DON BOSCO COLLEGE OF ENGINEERING

FATORDA, MARGAO, GOA – 403 602.

DEPARTMENT OF MECHANICAL ENGINEERING

2023 – 2024

Internship Report
By
ROLLAN FERNANDES
(2012030)

Under the Guidance of

Mr. SUJAY SHIRODKAR

CO-FOUNDER OF CARBON E

CARBON-E

BACHELOR OF ENGINEERING: GOA UNIVERSITY

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 DON BOSCO COLLEGE OF ENGINEERING
FATORDA, MARGAO, GOA- 403602.
2022 – 2023

CERTIFICATE
This

Internship Report
Submitted in partial fulfillment of the requirements for Bachelor’s Degree in Computer
Engineering of Goa University is the bonafide work of

Rollan Fernandes
(2012030)

___________

Mr. CHETAN GAONKAR

ASSISTANT PROFESSOR

INTERNAL GUIDE

_____________ ____________

DR. PRAVIN VEREKAR Dr. Neena Panandikar

HEAD OF PRINCIPAL
DEPARTMENT
Mechanical Engineering

ii
 DON BOSCO COLLEGE OF ENGINEERING
FATORDA, MARGAO, GOA- 403 602.
2022 – 2023

CERTIFICATE

Internship Report
Submitted by
ROLLAN FERNANDES
(2012030)

In partial fulfillment of the requirements of the Bachelor’s Degree in Mechanical

Engineering of Goa University is evaluated and
found satisfactory.

DATE: _____________ EXAMINER 1: _______________

PLACE: _____________ EXAMINER 2: _______________

iii
Attach photocopy Company Certificate Here

iv
 ABSTRACT

The Industrial Training Report is prepared after completion of 8 weeks of Industrial Training
at CARBON-E. Completion of 8 weeks of Industrial Training is compulsory for the Bachelor
of Engineering degree. It is conducted after the completion of sixth semester in Bachelor of
Engineering course. Engineering graduates are highly competent with their technical skills, but
they lack practical exposure to managerial skills, confident attitude, interpersonal skills when
they first step into the Industry.

The primary objective of Industrial Training program is to overcome such problems faced by
a technical student, and to build up a sound appreciation and understanding of the theoretical
principals learned, by exposing them to the Industrial environment. It is oriented toward
developing the skill, knowledge, attitudes needed to make an effective start as a member of the
Engineering profession. I am fortunate to have my Industrial Training experience at CARBON-
E. from 31st August 2023 to 23rd September 2023. I had a very successful training period, the
experience and the knowledge I gained is very valuable for my future career. Here in this report,
I present the experience, knowledge, and skills I gained during the training period.

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 ACKNOWLEDGEMENT

I am using this occasion to state my gratitude to all those who helped to

attend the Internship training at CARBON E. It meant a great deal for me
as it helped me with my practical and theoretical knowledge and changed
my perspective of the industry. I am also grateful having a chance to meet
so many wonderful people and professionals who helped me through this
internship period.

Next. I would like to thank our Principal Dr. Neena Panandikar and our
HOD Prof. Pravin Vernekar for allowing me to do the training.

I express my deepest gratitude to Mr. Sujay Shirodkar (CO-FOUNDER

OF CARBON E) for guiding us and giving necessary advices and also
arranging all the facilities in our support and being the best mentor to us.
Despite being busy with work I am very grateful to him for such
admonition. I would also like to thank my internal guide, Prof Chetan for
his support.

The internship commenced on 31st August and ended on 23rd September.

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TABLE OF CONTENTS
SR.NO CONTENTS PAGE NO
TITLE PAGE i
CERTIFICATE I ii
CERTIFICATE II iii
COMPANY CERTIFICATE iv
ABSTRACT v
ACKNOWLEDGEMENT vi
TABLE OF CONTENTS vii
LIST OF FIGURES ix
1 INTRODUCTION 1-2
STUDY TASK
2.1 VEHICLE BRAKING SYSTEM
2.2 MATERIAL FAILURE
2
2.3 AUTOMOBILE SAFETY AND AUTOMATION
2.4 MOTORS
3.1 LEADERSHIP TRAINING

3 3.2 PELTEIR DEVICE

3.3 COPPER TUBES

4.1 INTRODUCTION TO AUOTDESK

FUSION360

4.2 MODELLING OF A COOLING FAN

4 4.3 MODELLING OF BLDC MOTOR

4.4 MODELLING OF MACHINE COMPONENT

5.1 INTRODUCTION TO 3D PRINTING

5.2 INTRODUCTION TO ULTIMAKER CURA

5
5.3 COMPONENT 3D PRINTING

vii
 6.1 INTRODUCTION TO ELECTRONICS
6
7.1 INTRODUCTION TO ARDUINO

7 7.2 WORKING WITH ARDUINO

8 8.1 PROJECT: MINI CONVEYOR BELT

9 CONCLUSION

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LIST OF FIGURES
FIGURE.NO DESCRIPTION PAGE.NO
1a Stress and Strain Diagram 6
2b Illustrative diagram representing coil placement 11
3a Construction of Peltier Device 13

3b Working of Copper Cooling Tubes 13

4a Completed CAD modelled of cooling fan 15
4b Completed CAD model of BLDC motor 15
4c Cross sectional view of the BLDC motor 15
4d Given 2D drawings 16
4e Modelled Side Mount 16
4f Modelled Lockpin 17
4g Modelled Part L 17
5a Cura software Interface 18
5b Gear 19
5c Key chain 19
6a Working of Potentiometer 22
6b Potentiometer 22
7a Arduino IDR Interface 24
7b LED ON 25
7c Led Off 25
7d Shoes the Fading of the Light Intensity 25
7e Distance Measured by the Ultrasonic Sensor 26
7f Shows The Movement Of The Servo Motor 26
8b CAD model 27
8b Mini Conveyor Belt 27

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x
CHAPTER I
COMPANY INTRODUCTION
Carbon-E is a startup dedicated to Robotics and automation product development. It deals
with industrial projects involving research, development and optimization. Other services
offered by Carbon-E are as follows.

1.1 Machine design and Special Purpose Machine (SPM) development

Automation and technological advancements have drastically changed the manufacturing

industry. One such aspect is Special Purpose Machine (SPM) design. As SPM is not created
on standard manufacturing programs, immaculate design is crucial to ensure product
performance and safety. At Vee Technologies, we help develop technologically advanced
machines that meet your specific needs by employing a highly specialized team that provides
assistance with the design of the specialized tools and machinery. No matter how small or big
your design requirements are, we are equipped to precisely cater to it. From the initial
conceptualization phase to complete design, we provide you with end-to-end design support.

We specialize in providing designs for a wide array of applications, which include:

 Specialized industrial machines

 Processing and packaging equipment
 Welding automation
 Gantry pick and place systems
 Automated test equipment
 Tooling systems for casting and sheet metal
 Specialized manufacturing equipment
 Articulating arms
 Part transfer chutess
 Rapid prototyping

1.2. Software development in the field of machine vision and system automation

Machine vision systems are a set of integrated components that are designed to use
information extracted from digital images to automatically guide manufacturing and
production operations such as go/no testing and quality control processes. These systems can
also play a role in automated assembly verification and inspection operations through their
ability to guide material handling equipment to position products or materials as needed in a
given process. They have wide applications across different industries and can be used to
automate any mundane, repetitive tasks that would become tiring to a human inspector or
operator. The use of machine vision systems allows for 100% inspection of products or parts
in a process, resulting in improved yields, reductions in defect rates, increased quality, lower
costs, and greater consistency of process results.

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1.3. Autonomous vehicles

An autonomous vehicle is one that can drive itself from a starting point to a predetermined
destination in "autopilot" mode using various in-vehicle technologies and sensors, including
adaptive cruise control, active steering (steer by wire), anti-lock braking systems (brake by
wire), GPS navigation technology, lasers and radar.

14. Modelling and 3D printing

3D printing is a process in which a digital mode! is turned into a tangible, solid, three-
dimensional object, usually by laying down many successive, thin layers of a material. 3D
printing has become popular so quickly because it makes manufacturing accessible to more
people than ever before. This is partly due to the price (the starting price for a basic 3D
printer is about $300), but also the small size of the printers compared to traditional
manufacturing

15. Consultancy services in multidisciplinary engineering fields.

The professional services thus inter alia involve pre-feasibility studies, feasibility studies,
basic studies, detailed engineering, project management, procurement assistance, construction
monitoring supervision, inspection & expediting, testing and commissioning and were called
for, operation and maintenance

Location

Carbon-E
Cubical 2, CIBA Ver Goa 403722
Faded in 2030
Projects completed 200+

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CHAPTER 2
The company deals with industrial projects pertaining to multiple discipline. The projects
require the knowledge of multiple engineering fields. The internship started with general
overview and study of multiple concepts. Following is the summary of the study task.

2.1.1 Concept of momentum

Momentum is a physical quantity that measures the amount of motion an object
(ii) it is defined as product mass and velocity [kg=m/s]
(iii) Momentum is an vector quantity.

2.1.2 Different types of Mechanical Braking methods in modern cars/bikes.

The different types of mechanical braking methods in modern cars/bikes are

 Band Brake – Have flexible band around that wraps the outside of a Drum and
tightens when brakes are applied. They are simple and cheap but have low braking
efficiency and high wear.
 Disk brake: It is a type of a brake that uses calipers to squeeze pads against the disc
or a rotor creating friction . They are easy to install and maintain and dissipate heat
easier. But they are also expensive, non-self energizing and are prone to noise .
 Drum brake :it is a type of brake that uses friction caused by shoes or pads that press
against a rotating drum attached to the wheel. they have lower cost , better corrosion
resistance and self energizing but have lower braking performance and higher heat
generation.
 Spring brakes : these have springs that apply force to stop the motion . they are used
as parking brakes or emergency brakes in some vehicles . but can be slow to release
and noisy .
 Cone brakes :they have cones that fit into each other to transmit torque . they have
increased surface area and quicker deceleration but can be difficult to adjust and are
prone to slipping .

2.1.3 The concept of energy conversion during Braking

In traditional braking system , the kinetic energy of the vehicle in converted to heat due to
friction in brakes, the heat is wasted and cannot be recovered . the energy wasted during
braking depends on the type of braking system used .
These is, just to get an perspective of much energy is wasted during braking .
Assumptions
(I) Type of brake is disc brake.
(II) Weight of the car + person driving the car == 1100kg
(III) The car is travelling with a velocity of 113kph
therefore To bring car running at 113 kph to a complete halt, we wasted 538.48kJ of energy .

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2.1.4 Regenerative Braking System

Regenerative braking is a technique that captures the kinetic a moving vehicle and converts it
into electricity that can be used or stored for later use. It reduces the need for conventional
brakes and saves energy . It is used in electric and hybrid vehicles to recharge their batteries.

2.1.5 ABS systems

ABS [Anti-lock Braking System) Braking system is a safety feature that prevents the wheels
from locking and skidding when you brake hard. It helps to maintain control of the steering
and reduce braking distances .It works by monitoring the speed of the wheel and adjusting the
brake pressure accordingly.

Pros

i. It stops the car at a shorter distance than conventional brakes

ii. It prevents the wheels from Locking up and avoids uneven tyre wear
iii. It increases control and enables steering during braking
iv. It enables the possibility of traction control system.
v. It reduces skidding on wet roads and improves handling
vi. It lowers insurance cost.

Cons

i. It may increase braking distance on loose surface such is gravel and snow
ii. It may be more expensive to maintain and repair than conventional brakes.
iii. It may not work well if the tyre are worn out or under inflated .
iv. It may malfunction due to sensor failure or electrical issues.

2.1.6 EBD systems

EBD [Electronic Brakeforce Distribution] is a system that enables the distribution braking
force to the individual wheels of the car depending of factors such as load, speed, road
condition etc.
This makes braking more efficient and shortens the braking distance of the car .
It uses the vehicles ABS and ESC [Electronic Stability Control] to determine the ideal force
distribution to all four wheels in a braking event.

Pros
i. It improves vehicle stability and control during braking
ii. Prevents wheel lock Up and skidding

Cons:
i. It may increase cost and complexity of braking system.
ii. It may require regular maintenance and calibration
iii. It may not work well on slippery or uneven surfaces.

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2.1.7 Wide tyres v/s Narrow tyres. which is better for high speed car?

Wide tires offer better traction on dry surfaces, increased stability and sportier appearance,
while narrow tires provide improved wet traction, enhanced fuel efficiency and smoother
ride.

Wide tires also increase rolling resistance and fuel consumption. while narrow tires may
have less grip on dry surfaces and decreased handling.

Between wide tyre and Narrow tyre for an high speed car the choice depends on of the
personal preference of the driver / the owner and also on the driving conditions.

2.2.1 List and Explain intermolecular Forces.

Intermolecular forces are forces of attraction or repulsion between neighboring particles
(atoms, ions etc.).
-Intermolecular forces affect the physical states and properties of substances, such as
melting point, boiling point, vapour pressure ,evaporation, viscosity, surface tension and
solubility.
Different types of Intermolecular forces are:

i. Hydrogen bonding : A strong attraction between hydrogen atom bonded to an highly

electro negative atom. [eg: O, N, F]
ii. Ion dipole forces: An attraction between ion and a polar molecule
iii. Dipole – Dipole interactions: Attractive forces among polar molecules.
iv. Ion-induced dipole interactions: Attractive force between an ion and a non-polar
molecule that becomes polarized By the presence on an ion.

v. Dipole-induced dipole interactions: Attractive forces between a Polar molecule and a

non-polar molecule that becomes polarized by the polar molecules presence

vi. Van der Waals forces: A collective term for the weak attraction between non-polar
molecules of induced dipoles.

2.2.2 Different types of material failure

Material failure is a loss of function or performance due to external loads or environmental

conditions
There an different types material failure ,depending upon the nature and mechanism of
failure they are :

i. Brittle failure: “The breakage of material due to sudden fracture without significant
plastic deformation
ii. Ductile failure: the deformation of a material due to yielding or excessive plastic
strain, which lead to necking or tearing

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 iii. Fatigue failure : the weakening or cracking of a material due to repeated or cyclic
loading ,which may cause failure at lower stress level than static strength .

iv. Embrittlement failure: The loss of ductility or toughness of a material due to exposure
to high temperature , hydrogen chemical ,radiation or stress .

v. Environmental related failure: The detoriation or corrosion of a material due to

interaction with the surrounding medium such as oxygen, water and salts etc.

vi. Creep deformation : The gradual and permanent deformation a material under
constant stress or temperature over a long period of time.
vii. Buckling: The sudden and unstable deformation of a slender structure or a member
due to compressive loading.

viii. Stress on strain failure: The failure of a material when the stress and strain exceeds
the limit of threshold value for the material.

2.2.3 Stress-Strain graph of Ductile v/s Brittle material.

Fig 2a : Stress and Strain diagram

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2.2.4 When are brittle materials preferred over ductile materials.

Brittle materials are hard but liable to break easily while ductile materials are able to be
drawn out into thin wires without fracture .brittle materials are preferred over ductile
materials when high strength and low deformation are required such as glass , ceramics
,concrete etc.

2.2.5 Crack propagation and how can it be prevented?

Crack propagation is the process of preventing a crack growing in a material under stress. It
can lead to failure of a material or structure.

Crack propagation can be prevented by:

i. Forming dimples on the surface of a metal component indue compressive residual
stress.
ii. Avoiding craters and using ductile filler materials for welds
iii. Using jamming mechanisms.(granular jamming, shape shifting jamming, interfacial
jamming)
iv. Avoiding stress corrosion cracking by reducing stress , changing environment or
using resistant material .

2.2.6 Working of an Bullet Proof Jacket

A bullet proof jacket is like an armor that helps to protect the wearer from firearm. A bullet
proof jacket consist of two main component a carrier and ballistic panel

Working :
When a bullet strikes a bullet proof jacket it encounters resistance from the ballistic panel
,which absorbs and disperses the energy into the vest .the panel causes the bullet to slow
down and deform. the deformation of the bullet causes it to lose its penetration ability and
spreading the energy over a larger area. The panel also prevents fragmentation from the
explosion from reaching the wearers body .

2.3.1 Crumple Zone

A crumple zone is a part of a vehicle that is designed to deform and absorb energy of an impact
in a collision, to protect the passengers .
It works by increasing the time and the distance over which the change in velocity occurs
reducing the force on the car and the occupants.

2.3.2 Working of Airbags

Airbags are the safety mechanism provided in a car to protect the occupants during a collision
when a car hits something the acceleration is detected by the accelerometer . if the
deceleration is strong enough , the accelerometer activates the airbag circuit which sends an

7
electric current or a signal to the inflator within each bag. the inflator has an ignitor which
begins a chemical reaction to produce gas .
the airbag than bursts out of its housing and inflates .this entire process happens in one-
twentieth of a second or less

2.3.3 Seatbelt mechanism

A seatbelt mechanism is a device that restrains a person in a vehicle seat in a event
of a crash.

The components of the seatbelts are:

i. Webbing: the webbing is a part of the seat that goes around your body .it is made of
strong and flexible material
ii. Retractor: the retractor is a spring loaded device that keeps the webbing taut and
prevents it from getting tangled .
iii. Buckle: the buckle is the device that you use to fasten the seatbelt it has a tongue and
a groove .
iv. Locking mechanism: the locking mechanism is a device that prevents the seatbelt
from loosening during the crash .

Working : The seat belt system consists of webbing that is connected to a retractor
mechanism. A spool is attached to one of the ends of the webbing as well, being the main
element in the retractor. Inside the retractor is a spring that applies torque to the spool causing
it to rotate. This winds up any loose webbing that may remain

When the seat belt is unspooled and is across the person’s body, the webbed fabric ends in a
metal tab, called the tongue. The tongue is inserted into the buckle. The buckle contains a
spring-loaded latch that locks onto the tongue and holds it in place

If worn properly, a seat belt will spread the stopping force across the seat belt wearer’s pelvis
and rib cage. These areas of the torso are two of the more sturdy parts of the body, so
directing the force in those areas works to minimize the effect of the crash on the body

2.3.4 Tesla is one of the most advanced car manufacturers. How can they
achieve such high safety ratings
Tesla has high safety ratings because of following reasons:
i. Strong body structure: Tesla vehicles have a strong body structure that is designed to
absorb energy in the event of a crash. The battery pack is also mounted low in the
vehicle, which helps to lower the center of gravity and reduce the risk of rollover.
ii. Advanced safety features: Tesla vehicles come standard with a number of advanced
safety features, including automatic emergency braking, lane departure warning, and
adaptive cruise control. These features can help to prevent accidents from happening
in the first place.
iii. Over-the-air updates: Tesla vehicles can receive over-the-air software updates that can
improve their safety performance over time. For example, Tesla has released updates
that have improved the performance of its automatic emergency braking system.

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 iv. In addition to the above, Tesla is also constantly innovating in the area of safety For
example, Tesla is developing a new self-driving system that it believes will be much
safer than human drivers. Tesla is also working on new ways to improve the safety of
its battery packs and other critical components.

2.3.5 Why was the radar sensor in Tesla cars discontinued?

According to tesla, using only cameras for its autopilot system would allow for a robust and
consistent in a wider range of environments and scenarios
Tesla also claimed that Tesla Vision would improve safety and reliability by reducing the
potential sensor conflicts or false alarms
Tesla said also claims that their neural networks have become strong enough to handle the
complex and diverse situation on the roads without relying on radar an ultrasonic sensors.

2.3.5 lane Assist, parking assist and cruise control

Lane assist: is a system that detects when your vehicle is drifting out of the lane and applies
a corrective steering force to keep you in the lane

Parking Assist: is a system that helps you park your vehicle by automatically steering,
Braking or accelerating the vehicle is a parking space.

Cruise control: is a system that automatically adjust the vehicles a speed to keep a preset
distance between it and the vehicle in front speed of it.

2.4.1 Why is capacitor required in some AC motors?

AC capacitor is required for some single phase motors to energize The second phase
winding. and create a rotating magnetic field while motor is running
The capacitor provides the initial jolt of electricity the motor needs to run successfully
It stores electricity and sends it to the motor in a powerful burst that gets the unit reved up as
it starts the cooling cycle .

2.4.2 Difference between synchronous and asynchronous motors?

Characteristic Synchronous motor Asynchronous motor

Slightly less than stator magnetic
Rotor speed Equal to stator magnetic field speed
field speed (slip)
Induction from stator magnetic
Rotor excitation DC current
field
Cost More expensive Less expensive
Speed operation Constant, regardless of load Varies with load

Can operate at leading, lagging, or Can only operate at lagging power

Power factor
unity power factor factor

Efficiency Higher Lower

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 Common Power factor correction, driving loads
General-purpose applications
applications at low and constant speed

2.4.3 Servo Moto working.

A servomotor is a closed loop mechanism that uses feedback to control its motion and final
position.
The input to its control is a signal representing the position commanded for the output shaft
The motor Is paired with some type o f a position encoder to provide position and speed
feedback.
The measured position of the output shaft is compared with the command position the
external input to the controller .
If the output position differs from the required an error signal is generated which causes the
motor to rotate in either direction to bring the output shaft to the appropriate position .
Once reached the correct position the error signal reduces to zero and the motor stops

2.4.4 How to convert a stepper motor

Stepper motor and servo motor are two different types of motors that work on different type
of principle so it is not a straight forward process to convert stepper to servo motor .
However ,it is possible to use stepper in a similar way to a servo by adding a encoder or a
potentiometer to provide a feedback of the output shaft .

2.4.5 Axial motor vs Radial motor .Which is better ?

Axial flux motor also called a pancake motor is a type of motor where the magnetic field is
aligned along the axis of rotation.
Radial flux motors is an electric motor that generates magnetic flux perpendicular to the
axial .

Regarding which is better depends on the application:

Axial flux motors offer a higher power to weight ratio making them suitable for application
such as electric vehicles and drones where space and weight are key consideration .Whereas
radial flux motors have been commercially successful for decades and are considered more
versatile in their application.

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 Fig 2b: Illustrative diagram representing coil placement

2.4.6 How to control the speed of a 3phase motor?

i. Changing frequency: The speed of the motor in directly proportional to the frequency
therefore increasing or decreasing the frequency will increase or decrease the sped of
motor
ii. Changing voltage
iii. Using a variable frequency drive (VFD): VFD in device That can vary the frequency
and voltage supplied to the motor, allowing precise control over its speed.
iv. Pole changing: some three phase motors have multiple sets of winding allowing them
to operate at different speeds depending on which set of winding is energized by
changing which set of the winding are energized you can change the speed of the
motor.

2.4.7 Type of motors used in tesla car

Tesla uses different type of electric motor in their cars depending On The model and
Model S and Roadster: AC induction motor
Model 3 and Model X: DC brush motor
Model Y : AC induction or PSMR motor.

2.4.8 Koenigsegg raxial motor.

Koenigsegg raxial motor is a new type of electric motor developed by Koenigsegg
Automotive AB.it combination of radial and axial flux motor which gives a compact motor
with lots of low rpm torque and high peak power .
Despite the compact size the radial flux motor is claimed to produce an horsepower of 339.9
and 442ft-lbs torque all in an ultra light 30 kilogram power unit .

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CHAPTER 3

3.1 LEADERSHIP TRANING

The task required us to watch a video of a presentation by Simon Sinek on how Leaders Eat
Last: Why Some Teams Pull Together and Others Don’t.

In this video Sinek says that effective leaders create a “Circle of Safety” for their teams,
where they feel secure, valued, and trusted. Which in turn fosters cooperation, innovation,
and loyalty among team members.

Sinek explains the biological basis of trust and safety, and how the brain releases different
chemicals depending on the situation. He identifies four chemicals that shape our behavior
and happiness: endorphins, dopamine, serotonin, and oxytocin and also mentions cortisol,
which is released when we feel stressed or threatened.

He also provides examples of organizations and leaders who have created a culture of trust
and safety, such as the Costco, Apple and US Marine Corps where he gave an example of
how his friend David Marquet transformed the performance of the USS Santa Fe, a nuclear-
powered submarine, by changing the leadership style from command-and-control to
empowerment and trust.

Sinek emphasizes on the importance of small actions that signal that we care about each other
and the group. These include acts of kindness, active listening, and expressions of gratitude.

Sinek concluded by urging leaders to put the well-being of their teams before their own, and
to create environments where people can thrive and fulfill their potential. He says that leaders
eat last, meaning that they sacrifice their own needs for those in their care.

3.2 PELTIER DEVICE

A Peltier device employs a phenomenon known as the Peltier effect. This is a thermo-electric
effect that creates a heat flux between the junction of two different types of materials when an
electrical current is passed through them 12. As a result, one side of the device becomes hot,
while the opposite side cools down. The device is also known as a Peltier cooler, heater, or
thermoelectric heat pump 1

A Peltier device is constructed using two different types of materials, typically n-type and p-
type semiconductor materials, which are sandwiched between two ceramic plates

The primary advantages of a Peltier cooler compared to a vapor-compression refrigerator are

its lack of moving parts or circulating liquid, very long life, invulnerability to leaks, small
size, and flexible shape 1. Its main disadvantages are high cost for a given cooling capacity
and poor power efficiency (a low coefficient of performance or COP)

12
 Fig 3b : Construction of Peltier Device

3.3 COPPER COOLING TUBES

WORKING

Heat pipes are devices that transfer heat between two solid interfaces using phase transition
of a working fluid 1. The heat source heats up one end of the pipe, called the evaporator
section, and the working fluid in this section absorbs the heat and turns into a vapor. The
vapor then travels along the heat pipe to the cold interface and condenses back into a liquid,
releasing the latent heat. The liquid then returns to the hot interface through capillary action,
centrifugal force, or gravity, and the cycle repeats

CONSTRUCTION

A heat pipe is typically made up of three components: a sealed tube, a working fluid, and a
wick structure 12. The tube is usually made of a material that is compatible with the working
fluid, such as copper for water heat pipes or aluminum for ammonia heat pipes 1. The tube is
partially filled with the working fluid and then sealed. The working fluid mass is chosen so
that the heat pipe contains both vapor and liquid over the operating temperature range 1. The
wick structure is used to transport the liquid back to the evaporator section through capillary
action, centrifugal force, or gravity

Fig 3.2 : Working of Copper Cooling Tubes

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CHAPTER 4

4.1 INTRODUCTION TO AUTODESK FUSION 360

Fusion 360 is 3D design software used for product design, engineering, and product testing. It
offers a wide range of features and capabilities, including the ability to create models using
CAD, engineering drawings, photos, and videos. Some of Fusion 360’s main uses include
product design and engineering, product testing, product visualization, and creating virtual
prototypes

4.1.1 USES OF FUSION 360 IN 3D MODELING

In today’s world, technology is constantly evolving and improving. With new software and
programs being created every day, it can be hard to keep up with the latest trends and
technologies However, one program that is worth learning is Fusion 360. Fusion 360 is a 3D
modelling software that can be used for a variety of purposes, such as product design,
engineering, manufacturing, and more.

Fusion 360 is so versatile. It can be used for both personal and professional projects
Additionally, Fusion 360 is cloud-based, which means it can be accessed from any device or
computer with an internet connection. This also makes it easy to collaborate with others on
projects

4.1.2 MODELING TOOLS

Fusion 360 is a 3D CAD, CAM, and CAE software developed by Autodesk company. It has a
wide range of uses in engineering and manufacturing, from product design to production.

(I) One of the most powerful features of Fusion 360 is its ability to create splines. Splines are
used to create smooth curves and shapes, which can be difficult or impossible to achieve with
traditional CAD tools
(II) Another powerful feature of Fusion 360 is its trim tool. The trim tool allows you to
remove unwanted material from a 3D object quickly and easily.
(III) The fillet tool is also useful for removing unwanted material from objects. The fillet tool
creates a smooth transition between two surfaces, making the object look more polished and
professional.
(IV) One of the most popular features of Fusion 360 is its circular pattern tool

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4.2 Modelling and assembly of a cooling fan

The following part involves the pattern geometry of a curved profile. The added complexity
was to achieve motion of the fan using the assembly feature in Fusion360.

Fig 4a : completed CAD modelled of cooling fan

4.3 Modelling and assembly of an BLDC motor

This task involved modelling and assembling the sator and the rotor of the bldc motor using
the features of fusion 360.

Fig 4b: Completed CAD model of BLDC motor Fig 4c : cross sectional view of the BLDC motor

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4.4 Modelling of Machine component

In this task a 2D engineering drawing was given, and the task was to reproduce the part in 3D
using Fusion360. Here the understanding of the graphic design was tested.

Fig 4d: Given 2D drawings

Fig 4e: Modelled Side Mount

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Fig 4f : Modelled Lockpin

Fig 4g: Modelled Part L

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CHAPTER 5
5.1 Introduction to 3D Printing
3D printing or additive manufacturing is the construction of a three-dimensional object from
CAD model or a digital 3D model. It can be done in a variety of processes in which material
is deposited, joined or solidified under computer control, with material being added together
(such as plastics, liquids or powder grains being fused), typically layer by layer

In the 1980s, 3D printing techniques were considered suitable only for the production of
functional or aesthetic prototypes, and a more appropriate term for it at the time was
prototyping. As of 2019, the precision, repeatability, and material range of 3D printing have
increased to the point that some 3D printing processes are considered viable as an industrial-
production technology, whereby the term additive manufacturing can be used synonymously
with 3D printing. One of the key advantages of 3D printing is the ability to produce very
complex shapes or geometries that would be otherwise impossible to construct by hand,
including hollow parts or parts with internal truss structures to reduce weight. Fused
deposition modeling (FDM), which uses a continuous filament of a thermoplastic material, is
the most common 3D printing process in use as of 2020

5.2 Introduction to Ultimaker Cura

Ultimaker Cura is a free and easy-to-use 3D printing software that is trusted by millions of
users worldwide It allows you to fine-tune your 3D model with over 400 settings for the best
slicing and printing results

The software is compatible with Ultimaker 3D printers as well as many third-party

machines . It can prepare your models for printing within a few clicks from the recommended
print overview, or optimize your printing strategy with hundreds of custom settings

Ultimaker Cura is designed to suit your workflow and offers seamless integration with all
Ultimaker products. It also has CAD plugin integration with SolidWorks, Siemens NX,
Autodesk Inventor, and more . The software supports file types such as STL, OBJ, X3D,
3MF, BMP, GIF, JPG, and PNG .

Fig 5a: Cura software Interface

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 5.3 Component 3D Printing

This task was divided in two parts :

1) We had to outsource a part for 3d printing from sites like thingiverse etc, here we learned
how to operate a 3d printer.

Fig 5b : Gear

2) We had to design a part for 3d printing but the print was not supposed to take more than
30 min here we learned how to optimize our design for 3d printing.

Fig 5c: Key chain

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CHAPTER 6

6.1 Introduction to electronics

Electronics is the study of how to use different materials and devices to control the flow of
electrons and create circuits that can perform various functions or tasks. For example,
electronics can be used to make computers, phones, TVs, radios, robots and etc.

6.1.1 Resistors Capacitors, Transistors, Diode, Inductor

A resistor is a passive two-terminal electrical component that implements electrical
resistance as a circuit element. resistors are used to reduce current flow, adjust signal levels,
to divide voltages, bias active elements, and terminate transmission lines, among other uses 1.

Diode: A diode is a two-terminal electronic component that allows the flow of current only in
one direction. It is used for rectification of alternating voltage, overvoltage protection,
cascade connections, and used with relays against back EMF protection, among other uses 12.

Transistor: A transistor is a semiconductor device used to amplify and switch electronic

signals and electrical power. It has three terminals: the emitter, the base, and the
collector. Transistors are used in amplifiers, oscillators, modulators, demodulators, and
transmitters 3.

Inductor: An inductor is a passive two-terminal electrical component that stores energy in a

magnetic field when electric current flows through it. Inductors are used in filters,
transformers, oscillators, and power supplies 45.

Capacitor: A capacitor is a passive two-terminal electrical component that stores energy in

an electric field when electric current flows through it. Capacitors are used in resonant or
time-dependent circuits as a timing element, filters, oscillators, and power supplies 4

6.1.2 Motors
An electric motor is an electrical machine that converts electrical energy into mechanical
energy. electric motors operate through the interaction between the motor's magnetic
field and electric current in a wire winding to generate force in the form of torque applied on
the motor's shaft.
Electric motors may be classified by considerations such as power source type, construction,
application and type of motion output. They can be brushed or brushless, single-phase, two-
phase, or three-phase, axial or radial flux, and may be air-cooled or liquid-cooled.
Applications include industrial fans, blowers and pumps, machine tools, household
appliances, power tools, vehicles, and disk drives

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6.1.2.1 Construction of Servo and stepper motor

A servomotor is a motor that is used within a position-control or speed-control feedback

system. Servomotors are used in applications such as machine tools, pen plotters, and other
process systems. Motors intended for use in a servomechanism must have predictable
characteristics for speed, torque, and power.
Construction of Servo Motor
The Servo motor is DC motor which has 5 following parts:-
1. Stator Winding: This type of winding wound on the stationary part of the motor. It
is also known as field winding of the motor.
2. Rotor Winding: This type of winding wound on the rotating part of the motor. It is
also known as an armature winding of the motor.
3. Bearing: These are of two types, i.e, font bearing and back bearing which are used
for the movement of the shaft.
4. Shaft: The armature winding is coupled on the iron rod is known as the shaft of the
motor.
5. Encoder: It has the approximate sensor which determines the rotational speed of
motor and revolution per minute of the motor.
Stepper motors is a motor that can be rotated to a specific angle in discrete steps with ease
Stepper motors are often used in computer printers, optical scanners, and digital photocopiers
to move the active element, the print head carriage, and the platen or feed rollers.
Construction: Stepper motor is made up of the stator and rotor. The rotor is the movable
part which has no winding, brushes and a commutator. The stator is made up of multipole and
multiphase winding, usually of three or four phases winding wound for a required number of
poles decided by desired angular displacement per input pulses.

6.1.3 Motor drives

A motor driver is a device that drives motors by converting low-voltage, high-current control
signals into high-voltage, high-current power to drive the motor
There are different types of motor drivers available in the market, such as L293D Motor
Driver IC, BTS7960B 43A H-Bridge Motor Driver, TB6612FNG Dual DC Motor Driver,
TB6560 Stepper Motor Driver, and others .

6.1.4 Potentiomter
A potentiometer is a three-terminal variable resistor that is used to control the flow of electric
current by manually varying the resistance.
The potentiometer consists of a resistive element, a sliding contact (wiper) that moves along
the element, making good electrical contact with one part of it, electrical terminals at each
end of the element, a mechanism that moves the wiper from one end to the other, and a
housing containing the element and wiper . The resistive element can be flat or angled. Each
end of the resistive element is connected to a terminal on the case. The wiper is connected to
a third terminal, usually between the other two

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1

Fig 6a: Working of Potentiometer

Fig 6b: Potentiometer

They are used as voltage dividers in electronic circuits, such as volume controls on audio
equipment, and to measure voltage by comparing the measuring voltage with voltage across
the resistance of the potentiometer They can be used as position sensors in wood processing
machines, injection mold machines, and medical equipment .

6.1.5 Sheilds and their functions

In electronics, a shield is a conductive barrier that is used to protect electronic devices from
electromagnetic interference (EMI) and radio frequency interference (RFI)
As they can cause can cause electronic devices to malfunction or fail, so shielding is an
important part of electronic design .

There are different types of shield used in electronics.

Arduino shields are add-on boards that can be attached to an Arduino microcontroller board
to provide additional functionality . These shields can be used to add features such as Wi-Fi,
Bluetooth, motor drivers, power supplies, and more .

Electromagnetic shield is used to prevent signals from being interrupted by external

electromagnetic signals

Electrostatic shield is used to protect sensitive components or circuits from static electricity
events. In electrostatic shielding, the circuit or component to be protected is placed inside an
enclosure.

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CHAPTER 7

7.1 Introduction to Arduino

Arduino is an open-source electronics platform based on easy-to-use hardware and
software. Arduino boards are able to read inputs - light on a sensor, a finger on a button, or
a Twitter message - and turn it into an output - activating a motor, turning on an LED,
publishing something online.
You can tell your board what to do by sending a set of instructions to the microcontroller
on the board. To do so you use the Arduino programming language (based on Wiring),
and the Arduino Software (IDE), based on Processing.
Arduino was born at the Ivrea Interaction Design Institute as an easy tool for fast
prototyping, aimed at students without a background in electronics and programming.
Arduino also simplifies the process of working with microcontrollers, but it offers
advantage for teachers, students, and interested amateurs over other systems as they are

 Inexpensive

 Cross-platform

 Simple, clear programming environment

 Open source and extensible software

7.1.2 Learning Arduino Programming

The Arduino API [ Arduino Programming Language ] , consists of several functions,

variables and structures based on the C/C++ language.

The Arduino API can be divided into three main parts: functions, variables and structure:

Functions: for controlling the Arduino board and performing computations. For example, to
read or write a state to a digital pin, map a value or use serial communication.

Variables: the Arduino constants, data types and conversions. E.g. int, Boolean and array.

Structure: the elements of the Arduino (C++) code, such as

 sketch loop(), setup())

 control structure (if, else, while, for)
 arithmetic operators (multiplication, addition, subtraction)
 comparison operators, such as =(equal to), != (not equal to), > (greater than).

The Arduino API can be described as a simplification of the C++ programming language,
with a lot of additions for controlling the Arduino hardware

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Program Structure

The absolute minimum requirement of an Arduino program is the use of two

functions: void setup() and void loop(). The "void" indicates that nothing is returned on
execution.

Void setup()

This function excecutes only once,when the Arduino is powered on. Here we define things
such as the mode of a pin (input or output ) the band rate of serial communication or the
initialization of a library.

Void loop()

This is where we write the code that we want to execute over and over again, such as turning
on/off a lamp based on an input, or to conduct a sensor reading every X second.

The above functions are always required in an Arduino sketch, but you are of course able
to add several more functions, which is useful for longer programs.

The "Sketch"

In the Arduino project, a program is referred to as a "sketch". A sketch is a file that you
write your program inside. It has the .ino extension, and is always stored in a folder of the
same name. The folder can include other files, such as a header file, that can be included in
your sketch.

Fig 7a : Arduino IDE interface

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7.2 Working with Arduino

Here we had to perform different task using Arduino .the basic knowledge about Arduino
programming and electronics was tested .

7.2.1 Led control using Switch

In this task we are asked to turn on and off the led by a press of a button using Arduino .

FIG 7b: LED OFF FIG 7c: LED ON

7.2.2 Brightness control using Arduino

In this task we had to control the brightness of the led using Arduino .

FIG7d :SHOWS THE FADING OF THE LIGHT INTENSITY

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7.2.3 Ultrasonic sensor Control

In this task we had to program the ultrasonic sensor to measure the distance of a moving
object .

Fig 7e : MEASURING OF DISTANCE OF AN OBJECT BY THE ULTRASONIC SENSOR

7.1.4 Servo motor Control

the task here was to control the angle of rotation of the servo motor shaft using a Arduino .

FIG 7f : SHOWS THE MOVEMENT OF THE SERVO MOTOR

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8.1 PROJECT : Mini Conveyor Belt
A conveyor belt is a system that uses a flexible material, such as rubber or polymer, to
transport items from one point to another. Conveyor belts are widely used in various
industries, such as manufacturing, distribution, and warehousing, to automate and speed up
the production and delivery of goods. Here, we have tried build our own conveyor belt using
simple materials and components.

Working: The conveyor mechanism consists of two pulleys. One pulley is mounted on a
tensioner mechanism and the other pulley is connected to a stepper motor via gears.

Stepper motor allows for precise movement of items on the conveyor belt and the speed is
controlled using a stepper motor driver connected to an arduino microcontroller board.

Tensioner mechanism allows for belt tension setting along with alignment of the pulley. The
pulleys are specially designed with gear built into it and its manufactured using 3D
printing process.

Components:

 Cut acrylic parts for frame and tensioner mechanism

 Stepper motor
 3d printed pulleys with built in gear
 Fabric belt
 Stepper motor driver
 Arduino Uno

Application: robotics and education

Fig 8a : CAD model Fig 8b: Mini Conveyor Belt

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 CONCLUSION

This internship has been an invaluable experience. I gained basic understanding of vehicle
braking systems, material failure concepts, automobile safety and automation safety features,
types of motors and their workings, Potentiometers, Peltier devices and copper tubes. I also
learned 3D modeling with fusion360,3D printing and Arduino programming.

I would conclude saying that this internship has not only widened my scope of knowledge but
has thought me lot of interesting things which will help me in my future and that my time at
this organization has been amazing.

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