ENGINEERING AND

DESIGN/RESEARCH AND
DEVELOPMENT DEPARTMENT
 OBJECTIVE OF E&D/R&D

DESIGN , DEVELOPMENT AND IMPROVEMENT OF

PASSIVE ELECTRONIC COMPONENTS

(ELECTROLYTIC CAPACITORS,FILM

CAPACITORS,SUPER CAPACITORS, etc)

 ABOUT R&D
 KCCL’s R&D LABORATORY IS NAMED AS KER&DC(KPP NAMBIAR ELECTRONIC
RESEARCH AND DEVELOPMENT CENTRE) AND IT IS RECOGNISED BY DSIR
(DEPARTMENT OF SCIENTIFIC AND IDUSTRIAL RESEARCH) – GOVT OF INDIA
 LOCATED AT KPP NAMBIAR SMARAKA BUILDING
 R&D HAS 3 SUBDIVISIONS
 MATERIAL DEVELOPMENT CENTRE
 ELECTRONIC AND CALIBERATION TEST LABORATORY
 ELECTRICAL AND TESTING LABORATORY
 R&D HAS INDIGENISED THE FOLLOWING ACTIVITIES
 ETCHING PROCESS
 FORMING PROCESS
 ELECTROLYTE FORMULATION AND MANUFACTURING
 RESIN FORMULATION, PLANT CONSTRUCTION AND MANUFACTURING
 SEVERAL CUSTOM MADE SYSTEM AUTOMATION WHICH IS NOT FEASIBLE TO
OUTSOURCE
 ROLES AND RESPONSIBILITIES
 E&D
 Providing design specification for existing products
 Handling design modifications as per market requirements
 Certification process (BIS/CE) working closely with QA and Marketing
 New project installation – working closely with vendors
 R&D
 Quality related trials and evaluation of data for product modification
 Continuous improvement of projects
 New project technical feasibility studies
 Machine specification development and process definition along with PE dept
INTRODUCTION TO KELTRON
PRODUCTS

RESISTORS

PRODUCTS CAPACITORS

CRYSTALS
 KELTRONCAPACITORS

NON-
ELECTROLYTI ELECTROLTIC
C (electronic)

MPP FILM
CAPACITOR
ALUMINIUM EDLC
ELECTROLYTI CAPACITORS
C (supercapacitor) IS 1709
FAN IS 2993
CAPACITORS MOTOR
RUN
HIGH NON
RADIAL AXIAL MOTOR
CV POLAR
RADIAL START
 What is a capacitor……?
 PASSIVE ELECTRICAL COMPONENT

 STORES ELECTRIC CHARGES WHEN POTENTIAL IS

APPLIED BETWEEN TETMINALS

 2 CONDUCTIVE PLATES SEPERATED BY A DIELECTRIC

(INSULATOR) MATERIAL

 THERE ARE SEVERAL VARIETY IN THE CONSTRUCTION.

CAPACITORS ARE MAINLY CLASSIFIED BASED ON THE
DIELECTRIC USED. FOR ex AL ELECTROLYTIC USES
ALUMINIUM OXIDE AS DIELECTRIC, FILM CAPACITORS USE
POLYPROPYLENE FILM OR POLYESTER FILM AS DIELECTRIC
MAIN APPLICATIONS

 ENERGY STORAGE
 RIPPLE VOLTAGE REDUCTION
 VARIOUS ELECTRONIC CIRCUIT APPLICATIONS
 AC MOTORS, RATED FOR SINGLE PHASE
 POWER FACTOR IMPROVEMENT (single and
three phase)
 CAPACITANCE (C)
 MEASURE OF HOW MUCH CHARGE(Q) IS STORED FOR
A GIVEN VOLTAGE (V) WITH GIVEN CAPACITANCE
CAPACITANCE, C = Q/V
 UNIT OF CAPACITANCE IS FARAD (F)

Capacitor Design Eqn , C = (ε0εrA)/d

ε0 – Absolute permittivity (Vacuum/free space) = 8.85x10⁻¹²F/m
εr – Relative permittivity /Dielectric constant
εr for air – 1.0
A – Area of plates for Aluminium oxide – 8 to 9
For Polypropylene – 2 to 2.3
d – Thickness of dielectric
 ALUMINIUM ELECTROLYTIC
CAPACITORS (in general)
CHARACTERISTICS:

 ANODE (+) FOIL HAVING Al2O3 AND CATHODE (-) FOIL WITHOUT Al2O3 AND CONDENSER
GRADE PAPER ARE WOUND TOGETHER TO FORM ELEMENT.

 DURING WINDING CONNECTING TERMINALS ARE ATTACHED TO EACH FOILS BY A PROCESS

KNOWN AS STITCHING.

 THE ELEMENTS ARE VACUUM IMPREGNATED WITH APPROPRIATE ELECTROLYTE. IN THE

ACTUAL WORKING CONDITION THE ELECTROLYTE IS THE REAL CATHODE AND THE CATHODE
FOIL USED IS ACT ONLY AS AN ELECTRICAL SUPPLY MEANS TO THE ELECTROLYTE.

 THE IMPREGNATED ELEMENTS ARE HERMETICALLY SEALED.

 THE CAPACITORS ARE THEN AGED AT PROPER VOLTAGE AND TEMPERATURE. THE AGEING IS
TO DEVELOP OXIDE FILM ON THE ANODE FOIL AT THE OXIDE FILM DAMAGED AREA (SLIT
EDGE AND STITCHED PORTION).
 ALUMINIUM OXIDE (Al2O3) ACTS AS A DIELECTRIC

 ELECTROLYTE FILL IN THE TUNNELS OF ETCHED SURFACE OF ANODE FOIL

THEREBY INCREASING THE EFFECTIVE SURFACE AREA

 WIDELY USED, AS THEY OFFER LOWEST COST PER CAPACITANCE VALUE

 FIXED CAPACITANCE VALUE

 NON POLAR AND MOTOR START

CAPACITORS ARE CHARACTERISED BY TWO ANODE FOILS

Radial Axial
 CONSTRUCTION
 START WITH HIGH PURITY ALUMINIUM FOIL
Aluminium foil

 BOTH ANODE AND CATHODE FOILS ARE CHEMICALLY ETCHED TO INCREASE THE
SURFACE AREA

 ELECTROLYTE FILLS IN THE ETCHED TUNNELS OF THE FOIL

TO HARVEST THE INCREASE IN AREA DUE TO ETCHING

 MORE SURFACE AREA = MORE CAPACITANCE [C= (ε0εrA)/d] Etched and formed foil

 AN ALUMINIUM OXIDE DIELECTRIC IS ELECTRO CHEMICALLY FORMED ON THE

ANODE FOIL (+) SURFACES. THE PROCESS IS KNOWN AS FORMING.
 ALUMINIUM ELECTROLYTIC CAPACITOR
PRODUCTION

RUBBER BUNG
PVC SLEEVE
ANODE

CATHODE
 PARAMETERS OF ELECTROLYTIC
CAPACITORS
1. CAPACITANCE VALUE (C) (F)

2. RATED VOLTAGE (V) (Volt) – maximum voltage at which the capacitor is designed to work

3. RATED TEMPERATURE (ᵒC) – minimum to maximum temperature the capacitor is designed to work

4. LEAKAGE CURRENT (LC)(µA) – current leakage through Al2O3 dielectric, it should be within a
specified value.

5. DISSIPIATION FACTOR (DF)(%) – power loss when current is applied, lower the value, greater the
capacitor performance.

6. EQUIVALENT SEIRES RESISTANCE (ESR)(Ω) – resistance exhibited by a capacitor during charging and
discharging

7. IMPEDANCE (Z)(Ω) – It is mainly vector addition of capacitive reactance and the ESR of the capacitor

8. RIPPLE CURRENT – It is the upper limit of charge/discharge current that a capacitor can handle
during working.
 ALUMINIUM ELECROLYTIC
CAPACITORS
a) RADIAL TYPE CAPACITORS b) AXIAL TYPE CAPACITORS
PARAMETERS
• CAPACITANCE
•WORKING VOLTAGE

At KELTRON At KELTRON
CAPACITANCE RANGE- 0.1μF to 22000 μF CAPACITANCE RANGE- 1μF to 22000 μF
WORKING VOLTAGE – 6.3V to 500V WORKING VOLTAGE – 6.3V to 400V
TEMPERATURE – 85ᵒC/105ᵒC TEMPERATURE – 85ᵒC
 c) HIGH CV (LARGE CAN TYPE)

CAPACITORS

SCREW TERMINAL TYPE SNAP IN TERMINAL TYPE

LUG TERMINAL TYPE
At KELTRON
CAPACITANCE RANGE - 47μF to 560000 μF
WORKING VOLTAGE – 16V to 450V
TEMPERATURE – 85ᵒC/105ᵒC
 d) NON POLAR RADIAL CAPACITORS
 NON POLARISED (DOUBLE ANODE TYPE)
 AUDIO SIGNAL CIRCUITS

At KELTRON
CAPACITANCE RANGE – 0.1μF to 2200 μF
WORKING VOLTAGE – 6.3V to 100V
TEMPERATURE – 85ᵒC
 e) AC MOTOR START CAPACITORS
 NON POLARISED (DOUBLE ANODE TYPE)
 USED DURING MOTOR START PHASE
 DISCONNECTS WHEN MOTOR REACHES A
PREDETERMINED SPEED

At KELTRON
CAPACITANCE RANGE- 20μF to 1020 μF
WORKING VOLTAGE – 110VAC to 330VAC
TEMPERATURE RANGE– -30ᵒC to 70ᵒC

SINGLE CAN CAPACITORS

DOUBLE CAN CAPACITORS
 EDLC CAPACITORS (SUPERCAPACITOR)

 ELECTRIC DOUBLE LAYER CAPACITORS

 PROJECT ONGOING - PLANT UNDER CONSTRUCTION
 APPLICATIONS
 WIND TURBINES
 ELECTRIC VEHICLES
 SPACE APPLICATIONS etc
 FILM CAPACITORS
 NON POLARISED (AC CAPACITORS)
 DIELECTRIC –PLASTIC FILM (POLYPROPYLENE)
 CONDUCTING PLATES ARE FORMED BY VAPOUR DEPOSITION OF Al &
Zn ON FILMS
 METALLIZED FILMS ARE WOUND TO FORM
CAPACITOR ELEMENT
 ZINC SPRAY ON BOTH ENDS OF ELEMENT FOR
DEVELOPING END TERMINALS
 ELEMENT HEATING/VACUUM DRYING AT 85/105ᵒC
 TERMINAL WIRES ARE ATTACHED/SOLDERED
 THE CAPACITORS ARE SELF HEALING TYPE(SH)
 Contd..
 POTTING - FINISHED ELEMENT IS PLACED IN A PLASTIC/METAL CAN AND
RESIN+HARDENER MIX IS POURED TO ENCAPSULATE THE ELEMENT.
WITHIN A COUPLE OF HOURS THE POURED COMPOUND SOLIDIFIES.
 THIS PROVIDES PROTECTION OF ELEMENT FROM ATMOSPHERIC
OXIDATION AND MOISTURE
 RESIN TYPE USING – POLYURETHANE/EPOXY
 HARDENER TYPE USING – PMDI/AMINES
 TESTING
 HIGH VOLTAGE WITHSTANDABILITY
TESTING
 CAPACITANCE AND TAN δ TESTING

FINISHED CAPACITOR
 APPLICATIONS
 TO RUN AC MOTOR IN SINGLE PHASE
 INDUCTION HEATING
 POWER CORRECTION
 INVERTERS
 PARAMETERS
 RATED VOLTAGE
 CAPACITANCE
 DISSIPATION FACTOR (TAN δ)
 TEMPERATURE CATEGORY
MAIN CLASSIFICATION

 IS1709 quality standards for fan capacitors

(generally 2μF to 6μF range)
 IS2993 quality standards for motor run
capacitors (generally 8μF to 72 μF )
 FILM CAPACITORS
 METALIZED POLYPROPYLENE FILM CAPACITORS (MPP)

PTU & PTS SERIES

PPW SERIES PRW SERIES
Capacitance range - 2.0 MFD
to 72 MFD
Rated capacitance tolerance - ±5%
Rated Voltage - 440 VAC
Rated Frequency - 50 / 60
Hz
Temperature Category - -250C to
+850C
Reference Standard IS - IS1709 /
IS 2993
DAT/DAW (DUAL) CAPACITORS ARW SERIES
 RESISTORS
 PASSIVE 2 TERMINAL ELECTRICAL COMPONENT
 REDUCES CURRENT FLOW
 OHM’S LAW
V= IR V- voltage, I-current, R-resistance
 THE TWO MAIN CHARACTERISTICS OF A RESISTOR ARE ITS
RESISTANCE, R, IN OHMS AND ITS POWER RATING, P, IN
WATTS.
 THE WATTAGE RATING INDICATES THE AMOUNT OF POWER
THE RESISTOR CAN SAFELY DISSIPATE AS HEAT.
P =IV = I²R = V²/R
TYPES OF RESISTORS
 Wire-wound resistors
 Carbon-composition resistors
 Film-type resistors
 Carbon film
 Metal film
 Surface-mount resistors (chip resistors)
 Fusible resistors
 Thermistors
 CARBON FILM RESISTORS
 CERAMIC CORE SUBSTRATE
 CARBON FILM COATING ON CORE
 HELIX IS CUT TO IN THE FILM TO GET DESIRED
CERAMIC CORE
RESISTANCE
 Resistance R = (ρL)/A
ρ – Resistivity L – Length , A- Area
 Higher the helical length higher the resistance
 END CAPS ARE ATTACHED TO BOTH ENDS AND
TERMINAL LEADS ARE SOLDERED
 THE ELEMENT IS COATED WITH EPOXY RESIN

 AVAILABLE WATTAGE (W) : 0.125,0.25,0.5,1

 AVAILABLE COLOUR : GREEN, BEIGE
 METAL FILM RESISTORS
 PROCESS SIMILAR TO CARBON FILM RESISTORS

HERE METAL IS COATED

NICKEL CHROMIUM ALLOY

TIGHT TOLERANCE COMPARED TO

CARBON FILM RESISTORS

AVAILABLE WATTAGE (W) : 0.125,0.25,0.5,1

AVAILABLE COLOUR: BLUE , DARK BROWN

 PARAMETERS
 RESITANCE (R)
 POWER RATING (W)
 TOLERANCE (%)
 TEMPERATURE COEFFICIENT (ppm/ᵒC)
 CLIMATIC CATEGORY
COLOUR CODE OF RESISTORS
 CRYSTALS
 QUARTS CRYSTALS (PRINCIPLE – PIEZOELECTRICITY)

 SYMPLE WATCH CRYSTALS TO HIGH PERFORMANCE CRYSTAL

RESONATORS.

 INDUSTRIAL,MILITARY AND SPACE (ISRO) APPLICATIONS,

INCLUDING HIGH SHOCK AND VIBRATION VERSION .

 TEMPERATURE RANGES -55 TO 200 °C

 RANGE OF FREQUENCY : 1 KHz - 125 MHz

 FOR TRANSMISSION ,RECEPTION AND FOR MICROPROCESSOR

APPLICATIONS

 32.768 KHz FOR WATCHES AND CLOCKS