LINKK BUSWAY SYSTEMS SDN BHD

Holes can also made from another machine which is hole punching machine

After epoxy procedure, the wrapping papers at the conductor area are removed

Cutting

Dimension of cutting is standardize as shown below

• R and N - extra 14mm
• Y and B - extra 2mm
• Earthing - extra 22mm

If it the dimension is 200mm lesser than standard dimension, it means it requires joint for connections

Washing and Cleaning

Welding and Grinding

• Welding procedure is done when there are connections of metals at different angles are needed

Metal adjusting procedure before welding

Welding process

• Metal has oily and dusty surface

• it is cleaned with soap and then proceed with clean water rinsing, at last, drying.

• it needs to be cleaned in order to have better results in epoxy procedure

Welded metals before grinding process

Removal of protruded materials

Grinding process to smoothen the welded material

Stock Storage Area

Stock Arrival and Storing

After Stamping

Stamped metal

During Stamping

Shearing Machine (Copper)

Stamping

Drilling Process in making holes

Before Stamping

Hole Punching Machine

Cutting, Drilling and Bending

JIH- I 8CD (copper and aluminium)

• stocks that are newly arrived are stored in store room (tiny units), and outside store room (large unit, e.g: metals)

• every stocks acquiring requires record for reference

• the stamping procedure is similar for both aluminium and copper
• the stamping is required to make sure each flange end gap between each others are 12mm.
• Thus, R and N metal stamped with 18mm whereas Y and B metal stamped with 6mm
• Earthing metal stamped with 26mm
• Flange end dimension shall be approximately 68.5mm for R,Y,B,N
• Earthing end dimension is 69mm

Bending Machine

JIH- I 8A (aluminium)

1) 3 types of cutting machine

• Shearing Machine (Copper)
• JIH- I 8CD (Copper/ Aluminium)
• JIH- I 8A (Aluminium)

2) Drilling Machine

• mainly used for hole drilling or removal of unwanted parts

3) Bending Machine

• used to bend metals

Conductor Area Wrapping using Gloves

Conductor Area Wrapping

• Before proceed with epoxy procedure, conductor area is wrapped

• It prevents the epoxy affects the conductor area

• the cellophane tape and glove are used as the material for wrapping

Production Process

Labelling

IP 65

Dust Tight

Protection against jets of water, limited ingress permitted.

LINKK BUSWAY SYSTEMS (M) SDN BHD

3P4W+50%E

3 phase 4 way 50% earth

Epoxy and Testing

LV 1 KV AND BELOW

low voltage 1kV and below

1) Stocks Arrival and Storing

2) Cutting, Drilling and Bending

3) Welding and Grinding

4) Stamping

5) Washing and Cleaning

6) Conductor Area Wrapping

7) Epoxy and Testing

8) Colouring

9) Assemble and Testing

10) TOU Box

11) Packaging

12) Labelling

LK-129-1-01-R4-01

Removal of glue and dirt using pocket knife

BoQ Number for reference

• After the removal of wrapping papers and tape, workers are required to remove the melted glue around the conductor area

• Glue has bad effect for the colouring of flange end thus it must be cleared

• Metals are then tested to check any holes at the epoxy area to avoid leakage of current

Meter reading shown for the holes detection test after epoxy procedure

E

Conductive Brush used for scanning of holes during the test

N

Y

R

B

Epoxy and Testing

Presenter: Tang Kee Cheong

In epoxy process, the procedure is shown below:

• metals put into the first oven (210 degree celcius - 1 hour)
• metals taken out to be dipped into epoxy pool
• metals put into second oven, approximately 200 degree celcius for 1 hour 15 minutes when Papillon powder is used, 230 degree celcius for 50 minutes when platinum phase powder is used)

Thank You

226 degree Celcius on the second oven during the epoxy procedure

207 degree Celcius on the first oven during epoxy procedure

Packaging

Colouring

TOU BOX

• After all the necessary tests done, the completed model will be packaged with woods and stored

• The packaged stock are ready to be shipped

• No colouring machine in factory

• Metals sent to other factory for colouring

• Silver colour is used

Assemble and Testing

Riveting procedure in housing formation

• There are many materials contained in the TOU Box

• However the materials are mainly from outsource

• The materials are assembled by workers to form a fully functional TOU Box

Applying polyester on the housing as insulator

Before Colouring

After Colouring

Insertion of R,Y,B,N and E to the housing

• In assembly area, workers start to unwrap the materials obtained from the coloured metals as well as getting materials needed from the store for assemble process

Process of assemble are listed below:

1) Formation of housing of busduct

2) Insertion of RYBN and E to the housing

3) Addition of joint connection for shorter busduct

4) 5kV Testing on assembled busduct

Medium TOU Box

Small TOU Box

Matching the dimension of conductor area

Riveting the top cover of the flange end elbow feeder

Connections of cable for 5kV test

Joint of feeders

Parameters used for the testing procedure