Ebbin Daniel worked on various maintenance and troubleshooting tasks as an electrical engineer from October 3rd to 10th. Some of the key tasks included troubleshooting issues with a cuber machine and pallet stacking machine by checking wiring and limit switches. He also replaced a faulty hydro probe sensor on a mixer and upgraded old proximity sensors. Current projects included developing a program to automatically adjust the height of pavers and creating an electrical maintenance checklist.

1. WEEKLY REPORT
- - Ebbin Daniel
OCT 3 - OCT 10
Electrical Engineer

2. CONTENTS:
1. Maintenance and troubleshooting
a. Troubleshooting the Cuber Machine at the Block Plant
b. Rewiring of the Sensor at the pallet stacking machine.
c. Replacement of the Hydro probe sensor on mixer 1.
d. Troubleshooting and rewiring of the Limit switches on the batching conveyor belt.
e. Upgradation of the old proximity sensor to new prox sensors with lasers for height
adjustment in pallet transfer mechanism.
2. Current Projects
a. Height adjustment for pavers on wet side.
b. Checklist for Electrical Maintenance.

3. A.Troubleshooting the Cuber Machine at the Block Plant
Cause of the Problem:
 Cylinder not moving forward.
 No fuse blown.
 Cuber schematics incomplete without any proper information.
 All wires intact without any sign of a loose contact.
Troubleshooting:
 PLC program was opened to find the termination point.
 Program suggested that both forward and reverse limit switches was not made.
 Any one of the switch had to be made for automatic operation.
 Manually limit switch was turned ON for one side.
 Now both operation was running fine automatically.
B. Rewiring of the sensor at the pallet stacking machine.
Cause of the Problem:
 Different wire joints hanging out.
 Loose connection.
 Possibility of wire breaking off from the joints.
Troubleshooting:
 The Sensor was totally wired as one connection without any joints.
 Sensor was adjusted to its position.
 Wiring and positioning the wires in the apt location was carried out.

C.Replacement of the Hydro probe sensor on mixer 1.
Cause of the Problem:
 Hydro probe sensors showing different readings.
 Frequent complaint logs due to the Hydro Probe sensor.
 Affecting the production and production time.
Troubleshooting:
 The sensor was first scanned for possible usage.
 It was concluded that the sensor was too old and needs to be replaced.
 New Probe sensor was installed along with the Maintenance department.
 Probe readings were tested and verified.

4. D. Troubleshooting and rewiring of the Limit switches on
the batching conveyor belt.
Cause of the Problem:
 Belt 1 was not moving during batching process.
 Production was down.
 Limit switches had no power in them.
Troubleshooting:
 Wire to the limit switches was traced out.
 A wire break was found near the power cabinet.
 The wire was joined and reinstalled.
E.Upgradation of the old proximity sensor to new prox sensors
with lasers for height adjustment in pallet transfer
mechanism.
Cause of the Problem:
 Complaint log in the production sheet regarding pallet transfer.
 Frequent change in position of the sensor which it would move every time.
 Every time it had to manually adjusted.
 Frequent loss of production time.
Troubleshooting:
 New proximity sensors were used which had laser in-built.
 With the laser function a height of 18cm default was locked to read the pallets in case of any
movements so that the operator does not have to change positions every day.
 The sensor was installed and rewired.
 The sensor was tested and it worked fine.

5. Current Projects:
A.Height adjustment for pavers on wet side.
 The program for height was written and tested.
 Laser sensors with distance measuring capacity is used.
 Initial testing is done.
 Results concluded that the laser readings are moving by 2 or 3 units might be because of
vibration or because of using an old sensor.
 Perfect place for mounting is still under testing.
 Cost effectiveness is also calculated sidewise.
 Next testing might be carried out this coming Wednesday during cleanup.

B. Checklist for Electrical Maintenance.
 An Excel file for making a checklist for electrical Maintenance is made.
 It involves different days with different schedules for checking various machines.
 It also includes clean up time.