Documente Academic
Documente Profesional
Documente Cultură
OF
SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN
AT
Submitted By:
Name: Amber Bhaumik
UPT No.: 5594/13
College: Chitkara Inst. of Engg. & Tech., Rajpura
ACKNOWLEDGEMENT
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
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
CHAPTER 1
INTRODUCTION
With the ongoing revolution in the field of electronics & communications where innovations are
taking place at the blink of an 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 between 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.
The word quality holds out different meaning for different people, 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.
And all the credit goes to organization Bharat Electronics Ltd.
CHAPTER 2
COMPANY PROFILE
Bharat Electronics Limited (BEL) is a state-owned electronics company with about nine
factories, and few regional offices in India. It is owned by the Indian Government & primarily
manufactures advanced electronic products for the Indian Armed Forces.BEL is one of the eight
PSUs under Ministry of Defence, Government Of India. It has even earned the government's
Navratna status.
Bharat Electronics Limited (BEL) was set up at Bangalore, India, by the Government of India
under the Ministry of Defence in 1954 to meet the specialised electronic needs of the Indian
defence services. Over the years, it has grown into a multi-product, multi-technology, multi-unit
company serving the needs of customers in diverse fields in India and abroad . BEL is among an
elite group of public sector undertakings which have been conferred the Navratna status by the
Government of India.
The growth and diversification of BEL over the years mirrors the advances in the electronics
technology, with which BEL has kept pace. Starting with the manufacture of a few
communication equipment in 1956, BEL went on to produce Receiving Valves in 1961,
Germanium Semiconductors in 1962 and Radio Transmitters for AIR in 1964. In 1966, BEL set
up a Radar manufacturing facility for the Army and in-house R&D, which has been nurtured
over the years. Manufacture of Transmitting Tubes, Silicon Devices and Integrated Circuits
started in 1967. The PCB manufacturing facility was established in 1968. In 1970, manufacture
of Black & White TV Picture Tube, X-ray Tube and Microwave Tubes started. The following
year, facilities for manufacture of Integrated Circuits and Hybrid Micro Circuits were set up.
1972 saw BEL manufacturing TV Transmitters for Doordarshan. The following year,
manufacture of Frigate Radars for the Navy began. Under the government's policy of
decentralization and due to strategic reasons, BEL ventured to set up new Units at various
places. The second Unit of BEL was set up at Ghaziabad in 1974 to manufacture Radars and
Tropo communication equipment for the Indian Air Force. The third Unit was established at
Pune in 1979 to manufacture Image Converter and Image Intensifier Tubes. In 1980, BEL's first
4
overseas office was set up at New York for procurement of components and materials.
In 1981, a manufacturing facility for Magnesium Manganese Dioxide batteries was set up at the
Pune Unit. The Space Electronic Division was set up at Bangalore to support the satellite
programme in 1982. The same year saw BEL achieve a turnover of Rs.100 crores. In 1983, an
ailing Andhra Scientific Company (ASCO) was taken over by BEL as the fourth manufacturing
Unit at Machilipatnam. In 1985, the fifth Unit was set up in Chennai for supply of Tank
Electronics, with proximity to HVF, Avadi. The sixth Unit was set up at Panchkula the same year
to manufacture Military Communication equipment. 1985 also saw BEL manufacturing on a
large scale Low Power TV Transmitters and TVROs for the expansion of Doordarshan's
coverage.
1986 witnessed the setting up of the seventh Unit at Kotdwara to manufacture Switching
Equipment, the eighth Unit to manufacture TV Glass Shell at Taloja (Navi Mumbai) and the
ninth Unit at Hyderabad to manufacture Electronic Warfare Equipment. In 1987, a separate
Naval Equipment Division was set up at Bangalore to give greater focus to Naval projects. The
first Central Research Laboratory was established at Bangalore in 1988 to focus on futuristic
R&D. 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 75,000 Electronic Voting Machines.
The agreement for setting up BEL's first Joint Venture Company, BE DELFT, with M/s Delft of
Holland was signed in 1990. 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 first disinvestment (20%) and
listing of the Company's shares in Bangalore and Mumbai Stock Exchanges took place the same
year. BEL Units obtained ISO 9000 certification in 1993-94. The second disinvestment (4.14%)
took place in 1994. In 1996, BEL achieved Rs.1,000 crores turnover.
In 1997, GE BEL, the Joint Venture Company with M/s GE, USA, was formed. In 1998, BEL set
up its second overseas office at Singapore to source components from South East Asia. The year
5
2000 saw the Bangalore Unit, which had grown very large, being reorganized into Strategic
Business Units (SBUs). There are seven SBUs in Bangalore Unit. The same year, BEL shares
were listed in the National Stock Exchange. In 2002, BEL became the first defence PSU to get
operational Mini Ratna Category I status. In June 2007, BEL was conferred the prestigious
Navratna status based on its consistent performance.
CHAPTER 3
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. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
COMPLEX
Ghaziabad
Panchkula
Navi Mumabi
Kotdwara
Pune
Hyderabad
Banglore
Machlipatnam
Chennai
STATE
Uttar Pradesh
Haryana
Maharashtra
Uttaranchal
Maharashtra
Andhra Pradesh
Karnatka
Andhra Pradesh
Tamilnadu
In 1954 with a factory of Jallahali, Bharat Electronics grew into nine units, spread all over India.
The locations & products of the units are given below:1.
BANGALORE: This is also called BG Complex. Jallahali unit which is the mother unit
is now a part of the BG Complex. This is the biggest unit with approx. 10,000 employees
working here. Among the products here, the important ones are:
Communication equipment
Air & Doordarshan equipment like mobile van for live telecast etc.
Radar-mobile, one dimensional, 3-dimensional & multi-dimensional Radars are
manufactured here. Different range of semi-conductor devices like ICs.
Resistors & black & white color TV picture tube glasses.
ISROs requirements are met at space electronics department at Bangalore. Satellite
launch vehicle was also manufactured here.
2. GHAZIABAD: This is the second unit which was set up in 1974, & approx. 2500
employees working here. Radars & some communication equipment are The products
manufactured here are:
Radars
SATCOM
Microwave components
3. PUNE: To diversify further one more branch was added 1979 & this was in Pune. In
this branch around 700-800 employees are working. The product profile includes:
4. MACHLIPATNAM: There was one Andhra scientific company, which was a sick unit.
This was taken over by BEL & is called ASCO unit in 1983. The products include:
5. NAVI MUMBAI: This is an industrial place near Mumbai. This unit makes:
10
CHAPTER 4
11
Bharat Electronics Limited is a major supplier of products and turnkey systems to the Indian
Defence Services. Over the years, BEL has diversified into manufacturing many civilian
products as well. Large turnkey telecommunication solutions are also being offered to civilian
market. BEL has been involved in providing state-of-the-art communication equipment to the
Indian Army, be it hand held mobile radios and terminals, ground based systems, airborne and
even ship borne equipment and systems. The communication equipment developed here cover
HF, VHF, UHF, and V/UHF frequency bands. The most important project of BEL under the
communication equipment is STARS-V which provides secure mode of data transfer. In
STARS-V, the data to be transferred is first encrypted using a microprocessor which could be
read only by a similar device with same coding. Now the latest technology of frequency
hopping is being implemented which is a very useful tool in making a secure data transfer
system. BEL manufactures a lot of product which is very difficult to list but some of the major
products were as follows:
Telecommunication
Radars
STARS-V
SECTEL
CNR
HUD
LUP
TIDEX
SECURE FAX
CUSTOMER
Indian Defence Services , Para -Military Forces
Indian Defence Services, Civil Aviation,
Meteorological Department, ISRO
Department of Telecommunication, Para- military
forces, Power Sector, Oil Industry, Railways
12
4.
5.
6.
7.
8.
Broadcasting Equipment
and Studio Systems
Electronic Voting Machine
Solar Products & Systems
Turnkey
Systems,
Governance
Networks
Components
Exports play a key role in BEL's strategic perspective. A number of International companies are
using the facilities at BEL for contract Manufacturing.. The broad list of products and services
being exported is given below:
Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
EXPORTS/INTERNATIONAL MARKET
PRODUCT
CUSTOMER
Defence Communication
Botswana, Indonesia, Suriname,
equipment
Malaysia
and spare parts
Radars & Sub-systems
Indonesia, Egypt, Switzerland
Electronic Warfare products Russia, Brazil
and
services
Opto-electronics products
Sri Lanka, Nepal, Israel, South Africa
Semiconductor devices,
Malaysia, Singapore, Turkey,
Microwave
Netherlands, UK, USA, France, Hong
Tubes
and Transmitting Kong
Tubes
Solar Products & Systems
Suriname, Germany, Zimbabwe,
Botswana, Kenya, Nigeria
Telecom
and SATCOM
Nigeria, Kenya
systems
Radio & TV Broadcasting Nepal, Mauritius
products
and Systems
13
9.
10.
Vacuum Interrupters
CHAPTER 5
14
1. Electronic Voting Machines:The world's largest democracy with 671 million voters went to polls in April - 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). 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, the country's technological as
well as grassroots democratic capabilities. About half a million of the EVMs deployed in these
elections were designed, manufactured and delivered by Bharat Electronics Limited (BEL), a
Public Sector Enterprise of the Government of India. Today, the Electronic Voting Machines
have made an easy passage to India's hundreds of thousands of villages. There is widespread
awareness of its reliability and adaptability, so also the political recognition. All these have been
15
achieved through a series of meticulously planned events like exhaustive training to the polling
officials, mass awareness programmes to educate voters, especially the overwhelming majority
of those who live in the remote villages of India, etc. Technical experts from Bharat Electronics
Ltd. worked untiringly alongside the Indian Election Commission officials offering support and
assistance for these activities and also during the elections, ensuring that the whole process
succeeded and it is remarkable that there have been no problems with the machines worth
speaking about.
The 2004 general elections in India, where millions of voters cast their votes through the
electronic voting machines and the results of which were declared in one single day, was indeed
a landmark success for the application of technology for sustained development of society.
set and RCU is also provided. The radio set can be configured for fully automatic rebroadcast
operation. It is also possible to setup rebroadcast over two wires for voice clear mode only.
External data interface is provided on the front panel to facilitate data communication with
suitable modem. The radios are fully modular in construction. They are designed to perform in
conformance to MIL 461class of EMI/EMC specifications. 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. MARK I:This is the first stage of STARS-V .This set is heavy and the if any need repair then difficulty to
find out the fault .And the major difference is frequency hopping is not possible. There are two
power mode 5W, 25W and the frequency range only used by army is (30-87.97MHz)
2. MARK II:This is the modified stage of the MARK-I. It is light in weight then the MARK-I. And the major
difference is frequency hopping is possible.it consist of seven modules are given as
A2-Power amplifier A417
Receiver card A5Synthesizer Card A11Fequency hoping card A6controller card A7-secure
card A8-display card
18
19
20
21
22
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. In some optical
layouts combiners may also have a curved surface to refocus the image from the projector. The
computer provides the interface between the HUD (i.e. the projection unit and the systems/data
to be displayed and generates the imagery and symbols to be displayed by the projection unit.
Generations HUDs are split into four generations reflecting the technology used
to generate the images.
Second GenerationUse a solid state light source, for example LED, which is
modulated by an LCD screen to display an image. These systems do not fade or require
the high voltages of first generation systems. These systems are on commercial aircraft.
Fourth GenerationUse a scanning laser to display images and even video imagery on a
clear transparent medium. Newer micro-display imaging technologies are being
introduced including
23
9. BHARANI RADAR
Low level Light Weight 2D Radar - BHARANI: is a light weight, 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, RPVs,
helicopters and fixed wing aircraft flying at low and medium altitudes. The radar can be
transported by vehicles, animal transport or group of men or as helislung loads. It can be
dismantled into packages to facilitate quick installation and re-location in mountainous terrain. It
will act as an early warner to air defence weapon systems employed to provide protection to
vulnerable areas or vulnerable points.
The system consists of radar, Commander Display Unit (CDU) and messaging unit Target
Designation Unit (TDU) and Target Data Receivers (TDR). One radar can service upto 10 TDRs
using existing combat radio resources/ network. The CDU can be located upto 750m from the
radar. The radar with modular architecture, advanced ECCM features, ruggedness as per Mil
standards can be operated in varied conditions including extreme climatic and geographical
conditions and in battle field situations, especially offensive EW environment. The radar detects
and tracks short range air-to-ground threats with a high probability of detection. The radar has an
integrated IFF that can detect, confirm, classify and attain IFF status on every target in the battle
space under surveillance.
24
It has a range of 50 KMs and can operate at an altitude of 75 mtrs to 5400 mtrs. It operates in L
band.
25
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; thereby making the radar system extremely reliable. The radar is easily re-locatable
and can be deployed or decamped in less than 15 minutes. The radar is engineered in multiple
packages to enable easy transportability in mountainous terrain by vehicles, group of men, or as
an under slung carriage by a helicopter. 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. The
facility also enables the Commander to deploy the radar at a tactically favourable point. The
quadri pod-mounted radar is built to operate in networked or stand-alone mode to support joint
or independent operations by Air Force. Multi ECCM features help the radar to deliver intended
performance even under intense hostile EM environment. Rohini being compact, lightweight and
modular, can be used in different innovative roles like air space surveillance in urban areas for
VVIPs, large critical installations.
26
CHAPTER 6
27
BEL Panchkula has different divisions which are further divided into departments-
STDS (STANDARDS) These are the standards for Drafting, Design manure,
Quality standards.
2. MFG (MANUFACTURING):
WA (WORK ASSEMBLY) There are different types of work assembly i.e PCB
assembly, Module assembly, Final assembly.
SC (SUB CONTRACT)
3. MM (MATERIAL MANAGEMENT):
HS (HOLDING STORE) It has different bins that holds items after inspection.
MC (MATERIAL CONTROL)
FGS (FINISH GOODS STORE) After finishing the project it is sent to FGS for
final packing.
SELF CERT (SELF CERTIFICATION) It is the department which visits the place
where work is going on.
29
5. QA (QUALITY ASSURANCE):
It deals with the quality of the material.
R&E (RELIABILITY & EVALUATION) - The materials are checked before giving it
to customers.
CRECHE
CANTEEN
WELFARE
9. IS / MS (INFORMATION SYSTEMS):
31
CHAPTER 7
32
SUB DEPARTMENTS
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:
34
Expanded Forms
SMD Surface-mount devices (active, 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
1. Loader
MODEL: L-SIZE
MAKE: AUTOVEYOR
Loader as the name suggest load the pcb on which component are to be mounted. 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. The height is 930 mm from the ground
2. Stencil Printer
36
Make: DEK
Model: ELA-VI
Huge print area capability
The huge print area capability allows printing up to 1200mm x 400mm. It accepts standard SMT
frame sizes from 350 x 350 mm to 1480 x 500 mm (for SP1200), 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.
37
38
39
Model: SJ50-SERIES II
PCB is inspected carefully for their components. Due to small size of components SMT board
requires very careful inspection particularly for solder ball, improperly soldered joints and
missed solder connections, etc. Some components are specially difficult to inspect like quad
PLCCs (Plastic Loaded Chip Carrier) i.e. IC having J profile pins along each four sides and it
has more than 28 pins.
40
41
WORK ASSEMBLY
It is an important department of the manufacturing division. The assembly of the different
components takes place here to make a complete product. Many of the accessories related to the
products are also manufactured here. Some of them are as follows:
1. Handsets
2. Data Cables
3. Fill Guns
It is basically divided into two parts wiz:
1. PCB Assembling: in this section PCB are manually assembled and components are
mounted using manual soldering. This is in the case of large components. There four
lines dedicated to this work.
2. Integration: in this section the integration of the different components to form the
complete product takes place is also called as final assembly. The works carried out in
this section can be described as follows:1. Cable Forming
2. Cable Assembly
3. Modules Assembly
4. Stag Integration
5. Cable Harness
6. Final Integration
7. RF & Data Cables Forming
42
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. The testing process is explained in the next section.
Main testing
PCB level testing takes place in many stages. Firstly, the PCBS are kept in chamber with a
temp. of +50C and -30C. This is done to check the stability of characteristic of PCB as well as
43
its components. This process is done for approx. 80 hours. This is called ageing process.
The PCB that passes out of the ageing process are then brought out in the block to put them
through test jigs. These test jigs provide perfect environment In terms of signals that actual set
will face in the field. In testing, product is subjected to adverse condition to check the reliability
of product under condition defence forces will use.
The PCB is sent to assembly section back and they come out clear from test jigs. Now in
assembly section all components are packed finally. These packed sets are now sent for main
testing. The main testing includes many tests. The first test is BUMP TEST. This is done to check
the resistance of set against mechanical bumps and vibrations.
Next is THERMAL SHOCK test to check the adaptability of set to sudden change in
temperature. Thermal shocks are given. The sets are subjected to temp. Range of 40C-70C.
LEAKAGE TEST is done to check the set for any leakage. In this the radio set is immersed in
water. The air is filled inside set through a nozzle at a pressure of 3 PSI. if air bubbles appear ,
set is sent for repairing. There is a spatial section in testing by the name CIPHER. Here the
encryption part of PCB is enabled and checked. Entry in this section is strictly restricted for
anyone, apart from authorized personnel.
44
CHAPTER 8
45
The industrial training at B.E.L. has given me an exposure of the activities of a defense unit. This
being a large organization deals with wide spectrum of technologies.
During my training in B.E.L, I came to know about different range of products , 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.
APPLICATIONS OF PRODUCTS :1. STARS- V- 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.
2.
CNR This radio works in Anti jam frequency hopping and fixed frequency modes
with built in high grade digital secrecy.
3. SECTEL- Here the encrypted speech is transmitted over the telephone line
using a FULL Duplex QASK modem. At the receiver end, the encrypted
data stream is demodulated / decrypted and the orinal speech is synthesized.
The user can switch between clear and secure mode during the same call.
46
5. DBC- It is to charge the two batteries at the same time which is used in VPS set.
It can work with AC as well as dc input also .It is also shockproof.
CONCLUSION
The six weeks of summer training at BEL, PKL unit generated a lot more interest in my subject.
It made me more aware of the scope of Electronics & Communication Engineering. It has also
made me appreciative of an industrial work environment.
Undergoing training on the indoor substation has helped me integrate conceptual knowledge with
real life application. I was fortunate to have personal guidance from experienced professionals
who took been interest in explaining the working details of various equipments.
I feel that without this opportunity, my own understanding of this subject and also the motivation
to acquire more knowledge would have remained incomplete.
Well, 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.
To know the technical know-how, industrial training is the best way to move forward.
47
BIBLIOGRAPHY
[1] THE MAIN RESOURCES OF THE WORK WERE THE FACULTY OF HRD
DEPARTMENT.
[2] WEBSITE:
http://www.bel-india.com/
48