SUMMER TRAINING REPORT

MAHENDRA KUMAR VERMA Roll No. 0921531041 B.TECH (ECE)

SHREE GANPATI INSTITUTE OF TECHNOLOGY
Mahendra Kumar Verma[SGIT]

ROLL NO. 0921531041

Mo.9716405186 7/10/2012

MICROWAVE ELECTRONICS DIVISION CENTRAL ELECTRONICS LIMITED SAHIBABAD GHAZIABAD (U.P.) INDIA

Acknowledgements
P r e p a r i n g a p r o j e c t o f t h i s n a t u r e i s a n a r d u o u s t a s k a n d I w a s fortunate enough to get support from a large number of persons to w h o m I s h a l l a l w a ys r e m a i n g r a t e f u l . I w o u l d l i k e t o r e c o r d m y gratitude to Central Electronics Ltd for allowing me to undertake this project. I would also like to thanks all the respondents for give me their precious time and relevant information and experience, I require which this project would have been different stories. Finally we extend our gratefulness to one and all who are directly or indirectly involved in the success-Full completion of this project work.

Mahendra Kumar Verma

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CONTENTS
1. Company profile......................................................................4 1.1. The organisation CEL....................................................4 1.2. Divisions of CEL...........................................................4 2. Microwave electrionics division................................................5 2.1. Phase controlled module................................................5 2.2. Power deviders/combiners.............................................5 2.3. Hybrid couplers.............................................................6 2.4. Phase/frequency correlator.............................................7 2.5. C-band ferrite phase shifters..........................................7 2.6. X-band ferrite phase shifters..........................................8 3. Railway electronics...................................................................9 4. Solar photovoltic division.......................................................9 5. Cathodic protection.................................................................11 6. Ceramics..................................................................................12 7. Working of phased array radars............................................14 7.1 phased array antenna.......................................................14 7.2 possible arrangements.......................................................15 7.3 linear arrays......................................................................16 7.4 planner arrays...................................................................17 7.5 frequency scanning arrays.................................................18 7.6 phase increment calculating...............................................19

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1. COMPANY PROFILE
Central Electronics Limited is a Public Sector Enterprise under the Department of Scientific and Industrial Research (DSIR), Ministry of Science & Technology, Government of India. It was established in 1974 with an objective to commercially exploit the indigenous technologies developed by National Laboratories and R&D Institutions in the country. CEL is one of the rare companies, which utilized the homegrown technologies during all these years of its existence. CEL has developed a number of products for the first time in the country through its own R&D efforts and in close association with the premier National & International Laboratories including Defense Laboratories. In recognition of all these efforts, CEL has been awarded a number of times with prestigious awards including National Award for R&D by DSIR. CEL is pioneer in the country in the field of Solar Photovoltaic (SPV) and it has developed stateof-the-art technology with its own R&D efforts. Its Solar products have been qualified to International Standards EC503/IEC1215 by the European Commission, Joint Research Centre, and ISPRA, ITALY. CEL, pioneer in the field of Railways Safety & Signaling, has been identified as a major indigenous agency for design and development of modern electronic Signaling and Safety equipment by Indian Railways. The equipment manufactured in CEL finds extreme usage in Railways in the form of Axle Counter, Axle Counter Block System and Train Approach Warning Devices. CELs Digital Axle Counter is approved as per European CENELEC safety level SIL-4 by RDSO (Research, Design and Standard Organization of Indian Railways) as an approved source in Part-I (i.e. approved for bulk production) for various Railway Safety and Signaling Equipments for more than 25 years. CEL has developed a number of critical components for strategic applications and is supplying these items to Defence

1.1 Divisions of CEL

1. 2. 3. 4. 5. Microwave electronics division Railway electronics Cathodic protection Ceramics Photovoltic cells division

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2. MICROWAVE ELECTRONICS DIVISION

CEL has the capability and infrastructure for the design and manufacture of Microwave ferrite phase shifters or Phase Control Modules (PCM) for use in the phased array radars - a capability possessed by very few in the world. In addition, CEL has also the Software & Hardware capability to design/manufacture DF systems. Phase/Frequency Correlators, Antennas, selected MW Components, such as Filters, Power Dividers/Combiners, Hybrid Couplers, specific MIC/MWIC components in Microstripline/Stripline/Finline geometry, design of ASIC, etc. Technology linkages have been institutions/laboratories of the country.

setup

with

the

following

prestigious

R&D

Electronics Radar Development Establishment (LRDE), Bangalore. Defence Electronics Research Laboratory (DLRL), Hyderabad. Defence Research and Development Laboratory (DRDL), Hyderabad. Indian Institute of Technology (IIT), Delhi. Solid State Physics Laboratory (SSPL), Delhi. Defence Electronics Applications Laboratory (DEAL), Dehradun.

2.1. PHASE CONTROL MODULE : A Phase Control Module (PCM) forms the core element of the phased array radar that acquires the basic capability of inertialess switching of the RF beam and scanning in minimal time. The design of C - and X- band phase shifters has been standardised at CEL. In this regard, significant progress has been made on the project in close collaborations with Indian Institute of Technology (IIT), Delhi and Solid State Physics Laboratory (SSPL), Delhi. Presently, CEL is supplying PCMs to Electronics and Radar Development Establishment (LRDE), Bangalore, for use in the Rajendra Radar. Parameter C Band X Band Bandwidth 500MHz 500 MHz RF Power 250 W Peak 150 W Peak Switching Time 150 ms 150 ms Insertion Loss 0.6-0.8 dB 0.7-0.9 dB Operating Temp. 0 to +60 C 0 to +60 C Temp. Stability 0.5 deg/ C 0.5 deg/ C Weight 80 gms 30 gms 2.2. POWER DIVIDERS/COMBINERS : A power splitter is a passive device which accepts an input signal and delivers multiple output signals with specific amplitude and phase characteristics. We can design and develop N-port power dividers for any specified band and for given specifications. The dividers being reciprocal
m

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in nature may be used as power combiners as well. SPECIFICATIONS : Amplitude Phase Balance Balance 0.5-2 GHz 0.2 dB 25 dB 0.1dB 1 2-8 GHz 0.4 dB 25 dB 0.3 dB 1.5 8-18 GHz 0.75 dB 20 dB 0.5 dB 2 DLRL, Hyderabad has transferred the technology for these components to CEL. 2.3. HBYBRID COUPLERS : Hybrid, a four port symmetrical device is a special class of directional couplers. Quadrature and 180 deg hybrids are the most commonly used microwave components. We can take up development of directional couplers in a specified configuration for a specified frequency band. SPECIFICATIONS : Freq.Band Ins. Loss Return Loss Amplitude Balance Phase Balance 0.5-2 GHz 0.2 dB 25 dB 0.1dB 2.5 2-8 GHz 0.4 dB 24 dB 0.3 dB 3 8-18 GHz 0.75 dB 20 dB 0.5 dB 3.5 The basic design for the couplers has been acquired from DLRL, Hyderabad. 4.4. PHASE/FREQUENCY CORRELATOR : Frequency correlators are used in systems for measuring frequency, and the phase correlators are used to correlate the phases of two signals of same frequency. Output of these devices are two video signals in quadrature, which correlate the phase/frequency of the incoming signals. CEL has complete production and development base for these devices. The basic design of these correlators has been transferred from Defence Electronics Research Laboratory, Hyderabad. PARAMETER SPECIFICATIONS Frequency Range 0.5 - 2GHz 2 - 8 GHz Deviation from Best 15 15 Fit Straight Line Input VSWR 2.5 Typ. 3.0 Max 2.5 Typ. 3.0 Max Output Video 50mv Min. 50 mv Min. Voltage Levels 300mv Max. 300mv Max RF Input Power +8 to +12 dBm +8 to +12 dBm Operational Temp. -40C to +70C -40C to +70C Freq.Band Ins. Loss Return Loss

2.5. C-BAND FERRITE PHASE SHIFTER

Data Sheet: F0003

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Electrical Specification Frequency Range Bandwidth Applications

5.0 to 6.5 GHz 10% 4 kW 75 W 0.9dB @ 20C av. 0.25B @ 25C av. 20 dB 10 kHz

Peak Power

3-D Air, Ground and Naval Average Power Radars Satellite Beam Forming Insertion Loss Networks Insertion Loss Modulation Return Loss PRF Phase (inclusive phase) Phase Bits Frequency Bits Switching Time Power Consumption Temperature Range Connectors Interface Weight Accuracy of insertion

Features

Frequency ranges available include S-Band to Ku-Band High peak and average power designs Integrated electronic driver Temperature compensation BITE Accurate differential and insertion phase control Transmit/receive operati

3 rms 8 2 10 Sec +24V 600mA av current -40 C to +100 C 10mm high Waveguide WR159 Tx/Rx mode. Serial & Parallel Interface 1.2kg nominal

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2.6. X-band dual channel ferrite phase shifter

Data Sheet: F0002 Applications

Electrical Specification 10.0 to 14.0 GHz 15% 2 kW (approx) 100 W 0.25dB max 0.02dB max 25 dB 120

3-D Air, Ground and Naval Radars Frequency Range Beam Forming Networks Phase element for a Power Bandwidth Divider or SPDT switch Peak Power Average Power Insertion Loss Insertion Loss Modulation Return Loss Phase range Insertion Phase Shift repeatability between channels Phase Dispertion over a 15% bw Differential Phase Tracking between channels Differential Phase shift variation across operating Temperature range

Features

Frequency ranges available include S-Band to Ku-Band High Peak and Average Power Designs Optional Integrated Electronic Driver Temperature Compensation BITE Accurate Differential and Insertion Phase Control Transmit/Receive Operation

2 max

1.5 max

4 max

30 max

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Insertion Phase Variation Power Consumption

0.3/C max +24V 600mA av current

Temperature Range - Operating - Storage Connectors -15C to +90C -40C to +100C Waveguide WG height 4.76mm WR75

Interface

N/A. Within the context of the final system the unit plugs directly into a PCB. 50g max

Weight

3. RAILWAY ELECTRONICS
Electronic Systems Group This Unit of the company is a pioneer in the design and manufacture of Railway signaling and safety equipment and other electronic products. The Company is a pioneer in the design and manufacture of Railway signaling and safety equipment on turnkey basis. Various solutions provided include; Single Section Digital Axle Counter DACF 700 A/ AP Salient Features: Track side electronic counting equipment

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Web type Axle Detector Compatible with 90R 52Kg and 60 Kg rail profiles Detection of all wheels with diameter > 400mm Normal operation during water logging on rails Easy to install, commission and maintain

Universal Axle Counter ACS - 55 / 56 / 57 Salient Features: Conventional & low cost Axle Counter Eliminates the need for wooden sleepers Centrally powered battery of 24 V/80 AH Green/Red LED indication for track clear/ occupied status Reset facility for maintenance.

Axle Counter Block System DBS-245B / SBS-247A Salient Features: Electronic Signaling system for Block proving Last vehicle is checked automatically Line clear by pressing push button on SM Panel Train on Line and Line Closed conditions is achieved automatically Modular design of equipment Easy to install and maintain

Multi Section Digital Axle Counter MSDAC 730 Salient Features: Track side electronic field units Web type Axle Detectors Section wise vital relay output Can monitor upto 40 detection points ESM monitoring panel for maintenance Section wise reset facility

Train Actuated Warning Device - TAWD 62/63 Salient Features:

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Train detection at remote units for warning Automatic actuation and stopping of warning at gate Warning stops just after train departs LC gate 10 minutes stand by mode operation Data and power to remote units on 1/2 quad cable Solar powered system (24V DC) 100db audio warning to the road user Red and Yellow LED signals for road user

4. Solar Photovoltaic Division

The function of this business unit is to manufacture and market Solar Voltaic Cells, Modules and complete systems in India & Abroad. Central Electronics Limited (CEL) is the pioneer and the largest manufacturers of Solar-Photovoltaic (SPV) Cells, Modules and Systems in India. Through sustained in-house development and constant R&D efforts, spread over a decade of continuous efforts, the company has converted a laboratory into an industrial technology. CEL, with its commitment to harness the solar energy, has opened up new vistas in the field of solar photovoltaic. Backed by an integrated production facility to manufacture Mono-Crystalline Silicon Solar Cells and Modules with the state-of-the-art screen-printing technology, the company has supplied more than 1.5 Lakhs SPV Systems in India and abroad, covering both rural and industrial applications CEL products conform to stringent National & International Standards. The PV modules are tested to JPL Block V.1981 and European Solar Test Installation (ESTI) Standards. Our modules have been successfully tested by Solar Energy Centre (SEC) of the Ministry of Non-conventional Energy Sources (MNES), Govt. of India and JRC-EC, Ispra, Italy. CEL's Solar Photovoltaic modules are the only ones from India certified both for design and quality by the European Commissionn - Joint Research Centre at Ispra, Italy

5.CATHODIC PROTECTION

If your Organization is transporting petrochemicals through underground pipelines, you are probably spending a lot on maintenance costs. Because underground pipelines come into contact with water and water saturated soil which contain salt and oxygen. Due to this combination, an electro-chemical reaction takes place between metal and surrounding
m

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soil, resulting in corrosion of a complex nature. This results in damage to underground pipelines and leakage of valuable petrochemicals that may go undetected for a long time. Periodic change of pipelines, as a remedy, results in disruption of supply and involves extremely high investments. CEL supplies Automatic Electronic Cathodic Protection (Anti-corrosion) Systems for the protection of Oil/Gas Pipelines to Organizations like Indian Oil Corporation (IOC), Oil & Natural Gas Corporation Ltd.(ONGC), Gas Authority of India Ltd. (GAIL), etc. CEL supplies the CP Systems with Solar Photovoltaic or Thermo Electric power sources or for operation on Grid Supply. CEL's cost effective Anti-Corrosion Technology for Underground Pipelines: Now, CEL brings you the Solar Powered Cathodic Protection System, an impressed current type cathodic protection method that continuously guards underground pipelines against rust and corrosion, in all kinds of soils and weather. This system forces a continual flow of electric current to pass from the embedded anode through the soil and into the pipeline, thus creating an electric field at the surface of the metal. The result is an invisible shield over the entire length of the pipeline to guard against all corrosive elements, at all times. This extends the life of the pipeline and eliminates the need for replacement. In addition, the system is solar powered and runs on solar energy which is entirely free! This system also stores the energy provided by the solar photovoltaic cells in a battery bank. This enables it to provide a continual source of energy, even in remote, unelectrified areas. This makes running costs almost negligible. However, it also compares favorably on investment even when it is worked on A.C. mains. An added advantage is the fact that since the system is modular it is adaptable to small as well as long sections of pipelines and can be custom-built to fit individual needs.

6.CERAMICS

A variety of Piezo ceramics materials based on Lead Zirconate Titanate composition have been standardized for low power as well as high power applications. These materials can be tailor made to various shapes and sizes. To meet customer requirements, CEL's capability in the area

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of High Alumina up to 99% is planned to be exploited to meet potential large volume requirements of substrates, bearings, bulletproofing etc. Piezoelectric Ceramics Transducer Elements: Central Electronics Ltd. has standardized a variety of piezoelectric ceramic materials based on Lead Zirconate Titanate compositions, these materials can be tailor-made to various shapes and dimensions to suit individual requirements. The piezoelectric Ceramics Elements made by CEL are already in use in the industry, research institutions and defence establishments. The major advantage of piezoelectric ceramic bodies is that they have a high electrical to mechanical or vice versa conversion efficiency, Which makes it a versatile material for a variety of transducer applications. PZT-A is used for low power systems and in other applications where is required high dielectric constant, high voltage sensitivity, volume resistivity and stability over a wide temperature range. It is most suitable for making the low power transducers, acoustic sensing elements, flaw detection probes etc. PZT-B is used for high power applications where high electro-m3echanical coupling coefficient and low di-electric losses under high driving field and a high coercive field are essential. This accepts more AC driving field without depoling and is ideally suited for high power electro-acoustic devices, ultrasonic cleaners, high voltage generators, high power sonar, etc. PZT-C is again used for high power applications. It is an excellent choice when the highest electrical drive is required. Due to its excellent dielectric stability and low mechanical loss at high drive conditions it is used for ultrasonic welding, ultrasonic mixing/dispersion, ultrasonic surgery and some chemistry etc. PZT-5J is used for low power applications where high permittivity and a high piezo electric voltage constant required. This material is used in fuses, hydrophones and other applications that require a combination of high energy and high voltage output. PZT 5H is again used for low power applications where extremely high permittivity, coupling co-efficient and piezoelectric charge constant required. It is an excellent material for field flow sensors, level sensors, ultrasonic NDT applications and material imaging applications MATERIAL CHARACTERISTICS A PHYSICAL SYMBOL PZT -A PZT-B PROPERTIES * 1 Density gm/cc r 7.6 7.5 2 Curie Temperature Tc. 320 C 300 C 3 Mech. Q Qm 85 400 B DIELECTRIC PROPERTIES:
m

PZT-C PZT-5H PZT-5J PZT-5C 7.6 300 C 1000 7.4 210 C 70 7.5 225 C 70 7.6 180 60

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1 Dielectric Constant at 1 K3t 1600 KHz 2 Dissipation factor at 1 D.F. 0.02 KHz 3 Resistivity W.cm 10 12 C ELECTRO-MECHNICAL DATA: 1 Coupling co-efficient kp 0.55 K31 0.31 K33 0.68 2 Piezoelectric Charge d33 3.50 constant (10 12 Coulombs/Newton) 3 Piezoelectric voltage g33 25 constant (10 -3 volts meter/Newton) D FREQUENCY CONSTANTS: 1 Radial Mode (Hz -meter) Np 2000 2 Thickness Mode (HzN3T 1800 meter)

1250 0.005 10 12 0.52 0.28 0.65 2.40

1000 0.004

3250 .02

2600 .02

4200 .02

0.51 0.30 0.60 225

0.56 0.34 0.68 580

0.62 0.37 0.72 480

0.65 0.40 0.70 700

22

25.4

20

20

17.4

2200 1900

2340 2070

2000 1950

1980

1980 1890

* These typical values are provided for design information only. Standard tolerances are +/- 20% of these values measured after 24 hours of Polarization at 25oC. Piezoelectric Elements

Circular Discs of different diameters to a maximum of 100 cm and thickness upto 15 mm can be supplied. Frequency Discs available upto 10 MHz Square plates. Cylinders and Rings. Piezoelectric elements for gas ignition. Transducer plates for Electronic Buzzers, Alarms, etc./
o

Working of phased array radar

7.1 Phased Array Antenna

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Figure 1: left: two antenna elements, fed with the same phase, right: two antenna elements, fed with different phase shift A phased array antenna is composed of lots of radiating elements each with a phase shifter. Beams are formed by shifting the phase of the signal emitted from each radiating element, to provide constructive/destructive interference so as to steer the beams in the desired direction. In the figure 1 (left) both radiating elements are fed with the same phase. The signal is amplified by constructive interference in the main direction. The beam sharpness is improved by the destructive interference.

In the figure 1 (right), the signal is emitted by the lower radiating element with a phase shift of 22 degrees earlier than of the upper radiating element. Because of this the main direction of the emitted sum-signal is moved upwards. (Note: Radiating elements have been used without reflector in the figure. Therefore the back lobe of the shown antenna diagrams is just as large as the main lobe.) The main beam always points in the direction of the increasing phase shift. Well, if the signal to be radiated is delivered through an electronic phase shifter giving a continuous phase shift now, the beam direction will be electronically adjustable. However, this cannot be extended unlimitedly. The highest value, which can be achieved for the Field of View (FOV) of a phased array antenna is 120 (60 left and 60 right). With the sine theorem the necessary phase moving can be calculated. The following figure graphically shows the matrix of radiating elements. Arbitrary antenna constructions can be used as a spotlight in an antenna field. For a phased array antenna is decisive that the single radiating elements are steered for with a regular phase moving and the main direction of the beam therefore is changed. E.g. the antenna of the RRP 117 consists of

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1584 radiating elements arranged in an analogue beamforming architecture. More sophsticated radar sets use the benefits of a Digital Beamforming architecture.
Advantages

Disadvantages

high gain width los side lobes Ability to permit the beam to jump from one target to the next in a few microseconds Ability to provide an agile beam under computer control arbitrarily modes of surveillance and tracking free eligible Dwell Time multifunction operation by emitting several beams simultaneously Fault of single components reduces the capability and beam sharpness, but the system remains operational

the coverage is limited to a 120 degree sector in azimuth and elevation deformation of the beam while the deflection low frequency agility very complex structure (processor, phase shifters) still high costs

7.2 Possible arrangements

Linear arrays

Figure 3: linear array of a phased-array antenna These antennae consist of lines whose elements are fed about a common phase shifter. A number of vertically about each other mounted linear arrays form a flat antenna.

Advantage: simple arrangement Disadvantage: Ray deflection only in a single plane possible Examples given:

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o o o

PAR-80 (horizontal beam-deflection) and RRP-117 (vertical beam-deflection) Large Vertical Aperture (LVA), an antenna with fixed beam pattern.

This kind of the phased-array antenna is commonly used, if the beam-deflection is required in a single plane only because a turn of the complete antenna is anyway carried out ( RRP-117).

Figure 4: planar array of a phased-array antenna

Planar Arrays
These antenna arrays completely consist of singles radiating elements and each of it gets an own phase shifter. The elements are ordered in a matrix array. The planar arrangement of all elements forms the complete phased-array antenna.

Advantages: Beam steering in two planes or even the digital beamforming is possible. Disadvantage: complicated arrangement and more electronically controlled phase shifter needed Examples given: AN-FPS-85 and Thomson Master-A

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Figure 5: frequency scanning array

7.3 Frequency Scanning Array

Frequency scanning is a special case of the phased array antenna where the main beam steering occurs by the frequency scanning of the exciter. The beam stearing is a function of the transmitted frequency. This type of antenna is called a frequency scanning array. The normal arrangement is to feed the different radiating elements from one folded waveguide. The frequency scanning array is a special case of serial feeding type of a phased array antenna and is based on a particular property of wave propagation in waveguides. The phase difference between two radiating elements is n360 at the normal frequency. By changing the frequency, the angle s between the axis of the main beam and the normal on the array antenna changes. Height information is generated using the following philosophy:

If the transmitted frequency rises then the beam travels up the face of the antenna; If the transmitted frequency falls then the beam travels down the face of the antenna.

As frequency is varied, the beam axis will change, and scanning can be accomplished in elevation. The radar set is designed so that it keeps track of the frequencies as they are transmitted and then detects and converts the returned frequencies into 3D display data.

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7.4 Phase increment calculating

Note that frequency scanning reduces the value of using frequency change as a means of achieving other valuable effects (benefits of pulse compression). The phase shift between two successive elements is constant and is called phase-increment. How large is this phase shift to reach a certain value of the beam steering? A linear arrangement by isotropic radiating elements is looked at.

Figure 6: grafic derivation of the formula

Example given:

A radar set works with a wavelength of =10 cm. The distance between the radiating elements is 15 cm. We can neglect the propagation time differences by the feeder.

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The beam steering shall be s= 40. Which value shall have to have the phase shifter no. 8 (on the left side) to get this beam steering?

Task:

We start with the calculation of the phase-increment. Because of the trigonometrical function we need a calculator anyway: =(36015 cm/10 cm)sin(40) = 347.1. This means the radiating element no. 8 needs the phase shift value 8 = 7 347.1 = 2429.7. On reason of the periodicity of the sine function a phase shifting of n360 is the same as 0. Therefore we can as long as deduct 360 till there is a angle between 0 and 360 of the result. We get therefore for the phase shifter number 8 (left corner) a phase shift value of 8 = 269.7. A part of this phase shift is realized by the delay in the feeding line yet.

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