Bel Report

TRAINING REPORTOF SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN AT “BHARAT ELECTRONICS LIMITED, Panchkula” SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN ELECTRONICS AND COMMUNICATION ENGG. Submitted By: Name: Amber Bhaumik UPT No.: 5594/13 College: Chitkara Inst. of Engg. & Tech., Rajpura Under the Guidance of: Name: Anish Chauhan Desig.: Sr. Asstt. Engineer Department: HRD BHARAT ELECTRONICS LIMITED (A GOVT. OF INDIA ENTERPRISE, MINISTRY OF DEFENCE) 405, INDUSTRIAL AREA, PHASE-III PANCHKULA – 134113 (HARYANA) ACKNOWLEDGEMENT I am highly grateful to Bharat Electronics Limited Panchkula, one of the leading defense organizations of the nation, for providing me an opportunity to undertake six weeks training at their manufacturing premises at Panchkula, Haryana. It was a great learning experience as I was introduced to various aspects of the working of the organization, the latest state of the art technologies & machines used in the manufacturing processes. It was wonderful to see the company striving hard to keep up the national security at par with the rest of the world. I would like to express my sincerest gratitude towards Mr. Anish Chauhan (Sr. Assistant Engineer) and Mr. Pankaj Singhal (Manager, Work Assembly Section) for their regular support and guidance that helped me in successful completion of my six weeks training. At the end I would like to thank all the staff members of BEL, Panchkula who made this training a rich learning experience. 1 PREFACE With the ongoing revolution in electronic & communication where innovations are taking at the blink of eye, it is impossible to keep the pace with the emerging trends. Excellence is an attitude that whole of human race is born with. It is the environment that makes sure that whether the result of this attitude is visible or otherwise. A well planned, properly executed and evaluated industrial training helps a lot in including a professional attitude. It provides a linkage b/w the student and industry to develop an awareness of industrial approach to problem solving, based on broad understanding of process and mode of operation of organization. During this period, the student gets the real experience for working in the actual industry environment. Most of the theoretical knowledge that has been gained during the course of their studies is put to test here. Apart from this the student gets an opportunity to learn the latest technology, which is immensely helps in them in building their carrier. I had the opportunity to have a real experience on many ventures, which increased my sphere of knowledge to great extent. I got a chance to learn many new technologies and was also interfaced to many instruments. And all this credit goes to organization Bharat Electronics Ltd. CONTENTS 2 CHAPTER PAGE NO. 1. INTRODUCTION......................................................................................................................2 2. COMPANY PROFILE................................................................................................................4 3. MAUFACTURING UNITS........................................................................................................8 4. PRODUCTS & MARKET OF BEL.........................................................................................12 5. BEL PANCHKULA & ITS PRODUCTS.................................................................................16 6. DEPARTMENTS & FUNCTIONS...........................................................................................29 6.1 DEVLOPMENT AND ENGINEERING........................................................................29 6.2 MANUFACTURING......................................................................................................29 6.3 MATERIAL MANAGEMENT.......................................................................................30 6.4 MARKETING.................................................................................................................30 6.5 QUALITY ASSURANCE...............................................................................................30 6.6 PLANT & SERVICES....................................................................................................31 6.7 HUMAN RESOURCE & ADMINISTRATION.............................................................31 6.8 FINANCE & ACCOUNTS.............................................................................................31 6.9 INFORMATION SYSTEMS..........................................................................................31 6.10 QUALITY MANAGEMENT........................................................................................32 7. SUB DEPARTMENTS..............................................................................................................34 7.1 PRODUCTION, PLANNING & CONTROL..................................................................34 7.2 ADVANCED MANUFACTURING FACILITY.............................................................34 7.3 WORK ASSEMBLY........................................................................................................43 7.4 TESTING & INSPECTION.............................................................................................44 8. RESULTS & DISCUSSIONS...................................................................................................46 CONCLUSION BIBLIOGRAPHY 3 CHAPTER 1 1 . I got a chance to learn many new technologies and was also interfaced to many instruments. but for an industry it is most important and can be defined as ―The totality of features and characteristics of a product / services that bear on its ability to satisfy given needs. I had the opportunity to have a real experience on many ventures.INTRODUCTION With the ongoing revolution in the field of electronics & communications where innovations are taking place at the blink of an eye. It provides a linkage between the student and industry to develop an awareness of industrial approach to problem solving. Most of the theoretical knowledge that has been gained during the course of their studies is put to test here. 2 . the student gets the real experience for working in the actual industry environment. which increased my sphere of knowledge to great extent. properly executed and evaluated industrial training helps a lot in including a professional attitude. And all the credit goes to organization Bharat Electronics Ltd. During this period. Apart from this the student gets an opportunity to learn the latest technology. it is impossible to keep the pace with the emerging trends. A well planned. The word quality holds out different meaning for different people. based on broad understanding of process and mode of operation of organization. It is the environment that makes sure that whether the result of this attitude is visible or otherwise. Excellence is an attitude that whole of human race is born with. which is immensely helps in them in building their carrier. CHAPTER 2 3 . manufacture of Frigate Radars for the Navy began. The following year.COMPANY PROFILE Bharat Electronics Limited (BEL) is a state-owned electronics company with about nine factories. BEL set up a Radar manufacturing facility for the Army and in-house R&D. In 1966. by the Government of India under the Ministry of Defence in 1954 to meet the specialised electronic needs of the Indian defence services. with which BEL has kept pace. Bharat Electronics Limited (BEL) was set up at Bangalore. facilities for manufacture of Integrated Circuits and Hybrid Micro Circuits were set up. and few regional offices in India. Under the government's policy of decentralization and due to strategic reasons. In 1980. BEL ventured to set up new Units at various places. The third Unit was established at Pune in 1979 to manufacture Image Converter and Image Intensifier Tubes. The growth and diversification of BEL over the years mirrors the advances in the electronics technology. It has even earned the government's Navratna status. Germanium Semiconductors in 1962 and Radio Transmitters for AIR in 1964. India. Silicon Devices and Integrated Circuits started in 1967. BEL is among an elite group of public sector undertakings which have been conferred the Navratna status by the Government of India. Manufacture of Transmitting Tubes. The PCB manufacturing facility was established in 1968. The second Unit of BEL was set up at Ghaziabad in 1974 to manufacture Radars and Tropo communication equipment for the Indian Air Force. it has grown into a multi-product. It is owned by the Indian Government & primarily manufactures advanced electronic products for the Indian Armed Forces. manufacture of Black & White TV Picture Tube. In 1970. BEL's first 4 . which has been nurtured over the years. multi-technology. The following year. Government Of India.BEL is one of the eight PSUs under Ministry of Defence. multi-unit company serving the needs of customers in diverse fields in India and abroad . 1972 saw BEL manufacturing TV Transmitters for Doordarshan. X-ray Tube and Microwave Tubes started. Over the years. Starting with the manufacture of a few communication equipment in 1956. BEL went on to produce Receiving Valves in 1961. The Space Electronic Division was set up at Bangalore to support the satellite programme in 1982. The first disinvestment (20%) and listing of the Company's shares in Bangalore and Mumbai Stock Exchanges took place the same year. The same year saw BEL achieve a turnover of Rs. 1985 also saw BEL manufacturing on a large scale Low Power TV Transmitters and TVROs for the expansion of Doordarshan's coverage. In 1981. the fifth Unit was set up in Chennai for supply of Tank Electronics. Recently this became a subsidiary of BEL with the exit of the foreign partner and has been renamed BEL Optronic Devices Limited. The second Central Research Laboratory was established at Ghaziabad in 1992. the eighth Unit to manufacture TV Glass Shell at Taloja (Navi Mumbai) and the ninth Unit at Hyderabad to manufacture Electronic Warfare Equipment.overseas office was set up at New York for procurement of components and materials.000 Electronic Voting Machines. The first Central Research Laboratory was established at Bangalore in 1988 to focus on futuristic R&D. In 1996. In 1997. a separate Naval Equipment Division was set up at Bangalore to give greater focus to Naval projects.100 crores. USA. the Joint Venture Company with M/s GE. The year 5 . with M/s Delft of Holland was signed in 1990. 1986 witnessed the setting up of the seventh Unit at Kotdwara to manufacture Switching Equipment. BEL Units obtained ISO 9000 certification in 1993-94. In 1983. 1989 saw the manufacture of Telecom Switching and Transmission Systems as also the setting up of the Mass Manufacturing Facility in Bangalore and the manufacture of the first batch of 75. a manufacturing facility for Magnesium Manganese Dioxide batteries was set up at the Pune Unit. The second disinvestment (4.000 crores turnover. In 1998. GE BEL. an ailing Andhra Scientific Company (ASCO) was taken over by BEL as the fourth manufacturing Unit at Machilipatnam. The agreement for setting up BEL's first Joint Venture Company.14%) took place in 1994. In 1985. with proximity to HVF. BEL set up its second overseas office at Singapore to source components from South East Asia. BEL achieved Rs. The sixth Unit was set up at Panchkula the same year to manufacture Military Communication equipment. In 1987. was formed.1. BE DELFT. Avadi. BEL shares were listed in the National Stock Exchange. In June 2007. BEL became the first defence PSU to get operational Mini Ratna Category I status. being reorganized into Strategic Business Units (SBUs).2000 saw the Bangalore Unit. 6 . In 2002. There are seven SBUs in Bangalore Unit. The same year. BEL was conferred the prestigious Navratna status based on its consistent performance. which had grown very large. CHAPTER 3 7 . 6. 5. 4. 7. 2. 9. 8. 1.MANUFACTURING UNITS BEL has a total of nine manufacturing complexes spread throughout the nation with Banglore being the biggest of them. The details about the different manufacturing units of BEL along with their product specialities are a s follows:Sr. 3. COMPLEX Ghaziabad Panchkula Navi Mumabi Kotdwara Pune Hyderabad Banglore Machlipatnam Chennai STATE Uttar Pradesh Haryana Maharashtra Uttaranchal Maharashtra Andhra Pradesh Karnatka Andhra Pradesh Tamilnadu 8 . No. Satellite launch vehicle was also manufactured here.  Resistors & black & white color TV picture tube glasses. X-ray tubes Batteries Electro-optics 9 . one dimensional. Among the products here.  Radar-mobile. The locations & products of the units are given below:1.In 1954 with a factory of Jallahali. Bharat Electronics grew into nine units.000 employees working here. PUNE: To diversify further one more branch was added 1979 & this was in Pune. This is the biggest unit with approx.  ISRO‘s requirements are met at space electronics department at Bangalore. The product profile includes:     Image convertor. spread all over India. & approx. Radars & some communication equipment are The products manufactured here are:    Radars SATCOM Microwave components 3. Jallahali unit which is the mother unit is now a part of the BG Complex. the important ones are:  Communication equipment  Air & Doordarshan equipment like mobile van for live telecast etc. 3-dimensional & multi-dimensional Radars are manufactured here. GHAZIABAD: This is the second unit which was set up in 1974. In this branch around 700-800 employees are working. BANGALORE: This is also called BG Complex. Different range of semi-conductor devices like ICs. 10. 2. image intensifier. 2500 employees working here. The products include:   Optical & optoelectronic equipment like binoculars. MACHLIPATNAM: There was one Andhra scientific company. microscopes Medical Electronics 5. multiplex equipments & exchanges etc.P. 10 . PANCHKULA: Panchkula & Kotdwara were proposed simultaneously by the Government in 1985. which was a sick unit. This was taken over by BEL & is called ASCO unit in 1983. But the place in U. This unit makes:  Glass shells for black & white TV picture tubes  Shelters for Electronic Equipment  Train Actuated Warning System  Electronic Equipment Assembly 6. This unit manufactures:   Tank related electronic equipments Optical fire control systems 9.4. 8. This unit manufactures radio relay. HYDERABAD: This is another unit of BEL which manufactures electronic warfare equipments. 7. CHENNAI: The eight unit of BEL was established in Chennai. for setting up a BEL unit could not be decided while that at Haryana was decided & hence this unit started earlier. KOTDWARA: This is a unit in Garhwal district of Uttaranchal. NAVI MUMBAI: This is an industrial place near Mumbai. It was proposed to set up one unit each in Haryana & Uttar-Pradesh. UHF transceivers etc. This unit manufactures only tactical communication equipment like VHF. CHAPTER 4 11 . BEL has been involved in providing state-of-the-art communication equipment to the Indian Army. ISRO Department of Telecommunication. the data to be transferred is first encrypted using a microprocessor which could be read only by a similar device with same coding. UHF. No. Oil Industry. Para. and V/UHF frequency bands.PRODUCTS & MARKET OF BEL Bharat Electronics Limited is a major supplier of products and turnkey systems to the Indian Defence Services. be it hand held mobile radios and terminals. BEL has diversified into manufacturing many civilian products as well. The most important project of BEL under the communication equipment is STARS-V which provides secure mode of data transfer.military forces. Meteorological Department. Para -Military Forces Indian Defence Services. Large turnkey telecommunication solutions are also being offered to civilian market. Telecommunication Radars STARS-V SECTEL CNR HUD LUP TIDEX SECURE FAX CUSTOMER Indian Defence Services . The communication equipment developed here cover HF. Radars & Sonars 3. In STARS-V. ground based systems. PRODUCT 1. Civil Aviation. Railways 12 . Now the latest technology of frequency hopping is being implemented which is a very useful tool in making a secure data transfer system. VHF. Defence Communication 2. Power Sector. BEL manufactures a lot of product which is very difficult to list but some of the major products were as follows: Integrated circuits and micro circuits X-ray tubes and magnetrons HF & broadcast equipment ACME MK II SPACE GUIDING EQUIPMENTS AIRBORNE GPS RECEIVER (UA-429) SRAX SECURE TELEPHONE DOMESTIC MARKET Sr. airborne and even ship borne equipment and systems. Over the years. Egypt. 6. Indonesia. Zimbabwe. 8. Turkey. Switching Industry. No. Broadcasting Equipment and Studio Systems Electronic Voting Machine Solar Products & Systems Turnkey Systems. Instrumentation Industry. Kenya. Israel.Police. Exports play a key role in BEL's strategic perspective. 3. UK. 7. 7. Public Sector Undertakings All India Radio and Doordarshan the National Radio & TV Broadcasters. 5. Nigeria Telecom and SATCOM Nigeria. equipment Malaysia and spare parts Radars & Sub-systems Indonesia. Microwave Netherlands. Kenya systems Radio & TV Broadcasting Nepal.4. (National Radio & TV Broadcasters) Election Commission Of India Individuals. 8. Singapore. Malaysia. Doordarshan. Hong Tubes and Transmitting Kong Tubes Solar Products & Systems Suriname. Governance Networks Components All India Radio. 2. Switzerland Electronic Warfare products Russia. EXPORTS/INTERNATIONAL MARKET PRODUCT CUSTOMER Defence Communication Botswana. Private and Government Organizations E. Nepal. 4. The broad list of products and services being exported is given below: Sr. Telephone Industry. France.. Suriname. Germany. South Africa Semiconductor devices. A number of International companies are using the facilities at BEL for contract Manufacturing. Mauritius products and Systems 13 . Entertainment Industry. 6. State Governments. Botswana. USA. 1. Brazil and services Opto-electronics products Sri Lanka. 5. Vacuum Interrupters Sri Lanka. UAE. Uganda. UK. South Africa Malaysia.9. Uganda. Malawi. Electronic Voting Systems 10. Turkey. Azerbaijan CHAPTER 5 14 . BEL PANCHKULA & ITS PRODUCTS Panchkula is a planned city in Panchkula District.00.000. It has a total employee strength of 600. The estimated population of Panchkula city. Exclusive use of EVMs across the length and breadth of a huge country like India came off splendidly and the unparalleled success of this bold and progressive experiment demonstrated to the rest of the world.Barwala Pinjore. It specialises in defence communication products and has recently started the manufacturing of RADARs also. It is a satellite city of the Union Territory of Chandigarh. the country's technological as well as grassroots democratic capabilities. About half a million of the EVMs deployed in these elections were designed. the Electronic Voting Machines have made an easy passage to India's hundreds of thousands of villages. The prestigious Chandimandir Cantonment Headquarters of the Indian Western Command. These three cities are collectively known as Chandigarh Tricity. The only Hill station in Haryana called Morni is also in this District. Kalka and Raipur Rani.May 2004 and elected a Government of their choice using the most powerful means of decision making in the world. The Electronic Voting Machine (EVM). in 2006. Haryana. manufactured and delivered by Bharat Electronics Limited (BEL). Electronic Voting Machines:The world's largest democracy with 671 million voters went to polls in April . is also located in Panchkula city. All these have been 15 . India. The complex at Panchkula is spread over an area of 63 acres. Today. is 2. Panchkula and Mohali (in Punjab) are two satellite cities of Chandigarh. Following are some of the important products manufactured by BEL Panchkula: 1. a Public Sector Enterprise of the Government of India. There is widespread awareness of its reliability and adaptability. There are five towns in the district named Panchkula. so also the political recognition. was indeed a landmark success for the application of technology for sustained development of society. The 2004 general elections in India. Intercom operation between radio 16 .VHF) is a family of fixed frequency and frequency hopping radio sets avai lable in 5W and 25W power output configurations. 2. voice secure and data modes. worked untiringly alongside the Indian Election Commission officials offering support and assistance for these activities and also during the elections. especially the overwhelming majority of those who live in the remote villages of India. The radios provide communication in voice clear. They can be controlled from a remote location upto 2 km. etc. STARS-V (Secure Tactical Army Radio System): STARS-V (Secure Tactical Army Radio System . where millions of voters cast their votes through the electronic voting machines and the results of which were declared in one single day. ensuring that the whole process succeeded and it is remarkable that there have been no problems with the machines worth speaking about. mass awareness programmes to educate voters.achieved through a series of meticulously planned events like exhaustive training to the polling officials. Technical experts from Bharat Electronics Ltd. All front panel controls (except ON/OFF) are extended using 2 wire cables to a Remote Control Unit (RCU) at the remote location. 97MHz) 2. External data interface is provided on the front panel to facilitate data communication with suitable modem.it consist of seven modules are given as ◦A2-Power amplifier ◦A417 . It is also possible to setup rebroadcast over two wires for voice clear mode only. The radios are fully modular in construction.set and RCU is also provided. The radio set can be configured for fully automatic rebroadcast operation. There are two power mode 5W. It is light in weight then the MARK-I. MARK –II:This is the modified stage of the MARK-I.And the major difference is frequency hopping is not possible.This set is heavy and the if any need repair then difficulty to find out the fault . 25W and the frequency range only used by army is (30-87. And the major difference is frequency hopping is possible. MARK –I:This is the first stage of STARS-V . STARS-V radios find use in Manpack as well as vehicular applications for providing voice and data communications in VHF frequency range of 30-88MHz There is two types of STARS-V:1. They are designed to perform in conformance to MIL 461class of EMI/EMC specifications. 88 MHz  2320 channels with 25 KHz spacing  1W/2W/5W/25W power outputs  Different models 250 hops per sec  Specifications Manpack / Vehicular roles Radio is based on DSP technology Frequency range of 30-88 MHz with 25 KHz channel spacing Supports 2320 channels with 10 preset channels and 10 hop sets Scan and BITE facility Automatic re-broadcast facility Direct serial data interface (RS-232C)Modular construction. The radio works in Anti-jam frequency hopping and fixed frequency modes with built-in high grade digital secrecy. Theradio supports both Voice and Data communication in clear as well as secure mode. CNR (Composite Net Radio) VHF Transrecievers (CNR) is a software controlled frequency hopping radio (Transmitter and Receiver)in the VHF frequency band of 30 – 88MHz the design of the radio is based on Digital Signal Processor (DSP) technology making use of Direct Digital Frequency Synthesis (DDFX).  VHF frequency range of 30 .Receiver card ◦A5Synthesizer Card ◦A11Fequency hoping card ◦A6controller card ◦A7-secure card ◦A8-display card 3. 18 . At the receiver end. The user can switch between clear and secure mode during the same call. SECTEL (Secure Telephone) Secure Telephone is a compact. It can operate over any standard voice channel of telephone networks like DOT hired mi l trunk single link circuits and STD channels.4. Speech is digitized using Linear Predictive Coding(LPC) technique and digitally encrypted by a highly complex crypto algorithm which ensures highest grade of secrecy. the encrypted data stream is demodulated decrypted and the original speech is synthesized. It replaces subscriber‘s normal telephone instruments. 19 . Key management is supported by Fill gun. full duplex digital Subscriber End Secrecy Device (SESD) providing highest grade of secrecy on normal telephone lines. It operates from 230 V AC mains using AC-DC adapter. The encrypted speech is transmitted over the telephone line using a Full Duplex QAS modem. Inbuilt Powerful Diagnosis feature (BITE) TX Inhibit (Sulk ) .4 kbps full duplex Memory dialling of 10 stored numbers Multifunction keypad for different functions Simple connectivity over standard two wire telephone lines 2 x 16 character LCD display to show the status LUP 291 is a UHF hand held radio with inbuilt high grade digital secrecy. Various programmable features like Scan.The operator interface is user friendly with minimum number of controls. Password etc. compact and light weight.5.2 V Primary & Secondary batteries Antennas : Helical and magnetic mount Complaint to MIL 461 EMI. 20 . The radio set has in-built mic and speaker. The radio set is state – of – the art design. The radio set is provided with helical and magnetic mount antennas. VOX headgear is also available as optional accessory for hands free operation. Clone . Erase and Whisper facilities7. Power Save. CTCSS frequency selection. SECURE UHF HANDHELD RADIO (LUP 291) High-grade speech secrecy Full duplex transmission in Secure and Clear mode Data rate 2. Interface is provided for Headgear and Crypto key loading . Continuous Tone coded squelches (CTCSS) RF Power Output: 5W /1 W (selectable). 4) To transmit a file. 7. go to transmit file menu.6. 2048 kbps. 1024. SMILE (Secure Multi Interface Link Encrypter) It is a bulk data traffic and radio relay with variable data rates of 64. 256. 128. 2) Secret ‗comport‘ on which the SEED connected to the pc and the main menu will be displayed. Description:1) Mother fillgun 2) Child fillgun 21 . full duplex secrecy deice. SEED (Subscriber End Encryption Device) It is compact. Description: 1) SEED Processor card PRGMD 2) Power supply card 3) Battery charger 4) Front panel card Application:1) Execute the application file provided for data communication. 3) Go to telephone dairy. 512. 384. 35 female interface card 8.Various card consist of SMILE: 1) PRGMD –controller card 2) PSU-card 3) Front panel card 4) V.35 male interface card 5) V. HUD (Head up display) The projection unit in a typical HUD is an optical collimator setup: a convex lens or concave mirror with a Cathode Ray Tube. This setup (a design that has been around since the invention of the reflector sight in 1900) produces an image where the light is parallel i. perceived to be at infinity. 22 . that redirects the projected image from projector in such a way as to see the field of view and the projected infinity image at the same time. The combiner is typically an angled flat piece of glass (a beam splitter) located directly in front of the viewer. or liquid crystal display at its focus.e. light emitting diode. the projection unit and the systems/data to be displayed and generates the imagery and symbols to be displayed by the projection unit.  Third Generation—Use optical waveguides to produce images directly in the combiner rather than use a projection system. Newer micro-display imaging technologies are being introduced including 23 .Combiners may have special coatings that reflect the monochromatic light projected onto it from the projector unit while allowing all other wavelengths of light to pass through.  Fourth Generation—Use a scanning laser to display images and even video imagery on a clear transparent medium. In some optical layouts combiners may also have a curved surface to refocus the image from the projector.  First Generation—Use a CRT to generate an image on a phosphor screen. which is modulated by an LCD screen to display an image. having the disadvantage of the phosphor screen coating degrading over time. for example LED.  Second Generation—Use a solid state light source. Generations HUDs are split into four generations reflecting the technology used to generate the images. These systems do not fade or require the high voltages of first generation systems. These systems are on commercial aircraft. The majority of HUDs in operation today are of this type. The computer provides the interface between the HUD (i.e. The radar detects and tracks short range air-to-ground threats with a high probability of detection. helicopters and fixed wing aircraft flying at low and medium altitudes. Liquid crystal on silicon (LCoS). It can be dismantled into packages to facilitate quick installation and re-location in mountainous terrain. Commander Display Unit (CDU) and messaging unit Target Designation Unit (TDU) and Target Data Receivers (TDR). classify and attain IFF status on every target in the battle space under surveillance.1. battery powered and compact sensor which provides 2D surveillance solution to alert Army Air Defence Weapon Systems mainly in mountainous terrain against hostile aerial targets like UAVs. confirm. One radar can service upto 10 TDRs using existing combat radio resources/ network. especially offensive EW environment. The radar with modular architecture. Digital micro-mirrors (DMD). animal transport or group of men or as helislung loads. 3. ruggedness as per Mil standards can be operated in varied conditions including extreme climatic and geographical conditions and in battle field situations. It will act as an early warner to air defence weapon systems employed to provide protection to vulnerable areas or vulnerable points. 24 . The radar can be transported by vehicles. The radar has an integrated IFF that can detect. Organic light-emitting diode (OLED). The CDU can be located upto 750m from the radar. 4. BHARANI RADAR Low level Light Weight 2D Radar . 2. RPVs. Liquid crystal display (LCD). advanced ECCM features. 9.BHARANI: is a light weight. The system consists of radar. azimuth and height information for each target with electronically steerable multi-beam technology in elevation. mountain tops and high altitude regions. Semi .ROHINI: ROHINI is a multifaceted ground based S-Band 3D Low Level Light Weight Surveillance Radar for deployment in diverse terrains like plains. Rohini detects and tracks heterogeneous air targets. DDS. deserts. digital receiver and programmable signal processor to provide 3D air space awareness with high accuracy. resolution and reliability. including helicopters. ROHINI RADAR Low level Light Weight 3D Radar . 25 .It has a range of 50 KMs and can operate at an altitude of 75 mtrs to 5400 mtrs. The radar can scan the valley. 10. It provides accurate range. It operates in L band. The radar sweeps 360° in azimuth and 30° in elevation to provide air space awareness. fighters and UAVs at low and medium altitudes.distributed active aperture radar uses advanced VLSI and high-speed digital technologies like high efficiency T/R modules. can be used in different innovative roles like air space surveillance in urban areas for VVIPs. group of men. The radar is easily re-locatable and can be deployed or decamped in less than 15 minutes. Multi ECCM features help the radar to deliver intended performance even under intense hostile EM environment.As all the main radar subsystems are on the rotating platform. this radar architecture obviates the two most common single point failures by dispensing with high power rotary joints and central transmitter. The remote operation of the radar through Commander's Display Unit (CDU) upto 1 km from the radar provides safety to the crew during operation. lightweight and modular. The quadri pod-mounted radar is built to operate in networked or stand-alone mode to support joint or independent operations by Air Force. 26 . thereby making the radar system extremely reliable. The facility also enables the Commander to deploy the radar at a tactically favourable point. or as an under slung carriage by a helicopter. large critical installations. The radar is engineered in multiple packages to enable easy transportability in mountainous terrain by vehicles. Rohini being compact. CHAPTER 6 27 . MFG (MANUFACTURING):  WA (WORK ASSEMBLY) – There are different types of work assembly i.  D&E CRYPTO – It is for designing of secure communication. Quality standards. Design manure. Module assembly.  WF (WORK FABRICATION) – It is the department for the mechanical work. 2. make the modifications to prepare design and related documents. They are:  D&E (DEVELOPMENT & ENGINEERING) – It is to design the project.  AMF (ADVANCED MANUFACTURING FACILITIES) – Advanced machines are used in the manufacturing of the projects as SMT (Surface Mounted Technology).DEPARTMENTS & FUNCTIONS BEL Panchkula has different divisions which are further divided into departments- 1.It is the Drawing office. Final assembly. it is 28 .  STDS (STANDARDS) –These are the standards for Drafting.  TIC (Technical Information Centre) – TIC is a library for designing purpose.  DRA OFFICE .e PCB assembly. D&E (Development and Engineering) This is a division which is further divided into departments. 29 .  TESTING – Products are tested by different tests  C TEST (CIPHER TEST) .an automatic system to mount the item on the PCB. PLANNING and CONTROL) – In this the work is planned.  IGS (INCOMING GOODS STORE)  MC (MATERIAL CONTROL) 4.  PPC (PRODUCTION.  TL (Technical Literature) – It is the booklet with the project having instructions.  PUR (PURCHASE DEPARTMENT) .It is the test for the secrecy.  PR (PUBLIC RELATION) –It is the relation with the customers.  FGS (FINISH GOODS STORE) – After finishing the project it is sent to FGS for final packing.This department purchases the materials.  SELF CERT (SELF CERTIFICATION) – It is the department which visits the place where work is going on. MKTG / PA (MARKETING / PRODUCT ASSURANCE):  MKTG (Marketing Division)  Sales – It is to prepare ESO equipment source order.  PS (PRODUCT SUPPORT) – It is done after sale services.  SC (SUB CONTRACT) 3.  ISM (INTEGRATED STORE MANAGEMENT)  HS (HOLDING STORE) – It has different bins that holds items after inspection.  PE (PRODUCTION ENGINEERING) – It is for the installation of the new machinery. MM (MATERIAL MANAGEMENT):  It is the management of the materials. Department for the sanction of money. F&A (FINANCE & ACCOUNT): FINANCE . 7.  AUDIT – Survey of the systems. (PERSONNEL) – In this department the recruitment of employees is done.The materials are checked before giving it to customers. horticulture. transport.  CRECHE  CANTEEN  WELFARE 8. (ESTABLISHMENT) – It is to use manpower in different areas. Services are water supply. electrical supply. 6.  ESTD. HR & A (HUMAN RESOURCES & ADMINISTRATION):  PERSON. P&S (PLANT AND SERVICES): It is the department for providing the services to company.  ACCOUNTS – It is the record of the money. QA (QUALITY ASSURANCE): It deals with the quality of the material.  BUDGET – It is made for one year.  INSP(WA) {INSPECTION IN WORK ASSEMBLY)  INSP(WF) {INSPECTION IN WORK FABRICATION)  R&E (RELIABILITY & EVALUATION) .5. 30 .  MEDICAL – Medical facilities are also available.  PAYROLL – It is the salary of the employees. Related to Salary.  IGI (INCOMING GOODS INSPECTION)  QCC (QUALITY CONTROL CIRCLE) – In this department there is a group of employees who discuss the problems.9.All Production Related work related to assy. 31 . General ledger etc. purchase etc. 10.  PAYROLL .  TES (TEST EQUIPMENT AND SUPPORT) – Calibration or measuring of instruments.  FINANCE . IS / MS (INFORMATION SYSTEMS):  MRP .Concerned with ledgers.stores.  6 SIGMA – It is the statistical Technique for maintaining Quality. QM (QUALITY MANAGEMENT):  ISO (INTERNATIONAL STANDARDS ORGANISATION) – It is to sell our products in the international market. sub-sidary ledgers. find out its solution and present it to manager. CHAPTER 7 32 . The management servicing department prepares the work order and gives it to PPC.e. 33 . it mainly performs three functions namely: Scheduling  Launching  Control The market section takes the order from the customer and gives the equipment stock order to PPC.SUB DEPARTMENTS PRODUCTION PLANNING AND CONTROL This sub-department forms the most important section among the others present because it forms the ‗backbone‘. Next function that comes is launched PPC prepares shop order and engineering documents such as drawings. Now PPC makes the list of each component involved in product. Right from the beginning till the end of the production of a particular set. Here the PPC keeps track of production i. the purchase requisition is given to purchase department and sub-contact department. The purchase now comes to the IGS (Inwards Goods Section) where it is tested in IGI. This function is called ―Launching‖. The pieces that are okayed are then stored in holding stores. This is called ―Scheduling‖. the responsibility lies in the hands of this section. Now comes material control. The stages involved are: 34 . in this department all the components are mounted on PCB‘s.ASSEMBLY SECTION /AMF (Advanced Manufacturing Facility) As the name suggests. It is one of the most important and technologically advanced department at BEL Panchkula. These PCB‘s are then sat properly in the complete set.It is divided into three sections: PCB assembly section  Coil winding section  Final assembly section First we will discuss in detail about the AMF section which uses the surface mounting technology to mount components on the PCBs a detailed structure of the complete AMF line is explained as follows: THE SMT LINE The various stages involved in the SMT in sequence are called the SMT line. Much of the pioneering work in this technology was by IBM. Components were mechanically redesigned to have small metal tabs or end caps that could be directly soldered to the surface of the PCB. passive and electromechanical components) SMT Surface-mount technology (assembling and mounting technology) SMA Surface-mount assembly (module assembled with SMT) SMC Surface-mount components (components for SMT) 35 .SURFACE MOUNT TECHNOLOGY Surface-mount technology was developed in the 1960s and became widely used in the late 1980s. Surface mounting lends itself well to a high degree of automation. and one-half to one-quarter the cost of equivalent through-hole parts. The design approach first demonstrated by IBM in 1960 in a small-scale computer was later applied in the Launch Vehicle Digital Computer used in the Instrument Unit that guided all Saturn IB and Saturn V vehicles. SMDs can be one-quarter to one-tenth the size and weight. reducing labour cost and greatly increasing production rates. Often only the solder joints hold the parts to the board. allowing much higher circuit densities. although parts on the bottom or "second" side of the board are temporarily secured with a dot of adhesive as well. Surface-mounted devices (SMDs) are usually made physically small and lightweight for this reason. Components became much smaller and component placement on both sides of a board became far more common with surface mounting than through-hole mounting. Expanded Forms SMD Surface-mount devices (active. This is the first step of SMT line It has five magazine to load pcb and each magazine has a maximum capacity of 50 pcb.SMP Surface-mount packages (SMD case forms) SME Surface-mount equipment (SMT assembling machines) 1. Loader MODEL: ―L-SIZE‖ MAKE: ―AUTOVEYOR‖ Loader as the name suggest load the pcb on which component are to be mounted. The height is 930 mm from the ground 2. Stencil Printer 36 . 37 .Make: ―DEK‖ Model: ―ELA-VI Huge print area capability The huge print area capability allows printing up to 1200mm x 400mm. or 350 x 350 mm to 736x 736 mm (for SP600L). Vertical Separation of Stencil from PCB 4 corner ball screw system provides excellent separation control of stencil for high quality solder paste printing Programmable Speed Control for both squeegee movement and stencil separation Dual Camera system for quick PCB alignment. It accepts standard SMT frame sizes from 350 x 350 mm to 1480 x 500 mm (for SP1200). MELF. mini MELF. CPS Fine pitch component up to 12 MIL Heads: Hydra Head (8 Nozzles) more speed Midas Head (1-Master Head) more accurate. Chip component=24000 CPH Fine pitch component=3500 CPH Placement accuracy: 45μm at 6-sigma fine pitch component 38 .3. Pick and place machine Make: ―siemens‖ Model: ―SIPLACE-HF‖ Component handling capacity: Flip chip. BGA. μ-BGA. 4.7‖ Reflow oven is that part of SMT process where all solder paste is re-heated and components are assumed to be properly connected. Reflow soldering machine Make: ―SEHO (Germany)‖ Model: ―MAXI POWER2. ◦Number of heating zone is six ◦Active cooling module ◦Flux manufacturing system ◦All convection heating type ◦Double peak in reflow zone 5. In this process the PCB is passed through different temperature. Automatic optical inspection Make: ―AGILENT‖ 39 . etc.Model: ―SJ50-SERIES II‖ PCB is inspected carefully for their components. improperly soldered joints and missed solder connections.  Optical character recognition (OCR)  Optical character verification (OCV) 40 . IC having J – profile pins along each four sides and it has more than 28 pins.e. Due to small size of components SMT board requires very careful inspection particularly for solder ball. Some components are specially difficult to inspect like quad PLCC‘s (Plastic Loaded Chip Carrier) i. the pump arrangement provides for the hot solder to flow. The solder temperature is continuously controlled by the PID controller and its thermo couples. for next two pre-heaters the temperature is 140 degree Celsius. 41 . The thinner is added to the flux so as to make the flux thinner. Next comes the preheater zone. the conveyor belt is set on the angle of 4 – 7 degrees. The waste material of the machine is known as dross. which can hold 10 PCBs at a time. While the solder is heated up inside the solder bath.6. It consists of 6 per-heaters. The next component in this machine is air knife where the excess flux is removed. After the solder bath. This machine costs around 30 lakhs. The solder nozzle then produces a solder wave. and the temperature for last two chambers is 180 degree Celsius. Wave Soldering Machine Wave soldering machine consists of the PCB carrier stand. The flux used for soldering is Rosion R8. This stand moves over the conveyer belt whose speed is 60 – 80 cm/sec. The box containing the solder is called the solder bath. The temperature of the solder bath is 250 – 270 degree Celsius. The temperature for the first 2 heaters is 100 degree Celsius. This machine also consists of the sensors which sense the green mask as well as the spot mask on the PCB such that the solder does not stays on it. which has the capacity of 400kg. WORK ASSEMBLY It is an important department of the manufacturing division. This is in the case of large components. Modules Assembly 4. PCB Assembling: in this section PCB are manually assembled and components are mounted using manual soldering. Stag Integration 5. Integration: in this section the integration of the different components to form the complete product takes place is also called as final assembly. Cable Forming 2. The assembly of the different components takes place here to make a complete product. Fill Guns It is basically divided into two parts wiz: 1. 2. Many of the accessories related to the products are also manufactured here. Data Cables 3. Cable Assembly 3. Some of them are as follows: 1. Cable Harness 6. Handsets 2. There four lines dedicated to this work. RF & Data Cables Forming 42 . Final Integration 7. The works carried out in this section can be described as follows:1. In PG-I manufacturing of STARSV is the main job. This is done to check the stability of characteristic of PCB as well as 43 .  PCB level testing  Main testing PCB level testing takes place in many stages. of +50°C and -30°C. TESTING & INSPECTION Testing & Inspection is done in every stage of PCB namely at:  Module stage  Sub-assembly  Final stage It is done after the environmental testing and before sending for testing. Testing of STARS-V is done in two main stages only. the PCB‘S are kept in chamber with a temp. The testing process is explained in the next section. The most important parameters that are to be followed during the inspection are as follows:1) The values of the various components 2) The visible characteristics of various active devices 3) Various interconnections 4) Whether the BEL standards are maintained or not Testing is very important in the production.The devices or products after being dispatched from this section are then forwarded to the testing section where they are tested for different parameters and finally the instruments which pass the test are further sent to the other departments. Firstly. The PCB that passes out of the ageing process are then brought out in the block to put them through test jigs. This process is done for approx. These packed sets are now sent for main testing. These test jigs provide perfect environment In terms of signals that actual set will face in the field. 44 . The PCB is sent to assembly section back and they come out clear from test jigs. The air is filled inside set through a nozzle at a pressure of 3 PSI. LEAKAGE TEST is done to check the set for any leakage. In this the radio set is immersed in water. set is sent for repairing. In testing. This is called ageing process. The sets are subjected to temp. Next is THERMAL SHOCK test to check the adaptability of set to sudden change in temperature.its components. The first test is BUMP TEST. Now in assembly section all components are packed finally. This is done to check the resistance of set against mechanical bumps and vibrations. Here the encryption part of PCB is enabled and checked. Range of 40°C-70°C. product is subjected to adverse condition to check the reliability of product under condition defence forces will use. The main testing includes many tests. if air bubbles appear . Thermal shocks are given. Entry in this section is strictly restricted for anyone. apart from authorized personnel. 80 hours. There is a spatial section in testing by the name CIPHER. CHAPTER 8 45 . ranging from communication equipments to hardware to software equipments and it goes in every strata of society like it is now usually used in military training academies.E. CNR – This radio works in Anti – jam frequency hopping and fixed frequency modes with built –in high grade digital secrecy. SECTEL. This being a large organization deals with wide spectrum of technologies.L. 2.L. 3. STARS.These radios are used in Manpack as well as vehicular applications for providing voice and data communications in VHF frequency range of 30-88 MHZ.E. At the receiver end.RESULTS & DISCUSSIONS The industrial training at B. the encrypted data stream is demodulated / decrypted and the orinal speech is synthesized. has given me an exposure of the activities of a defense unit. 46 . The user can switch between clear and secure mode during the same call.V. APPLICATIONS OF PRODUCTS :1. I came to know about different range of products . During my training in B.Here the encrypted speech is transmitted over the telephone line using a FULL Duplex QASK modem. ” 47 . SECURE UHF HANDHELD RADIO – this radio set is provided with helical and magnetic mount antennas. Well. industrial training is the best way to move forward. It has also made me appreciative of an industrial work environment. I was fortunate to have personal guidance from experienced professionals who took been interest in explaining the working details of various equipments.4. regarding future scope I think my training has given me enough motivation and an exposure that I will try to join defence services or get linked up with the defence of the country. It made me more aware of the scope of Electronics & Communication Engineering. my own understanding of this subject and also the motivation to acquire more knowledge would have remained incomplete. 5.It is to charge the two batteries at the same time which is used in VPS set. VOX headgear is also available as optional accessory for hands free operation. “To know the technical know-how. The radio set has in –built mic and speaker.It is also shockproof. I feel that without this opportunity. CONCLUSION The six weeks of summer training at BEL. DBC. It can work with AC as well as dc input also . Undergoing training on the indoor substation has helped me integrate conceptual knowledge with real life application. PKL unit generated a lot more interest in my subject. bel-india.BIBLIOGRAPHY [1] THE MAIN RESOURCES OF THE WORK WERE THE FACULTY OF HRD DEPARTMENT.com/ 48 . [2] WEBSITE:  http://www. 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