the primary insulation between the copper winding and steel core)
• Phase to phase insulation (the secondary insulation between the end turns of a random wound motor)
• Turn to turn insulation (the secondary insulation-applied to the surface of the copper
winding)Stresses that cause electrical motor failure include differential thermal stress, different
coefficients of expansion, varnish weakening at high temperatures, magnetic force due to winding
currents, environmental contaminants, and moisture. These stresses cause looseness, motion, and wear
of the insulation.
Why Perform Surge Testing?
Insulation deterioration is one of the first signs that a motor is going to fail electrically. Since secondary
insulation is least able to sustain wear, shorting usually occurs here before the thicker, ground wall
insulation is affected. Surge testing is a non-destructive test and detects the early stages of secondary
insulation deterioration. The cost of motor failure is measured by interruption of plant output as well as
extent of repair or replacement. Surge testing greatly decreases both. It detects failure early enough so
that repair or replacement can be scheduled during a normal shutdown rather than an emergency
outage. In addition, damage to the motor is minimized.
How is Surge Testing Performed?
The test can be performed on the motor winding without actually connecting to the motor itself. The
test equipment can be connected to the load side of the motor starter. During the test a voltage pulse is
placed across two of the three windings while the third is grounded. The magnitude of the pulse is

5. 4
approximately twice the operating voltage plus 1000 volts. Therefore, low voltage starters operating at
460 volts, are tested at approximately 2000 volts and medium voltage starters, operating at 2400 volts,
are tested at approximately 6000 volts. Pulses are produced at a frequency of 60 times per second and
dissipate in approximately 100 microseconds. The output, which is a dampened sign wave, is then
monitored on an oscilloscope. Since all three windings should have the same surge patterns, the two
patterns being monitored should appear as a single overlapping wave. This procedure is repeated for all
three pairs of windings. Series In some cases if the two waves separate as the test voltage is increased,
this indicates weakened insulation which in time will lead to electrical failure.
2. Strife Test
A highly accelerated life test (HALT), is a stress testing methodology for determining product reliability.
HALT testing is currently in use by most major manufacturing organizations to improve product
reliability in a variety of industries, including electronics, computer, medical and military.HALT can be
effectively used multiple times over a product's life time. During product development, it can find design
weakness when changes are much less costly to make. By finding weaknesses and making changes early,
HALT can lower product development costs and compress time to market. When HALT is used at the
time a product is being introduced into the market, it can expose problems caused by new
manufacturing processes. When used after a product has been introduced into the market, HALT can be
used to audit product reliability caused by changes in components, manufacturing processes or suppliers
etc.
Highly accelerated life testing (HALT) techniques are important in uncovering many of the weak links of
a new product. These discovery tests rapidly find weaknesses using accelerated stress conditions. The
goal of HALT is to proactively find weaknesses and fix them thereby increasing product reliability.
Because of its accelerated nature, HALT is typically faster and less expensive than traditional testing
techniques.
Environmental stresses are applied in a HALT procedure,[1] eventually reaching a level significantly
beyond that expected during use. The stresses used in HALT are typically hot and cold temperatures,
temperature cycles, random vibration, power margining and power cycling. The product under test is in
operation during HALT and is continuously monitored for failures. As stress-induced failures occur, the
cause should be determined, and if possible, the problem should be repaired so that the test can
continue to find other weaknesses.
A specialized environmental chamber is required for HALT. A suitable chamber also has to be capable of
applying pseudo-random vibration with a suitable profile in relation to frequency. The HALT chamber
should apply random vibration energy to 10,000 Hz in 6 DOF (degrees of freedom). Sometimes HALT
chambers are called repetitive shock chambers because pneumatic air hammers are used to produce

6. 5
vibration. The chamber should also be capable of rapid changes in temperature, 50 degrees C/minute
should be considered a minimum rate of change. Usually high power resistive heating elements are used
for heating and Liquid Nitrogen (LN2) is used for cooling. HALT is conducted before qualification testing.
By catching failures early, flaws are found earlier in the acceptance process, eliminating repetitive later-
stage reviews.
3. Thermal Test
Infrared and thermal testing is one of many Nondestructive testing techniques designated by the
American Society for Nondestructive Testing (ASNT).[1] Infrared Thermography is the science of
measuring and mapping surface temperatures.
"Infrared thermography, a nondestructive, remote sensing technique, has proved to be an effective,
convenient, and economical method of testing concrete. It can detect internal voids, delaminations, and
cracks in concrete structures such as bridge decks, highway pavements, garage floors, parking lot
pavements, and building walls. As a testing technique, some of its most important qualities are that (1) it
is accurate; (2) it is repeatable; (3) it need not inconvenience the public; and (4) it is economical." [2]
An infrared thermographic scanning system can measure and view temperature patterns based upon
temperature differences as small as a few hundredths of a degree Celsius. Infrared thermographic
testing may be performed during day or night, depending on environmental conditions and the desired
results.
All objects emit electromagnetic radiation of a wavelength dependent on the object’s temperature. The
frequency of the radiation is inversely proportional to the temperature. In infrared thermography, the
radiation is detected and measured with infrared imagers (radiometers). The imagers contain an
infrared detector that converts the emitting radiation into electrical signals that are displayed on a color
or black & white computer display monitor.
A typical application for regularly available IR Thermographic equipment is looking for “hot spots” in
electrical equipment, which illustrates high resistance areas in electrical circuits. These “hot spots” are
usually measured in the range of 40 °C to 150 °C (70 to 270 °F) above ambient temperatures. But, when
engineers use its patented proprietary systems to locate subsurface targets such as Underground
Storage Tanks (USTs), pipelines, pipeline leaks and their plumes, and in this project, hidden tunnels, we
are looking for temperature patterns typically in the range of 0.01 °C to 1 °C above or below ambient
temperatures.
After the thermal data is processed, it can be displayed on a monitor in multiple shades of gray scale or
color. The colors displayed on the thermogram are arbitrarily set by the Thermographer to best illustrate
the infrared data being analyzed.
In this roofing investigation application, infrared thermographic data was collected during daytime
hours, on both sunny and rainy days. This data collection time allowed for solar heating of the roof, and
any entrapped water within the roofing system, during the daylight hours. IR data was observed until

7. 6
the roof had sufficiently warmed to allow detection of the entrapped wet areas because of their ability
to collect and store more heat than the dry insulated areas. The wet areas would also transfer the heat
at a faster rate than the dry insulated roof areas. At this point in time, the wet areas showed up as
warmer roof surface temperatures than the surrounding dry background areas of the roof. During the
rainy day, with minimum solar loading, any entrapped leak plumes would become evident because of
their cooler temperature as compared to the dry roof areas
An infrared thermographic scanning system measures surface temperatures only. But the surface
temperatures that are measured on the surface of the ground, above a buried pipeline, are, to a great
extent, dependent upon the subsurface conditions.
The subsurface configuration effects are based upon the theory that energy cannot be stopped from
flowing from warmer to cooler areas, it can only be slowed down by the insulating effects of the
material through which it is flowing. Various types of construction materials have different insulating
abilities. In addition, differing types of pipeline defects have different insulating values.
4. Reliability Test
Software reliability testing is a field of software testing that relates to testing a software's ability to
function, given environmental conditions, for a particular amount of time. Software reliability testing
helps discover many problems in the software design and functionality.
Software reliability is the probability that software will work properly in a specified environment and for
a given amount of time. Using the following formula, the probability of failure is calculated by testing a
sample of all available input states. Mean Time Between Failure(MTBT)=Mean Time TO Failure(MTTT)+
Mean Time To Repair(MTTR)
Probability = Number of failing cases / Total number of cases under consideration
The set of all possible input states is called the input space. To find reliability of software, we need to
find output space from given input space and software.For reliability testing, data is gathered from
various stages of development, such as the design and operating stages. The tests are limited due to
restrictions such as cost and time restrictions. Statistical samples are obtained from the software
products to test for the reliability of the software. Once sufficient data or information is gathered,
statistical studies are done. Time constraints are handled by applying fixed dates or deadlines for the
tests to be performed. After this phase, design of the software is stopped and the actual
implementation phase starts. As there are restrictions on costs and time, the data is gathered carefully
so that each data has some purpose and gets its expected precision.To achieve the satisfactory results
from reliability testing one must take care of some reliability characteristics. For example, Mean Time to
Failure (MTTF)[3] is measured in terms of three factors: operating time, number of on off cycles, and

8. 7
calendar time.If the restrictions are on operation time or if the focus is on first point for improvement,
then one can apply compressed time accelerations to reduce the testing time. If the focus is on calendar
time (i.e. if there are predefined deadlines), then intensified stress testing is used.
Software reliability is measured in terms of mean time between failures (MTBF).
MTBF consists of mean time to failure (MTTF) and mean time to repair (MTTR). MTTF is the
difference of time between two consecutive failures and MTTR is the time required to fix the
failure. Reliability for good software is a number between 0 and 1. Reliability increases when
errors or bugs from the program are removed.
For example, if MTBF = 1000 hours for average software, then the software should work for
1000 h.
Flyback Converter

9. 8
The flyback converter is used in both AC/DC and DC/DC conversion with galvanic isolation
between the input and any outputs. The flyback converter is a buck-boost converter with
the inductor split to form a transformer, so that the voltage ratios are multiplied with an
additional advantage of isolation. When driving for example a plasma lamp or a voltage
multiplier the rectifying diode of the boost converter is left out and the device is called a
flyback transformer.The schematic of a flyback converter can be seen in Fig. 1. It is equivalent
to that of a buck-boost converter,[1] with the inductor split to form a transformer. Therefore
the operating principle of both converters is very close:When the switch is closed (top of Fig. 2),
the primary of the transformer is directly connected to the input voltage source. The primary
current and magnetic flux in the transformer increases, storing energy in the transformer. The
voltage induced in the secondary winding is negative, so the diode is reverse-biased (i.e.,
blocked). The output capacitor supplies energy to the output load.When the switch is opened
(bottom of Fig. 2), the primary current and magnetic flux drops. The secondary voltage is
positive, forward-biasing the diode, allowing current to flow from the transformer. The energy
from the transformer core recharges the capacitor and supplies the load.The operation of
storing energy in the transformer before transferring to the output of the converter allows the
topology to easily generate multiple outputs with little additional circuitry, although the output
voltages have to be able to match each other through the turns ratio. Also there is a need for a
controlling rail which has to be loaded before load is applied to the uncontrolled rails, this is to
allow the PWM to open up and supply enough energy to the transformer.
Operations
The flyback converter is an isolated power converter. The two prevailing control schemes
are voltage mode control and current mode control (in the majority of cases current mode
control needs to be dominant for stability during operation). Both require a signal related
to the output voltage. There are three common ways to generate this voltage. The first is to
use an optocoupler on the secondary circuitry to send a signal to the controller. The second
is to wind a separate winding on the coil and rely on the cross regulation of the design. The
third consists on sampling the voltage amplitude on the primary side, during the discharge,
referenced to the standing primary DC voltage.
The first technique involving an optocoupler has been used to obtain tight voltage and
current regulation, whereas the second approach has been developed for cost-sensitive
applications where the output does not need to be as tightly controlled, but up to 11
components including the optocoupler could be eliminated from the overall design. Also, in
applications where reliability is critical, optocouplers can be detrimental to the MTBF
(Mean Time Between Failure) calculations. The third technique, primary-side sensing, can
be as accurate as the first and more economical than the second, yet requires a minimum

10. 9
load so that the discharge-event keeps occurring, providing the opportunities to sample the
1:N secondary voltage at the primary winding (during Tdischarge, as per Fig3).
A variation in primary-side sensing technology is where the output voltage and current are
regulated by monitoring the waveforms in the auxiliary winding used to power the control
IC itself, which have improved the accuracy of both voltage and current regulation. The
auxiliary primary winding is used in the same discharge phase as the remaining
secondaries, but it builds a rectified voltage referenced commonly with the primary DC,
hence considered on the primary side.
Previously, a measurement was taken across the whole of the flyback waveform which led
to error, but it was realized that measurements at the so-called knee point (when the
secondary current is zero, see Fig. 3) allow for a much more accurate measurement of what
is happening on the secondary side. This topology is now replacing ringing choke
converters (RCCs) in applications such as mobile phone chargers.
Limitations
Continuous mode has the following disadvantages, which complicate the control of the
converter:The voltage feedback loop requires a lower bandwidth due to a right half plane
zero in the response of the converter. The current feedback loop used in current mode
control needs slope compensation in cases where the duty cycle is above 50%. The power
switches are now turning on with positive current flow - this means that in addition to
turn-off speed, the switch turn-on speed is also important for efficiency and reducing waste
heat in the switching element.Discontinuous mode has the following disadvantages, which
limit the efficiency of the converter:
High RMS and peak currents in the design
High flux excursions in the inductor
Applications
Low-power switch-mode power supplies (cell phone charger, standby power supply in
PCs)
Low-cost multiple-output power supplies (e.g., main PC supplies <250 W[citation
needed])
High voltage supply for the CRT in TVs and monitors (the flyback converter is often
combined with the horizontal deflection drive)
High voltage generation (e.g., for xenon flash lamps, lasers, copiers, etc.) Isolated gate
driver

11. 10
Major Office Locations in India
Gurgaon
(Corporate Office and Northern Regional Office)
Visit/Write
Philips India Limited
9th
Floor, DLF 9-B,
DLF Cyber City,
Sector 25, DLF Phase – 3,
Gurgaon – 122002, India.
Tel: +91-
Noida
(Lightig and healthcare)
Philips India Limited
C-46,47,Sector 57
Noida-201301
Kolkata
(Registered Office and Eastern Regional Office)
Visit/Write
Philips India Limited
7, Justice Chandra Madhab Road,
Kolkata – 700020, India.
Tel: +91-33-24867621
Bengaluru
Visit/Write
Philips India Limited
Philips Innovation Campus
MFAR Manyata Tech Park,
Nagavara,
Bangalore – 560045, India.
Tel: +91-80-41890000

12. 11
Chennai
(Southern Regional Office)
Visit/Write
Philips India Limited
Temple Towers, 5th
Floor,
Old No: 476, New No: 672,
Anna Salai, Nandanam,
Chennai – 600035, India.
Tel: +91-44-66501000
Hyderabad
Philips India Limited
6-3-1109/103, 3rd
Floor,
Jewel Pawani Towers,
Raj Bhavan Road, Somajiguda,
Hyderabad – 500082, India.
Tel: +91-40-66467676
Mumbai
(Western Regional Office)
Visit/Write
Philips India Limited
Technopolis Knowledge Park,
Mahakali Caves Road,
Chakala, Andheri (E),
Mumbai – 400093, India.
Tel: +91-22-66912000

13. 12
HISTORY
The Philips Company was founded in 1891 by Gerard Philips and his father Frederik.
Frederik, a banker based in Zaltbommel, financed the purchase and setup of a modest, empty
factory building in Eindhoven, where the company started the production of carbon-filament
lamps and other electro-technical products in 1892. This first factory has been adapted and is
used as a museum.
PHILIPS LOGO
PHILIPS CURRENT LOGO
Company Profile
Royal Philips- is a diversified health and well-being company, focused on improving people’s
lives through meaningful innovation in the areas of Healthcare, Consumer Lifestyle and
Lighting. Headquartered in the Netherlands, Philips posted 2013 sales of EUR 23.3 billion and
employs approximately 115,000 employees with sales and services in more than 100 countries.
The company is a leader in cardiac care, acute care and home healthcare, energy efficient
lighting solutions and new lighting applications, as well as male shaving and grooming and oral
healthcare.
Vision and Mission

14. 13
Vision
At Philips, we strive to make the world healthier and more sustainable through
innovation. Our goal is to improve the lives of 3 billion people a year by 2025. We will be the
best place to work for people who share our passion. Together we will deliver superior value for
our customers and shareholders.
Mission
Improving people’s lives through meaningful innovation.

15. 14
Refrences
1) www.philips.com
2) www.electrolux.com
3) www.wikipedia.com

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