Industrial Training Project 2012-13

To Study of the Electronic voting machine used by Election commission of India for voting Purposes

At

Prepared byAmit Aswal

BT-ME(0809540009)

Mahatma Gandhi Missions College of Engineering and Technology. Noida, U.P., India

Department of Mechanical Engineering

CERTIFICATE

This is to certify that Mr. /Ms. Amit Aswal of B. Tech. Mechanical Engineering, Class BT-ME Roll No.0809540009 has completed / partially completed / not completed his / her Industrial Training during the academic year 2011-2012 from 14.06.2012 to 19.07.2012 at Bharat Electronics Limited.

Training Coordinator

Head of the Department

CONTENTS
1.certificate1 2.Aknowledgement2 3.Preface.3 4.Bharat electronics industry4 5.Company profile..5 6.Formation of GZB.unit6 7.Rotation progame.7 8.customer profile8 9.Various specification in BEL...9 10.Test equipment and automation...10 11.Product range.11 12.P.C.B12 13Work Assembly13 14.Environmental lab...14 15.CS(Electrical)15 16.Magnetics..16 17.Microwave lab17 18.Equipment formation group.18 19.Design and engineering.19 20.Indroduction of RADAR20 21.Conclusion..21

Mahatma Gandhi Missions

College of Engineering and Technology.

Noida, U.P., India

Report on Practical Industrial Training Carried out at

From 14.06.2012 to 19.07.2012. Academic Year 2011-12 Submitted by: Amit Aswal Class:BT-ME Roll no-0809540009 Submitted to:
Mechanical Engineering Department, MGMs COET,

Noida.

ACKNOWLEDGEMENT
Industrial training is an indispensable part of the engineering curriculum. It provides the student with an opportunity to gain experience in the practical applications of their academic knowledge.

My training at Bharat Electronics Limited (BEL), 23/23B Ansari Road, Daryaganj, New Delhi-110002 was an extremely fruitful experience. I would like to express my sincere thanks to Mr. Agam Srivastava for his support and expert guidance throughout my tenure in BEL. I take this opportunity to also thank Mrs. Anita Dhir, Mr. R. K. Bhasin, Mr. Arun Sharma and all of those BEL employees, who offered their unconditional support and expert advice during the course of my training. Working with them was a delightful experience as they not only guided me throughout my project but also helped me in understanding the work culture of the organization. My mentors at BEL gave me the wisdom to tackle any situation with great precision and persistence.

DECLARATION
I hereby declare that this submission is my own work and that to the best of my knowledge and belief . It contains no material previously published or written by another person nor material which to a substantial extent has been accepted for the award of any other degree or diploma of the university or other institute of higher learning , except where due acknowledgement has been made in the text .

Signature: Name: Amit Aswal

Roll no. : 0809540009 Date: AUG 30

CONTENTS

1 2 3 4 5 6 7 8

: : : : : : : :

CERTIFICATE ACKNOWLEDGEMENT PREFACE BHARAT ELECTRONICS INDUSTRY COMPANY PROFILE FORMATION OF GZB. UNIT ROTATION PROGRAME INTRODUCTION TO RADAR

3.

PREFACE

With the ongoing revolution in electronics and communication where innovations are taking place at the blink of eye, it is impossible to keep pace with the emerging trends.

Excellence is an attitude that the whole of the 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 collocating a professional attitude. It provides a linkage between a student and industry to develop an awareness of industrial approach to problem solving, based on a broad understanding of process and mode of operation of organization.

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.

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 also interfaced too many instruments. And all this credit goes to organization Bharat Electronics Limited.

4. ABOUT BHARAT ELECTRONICS LIMITED (BEL) BHARAT ELECTRONICS LIMITED

THE INDUSTRY
After Independence India had many responsibilities from basic necessity to telecomm & defence equipment so after adoption of its constitution in 1950, the government was seized with the plans to lay the foundation of a strong, selfsufficient Modern India. On the industrial announced in the year 1952. It was recognized that in certain core sectors infrastructure facilities require huge investments, which cannot be met by private sector and as such, the idea of Public Sector Enterprise (PSE) was mooted. Under this a Professional Electronics company in India incorporated that was front, industrial policy resolution (IPR) was BHARAT ELECTRONICS LIMITED. BEL was established in 1954 as a Public Sector Enterprise under the administrative control of Ministry of Defence as the fountain head to manufacture and supply electronics components and equipment. BEL, with a noteworthy history of pioneering achievements, has met the requirements of state-of art professional electronic equipment for Defence, broadcasting, Civil Defence and telecommunications as well as the component requirement of entertainment and medical X-ray industry. Over the years, BEL has grown to a multi- product, multiunit and technology driven company with track record of a profit earning PSU.

BEL was born to meet the growing needs of Indian Defence services for
electronic systems. Employing the best engineering talent available in the country, BEL has progressed manufacturing state-of-the-art products in the field of Defence Electronics like Communications including encryption, Radars and strategic components. Over the years, BEL has diversified to meet the needs of civilian customers as well and has provided products and network solutions on turnkey basis to customers in India and abroad. With the Research & Development efforts, its engineers have fructified it into a world-class organization. The company has a unique position in India of having dealt with all the generations of electronic component and equipment. Having started with a HF receiver in collaboration with T-CSF of France, the companys equipment designs have had a long voyage through the hybrid, solidstate discrete component to the state-of-art integrated circuit technology. In the component arena also, the company established its own electron valve manufacturing facility. It moved on to semiconductors with the manufacture of germanium and silicon devices and then to manufacture of Integrated circuits. To keep in pace with the component and equipment technology, its manufacturing and product assurance facilities have also undergone sea change. The design groups have CADDs facility, the manufacturing has CNC machines and a Mass Manufacture Facility, and QC checks are performed with multi-dimensional profile measurement machines. Automatic testing machines, environmental labs to check extreme weather and other operational conditions are there. All these facilities have been established to meet the stringent requirements of MIL grade systems. Product mix of the company are spread over the entire electromagnetic (EM) spectrum ranging from tiny audio frequency semiconductor to huge radar systems and X-ray tubes on the upper edge of the spectrum. Its manufacturing units have special focus towards the product ranges like Defence Communications, Radars, Optical & Opto-electronics, Telecommunications, Sound and Vision broadcasting, Electronic components, etc. Besides manufacturing and supply of a wide variety of products, BEL offers a variety of services like Telecom and Radar Systems Consultancy, Contract Manufacturing, Calibration of test& measuring instruments, etc. At the moment, the company is installing MSSR radar at important airports under the modernization of airports plan of National Airport Authority (NAA).

independent agency to undertake contemporary design work on state-of-art and futuristic technologies. About 70% of BELs products are of in-house design. BEL was amongst the first Indian companies to manufacture computer parts and peripherals under arrangement with International Computers India Limited (ICIL) in 1970s. BEL assembled a limited number of 1901 systems under the arrangement with ICIL. However, following Governments decision to restrict the computer manufacture to ECIL, BEL could not progress in its computer manufacturing plans. As many of its equipment were microprocessor based, the company continued to develop computers based application, both hardware and software. Most of its software requirements are in real time. EMCCA, software intensive naval ships control and command system is probably one of the first project of its nature in India and Asia. BEL has won a number of national and international awards for Import Substitution, Productivity, Quality, Safety etc.

Today, BEL has set up impressive infrastructure spread in 9 location with 29-production division and manufacturing facilities in their ISO-9001/9002 certified production units around the country. They are Bangalore, Ghaziabad, Pune, Taloja (Maharashtra), Hyderabad, Panchkula (Haryana), Chennai, Machilipathnam (A.P.) and Kotdwara (U.P.) BEL has won a number of national and international awards for Import Substitution, Productivity, Quality, Safety Standardization etc. BEL was ranked no.1 in the field of Electronics and 46th overall among the top 1000 private and public sector undertakings in India by the Business Standard in its special supplement "The BS 1000 (1997-98)". This organization also stands on number 7 th position in the best 100 public and private companies according to the "electronic for u" in 2002. BEL was listed 3rd among the Mini Ratnas (category II) by the Government of India, 49th among Asia's top 100 Electronic Companies by the Electronic Business Asia and within the top 100 worldwide Defence Companies by the Defence News, USA.

VARIOUS UNITS
Its corporate office is at Bangalore. Bangalore complex is the BELs first and largest unit and it accounts for two-thirds of both the companys turnover and manpower. This units product range covers over 300 Defence and Civilian products. Ghaziabad is the second largest unit of BEL and it specializes in radars, communication equipments & microwave-components. In total BEL has got 9 units. These are distributed in all over the India as: BANGALORE (Corporate Office) GHAZIABAD PANCHKULA MACHILIPATNAM PUNE HYDERABAD CHENNAI KOTDWARA TALOJA

JOINT VENTURES
1. BE-Delft Electronics Limited
BE-Delft Electronics Limited, Pune, the first joint venture of the company with Delft Instruments, Holland and UTI was established in the year 1990 for conducting research, development and manufacture of Image Intensifier Tubes and associated high voltage power supplies for use in military, security and commercial systems. Its products include night vision goggles and binoculars, night vision weapon sights and low light level input applications.

2. GE BE Private Limited
GE BE Private Limited, Bangalore, a JV with General Electric Medical Systems, USA has been established in 1997-98 for manufacture of High End Rotating Anode Medical Diagnostic X-ray tube called CT MAX, which is used in CT Scanners. The joint venture unit will also establish a reloading facility for Xray tubes and will also market the conventional X-ray tubes made at Pune Unit of BEL. South ast Asia market are addressed by this joint venture.

3. BEL- Multitone Private Limited

A joint venture between Bharat Electronics and Multitone Electronics Plc, UK has also been established in Bangalore in 1997-98 to manufacture state-of-art Mobile Communication for the workplace. Multitone invented paging in 1956 when it developed the world's first system to serve the "life or death" environment of St. Thomas Hospital, London. With the strength of Bharat Electronics in the Radio Communications field and the technology of Multitone, in the field of Radio Paging, the joint venture company is in a position to offer tailor made solution to the Mobile Communication needs at workplace in various market segments.

CORPORATE MOTTO, MISSION AND OBJECTIVES

The passionate pursuit of excellence at BEL is reflected in repulsion with its customers that can be described in its motto, mission and objectives :

Corporate Motto

Quality, Technology and Innovation

Corporate Mission

To be the market leader in DefenceElectronics and in other chosen fields and products.

Corporate Objectives

(a)

To become a customer-driven company supplying quality products at competitive prices at the expected time and providing excellent customer support. To achieve growth in the operations commensurate with the growth of professional electronics industry in the country. To generate internal resources for financing the investments required for modernization, expansion and growth for ensuring a fair return to the investor. In order to meet the Nation's strategic needs, to strive for self reliance by indigenization of materials and components.

(b)

(c)

(d)

(e)

To retain the technological leadership of the company in Defence and other chosen fields of electronics through in-house. Research and Development as well as through collaboration/cooperation with Defence/National Research Laboratories, International Companies, Universities and Academic institutions. To progressively increase overseas sales of its products and services. To create an organizational culture which encourages members of the organization to realize their full potential through continuous learning on the job and through other HRD initiatives.

(f)

(g) (h)

Quality Policy BEL is committed to consistently deliver enhanced value to our customers, through continual improvement of our products and processes.

Quality Objectives (a) Effective and Efficient design and development process, considering the present and future needs of customers. Enhanced customer satisfaction by on-time delivery of defect free products and effective life cycle support. Continual upgradation and utilization of infrastructure and human resources. Mutually beneficial alliances with suppliers. Continual improvement of processes through innovation, technology and knowledge management.

(b)

(c)

(d) e)

The management of BEL is convinced of the need for Quality Enhancement, on a continuous basis, in the company. Need was felt to impart Education / Training to all the officers on the various facets of quality management. Accordingly, an institute called Bharat Electronics Quality Institute (BEQI) was established in 1999. Bharat Electronics Ltd., (BEL), a premier Professional Electronics Company of India, has established and nurtured a strong in-house R&D base over the years to emerge and remain as a market leader in the chosen areas of business in professional electronics. Besides, there are two Central Research Laboratories (CRL) located at Bangalore and Ghaziabad, to address futuristic technologies of interest to BEL.

Main areas of R&D activities at BEL include development of Military Radars, Naval Systems, Military Communication Products, Electronic Warfare Systems, Telecommunication products, Sound and Vision Broadcasting Equipment and Systems, Opto Electronic Products, and Electronic Components. CRL performs the dual role of carrying out blue sky research for the development of future technologies and supporting the D&E Divisions of BEL's nine units with state-of-the-art core technology solutions in areas like Embedded Computers and applications, Radar Signal Processing, VLSI designs, RF & Microwave Communication Technologies, Software modules etc.

BEL's R&D Units have state-of-the-art R&D infrastructure, facilities, and manpower with relevant technical expertise for product development. There are about 1000 engineers working in BEL on various D&E projects. BEL spends around 5 % of company turnover for the year on R&D every year. HRD Divisions of BEL take adequate initiatives for the all round development and expertise

5.

Defence Army

CUSTOMER PROFILE
Equipment
Tactical and Strategic Communication Equipment and Systems, Secrecy Equipment, Digital Switches, Battlefield Surveillance Radars, Air Defence and Fire Control Radars, Opto-Electronic Instruments, Tank Fire Control Systems, Stabilizer Systems, Stimulators and Trainers. Navigational, Surveillance, Fire Control Radars, IFF, SONAR Systems, Torpedo Decoys, Display Systems, EW Systems, Simulators, Communication Equipment and Systems. Surveillance and Tracking Radars, Communication Equipment and Systems, IFF and EW Systems. Communication Equipment and Systems. Precision Tracking Radars, Ground Electronics, Flight and On-Board Sub-systems. MW, SW & FM Transmitters. Low, Medium and High Power Transmitters, Studio Equipment, OB Vans, Cameras, Antennae, Mobile and Transportable Satellite Uplinks. TV Studios on Turnkey Basis for Educational Programs. Transmission Equipment (Microwave and UHF) and PCM Multiplex, Rural and Main Automatic Exchanges, Flyaway Satellite Terminals, Solar Panels for Rural Exchanges. MCPC VSATs, SCPC VSATs, Flyaway Earth Stations. Hub Stations, Up/Down Convertors, LNA Modems Airport Surveillance Radars, Secondary Surveillance Radars. Cyclone Warning and Multipurpose Meteorological Radars. Satellite Communication Equipment. Communication Systems, Radars. Communication Systems.

Navy

Air Force Non-Defence Para-Military Space Department All India Radio Doordarshan (TV Network) NCERT Department of Telecommunications Videsh Sanchar Nigam and other Corporate Bodies Civil Aviation Meteorological Department Power Sector Oil Industry Forest Departments, Irrigation & Electricity Boards Medical & Health Care Railways

Clinical and Surgical Microscope with Zoom. Communication Equipment for Metros, Microwave .

1. Components
Defence Transmitting Tubes, Microwave Tubes, Lasers, Batteries, Semiconductors-Discrete, Hybrid and Integrated Circuits. Transmitting Tubes, Microwave Tubes, and Vacuum Tubes.

Non-Defence All India Radio, Doordarshan (TV Network), Department of Telecomm and Civil Industries Entertainment Industry

Telephone Industry Switching Industry Instrumentation Industry Medical & Health Care

B/W TV Tubes, Silicon Transistors, Integrated Circuits, Bipolar and CMOS, Piezo Electric Crystals, Ceramic Capacitors and SAW Filters. Integrated Circuits, Crystals. Vacuum Interrupters. Liquid Crystal Displays. X-ray Tubes.

2. Systems / Network
Identity Card Systems Software, Office Automation Software, LCD On-line Public Information Display Systems Communication Networks / VSAT Networks.

6 Formation of unit
In the mid 60's, while reviewing the defence requirement of the country, the government focused its attention to strengthen the air defence system, in particular the ground electronics system support, for the air defence network. This led to the formulation of a very major plan for an integrated Air Defence Ground Environment System known as the Plan ADGES with Prime Minister as the presiding officer of the apex review committee. At about the same time, Public attention was focused on the report of the Bhabha Committee on the development and production of electronic equipment. The ministry of defence immediately realized the need to establish production capacity for meeting the electronic equipment requirements for its Plan ADGES. BEL was then entrusted with the task of meeting the development and production requirement for the Plan ADGES and in view of the importance of the project it was decided to create additional capacity at a second unit of the company. In December 1970 the Govt. sanctioned an additional unit for BEL. In 1971, the industrial license for manufacture of radar and microwave equipment was obtained; 1972 saw the commencement of construction activities and production was launched in 1974. Over the years, the Unit has successfully manufactured a wide variety of equipment needed for defence and civil use. It has also installed and commissioned a large number of systems on turnkey basis. The Unit enjoys a unique status as manufacturer of IFF systems needed to match a variety of Primary Raiders. More than 30 versions of IFFs have already been supplied traveling the path from vacuum technology to solid-state to latest Microwave Component based system. The operations at BEL Ghaziabad are headed by General Manager with Additional / Deputy General Manager heading various divisions - Design & Engineering Divisions, Development and Engineering-R, Development and Engineering-C and Development and Engineering-Antenna. Ghaziabad unit is primarily engaged in manufacture, supply and Turn-key execution of Radars, Communication equipments & Antennas /Systems for defence as well as non-defence sectors. It has four major manufacturing divisions i.e. Radar, Communication, Antenna & Microwave .

PRODUCT RANGE
The product range today companies:

1. Radar Systems:
3-Dimensional High Power Static and Mobile Radar for the Air Force. Low Flying Detection Radar for both the Army and the Air force. Tactical Control Radar Systems for the Army Battlefield Surveillance Radar for the Army 1. IFF Mk-X Radar systems for the Defence and Export 2. ASR/MSSR systems for Civil Aviation. 1. Radar & allied systems Data Processing Systems.

2.

Communications:

3. Digital Static Troposcatter Communication Systems for the Air Force. 4. Digital Mobile Troposcatter Communication System for the Air Force and Army. 5. VHF, UHF & Microwave Communication Equipment. 6. Bulk Encryption Equipment. 7. Turnkey Communication Systems Projects for defence & civil users. 8. Static and Mobile Satellite Communication Systems for Defence 1. Telemetry/Tele-control Systems.

3.

Antenna:
9. Antennae for Radar, Terrestrial & Satellite Communication Systems. 10. Antennae for TV Satellite Receive and Broadcast applications. 11. Antennae for Line-of-sight Microwave Communication Systems.

4.

Microwave Component:

1. Active Microwave components like LNAs, Synthesizer, and Receivers etc. 2. Passive Microwave components like Double Balanced Mixers, etc

Most of these products and systems are the result of a harmonious combination of technology absorbed under ToT from abroad, defence R&D Laboratories and BEL's own design and development efforts.

Organization:
The operations at BEL Ghaziabad are headed by General Manager with Additional / Deputy General Manager heading various divisions as follows: Design & Engineering Divisions : 1. Development and Engineering-R, 1. Development and Engineering-C, 1. Development and Engineering-Antenna. Equipment Manufacturing Divisions :

1) Radar, 1) Communication, Antenna, Systems, I. Microwave Components. a. b. c. d. e. f. g. h. Support Divisions :

Material Management, Marketing & Customer Co-ordination, Quality Assurance & Torque, Central Services, PCB & Magnetics, Information Systems, Finance & Accounts, Personnel & Administration, a. Management Services.

1. Design & Engineering:

The pace of development and technological obsolescence in their field of electronics necessitates a strong Research and Development base. This is all the more important in the area of defence Electronics. BEL Ghaziabad has since its inception laid a heavy emphasis on indigenous research and development. About 70% of its manufacture today relate to items developed in-house. For the development and production of the Mobile Troposcatter System and the IFF equipment, BEL was awarded the Gold Shield for Import Substitution.

Design facilities are also constantly being modernized and substantial computer-aided design facilities are being introduced including installation of mini- and micro-computers and dedicated design application. About 170 graduate and post-graduate engineers are working on research and development and indication of the importance R&D has in BEL's growth. Three Design and Engineering groups are product based viz. Communication, Radar and Antenna. These divisions are further divided into different departments to look after products of a particular nature. Each of them has a drawing office attached to them, which are equipped with latest drafting and engineering software. The PCB layout and PCB master making is done at CADD Centre. A central Records & Printing section takes care of the preserving the engineering documents and distribution thereof. Most of the engineering documents are available online.

2. Equipment Manufacturing Divisions:

As a supplier of equipment to the defence services and professional user, strict adherence to specifications and tolerances has to be in-built into the design and manufacturing process. For this BEL Ghaziabad has well defined standards and processes for as well as manufacturing and testing activities. Activities are divided into various departments like Production Control, Works Assembly, and QC WORKS. The manufacture and control of production is through a central system, BELMAC, BEL's own homegrown ERP system. Apart from conventional machines, BEL Ghaziabad has been equipped with several Computer Numerical Control (CNC) machines for ensuring repeat occurrences and increased throughput. A separate NC programming cell has been set up to develop the programs for execution on the CNC machines. 3.

Microwave Component Group:

Frequencies greater than 1 GHz is termed as Microwaves. Microwaves Integrated Circuits (MIC) used extensively in the production of subsystems for Radar and Communication equipment constitutes a very vital part of the technology for these systems and is generally imported. Owing to the crucial and building block nature of the technology involved, BEL is currently setting up a modern MIC manufacturing facility at a planned expenditure of Rs. 2 crore. When in full operation, this facility will be the main centre for the MIC requirements of all the units of the company. The manufacturing facilities of hybrid microwave components available at BEL, Ghaziabad includes facility for preparation of substrates, assembly of miniaturized component viz. directional couplers, low noise amplifiers, phase shiftier, etc

SPECIFIC PRODUCT OF BEL

Electronics Voting Machine IRMA, INDRA, Reporter, Flycatcher Simulators & Trainers Secure Facsimile (SECFAX) Integrated Fish finder Cum Navigational Guidance Systems (IFFNGS) GPS Based Vehicle Tracking Systems Energy Savers for Air Conditioners Alarm Systems for Railway Unmanned Level Crossings Pager Amplifier/UHF Paging Transmitter Cockpit Display System for LCA Automatic Test Equipment Cellular Antenna PC Mother Board SIMPUTER X-Ray Cables Television Receive Only Antenna Electronic Warfare Equipment Train Actuated Warning System Magnesium Manganese Dioxide Battery Packs Dosimeter Locket Telemedicine System VLSI & ASCIs

7 ROTATION PROGRAMME
Under this the students are introduced to the company by putting them under a rotation program to various departments. The several departments where I had gone under my rotational program is as follows:

1. TEST EQUIPMENT & AUTOMATION 2. P.C.B FABRICATION 3. QUALITY CONTROL (WORKS) 4. MAGNETICS 5. MICROWAVE LAB 6. ENVIRONMENTAL LAB 7. CS- ELECTRICAL 8. WORKS ASSEMBLY-RADAR

During the rotation period , I had to go to various departments, listed above to get some introduction about the work that is being done in that particular department. The co-operative staff at various department made the learning process very interesting, who allowed me to know more about the company in a very short time. The various departments are now given in detail.

TEST EQUIPMENT & AUTOMATION

This department deals with the various instruments used at BEL. There are three hundred equipments and they are of sixteen types.

Examples of some test equipment are:

1. Oscilloscope (C.R.O) 2. Multimeter 3. Signal Analyzer 4. Logical Pulsar 5. Counters 6. Function Generator etc.

Mainly the calibration of instruments is carried out here, they are compared with the standard of National Physical Laboratory (NPL). So it is said to be one set up down to NPL. As every instrument has a calibration period after which the accuracy of the instrument falls from the required standards. So if any of the instruments is not working properly, it is being sent here for its correct calibration. To calibrate instrument software techniques are used which includes the program written in any suitable programming language. So its not the calibration but the programming takes that time. For an industry to gets its instrument calibrated by NPL is very costly, so it is the basic need for every industry to have its own calibration unit if it can afford it. Moreover those unit can make memory by providing their standards to others. who have this

Test equipment and automation laboratory mainly deals with the equipment that is used for testing and calibration.This section calibrates and maintains the measuring instrument mainly used for Defense purpose. A Calibration is basically testing of equipment with a standard one. It is done with the help of standard equipment should be of some make, model and type. The national physical laboratory (NPL) New Delhi provides the standard values yearly. BEL follows International Standard Organization (ISO) standard. The test equipment is calibrated either half yearly or yearly. After testing, different tags are labeled on the equipment according to the observations. GREEN YELLOW RED ---O.K, Perfect --- Satisfactory but some trouble is present --- Cannot be used, should be disposed off.

PRINTED CIRCUIT BOARD (P.C.B.)

INTRODUCTION:As the name suggests, printed circuit board refers to a board on which a circuit is imprinted. The circuit appears as copper tracks on non conducting surface. Here the surface or the board is a glass epoxy sheet with copper coating on either both sides or on one side only. The board material is not restricted to glass epoxy only, it can be any hard surface (non conducting) with copper coating. In some cases we use Teflon sheets also. Generally the PCBs can be categorized in three forms viz.: SINGLE SIDED PCB DOUBLE SIDED PCB MULTI LAYERED PCB In the following sections we would consider the various steps which come together to fabricate a single or double sided PCBs :1-Launching 2-C.N.C. Drilling 3-Through Hole Plating 4-Photo Tool Generation 5-Photo Resist Printing 6-Pattern Plating 7-Resist/Tin Stripping & Etching 8-Solder Masking 9-Hot Air Leveling 10-Reverse Marking 11-Routing, Shearing & Deburring 12-Inspection

QUALITY CONTROL(WORKS ASSEMBLY)

According to some laid down standards , the quality control department ensures the quality of product . The raw materials and components etc. purchased are inspected according to the specifications by I.G. department . similarly Q.C. work department inspects all the items manufactured in the factory. The fabrication department checks all the fabricated parts and ensures that these are made according to the part drawing , painting , plating and stenciling etc are done as per BEL standards . The assembly inspection department inspects all the assembled parts such as PCB , cable assembling , cable form , modules ,racks and shelters as per latest documents and bel standards. The mistakes in the PCB can be categorized as1. D & E mistakes 2. Shop mistakes 3. Inspection mistakes The process card is attached to each PCB under inspection. Any error in the PC is entered in the process card by certain code specified for each error or defect. After a mistake is detected, following action are taken: 1. Observation is made 2. Object code is given 3. Division code is given 4. Change code is prepared 5. Recommended action is taken.

MAGNETICS
This department is making all types of transformers and coils that are used in various equipments. This department basically consists of four sections: 1. Planning section 2. Mechanical assembly section 3. Moldings section 4. Inspection The D & E department gives the following description numbers of layers, numbers of turns /layers, types of winding , gapes in core , insulation between layers , ac/dc impedance , dielectric strength , electrical parameters and earthing. The various types of transformer being made are: 1.Open type transformer 2.Oil cooling types transformer 3.Moulding type transformer 4.PCB moulding type transformer The transformer is mechanically assembled, leads are taken out and checking of specification is done . Winding machines are of three types: 1. Heavier one DNR for 0.1 to 0.4 mm diameter. 2. LC control machine 3. Torroidal machines having 32 operations from winding to mechanical assembly. The various types of windings used are :-

1. Hand-winding 2. Torroidal-winding 3. Sector-winding 4. Pitch-winding 5. Variable winding 6. Wave winding

Two types of cores used are : 1. E-type for 3-phase 2. C-type for singal phase Various procedures involved in the manufacture of transformers are;1. Formers of glass expoxy 2. Winding 3. Core winding 4. Varnishing 5. Impregnation various varnished coils are heated, than cooled, reheated and put into vacuum. Then air is blown to remove the humidity. 6. Moulding-araldite mixed with black dye is used to increase mechanical as well as electrical strength. Moulding is done at 120 degrees centigrade for twelve hours. 7. A RDB compound is used for leakage production . oil is boiled at 70 to 80 degrees under vacuum conditions to remove air bubbles . after the is the cols are dipped in varnish and core is attached. 8. Painting 9. Mechanical assembly

10. Termination 11. Testing: dielectric testing is done at 50 KV voltage applied for a minimum of one minute. During inspection, the following characteristics are checked :(a) Turn ratio (b) DC resistance of or each coil (c) Inductance (d) No load voltage (e) Leakage

MICROWAVE LABORATORY
This section deals with very high frequency measurements or very short wavelength measurements. The testing of microwave components is done with the help of various radio and communication devices. Phase and magnitude measurements are done in this section. Power measurements are done for microwave components because current and voltage are very high at such frequencies. Different type of waveguides is tested in this department like rectangular waveguides, circular waveguides. These waveguides can be used to transmit TE mode or TM mode.This depends on the users requirements.Waveguides work as high pass filters to waves passing through them. A good waveguide should have fewer losses and its walls should be perfect conductors.

In rectangular waveguides the distortion is minimum. Circular waveguides are used where the antenna is rotating. The power measurement being done in microwave lab. are in terms of S-parameters.

Mainly the testing is done on coupler and isolators and parameters are tested here. There are two methods of testing: 1.ATP (Acceptance Test Procedure) 2. PTP (Production Test Procedure) There are several gadget that being design from ATP and PTP technique .Those Depend upon the value of frequency gain, bandwidth, VSWR, phase, return loss, reflection etc. are checked. The instruments used for this purpose are as follows:1.Filters 2.Isolators 3.Reflectors 4.Network Analyzers 5.Spectrum Analyzers 6.Amplifiers and Accessories

CS -(ELECTRICAL)
The main task of this department is to supply power to the all

production units, administrative block and other parts of the factory. This department is arranged into one main station and five sub stations at different locations in the company. The power is received from the Uttar Pradesh Vidyut Board through 33 KV power line at the main station. At the main station the power is stepped down to 11KV using 33/11KV step down transformer. The main station is provided with gang-operated switch, air circuit breakers (ACB), oil circuit breaker (OCB). The air circuit breaker being used is of rating 11000 V , 800 A. The gang operated switch is to be operated always OFF-load. This is operated when there is some fault in the incoming power line. In case we operate the gang operated switch ON-load, large amount of sparks will be produced. There are two transformers at the main station. Out of these two only one is used at a time and second one is standby transformer. i.e. It is operated in case when first transformer does not work properly. Current transformers are used at the main station for the measurement of power consumption. Lighting arresters are used at the main station to protect the station and all the electrical equipments from being damaged. For extra security two different set of lighting arresters are used one above the other so that station is not damaged at any cost and the excess charge gets grounded.

There are five sub stations at BEL which receive the power from main station at 11 KV and stepped down to 433 V for the use of various machines in the factory. The transformers being used at various sub stations are of rating1600 KVA. These sub stations provide power to different divisions of the factory. Like the main station these stations are also provided with lighting arresters, ACBs, OCBs and gang operated switches. In case of power failure there are two generators, which can supply the power to production divisions only, and some other important sections. These generators are imported from Czechoslovakia and are of Ascorda make. These generators are air starting type and need a pressure of 1000 Pound for starting. These can develop a power of 325 bhp. And consume 400 Litres/Hr. of diesel each. Each generator is having 6 cylinders. These have a firing order of 15-36-24 to operate the cylinders in the same order. These are of capacity 860 KV and each generator generates 400 V at 50 Hz.This voltage is stepped up by a transformer to 11KV and supplied to the sub stations

ENVIRONMENTAL LAB
Various tests are conducted in the environmental lab in BEL in order to ensure reliability. Reliability is defined as the probability of a device performing its purpose adequately for the period intended under the given operating condition. In a given reliability is given as The standards available here are: JSS55555- Joint services specifications ( Military Standard of India) MII Standards U.S Military standers QM333 Civil Avitation and police

VARIOUS TESTS :1. Thermal Shock Test 2. High Temperature Operate and Storage 3. Low Temperature Operate and Storage 4. Altitude Test 5. Bump / Vibrations Test 6. Salt Spray Test 7. Tropical Exposure Test 8. Rain Test 9. Humidity Test 10. Dust Test 11.Transportation Test 12. Shock Test 13. Burn in Test

WORKS ASSEMBLY
This department plays an important role in the production. Its main function is to assemble various components, equipments and instruments in a particular procedure. It has been broadly classified as :

WORK ASSEMBLY RADAR

e.g.:INDRA-2, REPORTER

The stepwise process followed by work assembly department is: 1. Preparation of part list that is to be assembled. 2. Preparation of general assembly. 3. Schematic diagram to depict all connect to be made and brief idea about all components. 4. Writing list of all components. In work assembly following things are done.

Preparation:
This is done before mounting and undertakes two procedures.

Tinning:
The resistors, capacitors and other components are tinned with the help of tinned lead solution. The wire coming out from the component is of copper and it is tinned nicely by applying flux on it is so that it does not tarnished and seventh soldering becomes easy.

Bending:
Preparation is done by getting the entire documents j, part list drawing and bringing all the components before doing the work.

Mounting:
It means soldering the components of the PCB plate with the help of soldering tools. The soldering irons are generally of 25 W and are of variable temperature, one of the wires of the components is soldered so that they dont move from their respective places on the PCB plate. On the other hand of the component is also adjusted so that the PCB does not burn.

Wave Soldering:
This is done in a machine and solder sticks on the entire path, which are tinned. Wave soldering machine consists of following parts 1. Conveyor 2. Fluxer 3. Heater 4. Flux Cleaner

Touch up:
This is done by hand after the finishing is done.

Inspection:
This comes under quality work.

Heat ageing:
This is done in environment lab at temperature of 400C for 4 hrs and three cycles. Lacquering: Lacquering is only done on the components, which are not variable.

8 INTRODUCTION TO RADAR :
RADAR :RADAR is an abbreviation of word RADIO DETECTING AND RANGING. It is an electromagnetic system for detection and location of object. It operates by transmitting a particular type of waveform. An elementary form of radar consists of a transmitting antenna emitting electromagnetic radiation generated by an oscillator, a receiving antenna, and an energy detecting device or receiver. A position of the transmitted signal is intercepted by a reflecting object (target) and is re-radiated in all the directions. The receiving antenna collects the returned energy and delivers it to a receiver, where it is processed. The distance to the target is determined by measuring the time taken by the radar signal to travel and come back. The direction or angular position of the target may be determined from the detection of arrival of the reflected wavefront . APPLICATION OF RADAR has been employed on the ground, in air, on the sea and in space. Some important areas of applications are :Air traffic control ( ATC ) A ir craft navigation Ship safety Space Remote sensing Military WORKING OF A SIMPLE RADAR A simple RADAR system, as found on many merchant ships, has three main parts. These are:-

1. Antenna unit or the scanner. 2. the transmitter/receiver or transceiver and the visual display unit.

The antenna is about 2 or 3 meters wide and focuses pulses of very high frequency radio energy into a narrow vertical beam. The frequency of the radio waves is usually about 10,000 MHz. the antenna is rotated at the speed of 10 to 25 revolutions per minute so

that the radar beam sweeps through 300 degrees all around the ship out to a range of about 90 kilometers. In all RADARS it is vital that the transmitting and receiving in the transceiver are in close harmony. Everything depends on accurate measurement of the time which passes between the transmission of the pulse and the return of the ECHO about 1,000 pulses per second are transmitted. Though it is varied to suit requirements. Short pulses are best for short-range work, longer pulses are better for long range. An important part of the transceiver is the modulator circuit. This keys the transmitter so that it can oscillate, or pulses, for exactly the right length of time. The pulses so generated are video pulses. These pulses are short range pulses and hence cannot serve out purpose of long-distance communication. In order to modify these pulses into radio frequency pulses or RF pulses, we need to generate power. The transmitted power is generated in a device called magnetron, which can handle these very short pulses and very high oscillations. Between each pulse, the transmitter is switched off and isolated. The weak echoes from the target are picked up by the antenna and fed into the receiver. To avoid overlapping of these echoes with the next transmitted pulse, another device called duplexer is used. Thus, by means of a duplexer, undisturbed, two-way communication is established. The RF echoes emerging from the duplexer are now fed into the mixer where they are mixed with pulses of RF energy. These pulses are generated by means of a local oscillator. Once the two are mixed, a signal is produced in the output witch is of intermediate frequency range or IF range. The IF signals is received by a receiver where it is demodulated to video frequency range, amplified, and then passed to the display unit. The display unit usually carried all the controls necessary for the operation of the whole radar. It has a cathode ray tube, which consist of an electron gun in its neck. The gun shoots a beam of electron at a phosphorescent screen at the far end. The phosphorescent screen glows when hit by the electrons and, the resulting spot of light can be

seen through a glass surface. The screen is circular and is calibrated in degrees around its edge. The electron beam travels out from the center to the edge. This random motion of the electron beam, known as the trace, is matched with the rotation of the antenna. So, when the trace is at zero degrees on the tube calibration, the antenna is pointing dead ahead. The beginning of each trace corresponds exactly which the moment at which the radar energy is transmitted. When an echo is received it brightens up the trace for a moment. This is a blip, and its distance from the center of the tube corresponds exactly with the time taken for the radar pulse to travel to the target and return. So that blip on the screen gives the range and bearing of the target. As the trace rotates, a complete picture is built up from the coating of the tube. This type of display is called a PPI (plane position indicator) and is the most common form of presenting radar information. TYPES OF RADAR Based on its functions, RADAR may be classified as: 1. PRIMARY RADAR AND 2. SECONDARY RADAR A PRIMARY RADAR locates an object by transmitting a signal and detecting the reflected echo. A SECONDARY RADAR SYSTEM is similar in operation to primary radar except that the return signal is radiated from a transmitter on board the target rather than by reflection. In other words, secondary radar operates with a co-operative ACTIVE TARGET while the primary radar operates with a PASSIVE TARGET. But in cases such as controlling of air traffic, the controller must be able to identify the air craft and know whether it is of a friend or a foe. It is also desired to know the height of the aircraft, so that on the same source but flying at different levels can be kept apart. To give the controller this information, a second radar called a secondary surveillance radar (SSR) is used. This works differently and needs the help of the target aircraft. It senses out the sequence of pulses to an electronic black box, called an transponder fitted on the aircraft. The basic operation of a secondary radar is as follows:

SECONDARY RADAR SYSTEM The secondary radar system consists of an INTERROGATOR and a TRANSPONDER. The interrogator transmitter in the ground station interrogates transponder equipped aircraft, providing a two way data link to separate transmit and receive frequencies. The transponder, on board the aircraft, on receipt of a chain of pulses from the ground interrogator, automatically transmits a reply. The reply, coded for purposes of Identification is received back at the ground interrogator where it is decoded and displayed on a radar type presentation. The secondary radar gives the aircraft identity code and height data derived from a pressure capsule in the aircraft. In the Secondary Surveillance Radar (SSR), by providing the interrogation pulses above the minimum triggering level, the transponder makes a powerful reply. This enables the interrogator transmitters to be of lower power and the ground equipment simpler.

IFF ANTENNA

RF SWITCH UNIT

TRANSMITTER RECEIVER MK X DECODER MODE S DRAWER

REMOTE CONTROL PANEL CONTROL UNIT

(INTERROGATOR DECODER) GROUND / SHIP INTERROGATOR

PPI