GOVERNMENT POLYTECHNIC JALNA

Diploma in Mechanical Engineering

CAPSTONE PROJECT EXECUTION REPORT

Academic Year 2024-2025

CERTIFICATE
This is to certify that

Roll No. Enrollment No. Student Name Sign

02 2201200366 Rutik B Bobade

04 2201200368 Kishor B Chide

13 2201200393 Tanuja S Pungle

22 2201200426 Pooja M Borde

30 2201200451 Tushar l Kingre

32 2201200457 Prashant B Mohite

33 2201200459 Gajanan K Muley

34 2201200461 Aniket S Sukase

From government poly jalna College has completed Report on the Semester VI Project Reports
having title Maintenance of various measuring parameter kits.
in a group consisting of 8 persons under the guidance of S.S.Shahapure.

S.S.Shahapure A.A.Joshi
Project Guide Head of Department
Name & Signature Dr.N.R.Jawade
Of External (Principal)
Government Polytechnic Jalna
 Evaluation sheet For
Capstone Project Planning

Name of Program: - Mechanical engg Semester:- ME6-I

Course Title & Code:- CPP [22060]

Title of the Capstone Project: Maintenance of various measuring parameter kits.

Enrollment No. Name of Student

2201200366 Rutik B Bobade

2201200368 Kishor B Chide

2201200393 Tanuja S Pungle

2201200426 Pooja M Borde

2201200451 Tushar l Kingre

2201200457 Prashant B Mohite

2201200459 Gajanan K Muley

2201200461 Aniket S Sukase

A) POs addressed by the Capstone Project:1) design solution for well define follow
technical problem and assits with the design of system component or process to meet
specified needs

2)apply modern engineering tools to appropriate techniques to conduct standard tests and
measurement.
B) CO Addressed by the Capstone Project:1) select, collect and use required information
/ knowledge to solve the problems / compelete the task.

C) Other Learning Outcomes Achieved Through This Project

(1) Unit Outcomes: -
1) Select collect and use required information knowledge to
solve the problems/complete the task.
(2) Prepare a project proposal with action plan and time
duration scientifically before beginning of project.

D)Practical Outcomes:-
1) As per standard proper maintenance of various measuring parameter kits.
2)Outcomes in Affective Domain Outcome:
1) Follow safety practices.
2)Work as team leader /team member.

Name and signature of guide

 Acknowledgement

Primarily we would like to express my special thank of gratitude to my Project guide Prof.

S.S.Shahapure whose valuable guidance has been the once that helped me and my group

patch this project and make it full proof success. His suggestions and his instructions has

served as the major contributor towards the completion of the project. I would also like to

extend my gratitude to the HOD sir A.A.Joshi and Principal for providing us with all the

facilities that was required.

Project Members :-

1)Rutik B Bobade

2)Kishor B Chide

3)Tanuja S Pungle

4)Pooja M Borde

5)Tushar L Kingre

6)Prashant B Mohite

7)Gajanan K Muley

8)Aniket S Sukase
 Abstract
This project focuses on the maintenance and calibration of various measuring parameter kits used in in MEM LAB

and laboratory settings. The objective is to ensure the accuracy, reliability, and longevity of these kits, which are

crucial for precise measurements and data collection. Through regular calibration, preventive maintenance, and

prompt repairs, this project aims to minimize downtime, extend the lifespan of the kits, and ensure compliance with

industry standards. By maintaining detailed records of calibration, maintenance, and repair activities, the project

will ensure traceability and compliance, ultimately contributing to improved productivity and data integrity.
 CONTENT

Sr. Topic Page No.

No.

1 Introduction

2 Literature survey for problem identification and

specification

3 Detailed Methology

4 Result & discussion

5 Conclusion
6 Reference
 Introduction

The maintenance of various measuring parameter kits is a critical aspect of ensuring the

accuracy, reliability, and longevity of these essential tools in industrial and laboratory settings.

Measuring parameter kits, including temperature, pressure, flow, and level measurement devices,

play a vital role in data collection, process control, and quality assurance. However, like any

other equipment, these kits are subject to wear and tear, drift, and degradation over time, which

can compromise their performance and accuracy. This project aims to develop and implement a

comprehensive maintenance program for various measuring parameter kits, ensuring they

operate within specified tolerances and continue to provide reliable and accurate measurements.

By doing so, the project will contribute to improved productivity, reduced downtime, and

enhanced data integrity, ultimately supporting the overall efficiency and effectiveness of

industrial and laboratory operations.

 Literature Survey for problem identification and specification

In mechanical engineering and instrumentation MEM Lab, various measurement devices such as LVDT,

Thermocouples, Load Cells, and Stroboscopes are used extensively for experimental and practical learning.

These kits are sensitive and require proper maintenance to ensure accuracy, reliability, and longevity.

However, many institutions and industries face issues due to improper handling, delayed maintenance, and

lack of systematic monitoring.

 Review of Existing Equipments:

1. LVDT (Linear Variable Differential Transformer):

- Widely used in displacement measurement.

- Prone to core misalignment, electrical noise interference, and coil degradation.

- Studies (e.g., Bently & Hatch, 2003) suggest that frequent calibration and clean environments improve

performance.

2. Thermocouple:

- Used for temperature sensing in various ranges.

- Prone to corrosion, loose connections, and EMF interference.

- Research (e.g., Omega Engineering Manual, 2019) emphasizes the importance of periodic inspection and

recalibration.

3. Load Cell:

- Measures force and weight with high precision.

- Affected by overload, moisture, and cable fatigue.

- IEEE papers highlight the significance of routine testing and environmental sealing.
4. Stroboscope:

- Measures RPM or motion by flash synchronization.

- Requires accurate timing circuitry and clean lens conditions.

- Maintenance practices like battery checks, lens cleaning, and circuit verification are essential.

 Problem Identification:

- Instruments often show inconsistent readings due to neglect or improper maintenance.

- There is no centralized log or reminder system to track servicing dates.

- Calibration schedules are not automated, increasing human error chances.

- Students often lack awareness of equipment handling and care practices.

 Problem Specification:

The project aims to:

1. Identify common issues and failure patterns in MEM lab kits like LVDT, Thermocouple, Load Cell, and

Stroboscope.

2. Provide guidelines and maintenance protocols for each instrument.

3. Help instructors and lab assistants track instrument health and reduce repair costs through preventive care
 Detailed Methology
 Measuring Parameter Kits :-
1. Stroboscope: -

What is stroboscope? Working , Construction & Application

Stroboscope is a simple, portable, manually operated device used for
measurement of periodic or rotary motion.
Stroboscope Principle of Working
If a strong light is caused to flash on the moving object, the object will appear stationary, if
the flashing frequency is equal to speed of moving object. In other words, working principle
of stroboscope is "To synchronize a flashing light with rotation of shaft, making it appear as
standstill (stationary)."

Condition of Stroboscope
Frequency of flashing light should be equal to angular speed of shaft. Therefore, we need a
source of light, having provision of changing flashing frequency of light emitted.
Stroboscope or light source emits light radiations on the circular disc.

Construction of Stroboscope
Basically, stroboscope is a source of variable frequency flashing brilliant light (see Figure 1).
The flashing frequency can be set manually by the operator. Thus, in short, stroboscope
consists of a source of flashing light, whose frequency can be varied or controlled. This
source is called as Strobotron. A distinct or reference mark is made (put) on the shaft
(rotating body), whose speed is to be measured.
Working of stroboscope

The stroboscope is made to strike light on the mark. Circular (Rotary) knob is rotated
manually and flashing frequency of light is adjusted, until mark appears stationary. When
this condition is achieved, it means that, flashing frequency of light is equal to angular speed
of shaft. Rotation of circular knob can be read from the scale of stroboscope, which is
directly calibrated to give angular speed of shaft in r.p.m.

Default find in stroboscope :- 1) Resistor 50 / 5k replacement

2) 1 volt 2 Resistor

Fig.Resistor

SPECIFICATION

 5K resistor

 There are three important parameters that specify a resistor: value, tolerance, and

power rating.

 Standard resistors have four color bands. Three of the bands tell you the nominal

value, which means the value the resistor was designed to have. The fourth band tells

you the tolerance of the resistor, which indicates how far off the nominal value the

actual resistance could be.

 Precision resistors, which have more precise values than standard resistors, have five

color bands. Four of the bands tell you the nominal value. The fifth band tells you the

tolerance.
Procedure

1. Identify the Faulty Resistor: Visually inspect the circuit board for burnt or damaged

resistors. Use a multimeter to check the resistance values and confirm any discrepancies.

2. Note the Specifications: Before removing, note the resistor's specifications: resistance

(ohms), tolerance (%), and power rating (watts). For example, a 5KQ resistor rated at 50V.

3. Desolder the Faulty Resistor: Use a soldering iron and desoldering pump or braid to

remove the faulty resistor without damaging the circuit board.

4. Install the New Resistor: Insert the new resistor, ensuring it matches the original

specifications. Solder it in place, making clean and secure connections.

5. Inspect Your Work: Check for any solder bridges or loose connections. Ensure the resistor

is properly seated and that there are no short circuits.

6. Reassemble and Test: Once everything is in place, reassemble the stroboscope. Plug it in

and test its functionality, observing for proper operation.

2.Load cell :-

What is a Load Cell?

A load cell is a force transducer, by measuring force or weight through deflection. There are

several varieties of load cells, including strain gauge, hydraulic, pneumatic, and mechanical

versions.

Minimum Theoretical Background-

Load cell translate force into electrical signals, load cells are force transducers. Load cells

are made consisting of a steel cylinder with four identical strain gauges installed on it. Strain

gauges are extremely thin, heat-treated metallic foils that are chemically linked to a thin

layer of elastic material. The Wheatstone bridge circuit's four limbs are linked to these four

gauges.

Fig.Load cell
Working of load cell

When the load is applied to the body of a resistive load cell as shown above, the elastic

member, deflects as shown and creates a strain at those locations due to the stress applied.

As a result, two of the strain gauges are in compression, whereas the other two are in tension

as shown in below animation

During a measurement, weight acts on the load cell's metal spring element and causes

elastic deformation

This strain (positive or negative) is converted into an electrical signal by a strain gauge (SG)
installed on the spring element. The simplest type of load cell is a bending beam

with a strain gauge.

Default find in load cell :- 1) whole kit replaced

2) load cell changed
1) whole kit replaced

Fig. Circuit Diagram

The four strain gauges are configured in a Wheatstone Bridge configuration with four

separate resistors connected as shown in what is called a Wheatstone Bridge Network.

An excitation voltage – usually 10V is applied to one set of corners and the voltage

difference is measured between the other two corners. At equilibrium with no applied load,

the voltage output is zero or very close to zero when the four resistors are closely matched in
value. That is why it is referred to as a balanced bridge circuit.

When the metallic member to which the strain gauges are attached, is stressed by the

application of a force, the resulting strain – leads to a change in resistance in one (or more)

of the resistors. This change in resistance results in a change in output voltage. This small

change in output voltage (usually about 20 mVolt of total change in response to full load)

can be measured and digitized after careful amplification of the small milli-volt level signals

to a higher amplitude 0-5V or 0-10V signal.

These load cells have been in use for many decades now, and can provide very accurate

readings but require many tedious steps during the manufacturing process

2) load cell change

Fig. Load cell

Procedure
a. Make connections to load cell

b. Switch ‘ON’ unit

c. Check initially the output in ‘Zero’

d. Put dead weights on platform

e. Note readings Increase load on load cell

g. Take five readings with specific load

3) Thermocouple :-

What is a Thermocouple?

The thermocouple can be defined as a kind of temperature sensor that is used to measure the

temperature at one specific point in the form of the EMF or an electric current. This sensor

comprises two dissimilar metal wires that are connected together at one junction. The

temperature can be measured at this junction, and the change in temperature of the metal

wire stimulates the voltages.

The amount of EMF generated in the device is very minute (millivolts), so very sensitive

devices must be utilized for calculating the e.m.f produced in the circuit. The common

devices used to calculate the e.m.f are voltage balancing potentiometer and the ordinary

galvanometer. From these two, a balancing potentiometer is utilized physically or

mechanically.

Thermocouple Working Principle

The thermocouple principle mainly depends on the three effects namely Seebeck, Peltier,
and Thompson.

See beck-effect

This type of effect occurs among two dissimilar metals. When the heat offers to any one of

the metal wires, then the flow of electrons supplies from hot metal wire to cold metal wire.

Therefore, direct current stimulates the circuit.

Peltier-effect

This Peltier effect is opposite to the Seebeck effect. This effect states that the difference of

the temperature can be formed among any two dissimilar conductors by applying the

potential variation among them.

Thompson-effect

This effect states that as two disparate metals fix together & if they form two joints then the

voltage induces the total conductor’s length due to the gradient of temperature. This is a

physical word that demonstrates the change in rate and direction of temperature at an exact

position.

Construction of Thermocouple

The construction of the device is shown below. It comprises two different metal wires and

that are connected together at the junction end. The junction thinks as the measuring end.

The end of the junction is classified into three type’s namely ungrounded, grounded, and

exposed junction
How Does a Thermocouple Work?

The thermocouple diagram is shown in the below picture. This circuit can be built with two

different metals, and they are coupled together by generating two junctions. The two metals

are surrounded by the connection through welding.

In the above diagram, the junctions are denoted by P & Q, and the temperatures are denoted

by T1, & T2. When the temperature of the junction is dissimilar from each other, then the

electromagnetic force generates in the circuit.

If the temperate at the junction end turn into equivalent, then the equivalent, as well as

reverse electromagnetic force, produces in the circuit, and there is no flow of current through

it. Similarly, the temperature at the junction end becomes imbalanced, then the potential

variation induces in this circuit.

The magnitude of the electromagnetic force induces in the circuit relies on the sorts of

material utilized for thermocouple making. The entire flow of current throughout the circuit

is calculated by the measuring tools.

Thermocouple Type

Type J – It is a mix of Iron/Constantan. This is also the most used type of thermocouple. It

has the features of enhanced reliability, preciseness, and inexpensive. This device can be

operated only for lesser temperature ranges and has a short lifespan when operated at a high

range of temperatures.
The temperature ranges are:

Thermocouple grade wire – -346F to 1400F (-2100C to 7600C)

Extension wire (00C to 2000C)

This J-type has an accuracy level of

Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C or 0.4%

Procedure

1. Immerse Thermocouple hot junction and cold junction

2. Place Thermometer at hot pot

3. Keep system in ‘ON’ position for 10 minutes

4. Note down the temperature of Thermometer and indicator

5. Note down the EMF reading with the help of Multi meter.

Default find in thermocouple kit :- 1) thermocouple telipot changed

 2) kit 741 Amplifier base Changed

1) thermocouple telipot changed

Fig. Thermocouple telipot

It is a mix of Iron/Constantan. This is also the most used type of thermocouple. It has the

features of enhanced reliability, preciseness, and inexpensive. This device can be operated

only for lesser temperature ranges and has a short lifespan when operated at a high range of

temperatures.

2) 741 Amplifier base Changed

 Fig. 741 Amplifier base

The 741 operational amplifier can be utilized to amplify the small voltage output from a

thermocouple, enabling accurate temperature measurements. Thermocouples generate a

voltage proportional to the temperature difference between the hot junction and the cold

junction, typically in the range of millivolts

The amplified output from the 741 op-amp can be used for temperature measurement,

control, or monitoring applications, providing a useful solution for various industrial and

laboratory settings.
4) LVDT( Liner Variable Displacement Tranducer)

What is LVDT?

Linear Variable Differential Transformer, LVDT is the most used inductive transducer for

converting translating linear motion into electrical signal. This transducer converts a

mechanical displacement proportionally into electrical signal.

Construction:

LVDT is a transformer consisting of one primary winding P and two secondary

winding S1 & S2 mounted on a cylindrical former. The two secondary winding have equal

number of turns and placed identically on either side of the primary winding as shown in

figure below.
A movable soft iron core is placed inside the former. Actually the movable core is made of

nickel iron with hydrogen annealed. Hydrogen annealing is done to eliminate harmonics,

residual voltage of core and thus provides high sensitivity. The movable core also is

laminated in order to reduce eddy current loss. The assembly of laminated core is placed in a

cylindrical steel housing and end lids are provided for electromagnetic and electrostatic

shielding. The displacement to be measured is attached to this movable soft iron core.

LVDT- Working Principle:

Since the primary winding of Linear Variable Differential Transformer (LVDT) is supplied

with AC supply, it produces an alternating magnetic flux in the core which in turn link with

the secondary winding S1 and S2 to produce emf due to transformer action. The electrical

equivalent circuit of LVDT is shown below.

Let us assume that the emf produced in secondary winding S1 is Es1 and that in S2 is Es2. The
magnitude of Es1 and Es2 will depend upon the magnitude of rate of change of flux (dØ / dt)

as per the Faraday’s Law. The lower the value of ‘dt’, the more will be the emf induced. But

lower value of ‘dt’ means that core is moving faster. Thus we can say that the faster the

movement of core, the greater will be the magnitude of emf induced in secondary windings.

To get a single output voltage from the Linear Variable Differential Transformer (LVDT),

both the secondary winding are connected in series but in phase opposition as shown in

figure below.

Due to this connection, the net output voltage E0 of the LVDT is given as below.

E0 = Es1 – Es2

Since the secondary windings of LVDT are identical and placed symmetrically on either side

of core, therefore under normal position the flux linkage of both the secondary winding S1 &

S2 will be same. This means Es1 = Es2 and hence net output voltage E0 of LVDT = 0. This

position of soft iron core is called NULL position. Thus NULL position of Linear Variable

Differential Transformer is the normal position of movable core where the net output voltage

is zero

Now, as the core can either be moved toward right or left to the null position. Let us now
consider such movement of core under two cases.

Procedure

1. Connect the power supply chord at the rear-panel to the 230V 50Hz supply.

2. Switch ON the instrument by pressing down the toggle switch. The display glows to

indicate the instrument is ON.

3. Allow the instrument in ON position for 10 minutes for initial warm-up.

4. Rotate the micrometer till it reads "20.0."

5. Adjust the potentiometer at the front panel so that the display reads "10.0"

6. Rotate the core of micrometer till the micrometer reads "10.0"

7. Adjust the ZERO potentiometer till the display reads "00.0."

8. Rotate back the micrometer core upto 20.0

9. Adjust once again Potentiometer till the display read.

10. As the core of LVDT moves the display reads the displacement in mm.

11. Rotate the core of the micrometer in steps of 1 or 2 mm

12. Tabulate the readings and Plot the graph of Actual V/s indicator readings.
Default Find in LVDT :- 1) 741 IC Changed

2) wire soldering

1) 741 IC Changed

The 741 operational amplifier (op-amp) is a widely used integrated circuit (IC) that provides
high gain, high input impedance, and low output impedance. It is a general-purpose amplifier
suitable for various applications.

Key Specifications
- Input Offset Voltage: 1-6 mV (typical)
- Input Bias Current: 80-500 nA (typical)
- Input Offset Current: 20-200 nA (typical)
- Gain Bandwidth Product: 1 MHz (typical)
- Slew Rate: 0.5 V/μs (typical)
- Operating Voltage Range: ±3V to ±18V

2) wire soldering

Restoring Circuit Functionality

As I work on repairing the circuit, I notice that some wires have become disconnected from

their terminals. To get the circuit up and running again, I'll use my soldering skills to

reconnect the wires.

The Soldering Process

I'll carefully clean the terminals and wire ends, apply a suitable soldering flux, and then use
my soldering iron to melt the solder, forming a strong bond between the wire and terminal.

I'll make sure to apply the right amount of heat and solder to create a reliable connection.

Ensuring a Job Well Done

By soldering the disconnected wires, I'm confident that I'll be able to restore the circuit's

functionality and ensure it operates correctly. I'll double-check my work to guarantee a

strong and reliable connection, getting the circuit back to its optimal state.

Result & Discussion

Observation and Calculations of Stroboscope :-

Sr. Actual Speed Using Stroboscope Reading Error (rpm)

No. tachometer (rpm) (A) (rpm) (A – B)

(A)

Observation and Calculations of Load cell :-

Sr. Applied Load (Kg) Output Load Cell Difference (Kg)

No. (A) Reading (A-B)

(Kg) (B)

Observation and Calculations of Thermocouple :-

Sr. Indicator Reading EMF generate Actual Temperature

No. using Millivolts by Thermometer C

Thermocouple

3
 4

Observation and Calculations of LVDT :-

Sr. Actual Micrometer Indicator Reading Error (mm) % Error

No. Reading (mm) (LVDT)(mm)

Error = (Actual Scale Reading - Indicator Scale Reading)

% Error = (Error/ distance of Step) *100

Conclusion
 The maintenance of various measuring parameter kits is crucial for

ensuring the accuracy, reliability, and longevity of these essential tools. Through

this project, we have emphasized the importance of regular calibration,

preventive maintenance, and prompt repairs to minimize downtime and optimize

performance.

By implementing a comprehensive maintenance program, industries and

laboratories can ensure that their measuring parameter kits continue to provide

accurate and reliable measurements, ultimately contributing to improved

productivity, reduced costs, and enhanced data integrity.

The project's focus on maintenance strategies, troubleshooting, and repair

techniques will help extend the lifespan of measuring parameter kits, reduce

errors, and ensure the quality of measurements. By prioritizing maintenance,

organizations can protect their investments in these critical tools and maintain

the highest standards of quality and reliability.

Reference
1. Bently, D. E., & Hatch, C. T. (2003). Fundamentals of Rotating Machinery

Diagnostics. Bently Pressurized Bearing Company.

2. Omega Engineering. (2019). Thermocouple Theory and Application Manual. Omega

Engineering Inc.

3. IEEE Papers. Various publications on load cell testing and environmental sealing

(specific paper not cited—add DOI or title if known).

4. LABORATORY MANUAL FOR METROLOGY AND MEASUREMENT (313316),

Government Polytechnic Jalna.

5. Shree Electronics Shop – Local supplier reference for components.

6. https://instrumentationtools.com/bridge-circuit-construction/ – Source for Wheatstone

bridge and load cell circuit understanding.

7. https://instrumentationtools.com/strain-gauge-load-cell/ – Guide to strain gauge load

cell setup and procedure.

8. https://www.elprocus.com/current-sensor/ – Information on Seebeck, Peltier, and

Thompson effects in thermocouples.

9. https://etrical.blogspot.in/2016/09/basics-of-magnetic-circuit.html – Reference for

magnetic circuits.

10.https://electricalbaba.com/wp-content/uploads/2018/02/LVDT-2BNUL-2Bposition.jpg

– LVDT image and explanation.

11.https://etrical.blogspot.com/2017/11/faradays-law-electromagnetic-induction.html –

Faraday's Law reference for LVDT explanation.