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TO
Central
Acquisition
The unique feature of the radar is, its operation is fully automated and controlled from a Radar Console with sufficient menus, keys and hot keys. It is also supported by a tracker ball/mouse. Rohini is an offshoot of the fully and successfully developed and demonstrated radar called as 3D Central Acquisition Radar (3D-CAR). Rohini is designed to play the role of medium range surveillance radar mounted on a mobile platform. The radar carries out detection, tracking and interception of targets with an RCS of 2m2 upto 130 Kms in range. The antenna is rotated mechanically in azimuth to provide for coverage of 3600. To achieve a higher range, the radar is capable of being operated at a lower ARR of 7.5 RPM against the normal ARR of 15 RPM. Rohini is provided with all terrain mobility and various modes of
transportation. To achieve this goal a versatile mobile platform is developed. This product is fitted on a TATRA class of vehicle.
LAN interfaces are used to communicate with external systems. High-speed data transfer of target parameters can be done. This helps in data remoting upto a distance of 500 mtrs that can be extended with suitable repeaters.
The Radar Console is a local display. The color display has features for
monitoring of radar performance, the radar output selection for radar modes of operation. Interfaces to radar control signals are built-in. The Radar generates different videos viz., Analog and Digital videos at the Receiver and Signal Processor.
The Data centre is required to provide basic functions like viewing of the air picture, remote operation of radar, and radio communication. At the same time the cabin provides shelter for the operators, with reasonable level of comfort and, protected against heat, rain and dust. Data Centre also referred to as Operators workstation, is one of the three vehicles forming the Rohini configuration. Data centre has to meet the functional, operational, electrical and environmental requirements set by the user. The high power RF, low power RF, antenna, signal and data processor and a monitor console are all integrated into the sensor vehicle. This can, if needed, provide autonomous radar functionality. Data Centre will be separated from the sensor by maximum of 100 mts. The two are connected for exchange of data and control messages. Mobile power source is required to provide the main supply to Radar Sensor and Data Centre for electronic and mechanical units of Radar including air conditioning units. The total power requirement for both vehicles is approx. 60KVA. The radar normally operates at 15 RPM to get the optimum detection performance up to 150 Km against fighter class of aircraft. 7.5 RPM mode will be selected for getting higher detection ranges against larger crosssection targets [up to 200 Km]. 15 RPM mode is specifically provided, where faster update is needed. The Identification Friend or Foe (IFF) system is a good example of a secondary radar system that is in wide use in the military environment. A great deal of valuable information can be provided to the secondary radar by. the targets transponder. The transponder provides an identifying code to the
secondary radar that then uses the code and an associated data base system to look up aircraft origin and destination, flight number, aircraft type and even the numbers of personnel onboard. This type of information is clearly not available from a primary radar system
Sl. No
ITEM
REVATHI
ROHINI
1.
Up to 50
Up to 30
2.
3. 4. 5.
7+1
6.
TWT based 3.3% Duty Digital IF / Digital IF/DDS DDS Software Software Changes are Changes incorporated.Indigeno are us SHARC boards incorporate d.
3D-CAR
SCOPE:
The transmitter of CAR is capable of delivering RF peak power of greater than 140 KW and RF average peak power greater than 4 KW. The transmitter uses fully indigenous technology established by LRDE for 3D CAR programme. The transmitter is planned to be realized as production version M/S BEL Bangalore based on transfer of technology (TOT) from LRDE.
CONFIGURATION OF TRANSMITTER:
CONTROL RACK MONITORING PANEL CONTROL PANEL SYNOPTIC PANEL CPC INVERTER HIGH VOLTAGE RACK FDM COLLECTOR ASSEMBLY CATHODE ASSEMBLY BLOWER UNIT HEATER UNIT MICROWAVE RACK -TWT -RF PLUMBING -RF DRIVE UNIT -SSPA -ION PUMP CONTROLLER
REQUIREMENTS:
-600 +800 RF IN RF OUT LIQUID COOLING -45kV,5kW 33kV,18kW 3kV,ION PUMP -10V,10A
The requirement is to amplify the pulsed RF signal from 1W to 140 KW while maintaining the phase noise (additive noise) to 60 dBz/Hz at 100 Hz away as demanded by the system. In addition, a failsafe mode of delivering 2 KW of peak power to antennae, in case of liquid coolant as redundant measure. RTS -400 is the TWT based transmitter capable of delivering 140 KW of peak and 4 KW of average.
1 ph I/P
3 Ch LiqIn LIQUID COOLING UNIT 3 Ch LiqOut Liq Cool OK
Dehydrator
RTS-4000
3 ph I/P I/P
RF IN
TECHNICAL SPECIFICATIONS:
The Transmitter for 3D Surveillance radar REVATHI is a Coherent Master Oscillator Power Amplifier (MOPA) type employing Traveling Wave Tube (TWT) Type VTS 5754 D2 of M/s CPI, USA as final power amplifier. The transmitter is capable of delivering RF power of more than 140 kW (peak) and 4.0KW (average) in t he frequency band of 3.1 to 3.5 GHz, while maintaining phase noise performance of 60dBc/Hz at 100Hz away from carrier. M/s. BEL Bangalore is realizing the transmitter, based on TOT from LRDE.
The input output diagram of the transmitter is shown in fig 2.2.1. The
8.
Duty:
on
on
off
3.2
(max).
9. RF drive power level: (It has to be passed through this power level , before passing through TWT ) : - 5 DBM to 13 DBM.
10. Blanking (screening of particular area from where a lot of energy is coming): Sector blanking facility for full 360 degree azimuth. 11. Protection: crow bar protection technique is used. This method involves grounding the power by using and gate and a triode.
ENVIRONMENTALSPECIFICATIONS:
S.NO 1. 2. 3.
QUANTITY TEMPERATURE( centi grade) HUMIDITY ALTITUDE( meters) in OPERATING - 20 to 55 95% RH at 40 degrees 4160 NON OPERATING - 30 to 70 95% RH at 40 degrees 9100 -
TRANSMITTER CONTROL:Local: To control through control panel on the transmitter. Remote Control: to control from the operator console through control interface RS 422.
pressurizing and for TWT. General design of the cooling is worked out in such a way that the temperature rise for outlet coolant is around 10C than the inlet. The total heat load on liquid to air cooling unit is 25kW and for forced air cooling 3 kW. The TWT, High Power Ferrite Isolator and high voltage power supplies are cooled with de ionized water and ethylene glycol mixture (50: 50). Liquid cooling distribution is realized in such a way that the liquid cooling unit will have a minimal pressure on the connections. Forced air cooling is employed to other components using the ambient air properly filtered to ensure dust free air. A dry air with low dew point and dust particles is applied for wave guide channel.
FUNCTION
1. The Transmitter amplifies the pulsed RF signal from 1W to 120 kW while maintaining the phase noise (additive noise) to -60 dBc/Hz at 100 Hz away as demanded by the system. In addition, a Solid State Power Amplifier (SSPA) is provided, as a stand by option, to ensure fail-safe mode of delivering 1.5 kW of peak power to antenna, in case of failure of liquid coolant. 2 It employs a Traveling Wave Tube (TWT) Type VTS - 5754 D2 of M/s CPI, USA as final power amplifier. Low power amplifier stage (RF Driver) amplifies pulsed RF signal from 1 mW (0 dBm) to 3 - 4 W which is necessary to drive the TWT amplifier. 3. The RF Driver stage uses a Pin attenuator transistor followed by power amplifiers to amplify RF signal from 0 dBm to 37 dBm. This is followed by an isolator. The isolator protects the transistor power amplifiers against
excessive reflections from TWT. The signal is thereafter passed through a DC, a RF switch and an attenuator to cater for the three transmission modes. The sampled output of the DC is used for monitoring the input RF signal to the TWT. 4. The RF Driver output (approx. 3 to 4 W) is given to the input of TWT, which amplifies the pulsed RF signal from 3 Watts to a level of 120 to 185 kW at the TWT output. High power RF plumbing components are connected at the output of TWT. 5. The TWT output is given to an arc detector followed by a ferrite circulator. The Ferrite circulator is used to protect the microwave tube against
Collector Supply
failure /damage due to reflected power in case of excessive VSWR at Antenna input port. The output of Ferrite Circulator is given to High Power Dual Directional Coupler (DDC), which is used for measuring the transmitted and reflected power. If reflected power exceeds the specified limit of 2:1 VSWR, a video signal is generated to cut off the RF drive through control and protection circuit. The output of the DDC is given to Antenna. To connect all the components in the required form, flexible sections, E-bends, H-bends and straight sections are used. Three Phase power supply is passed through an EMI/EMC Filter unit to reduce EMI/EMC interference. The output of filter unit is given to Power Distribution unit to distribute power to various units of the transmitter. 6. Control and Protection Circuit ensures the sequential switching ON of the transmitter, continuous monitoring and interlocking of various parameters, detection and indication of errors. All these are achieved by dedicated hardware and software. 7. Synoptic Panel consists of LEDs, switches and LCD display. LEDs are used to show the status of the transmitter. They also show the fault, if any, in the transmitter. The LCD display, mounted on Synoptic panel, is used to show the value of cathode voltage & current, collector voltage and current. It also displays the Filament voltage and current, Grid + ve and -ve voltages and RF
forward power. 8. The Inverter unit converts the incoming ac supply to DC and then converts the DC to high frequency AC (Pulse width controlled square wave) operating at 20 kHz. The output of the Inverter unit is given to HV rack for generation of Cathode and Collector voltages of the TWT amplifier. 9. High Voltage Power Supply unit (HVPSU) is used to supply high voltage to collector and cathode of the TWT. 10. The Floating Deck Modulator (FDM) unit generates filament voltage with surge current protection and also generates grid +ve and grid -ve voltages. Switching of grid voltage as per pulse width and PRF requirements are also provided by FDM. Cooling Unit is used to cool the various components of the transmitter. The TWT, High 11.Power Ferrite Isolator, high Voltage Power supplies and RF dummy load are cooled with de-ionized water and ethylene glycol mixture (50:50). Forced air-cooling is employed to cool other components using ambient air which is filtered to ensure dust free air. 12. The Dry Air unit ensures that the wave guide is at all times pressurized and dry.
Transmitter is housed in 3 separate racks. 1. Microwave Rack consists of TWT, microwave plumbing components, SSPA and RF driver. 2. High voltage rack Consists of all high voltage components and FDM capacitor. 3. Control Rack Consisting of Monitoring and Diagnostics circuits, Control Circuits, Power distribution along with line filter unit and high voltage inverter unit.
collector assembly, heater and blower unit. The main function of the high voltage rack is to provide high voltage power supply to cathode and collector of the TWT. FDM is the most important component and it provides the filament supply, grid bias and grid positive and negative supply to the TWT. It also communicates with the CPC via optical links. Cathode assembly provides the cathode supply and collector assembly provides the collector supply to TWT. Heater unit is used for removing the moisture within the rack. Blower unit provides cooling for cathode and cathode assemblies.AC components probes in cathode and collector are used to get the sample of output voltage and same is used to control the pulse width of the inverter to achieve a regulation of .2%.
CONTROL RACK:
(i) (j)
FUNCTIONS OF FDM:
1. Generates filament supply for TWT with surge current protection. 2. Generates grid bias and the grid positive supplies. 3. Provides switching function. (Switching of TWT grid as per pulse width and the PRF requirement.) 4. Communication to CPC on optical link. All the circuitry necessary to achieve the following functions is floating at the cathode potential of 45 V DC and needs special consideration in engineering. All circuits are housed inside an equipotential surface.
SPECIFICATIONS OF FDM:
VOLTAGE SPECIFICATIONS: Voltage generation:
1. Filament voltage: 8V to 11V (adjustable.) 2. Filament current: 10 A with surge current limited to 15 A. 3. Voltage regulation: 0.01% 4. Grid positive voltage: 800 to 1100(adjustable.) 5. Grid current: 20 mA (adjustable) 6. Voltage regulation: 0.01% 7. Grid negative voltage: - 600 to 1100(adjustable.)
Switch specifications:
1) Switch output: - 800 to 1100 pulse. 2) Pulse width: 50, 25, 4 microseconds. 3) PRF: .5, 1, 4 (KHz) 4) Pulse rise time: < 0.5 microsecs. (The time taken by pulse to rise) 5) Pulse fall time : < 0.5 microsecs. (The time taken by pulse to fall.) 6) Pulse jitter: < 10 nsec. 7) Drop on the top of pulse :< 1V for 25 microsecs.
PROTECTIONS OF FDM:
1. Pulse width / PRF PROTECTION. 2. Short circuit protection.
3. Overload protection 4. Voltage too high and too low (window) protection 5. Thermal protection.
pulse to pulse current limiting using a current transformer and current limit comparator of UC 1526. The supply has electronic current limiting which limits the initial current the TWT initial surge current to 15 A and operates in current control mode until the filament warms up. It is also provided with hard current limiting by means of a series limiting resistor which is bypassed by operating a relay after 5 min from initial power on. The current control feature is available only when this card is operated along with filament supply and timer card 2 . the card also generates 115 V DC / 2 A supply , which is used as input for filament and grid fly back converter.
4) LVPSU CARD
It generates all low voltages power supplies like the + 24, + 15, - 15, + 5 V.three of these supplies (+ 15, - 15, + 5) are generated using the DC DC converter.
The grid supply is a switched mode power supply and the topology followed is a fly - back converter. The supply operates at a frequency of 25 KHz and PWM scheme is followed for regulation. the switching device is protected against over currents by pulse to pulse current limiting using a current transformer and current limiting comparator card IC 1526.The card is capable of generating output voltage of - 550 to - 650 V DC , 10 mA.
7) SWITCH CARD
It uses a fast high voltage switch of BHELKE make to switch the grid between + 870 V and 600 V at required pulse width and PRF, based on input command. The circuit configuration enables availability of continuous grid ve at TWT grid even if the bottom switch becomes faulty.
COLLECTOR ASSEMBLY
The collector assembly provides 33 KV dc supply required for TWT amplifier. It consists of a collector transformer, high voltage capacitors, a high voltage moulded diode resistor block, a two terminal spark gap, two high voltage DC probes, a high voltage AC compensated probe and a collector EHT meter card. Some high voltage distribution blocks are also used. The collector transformer takes 550 volts 20 KHZ inputs from the inverter assembly and gives the required 33 KV DC output. The high voltage compensated probe CP1 is used to get the sample output voltage and the same is used to control the pulse width of the inverted to achieve the required regulation of 0.002% on pulse to pulse basis. High voltage probe CP2 provides interlock to inverter and to CPC for proper collector. High voltage CP3 probe gives a sample to collector EH meter card which also takes a sample of cathode voltage to give the metering output for cathode and collector voltage. The two terminal spark gap is for protection of transmitter.
CATHODE ASSEMBLY
The cathode assembly provides - 45 KV DC supply required for the TWT
amplifier. It consists of a cathode transformer, a high wattage capacitor, a high voltage diode block, resistor plate assembly, a three terminal spark gap, two high voltage DC probes; a high voltage AC compensated probe, a crowbar trigger unit and a droop circuit. Some high voltage distribution blocks are also used. The cathode transformer takes 550 volts; 20 KHz input from the inverter assembly and give the required 45 KV DC output. The high voltage compensated probe CP1 is used to get the sample output voltage and the same is used to control the pulse width of the inverted to achieve the required regulation of 0.002% on pulse to pulse basis. High voltage probe CP2 provides interlock to inverter and to CPC for proper collector. High voltage CP3 probe gives a sample to collector EHT meter card. In case of fault CPC gives a control signal to the crowbar trigger unit, which gives a 25 KHz pulse to the three terminal spark gap to switch off the high voltage supply. The droop circuit is used for monitoring the droop voltage on the
monitoring panel, housed in control rack.
HEATER UNIT
The heater unit contains four heaters, each of 250 rating. The heater unit gets 230 V AC supply as soon as the transmitter is switched on and this supply is cut off automatically after ten minute. With the help of this unit, moisture is removed before high voltage is applied.
BLOWER UNIT
The blower unit contains twelve blowers, each operating at 230 volts AC. The
MICROWAVE RACK:
It consists of low power Low Power Driver for TWT, traveling Wave Tube (TWT), Ferrite Isolator, Dual Directional Coupler and Wave guide Channel. Low Power amplifier stage (RF Driver) amplifies pulsed RF signal from 1mW (0dBm) to 3-4 W, necessary to drive the TWT amplifier. Twt is the main power amplifier used in transmitter. It amplifies the pulse RF signal from 2W to a level of 125 to 185 KW at TWT output. Ferrite Isolator is used to protect the microwave tube against failure / damage due to reflected power in case of excess VSWR at Antenna input port. High Power Dual Directional Coupler (DDC) is used for measuring the transmit power and reflected power. To connect all components in the required form, flexible sections, E-bends, Hbends and straight sections are used.
Diagram of TWT
Ferrite circulator
Ferrite circulator is used to protect the microwave tube against failure / damage due to reflected power in case of excess VSWR at Antenna input port. The Four port Ferrite circulator type SC3-19 is used as an isolator.
Wave-guide Channel
To connect all the components in the required form, flexible sections, Ebends, H-bends and straight sections are used. Standard W/G sections are being used for this purpose.
When pulsed signal corresponding to the duty of transmitter is detected at TP1 and TP2, AD847 OPAMP amplifies it to about 7 times. IC 139 is used as a comparator. Transistor Q1 is ON when output at U 2 - 1 is high. The DC output corresponding to the peak amplitude of the input signal is measured at J 1 9 and GND. The output RC time constant is adjusted such a way that the DC value holds
till the next pulse arrives. the time constant derived by R5 and C1 should neither be too large, because in case of fault, where in the input will absent, the output should die down within minimum time and nor should be too small, that the output DC value droops down from the peak value at a much higher rate, before the next pulse comes.
Transmitter Solid State Power Amplifier (SSPA) Signal Data Processor (SDP) Display Console IFF Master Control Unit (MCU) Deployment Console Unit (DCU) Dehydrator Advance Land Navigation System (ALNS) PC Power Distribution Panel (PDP) EMI Filter
SUBMITTED
TUSHAR UPT NO. 634 ECE
(070271111)
AKGEC,
PREFACE
This six week training program is a part of 4-year B.Tech. course. Practical industrial training mainly aims at making one aware of industrial environment, which means that one get to know the limitation, constraints and freedom under which an engineer works. One also gets an opportunity to see from close quarter that indicates management relation. This training mainly involves industrial and complete knowledge about designing, assembling and manufacturing of equipment. During this period, the student gets the real experience for working in the 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 immensely helps in them in building their career.
ACKNOWLEGEMENT
First of all I would like to express my gratitude to Mr._________________ , HR Department for arranging my training for the duration of six weeks. The training schedule prepared by them gave me an opportunity to have an insight of working methodology and procedures of BEL. I would like to thank department of HRD for the cooperation. I offer my sincere gratitude to my guide ________________ for his continuous guidance and support. I would like to thank Mr.________________ and all the members of C.A.R radar assembly for helping me throughout my training. My special thanks to whole staff of BEL for accepting me as a trainee & helping me in Radar assembly. they proved themselves inspiring, helpful, productive and fruitful to me. It will be in debt on my part if I forgot to give my thanks to all those visible and invisible hands that helped me throughout my training period.
TUSHAR AGARWAL
CERTIFICATE
This is to certify that Mr. TUSHAR AGARWAL, student of B.Tech (Electronics and Communication), AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD successfully completed his six weeks training in BHARAT ELECTRONICS LIMITED, GHAZIABAD. A project on Central Acquisition Radar (3D-CAR) Transmitter was assigned to him. In this period he worked hard and made valuable contribution in developing the project. All his work is genuine and original and was timely completed.