Internship Report

Summer Internship Report
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Summer Internship Report | Munish Sharma
SUMMER INTERNSHIP REPORT

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Company: LG Electronics India Limited, Greater Noida
Division: Research and Development, Washing Machine (R&D WMC)
Duration: 8 weeks, June 01, 2015-July 31, 2015
Project Title: Development of the Washing Machine Sapience 21” Indonesia Export
Mentor: Mr. Ashish Chamoli, Asst. Manager-LGEIL Greater Noida
SUBMITTED TOWARDS PARTIAL FULFILLMENT OF THE REQUIREMENT
FOR
THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
(Electronics Engineering)
Submitted To:
Human Resource
LGEIL
Greater Noida (UP)
Submitted By:
Munish Sharma
University of Petroleum and Energy Studies
B.Tech (EE) SEM VII
SAP ID: 500023629

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DECLARATION
I hereby declare that the project work entitled Development of the Washing
Machine Sapience 21” Indonesia Export is an authentic record of my own work
carried out at LG Electronics India Pvt. Ltd. as a requirement of 2 months Summer
Internship for the award of degree of B.Tech (Electronics Engineering), University of
Petroleum and Energy Studies, Dehradun under the guidance of Mr. Vishal Goyal
(Manager) and My Mentor Mr. Ashish Chamoli (Asst.Manager) during June 01, 2015
to July 31, 2015.
Munish Sharma
500023629
Date: ___________________
Certified that the above statement made by the student is correct to the best of our
knowledge and belief.
Mr. Vishal Goyal
Manager, R&D WMC
LG Electronics India Limited
Mr. Ashish Chamoli
Asst. Manager, R&D WMC
LG Electronics India Limited
(Mentor)

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ACKNOWLEDGEMENT
I owe my great many thanks to numerous people who helped and supported me in
completion of the project.
My deepest thanks to Mr. Vishal Goyal, Manager, R&D WMC for giving me all his support,
suggestions, guidance and chance to do my best in a totally different manufacturing world.
The vision, integrity and sense of quality that I learnt from him are truly uncommon. I am very
much thankful to him for his wise and synergetic help throughout my training period.
I would take the opportunity to thank Mr. Ashish Chamoli, Mr. Sachin Saxena, and Mr. Jay
Prakash Sharma who showed their patience in explaining me the Electronic and Electrical
details related to washing machine.
The guidance and support received from my mentor Mr. Ashish Chamoli was vital for the
success of the project. I am grateful for his constant support and help.
My deep sense of gratitude to Mr. Om Chand Verma, Mr. Sanjeev Bakshi and Mr. Kamal
Kumar DQA department who spared their valuable time in spite of their busy schedule for
training me the Testing in the WMC Testing Labs.
I would also like to thank my Institution and my faculty members without whom this project
would have been a distant reality.

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 Declaration.....................................................................................................2
 Acknowledgement..........................................................................................3
 Abstract..........................................................................................................6
 About LG........................................................................................................7
 LG – The Company...........................................................................7
 Significance of Logo.........................................................................8
 The Vision........................................................................................9
 Past Record of LG..........................................................................10
 LG Philosophy.................................................................................12
 5S & 6 Tools ..................................................................................13
 The Product Portfolio....................................................................14
 The Product.................................................................................................17
 Parts of Semi-Automatic Washing Machine.................................18
 Project Details:…………………………………………………………………………...………....23
 Washing Machine-a brief Introduction………………………………..…….24
 Development of the WMC……………………………………………...………...25
 Testing in R&D LAB…………………………………...……………………………….29
 Analyzing the Circuit………………………………………………………………….35
 Conclusion and Learnings………………………………………………………….41
References............................................................................................................. 42

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ABSTRACT
LG Electronics provides a great platform for the budding engineers to gain a valuable
experience in such a large industry and that too in such a helpful and caring culture
as well as people.
Although the enormous amount of work done and experience gained in the past two
months can’t be just listed in a few lines but here is an overview of the internship.
My projects are basically divided into two parts:
i. On Development of the washing machine ,
ii. In the product reliability center.
iii.
At the R&D washing machine, my work mainly consisted of concept development
and its feasibility for various other aspects. The new concept is modeled along-with
some modifications in existing machine. Collection of data bank for competitor USP
features.
At the reliability center the work was more of the kind of testing of the new
machines developed by the R&D. The non-conformities, if any, were diagnosed, and
then a suitable countermeasure was suggested and implemented. The work in QA
department included First Part Analysis (FPA), where the dimensional tolerances of
the new parts are checked.

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LG Electronics
LG Electronics was established on October 1, 1958 (As a private Company) and in
1959, LGE started manufacturing radios, operating 77 subsidiaries around the world
with over 72,000 employees worldwide it is one of the major giants in the consumer
durable domain worldwide. The company has as many as 27 R & D centers and 5
design centers. Its global leading products include residential air conditioners, DVD
players, CDMA handsets, home theatre systems and optical storage systems. LG
globally believes in the philosophy of "Great Company, Great People," whereby only
great people can create a great company. The company's growth strategy is based
on "fast innovation" and "fast growth", through three core capabilities: product
leadership, market leadership, and people-centered leadership. The company has a
strong corporate culture fostering innovation, pioneering spirit and transparent
management across subsidiary and believes in empowering employees to achieve
leadership.
LG is the third largest Korean Company and it started its operation in India twelve
years back. LG has established its corporate office at Noida along with the
production facilities there. It has a network of 17 branches in major cities spread all
over India. LG is a company where they believe that people are the most important
resource. It was rated as the 8th best employer to work for in India by Business
Today in a survey conducted across a range of corporate all over India. “At LG we
always put people first.” this is the slogan with which the company is running its HR
policy. LG believes itself to be global company with presence over 175 countries
across the globe with a champion spirit.

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LG-THE SIGNIFICANCE OF LOGO
The letters "L" and "G" in a circle symbolize the World, Future, Youth, Humanity, and
Technology. Our philosophy is based on Humanity. Also, it represents LG's efforts to
keep close relationships with our customers around the world. The symbol consists
of two elements: the LG logo in LG Grey and the stylized image of a human face in
the unique LG Red color. Red, the main color, represents our friendliness, and also
gives a strong impression of LG's commitment to deliver the best. Therefore, the
shape or the color of this symbol must never be changed.
The circle symbolizes the globe. The stylized image of a smiling face in the symbol
conveys friendliness and approachability. Overall, LG’s symbol represents the world,
future, youth, human, and technology. The design is distributed as follows:
 The One eye: Goal-oriented, focused, confident.
 Upper- right hand space: Intentionally left blank and asymmetric, this
represents LG’s creativity and adaptability to changes.
Colors: LG Red, the main color, symbolizes friendliness, and also gives a strong
impression of LG's commitment to be the best. LG Grey represents technology and
reliability.

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THE VISION OF COMPANY
LG Electronics vision for the 21st century is to become a true global digital leader
through fast growth and fast innovation and to be known as a company who can
make its worldwide customers happy through its innovative digital products and
services. LG Electronics has set its mid-term and long-term goal to rank among the
top 3 electronics, information, and telecommunication firms in the world by 2010.
The company aims to utilize its core capabilities of product leadership, market
leadership and people leadership and enhance our corporate culture of team work
and fun workplace to achieve our mission of becoming "2 by 10", that is, double the
sales volume and profit by year 2010.
`

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PAST RECORD OF LG
 1947 ~ 1959- Birth of a new era for the chemical and electronics industry:
LG Group founder In Hwoi, Koo (penname: Yonam) established Lucky Chemical Industrial
Corp. (currently LG Chem.) in 1947, thus setting the LG history in motion. LG initially
manufactured a cosmetic called Lucky Cream. In 1954, LG became the first Korean
company to develop a brand of toothpaste using its own technology, beating the U.S.
brand Colgate, dominating the domestic toothpaste market. As such, as early as the
1950s, LG already established the foundation for its two major sectors, the chemical and
electrical/electronics businesses, thereby leading the development of Korea’s industries.
 1960 ~ 1969- Establishing the foundation for key industries:
During this period, LG established Honam oil refinery Co (currently GS Caltex) and fully
entered the electrical/electronics industry. In 1962, LG established Hanguk Cable
Industries (currently LS Cable), thus expanding its electrical and electronics business.
Moreover, Goldstar Co. (currently LG Electronics) produced Korea’s first electronic
products such as electric fans in 1960, refrigerators in 1964, black-&-white TVs in 1966,
air conditioners in 1968, and washing machines and elevators in 1969, Thus, LG became
Korea’s leading company in the chemical, energy, and electrical/electronic industries,
ushering in the 1970s with great promise.
 1970 ~ 1979- Solid business growth and expansion:

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Koo Cha-Kyung was sworn in as LG’s second chairman. In 1972, Lucky Chemical
(currently LG Chem.) posted 1.1 billion won in sales and surpassed the USD5.3 million
mark in exports. In 1973, LG established an educational foundation, Yonam Academy,
with which it began undertaking social community services through education.
 1980 ~ 1989- Age of globalization and development of cutting edge technologies:
LG led the development of cutting-edge products such as color TVs, VCRs, and
computers, Goldstar Cable (currently LS Cable) shifted from traditional copper cable
communications to optical communications and from ordinary cables to super-high-
voltage special cables, thereby realizing speedy cable replacement and producing quality
changes in the cable business. In celebration of its 40th founding anniversary in 1987, LG
built its office building, LG Twin Towers, in Yeouido, Seoul, thus further enhancing its
corporate profile.
 1990 ~ 1999- Great innovations for the 21st
century:
The company launched its corporate name, LG, and aimed to become a world-class
corporation cantered on four business fields such as chemicals/energy,
electronics/information/communications, financing, and services. In 1995, LG adopted a
new corporate name, LG, to secure a strong, distinctive corporate identity. With this, it
launched a full-scale drive towards globalization. Koo Bon-moo was sworn in as the
3rd LG Group Chairman, thereby opening a new LG era geared towards a second wave
of management innovations.
 2000 ~ today- Giant leap forward toward the future:
LG is striving to realize its goal of becoming a first-class global company in the 21st
century through innovation in thoughts and deeds. Its new visions are to develop into a
corporation whose members can exercise their potentials to the full, a corporation
whose shareholders’ value is maximized through transparent management and
corporation that satisfies and emotionally touches consumers and benefits the world
and society.

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LG PHILOSPHY
The management philosophy is ‘To create value for customers through management based
on esteem of human dignity’.
LG’s vision is to bring a smiling face to every home across the globe.
The logo of LG is in harmony with their vision.
The smiling face logo symbolizes five key concepts – World, Future, Youth, Human and
Technology.
LG believes that an effective combination of these elements would make better future a
reality for the organization.
LG has been exploring ways to develop, combine and apply technologies that would
customize products and services to meet customer needs and exceed their expectations.
LG aims at creating a healthy and better life for every family.

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5 S and 6 quality tools
5 S
1. Sort
2. Straighten
3. Shine
4. Standardize
5. Sustain
6 Quality Tools
1. Part Return Defect
2. Self and Sequential Inspection
3. Time Check
4. Main Process Control
5. Quality Audit
6. Quality Review

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THE PRODUCT PORTFOLIO
 LG PLASMA DISPLAY PANELS:
LG Electronics has achieved new dimensions of technological excellence among the
Plasma Display Panel manufacturers. The PDP is available in sizes of 40, 42, 50, 60 and
71 inch internationally.
LG has world’s slimmest panel at 78 mm to the world’s
biggest panel at 71”. The company is the only brand in
India which offers “The largest range of models in the
PDP category. Cutting Edge Technology such as Image Stick minimization, Orbiter,
Whitewash, Flexi PIP, Double Window Screen are some of the features which makes LG’s
PDPs, the best made Plasma Panels ever.
 LG TELEVISION:
In the Indian household scenario where space is a major
constraint, LG has come up with an innovative solution by way
of World’s slimmest Flat CRT TV, Slim-magic. In India, especially
in the metros, there is a major concern of smaller living space,
and LG’s latest innovation provides a solution to utilize the limited living area / space in
the most useful manner.
 LG REFRIGERATORS:
LG India launched the World’s First TV Refrigerator – TV DIOS
with a 13-inch hi-definition TFT LCD TV installed at the center
of its door. The 600 litres TV DIOS also has a built-in radio
tuner providing access to FM stations and is supported by
built-in speakers. It has an astounding silver nano-
antibacterial and nano-carbon deodorizing technology which has won LG the ‘KT new

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technology mark.’ Thus, this refrigerator brings together the best in food preservation
and storage with multi-media functions as a quintessential digital home appliance. LG
has a complete range of DIOS with over 30 different models world over.
 LG FROST FREE REFRIGERATORS:
LG has launched an exhaustive range of feature rich diamond cut
frost-free refrigerators ranging from a capacity of 230L to 751L. The
company currently has six variants in 230 liters capacity, four
variants in 250 liters and five variants each in 280 liters and 310
liters capacity respectively. The company also launched two
variants each in 350 litres & 390 litres capacity and 6 variants in
400+ ranges.
 LG NOTEBOOKS:
LG has launched two Premium state-of-the-art notebooks based
on the latest Intel’s Napa platform with dual CPU cores, developed
in INDIA by Intel.
Dual cores combine two cores in a computer’s CPU to deliver a 30
per cent better performance when processing multiple tasks.
These two LG Notebook models are LG P1 Express Dual and LG M1
Express Dual with 15.4 inch wide-screen and 15 inch TFT respectively.
These Notebooks from LG are a unique combination of design, performance
entertainment and security. These LG Express Dual-core processor based Notebooks are
exquisitely designed to give the users the experience of handling a sleek, gorgeous and
technologically rich notebooks.
 LG WASHING MACHINES:
LG Electronics, has unveiled the latest Front and Top Loading series
washing machines. Its futuristic wash features such as Fuzzy Logic
technology ensures that once you press the start button, smart sensors

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automatically detect the laundry load and water level. Adjustments are then made in the
water levels and cycle time based on the laundry load to give you that
perfect wash. Fuzzy Logic also detects machine imbalance and excessive
foam formation and adjusts the same for the best
washing performance. At the touch of a button LG
TROMM saves water and energy giving you a clean
and convenient wash. Turbo drum and 3 steps wash range of
machines, which delivers best towards washing and rinsing
performance. The washing machines also come with safety features such as imbalance
and door lock sensor with child-lock feature. The machines are equipped with self-tub
clean system for better hygiene.
 LG MICROWAVE OVENS:
LG has launched their high-end microwave ovens
SolarDOM and WaveDOM. The LG SolarDOM is
currently the world’s best microwave oven with its
unique Light wave Technology which enables three
times faster cooking, high nutrient retention, better
energy efficiency (50% saving) and high convenience
levels. The Round Cavity design makes it easy to clean and at the same time saves space.
It has an Indian Auto Menu option, Multi Rotisserie grill and Smart Guide Display.
Consumers also have an option of getting an installation kit if they have built-in type of
kitchens.
 LG AIR CONDITONERS:
LG has launched a wide range of window and split AC’s with Health Air System for cool,
clean and healthy air. LG has introduced AC’s with plasma
technology that helps in removing microscopic contaminants and
dust to eliminate offensive odors and prevent allergic reactions.
The range is from 0.75 to 4 tons. It also has multi split AC’s and
tower type AC’s to supplement its huge range of window and split AC’s.

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WASHING MACHINE
 Description of Important Parts of Semi-Automatic Washing Machine(SAWM):
 Base:
It is that part of the washing machine on which whole of the structure actually
rests. It supports a number of parts in itself like the wash motor, spin motor and
capacitor.
 Spin Motor:
The motor rotates the spin basket. It has a unidirectional motion and maintains a
RPM of about 1300.
Exploded Parts of Washing Machine

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 Wash Motor:
The motor rotates the pulsator and whole of the washing process is dependent
on this motor only. Its motion is bi-directional in nature. The RPM maintained is
around 1200 but the actual RPM that reaches the pulsator via a v-belt and
gearbox is around 110 RPM. The purpose of gearbox is toreduce the RPM of the
motor as the motors of higher RPM cost less.
 Pulsator:
This is the part, which actually encounters the cloths in the machine. It is rotated
with the help of motor and is connected directly to the gearbox. It has rib
structures on it, which help in turning the cloths around, and also propels their
Wash Motor

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vertical motion.
 Twin Tub:
It is the tub in which the cloths are placed. In one of its compartment is the
pulsator and in the another there is the spin basket. To make it leak-proof,
washers are provided below the pulsator.
 SD (Spin Dry) Basket:
It is placed in the smaller compartment of the tub. In this section the cloths are
kept for drying at high RPM.
 Wash Cover:
It is the cover of wash side of the twin tub.
 SD (Spin Dry) Cover:
It is the cover of spin side of the twin tub. With this cover the brake assembly is
attached with the help of brake wire. This is done to ensure that there is no
accident even if the SD cover is lifted when the rotation is still going on.

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 Out Case:
It is the outer body of the washing machine. It can be of sheet metal or plastic,
depending upon the model of the machine.
 Lint Filter:
Lint filter is fixed inside the twin tub. The main purpose of this filter is to collect
the lint coming out of the cloths, which might occur due to wear and tear of the
cloth.
 Safety Cover:
It is the cover between the SD basket and the SD cover. The main purpose of
using this cover is to prevent the flying out of cloths when the spin basket
rotates at a high RPM.

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 Panel:
This constitutes the brain of the machine i.e. the wash timer, the spin timer, the
drain selector and the power selector. It also contains the buzzer and the
harness of the motors.
Unlike most of the mechanical parts, which are assembled in the semi-automatic
washing machine (SAWM), the fully automatic washing machine (FAWM) has somewhat
electronic elements. Some of them are explained below.
 Clutch Assembly:
This is a complex part which controls and regulates the speed of the tub and the
Pulsator during different processes like wash cycle, rinse cycle and spin cycle.

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 BP Sensor:
It senses the amount of cloth in the machine in case the operator does not know
what water level must be chosen for the available quantity of the cloth. It works
on the principle of sensing of the air pressure generated by the cloths.
 The PCB:
It is the brain of the machine as it guides all the parts during the normal working
of the machine. It is pre-programmed with the time and control settings for
different processes available in the machine.

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Summer Internship PROJECT Details:
Company: LG Electronics India Limited, Greater Noida
Division: Research and Development, Washing Machine (R&D WMC)
Duration: 8 weeks, June 01, 2015-July 31, 2015
Project Title: Development of the Washing Machine Sapience 21” Indonesia Export
Mentor: Mr. Ashish Chamoli, Asst. Manager-LGEIL Greater Noida
DESCRIPTION
 Washing Machine- A brief Introduction.
 Understanding the Development of Washing Machine:
 Concept planning
 Design verification
 Product verification
 Product qualification
 Mass production
 R&D Testing of the Washing machine:
 Performance-testing
 Black-box testing (BBT)
 Spike-testing
 Spin-unbalance testing
 Vibration-testing
 Safety-testing
 Electrical-testing
 Analyzing the Circuit

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Washing Machine- A brief Introduction
 Washing machine is a machine used to wash laundry such as clothing and sheets.
 It was developed to reduce the manual labour spent on washing by hands.
HISTORY OF WASHING MACHINE:
 The earliest special-purpose washing device was the Washboard, invented in 1797 made
out of a wooden board with wooden ridges for the clothing to be rubbed upon.
 By the mid-1850s, stream-driven commercial laundry machines were developed in the
UK and the USA.
 In the UK, emphasis on the commercial and institutional washing machinery was more
given,
 Whereas, in the US, domestic machinery was emphasized more.
 The rotary washing machine was patented by Hamilton Smith in 1858.
WASHING MACHINE- TODAY
 The present day Washing machines are available in two variants:
 Semi-automatic washing machine(SAWM)
 Fully-automatic washing machine (FAWM)
 Features of the Fully-automatic washing machine are as follows:
 Soil level of the cloth
 Wash load sensing
 Inlet temperature
 Water level sensing
 Washing period
 Rinse cycles
 Spin period
 Washing Courses

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DEVELOPMENT OF WASHING MACHINE
• CONCEPT PLANNING
• DESIGN VERIFICATION
• PRODUCT VERIFICATION
• PRODUCT QUALIFICATION
• MASS PRODUCTION
1) Concept Planning (CP) Step
Product planning group (division) is in charge of this step, which is from Product Concept
Planning to commercialization confirmed meeting completed. This step to establish a
development plan based on the collected market information, evaluate sales price, design
SPEC. and function of competitive product to correspond to the market demand, set the target
Q.C.D of the product to be developed with competitiveness and finally determine it. That is
advance preparation step for design.
2) Project Planning (PP) Step
The laboratory is in charge of this step, which is from commercialization confirmed meeting to
project planning confirmed meeting. It builds-up a structural organization to accomplish the
development target (Q.C.D) decided at the product concept planning, sets the design standard
and determine the design standard and design Spec. by consulting with the related
department.
3) Design Verification (DV) Step
The laboratory is in charge of this step, which is from project planning confirmed meeting
completed to design verification (DV) fair. It embodies the various input data to accomplish the
decided development target(Q.C.D) and design Spec., produce a specimen before issuing the

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drawing and prevent the problems expected in mass production in advance by verifying and
correcting the specimen based on the design standard.
4) Product Verification (PV) Step
Production Engineering Group is in charge of this step, which is from Design Verification fair to
Product Verification (PV) fair completed. It develops mold and new part based on issued
drawing, assembles and inspects the approved parts at a production line according to QC
process, verifies and improves the decided target Q.C.D.(including design quality and
manufacture quality), and clarifies the management conditions in mass production.
5) Production Qualification (PQ) Step
Manufacturing division is in charge of this step, which is from Product verification(PV) fair to
Production Qualification fair completed. It decides a regular mass-production and shipping by
verifying and improving mass-production ability with mass-production more than 50ea)
according to the regular production system.
CONCEPT PLANNING
MAIN WORK DONE: Data Rendering
 A data bank was created for competitor USP (Unique Selling Proposition) features.
(Including whirlpool, Samsung, Whirlpool, Godrej, Panasonic etc. ).
 Different plastic and steel materials used for washing machines were also studied .
 New modifications in the existing machines were suggested.
 These included including some parts for concept development in the top loading
washing machine.
PRODUCT PLANNING
 Different parts required for the development of the concept were identified

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 Various world-wide manufacturers of related product and their specifications and
quality standards were viewed different modifications in parts of existing machine were
identified so that the new feature fit in perfectly.
 various factors like flow of liquid due to gravity , losses in the movement, viscosity were
considered
 It was modeled in 3D, (UG NX5) such that parts were properly aligned, and there was no
hindrance to the connectors being attached.
 The new feature and the new modified parts were then assembled with the existing
machine.
 An Iterative process was followed.
DESIGN VERIFICATION
 Prototype (Engg. Sample) was prepared
 It was tested for different solutions under different conditions.
 Measurement of quantity
 Measuring the relative viscosity
 the Impact of modifications done in previous stage is taken into account
 Different tests required for the development of the new machine is identified like
shower test or impact tests.
 Failures in some tests were analyzed and countermeasures were suggested.
 Cost is reviewed.

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PRODUCT VERIFICATION
 Part Reliability
o Drop test
o Heat Resistant test
o Endurance Test
o Hot and Cold Cycle Test
o Tensile test
 Product Reliability
o Wash performance test
o Temperature Rise test
o Rinse Performance test
o Spin Performance test
 FPA (First Part Approval)
o Marking up drawings for critical dimensions
o Measuring the dimensions
o Use of various instruments
o Deciding OK/NG/ Minor Acceptance on the basis of tolerance and criticality of
the dimensions
o If NG, requesting Vendor for improvement in the next round i.e. 2nd
FPA
o Test planning on the basis of reliability report

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TESTINGS PERFORMED IN R&D LAB
The various tests done on the new model of washing machine can be classified under the
following heads:
A. Electrical Characteristic Tests
B. Basic Performance Tests
C. General Performance Tests
D. Safety Tests
E. Durability & Structure Appearance Tests
These tests were conducted by me under the guidance of Mr. Sanjeev Bakshi and Mr. Kamal
Kumar in the “Reliability Lab” at LGEIL.
Following are the brief up of the test methods but the actual test readings are not given to
maintain the confidentiality of the work.

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BASIC PERFORMANCE TESTS:
These include those tests that are directly related to the performance (washing and
spinning) of the machine. These tests are:
1. WASHING PERFORMANCE STANDARD TEST:
 Purpose  To calculate the washing performance deviation according to laundry
distribution position inside the washing tub & cleansing ability followed by mechanical
operation of washing machine.
 Method 
i. Prepare detergent of density 0.2% i.e. 2gm of detergent per 1 litre of water.
ii. Measure the reflectance of sample of contaminated cloth using photometer.
iii. Attach the contaminated cloth to the rated test cloth.
iv. Input detergent and larger cloths by giving 3 folds & smaller cloths without fold.
v. Run the machine for one complete wash cycle i.e. 20 min. at rated voltage &
frequency.
vi. Dry contaminated cloth for about 12 hrs. Without squeezing in the area with no
direct ray of light.
vii. Again measure the reflectance of the attached cloth.
 Result  The test was passed by the machine as the difference in the reflectance values
before & after the test was more than what was required by the specs.
Chronometer Test Cloth

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2. SPIN DRYING PERFORMANCE STANDARD TEST:
 Purpose  To measure the drained amount of moisture contained in the laundry after
spin drying the cloths.
 Method 
i. Compose dry cloth & weigh it according to the rating of the washing machine
(Here 6 kg).
ii. Input wet laundry equally in the spin tub.
iii. Run one complete spin cycle at rated voltage & frequency.
iv. Measure cloth’s weight 30 sec after completing spin drying.
v. Spin drying rate(%) = _____Dried cloth’s wt._____ x 100
Cloth’s wt. after spin drying
M achine
Wash
R ate
(Std
M / C )
A vg.
SD
R ate
Wash
P er.
R ate
R esults
M / C -1 LG 0.473 2.34 1.08 OK
M / C -2 LG 0.494 4.43 1.13 OK

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 Result  The test was passed by the machine as the spin dry rate was more than 150%
which met the product standard of the machine.
3. RINSING PERFORMANCE STANDARD TEST:
 Purpose  To measure the amount of drained (rinsed) detergent used in washing.
 Method  As per IEC standard
1. Prepare detergent of density 0.2% i.e. 2gm of detergent per 1 litre of water.
2. Measure the weight of the cloths, which should be as per the rated capacity.
3. Input the cloths and the detergent solution as per the rated capacity.
4. Run the machine for one complete wash cycle at rated voltage & frequency.
5. Collect the drained extraction after wash in a beaker say Mw
6. After the last rinse when most of the detergent solution has been drained out again
collect the drained extraction in a different beaker, say Mr.
7. Again measure the weight after the wash cycle.
8. Collect Tap Water used during the wash cycle say Mt.
9. After collecting all three solutions titration is performed using HCl and Methyl Orange
Indicator.
 Result  The test was passed by the machine as the rinsing rate was more than 1 which
was required to meet the product standard of the machine.

33
4. CLOTH CIRCULATION TEST:
 Purpose  To apply the sensibility quality confirming method, which is thought to be
good washing cloth by looking the movement and condition turned upside down of the
cloth when washing, as an objective evaluation criteria.
 Method 
i. Input rated load in the machine and run the machine at rated voltage and
frequency.
ii. Visually evaluate no. of revolutions taken by the cloth in both sides.
iii. Now calculate the no. of revolution taken in one minute by the test cloth and
exclude the time of pause from the calculation of left & right reversing time.
iv. Calculation criteria of cloth rotation is given as follows:
AlKality LG MC1 LGMC2
Alkality of Wash solution (Mw ) in ml 11.4 9.9
Alkality of rinse water (Mr ) in ml 3.4 2.8
Alkality of tap water (Mt) in ml 0.6 0.6
Alkality of rinse water relative to tap water (Ar ) = Mr - Mt 2.8 2.2
Dry cloth weight (W) 9 9.05
Clothes mass after extraction in kg 13.715 13.708
Clothes mass after extraction minus dry mass (Wr) in kg 4.715 4.658
Amount of Wash Alkali per kg load -- Wr. (Mr-Mt) / W 1.47 1.13

34
Rotating Direction Rotating Angle Score
Left/Right
900
or less
900
~ 1800
or less
1800
~ 2700
or less
2700
~ 3600
or less
3600
~ 1.5 times or less
1.5 times ~ 2 times or less
2 times ~ 3 times or less
3 times ~ 4 times or less
More than 4 times
0
0.25
0.5
0.75
1
1.5
2
3
4
Up/Down 1800 0.5
 Result  Total cloth circulation should be more than 6 per minute. In actual test, the
value came out to be 14 which was far better than the specs.
5. SPINNING VIBRATION TEST:
 Purpose  To produce good operating environment and product reliability
improvement by regulating and measuring the vibration amount produced in out case
when spin-drying.
 Method 
i. Input rated load in the machine and run the machine at rated voltage and
frequency.
ii. Install the sensors at 9 symmetrical points each on the front, left and right side.
iii. Analyze the vibrating record sheet.
 Result  The test was passed by the machine as the vibration amplitude found in the
machine was quite less.

35
ANALYSING THE CIRCUIT
CLOTH WEIGHT PULSE
Cloth weight pulse uses the components like opto-coupler and triacs. It works on the
principle of back electromotive force.
TRIACS
TRIAC, from Triode for Alternating Current, is a genericized trade name for an electronic
component that can conduct current in either direction when it is triggered (turned on), and
is formally called a bidirectional triode thyristor or bilateral triode thyristor.
TRIACs belong to the thyristor family and are closely related to Silicon-controlled rectifiers
(SCR). However, unlike SCRs, which are unidirectional devices (i.e. can conduct current only
in one direction), TRIACs are bidirectional and so current can flow through them in either
direction. Another difference from SCRs is that TRIACs can be triggered by either a positive
or a negative current applied to its gate electrode, whereas SCRs can be triggered only by
currents going into the gate. In order to create a triggering current, a positive or negative
voltage has to be applied to the gate with respect to the MT1 terminal (otherwise known as
A1).
Once triggered, the device continues to conduct until the current drops below a certain
threshold, called the holding current.
The bi-directionality makes TRIACs very convenient switches for AC circuits, also allowing
them to control very large power flows with mill ampere-scale gate currents. In addition,
applying a trigger pulse at a controlled phase angle in an AC cycle allows one to control the
percentage of current that flows through the TRIAC to the load (phase control), which is
commonly used, for example, in controlling the speed of low-power induction motors, in
dimming lamps and in controlling AC heating resistors

36
OPTOCOUPLER
In electronics, an opto-isolator, also called an opto-coupler, photo-coupler, or optical
isolator, is a component that transfers electrical signals between two isolated circuits by
using light. Opto-isolators prevent high voltages from affecting the system receiving the
signal. Commercially available opto-isolators withstand input-to-output voltages up to 10 kV
and voltage transients with speeds up to 10 kV/μs. A common type of opto-isolator consists
of an LED and a phototransistor in the same package. Opto-isolators are usually used for
transmission of digital (on/off) signals, but some techniques allow use with analog
(proportional) signals.

37
OPERATION
An opto-isolator contains a source (emitter) of light, almost always a near infrared light-
emitting diode (LED), that converts electrical input signal into light, a closed optical channel
(also called di-electrical channel[7]
), and a photo-sensor, which detects incoming light and
either generates electric energy directly, or modulates electric current flowing from an
external power supply. The sensor can be a photo-resistor, a photodiode, a phototransistor,
a silicon-controlled rectifier (SCR) or a TRIAC. Because LEDs can sense light in addition to
emitting it, construction of symmetrical, bidirectional opto-isolators is possible. An opto-
coupled solid state relay contains a photodiode opto-isolator which drives a power switch,
usually a complementary pair of MOSFETs. A slotted optical switch contains a source of light
and a sensor, but its optical channel is open, allowing modulation of light by external
objects obstructing the path of light or reflecting light into the sensor.
BACK EMF
The counter-electromotive force also known as back electromotive force or counter EMF is
the voltage, or electromotive force, that pushes against the current which induces it. CEMF
is caused by a changing electromagnetic field. It is the effect of Lenz's Law of
electromagnetism. Back electromotive force is a voltage that occurs in electric motors
where there is relative motion between the armature of the motor and the external
magnetic field. One practical application is to use this phenomenon to indirectly measure
motor speed and position. Counter EMF is a voltage developed in an inductor network by a
pulsating current or an alternating current. The voltage's polarity is at every moment the
reverse of the input voltage
In a motor using a rotating armature and, in the presence of a magnetic flux, the conductors cut the
magnetic field lines as they rotate. The changing field strength produces a voltage in the coil; the
motor is acting like a generator. This voltage opposes the original applied voltage; therefore, it is
called "counter-electromotive force”. With a lower overall voltage across the armature, the current
flowing into the motor coils is reduced.
To experience the effect of counter-electromotive force one can perform this simple exercise. With
a window closed, lift the switch of an electric window in a car that is running at idle, and hold it
momentarily and notice the idle RPM drop. The electric motor in the door is stationary and
therefore the inrush current will be very high. The alternator will try to provide for the large current
which subsequently drags down the engine. As soon as the power window motor overcomes its
inertia and starts spinning, back EMF will be produced, exerting less load on the alternator. Hence,
the engine speed will return to normal.
In motor control and robotics, the term "Back-EMF" often refers to using the voltage
generated by a spinning motor to infer the speed of the motor's rotation.

38
POWER RELAY
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, or where several
circuits must be controlled by one signal. The first relays were used in long distance
telegraph circuits, repeating the signal coming in from one circuit and re-transmitting it to
another. Relays were used extensively in telephone exchanges and early computers to
perform logical operations
A type of relay that can handle the high power required to directly control an electric motor
or other loads is called a contactor. Solid-state relays control power circuits with no moving
parts, instead using a semiconductor device to perform switching. Relays with calibrated
operating characteristics and sometimes multiple operating coils are used to protect
electrical circuits from overload or faults; in modern electric power systems these functions
are performed by digital instruments still called "protective relays
BASIC DESIGN AND OPERATION
A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an
iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts . The armature is hinged to the yoke and mechanically
linked to one or more sets of moving contacts. It is held in place by a spring so that when
the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of
the two sets of contacts in the relay pictured is closed, and the other set is open. Other
relays may have more or fewer sets of contacts depending on their function. The relay in
the picture also has a wire connecting the armature to the yoke. This ensures continuity of
the circuit between the moving contacts on the armature, and the circuit track on the
printed circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic field that
activates the armature and the consequent movement of the movable contact either makes
or breaks (depending upon construction) a connection with a fixed contact. If the set of
contacts was closed when the relay was de-energized, then the movement opens the
contacts and breaks the connection, and vice versa if the contacts were open. When the
current to the coil is switched off, the armature is returned by a force, approximately half as
strong as the magnetic force, to its relaxed position. Usually this force is provided by a
spring, but gravity is also used commonly in industrial motor starters. Most relays are
manufactured to operate quickly. In a low-voltage application this reduces noise; in a high
voltage or current application it reduces arcing.
When the coil is energized with direct current, a diode is often placed across the coil to
dissipate the energy from the collapsing magnetic field at deactivation, which would
otherwise generate a voltage spike dangerous to semiconductor circuit components. Some

39
automotive relays include a diode inside the relay case. Alternatively, a contact protection
network consisting of a capacitor and resistor in series (snubber circuit) may absorb the
surge. If the coil is designed to be energized with alternating current (AC), a small copper
"shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase
current which increases the minimum pull on the armature during the AC cycle.[1]
A solid-state relay uses a thyristor or other solid-state switching device, activated by the
control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light-
emitting diode (LED) coupled with a photo transistor) can be used to isolate control and
controlled circuits.
EEPROM PART
EEPROM stands for Electrically Erasable Programmable Read-Only Memory and is a type of
non-volatile memory used in computers and other electronic devices to store small
amounts of data that must be saved when power is removed, e.g., calibration tables or
device configuration.
When larger amounts of static data are to be stored a specific type of EEPROM such as flash
memory is more economical than traditional EEPROM devices. EEPROMs are realized as
arrays of floating-gate transistors.
EEPROM is user-modifiable read-only memory (ROM) that can be erased and
reprogrammed repeatedly through the application of higher than normal electrical voltage
generated externally or internally in the case of modern EEPROMs. EPROM usually must be
removed from the device for erasing and programming, whereas EEPROMs can be
programmed and erased in-circuit. Originally, EEPROMs were limited to single byte
operations which made them slower, but modern EEPROMs allow multi-byte page
operations. It also has a limited life - that is, the number of times it could be reprogrammed
was limited to tens or hundreds of thousands of times. That limitation has been extended to
a million write operations in modern EEPROMs. In an EEPROM that is frequently
reprogrammed while the computer is in use, the life of the EEPROM can be an important
design consideration.

40
The EEPROM part consist of M93C46.The description of the IC is as follows:
WATER LEVEL SENSING PART
An inverter circuit outputs a voltage representing the opposite logic-level to its input. Inverters can
be constructed using a single NMOS transistor or a single PMOS transistor coupled with a resistor.
Since this 'resistive-drain' approach uses only a single type of transistor, it can be fabricated at low
cost. However, because current flows through the resistor in one of the two states, the resistive-
drain configuration is disadvantaged for power consumption and processing speed. Alternatively,
inverters can be constructed using two complementary transistors in a CMOS configuration. This
configuration greatly reduces power consumption since one of the transistors is always off in both
logic states. Processing speed can also be improved due to the relatively low resistance compared to
the NMOS-only or PMOS-only type devices. Inverters can also be constructed with bipolar junction
transistors (BJT) in either a resistor-transistor logic (Digital electronics circuits operate at fixed
voltage levels corresponding to a logical 0 or 1 . An inverter circuit serves as the basic logic gate to
swap between those two voltage levels. Implementation determines the actual voltage, but
common levels include (0, +5V)or a transistor-transistor logic (TTL) configuration.
DISPLAY PART
The display part of the circuit consists of LCD screen, LEDs and a Darlington sink driver.
Every component plays its role in the circuit. The hex inverter used here is ULN 2004AFW. In
electronics, the Darlington sink driver structure consisting of two bipolar transistors connected in
such a way that the current amplified by the first transistor is amplified further by the second one.
This configuration gives a much higher common/emitter current gain than each transistor taken
separately and, in the case of integrated devices, can take less space than two individual transistors
because they can use a shared collector. Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices in an integrated circuit.

41
CONCLUSION AND LEARNINGS
Professional End
 Understood the History, structure, principle of operation and the fabrication of the
Washing machine.
 Performed Black-box testing (BBT) of the Washing Machine.
 Performed Special tests such as Temperature-rise Test and Spike Test.
 Performed the Performance testing of the Washing Machine such as Rinse Performance,
Wash Performance, Spin performance, Water-extraction vibration and Spin-unbalance
standards.
 Performed the Electrical testing of the Washing Machine such as Power-consumption,
Drive-characteristics and Voltage-fluctuation Tests.
 Worked on GTEMS (Global Test Equipment Monitoring System).
Personal End
 Abiding by the rules of the organization strictly.
 Maintained discipline and proper dress code in the organization.
 Keeping in mind the reputation of the university and representing it in a very a
dedicated and respected manner.
 Handled the work-load and managing it with less time in an efficient way without
any flaws.
 Respected the senior officials, mentor, colleagues and other staff members.
 Worked-hard and divided the goals set for two-months into monthly-goals, weekly-
goals and daily goals.
 Maintained a healthy-relationship with everyone around.

42
REFERENCES
1. R&D , Washing machine
2. DQA, Washing machine
3. Installation manuals and service manuals
4. http://www.engineeringpolymers.com/
5. http://plasticsintl.com/
6. Wikipedia

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