Project Report

Submitted to the Department of Electronics

In Partial Fulfillment for the award of degree of

B.Tech (Electronics)

Under the Supervision of

MR. Anish chauhan (Senior Engineer Assistant)

By

NITIN DHINGRA (2306218)(2008)

BHARAT ELECTRONICS LTD.

Ambala College of Engineering and Applied Research, Mithapur

Kurukshetra University, Kurukshetra

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CERTIFICATE

TO WHOM SO EVER IT MAY CONCERN

This is to certify that Mr. NITIN DHINGRA bearing Roll No. 2306218 Department of

Electronics & communication Engineering , Ambala college of engineering & applied

Research , Mithapur , Ambala Affiliated to Kurukshetra University, has completed six

weeks training at BEL ,405 ,Industrial Area, Phase-III, Panchkula. His work and conduct

is found excellent to My knowledge .

Dated: MR . Anish Chauhan

Senior Engineer Assistance ,

(S.E.A)Bharat Electronics Ltd.,

Panchkula.

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ABSTRACT

During the first two weeks of my training, we were introduced to various departments of Bharat Electronics. During that period, we came to know about their working, their motive behind work and in which way they are contributing towards the development

Here in the Panchkula unit, I had the previlege of going through products used by our Indian Defence Services, At the time of war and day to day activities and in commercial applications.

Here are the following examples:

(a) STARS – V(secure tactical army radio system) – It was used in KARGIL WAR and it is used to provide 2320 Channels with 25 kHz spacing , 250 hops per sec for FH radios and has inbuilt GPS services .

(b) CNR( composite net radio) - It is frequency controlled hopping radio based on digital signal processing technology (DSP) . It has automatic re – broadcast facility and Modular construction.

(c) SECTEL( secure telephone ) - It is compact , full duplex Subscriber end Secrecy Device (SESD) Providing a high grade of secrecy on telephone lines .

(d) SECURE UHF HANDHELD RADIO- It is UHF handheld radio with inbuilt high grade digital secrecy.It has 16 preset frequencies, Antennas of helical and magnetic mount.

(e) DBC ( dual battery charger )- It is used the battery which is used in VPS set . It can charge the two batteries at the same time.

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I am highly indebted BEL Panchkula, one of the leading organizations of our nation, for getting me

undertake six weeks training course with them. It was really a very nice experience as we come to

know how actually the company strives hard to keep up the national security at par with the rest of the

world. I would like to express my gratitude towards Mr. Dinesh Kumar Dhiman (Manager HRD) who

allowed us to join BEL as a trainee & helped us in every possible way so that we could complete our

training successfully. I also thank Mr. Anish Chauhan (Senior Engineer Assistance, S.E.A), who was

there to support us whenever we needed help at every point of our training.

Last but not least I would like to thank all the staff members of BEL who made this training rich

experience & a success.

NITIN DHINGRA

UPPT NO. 3880

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CHAPTERS DESCRIPTION PAGE No. CHAPTER- 1 INTRODUCTION

CHAPTER- 2 REVIEW

CHAPTER- 3 TRAINING WORK

(a) Organization.

(b) Products Manufactured.

(c) Product Groups.

CHAPTER- 4 RESULTS AND

DISCUSSION

CHAPTER- 5 CONCLUSION AND

FUTURE SCOPE

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INTRODUCTION

With the ongoing revolution in electronic & communication where innovations are taking at the blink

of eye, it is impossible to keep the pace with the emerging trends. Excellence is an attitude that whole

of human race is born with. It is the environment that makes sure that whether the result of this attitude

is visible or otherwise. A well planned, properly executed and evaluated industrial training helps a lot

in including a professional attitude. It provides a linkage b/w the student and industry to develop an

awareness of industrial approach to problem solving, based on broad understanding of process and

mode of operation of organization.

During this period, the student gets the real experience for working in the actual industry environment.

Most of the theoretical knowledge that has been gained during the course of their studies is put to test

here. Apart from this the student gets an opportunity to learn the latest technology, which is immensely

helps in them in building their carrier. I had the opportunity to have a real experience on many

ventures, which increased my sphere of knowledge to great extent. I got a chance to learn many new

technologies and was also interfaced to many instruments.

The word quality holds out different meaning for different people, but for an industry it is most

important and can be defined as “The totality of features and characteristics of a product / services that

bear on its ability to satisfy given needs”.

And all this credit goes to organization Bharat Electronics Ltd.

REVIEW

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BHARAT ELECTRONICS AT A GLANCE

Bharat Electronics Limited (BEL) established in 1954 with its corporate office at Bangalore, has nine

units in the country. It is engaged in the design development and manufacture of sophisticated State-

of-the-art electronics equipments/components for the use of defence services, Para military

organisations and other governmental users like All India Radio, Doordarshan, Department of

Telecommunications, Police Wireless, Meteorological Department, etc. The BEL is also the premier

indigenous source for professional electronic equipment.

State-of-the-art manufacturing testing and quality assurance facility has been set up in all units of BEL.

On line computerization for materials management state-of-the-art test facilities, facilities for carrying

out environment and reliability checks electro-magnetic interference/Electro Magnetic Compatibility

Testing facility, Antenna Testing facility, back-up support from Standardization Technical information

and Documentation, Computer Aided Design and Manufacture have made BEL a modern professional

Electronic Company. All manufacturing divisions/units of BEL have been accredited with ISO

9002/ISO 9001.

Bharat Electronics Limited (BEL) designs, develops and manufactures state-of- the-art products in the

field of Radars, Defence Communications, Telecommunications, Sound and Vision Broadcasting,

Opto-electronics, Solar systems, IT products and Electronic components. BEL has the expertise in

engineering Radar, Telecom and Satcom networks, providing network solutions to meet customer

needs. These systems are supplied and commissioned on turnkey basis.

With over four decades of manufacturing experience Bharat Electronics Limited has pioneered the

professional electronics movement in India. With continuous upgradation of technology, commitment

to quality and constant innovation, BEL has grown into a multi product, multi unit, and multi

technology company

1. Around 72% of BEL’s turnover has been for the defence services and BEL’s

contributions to the Services in their various modernization programmes have been very

significant .BEL meets a variety of requirements of the Services in the area of Radars, Sonars,

Communication Equipment and Systems, SATCOM. Tank Electronics, Electronic Warfare

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Equipment etc., and meeting stringent Defence specifications with the assurance of Lifetime

product support.

2. BEL is also playing a significant role in the Civilian ‘professional Electronics’ sector of the

country particularly for the Ministry of Information and Broadcasting by supplying it with bulk

of its infrastructural requirements for Radio and TV Broadcasting , like Studio Equipment ,

Transmitters , Satellite , Uplinks, OB Vans etc .In the field of Telecommunication too , BEL

has an important part to play ,particularly in the area of transmission equipment where it had

met the significant requirements of the Bharat Sanchar Limited (BSNL).

3. BEL pioneered the growth of the Electronic ‘Components’

Industry in the country by setting up the manufacture of electron tubes [TV Picture Tubes for

the Consumer Electronics Industry, Transmiiting Tubes for AIR/DD

And the Industrial needs , Microwave Tubes , X- Ray tubes, Vaccum Interrupters etc.],

Semiconductors Devices , Integrated Circuits, Hybrid Micro Circuits.

4. All the Units of BEL are certified for ISO 9001/1994.

Action has already been iniated to graduate to ISO 9000:2000 standards.

5. MOU rating for the past five years in succession is excellent.

6. The Company won the “Golden Peacock” National Quality Award for outstanding

achievements in pursuit of total quality.

HISTORY & MILESTONES

HISTORY

SINCE 1954

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With over four decades of manufacturing experience Bharat Electronics Limited has pioneered the

professional electronics movement in India. With continuous upgradation of technology, commitment

to quality and constant innovation, BEL has grown into a multi product, multi unit, and multi

technology company.

BEL has set up impressive infrastructure and manufacturing facilities in their nine ISO certified

production units around the country.

BEL has also established two joint ventures - with General Electric Medical Systems, USA for X-ray

tubes and Multitone, UK for paging systems and has a subsidiary company BEL Optronic Devices

Limited for the manufacture of Image Intensifier tubes.

MILESTONES-BEL has nurtured itself to be known as one of the best publisector units in the

nation. A peep into Bharat Eectronics's Archives section, gives an idea of the progress at BEL.

2003 BEL celebrates its Golden Jubilee Year

2002 BEL acquires Category -I Mini Ratna status

2002 Foundation Stone laid for BEL's new corporate Office Building in Bangalore

2001 BEL bags National R & D Award in electronics Industry sector

2000 Bangalore Unit of BEL implements Rain Water Harvesting on an industrial basis

1999 Bharat Electronics Quality Institute

1998 - Hyderabad unit gets ISO 9002

1998 Kotdwara unit gets ISO 9001

1996 Joint venture with Multitone and GEMS

1994 ISO-9001 Accreditation

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1993 ISO-9002 Accreditation

1992 - Central Research Laboratory, Ghaziabad

1991 SATCOM

1990 EMI/EMC Test Facilities & Computer Software

1989 Telecom - Switching & Transmission System and Mass Mfg. Facility

1988 Central Research Laboratory, Bangalore

1987 Naval Equipment Division

1986 Kotdwara, Taloja & Hyderabad Units. Klystrons & Traveling Wave Tubes.

1985Madras & Panchkula Units, Broadcast & TV, Digital Communication Equipment

Divisions, Vacuum Interrupters

1983 (ASCO) Machilipatnam Integrated with BEL

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1982 Space Electronics division

1979- pune unit

1974 Ghaziabad unit

1972 B/W TV Picture Tubes

1971 Integrated circuits & hybrid Microcircuits

1970 X-Ray Tubes & Magnetrons

1968 HF & Broadcast equipment, Silicon Semiconductors

1967 Transmitting Tubes

1966 Radars

1962 Germanium Semiconductors

1961 Receiving Valves

1956 Equipment Production started at Bangalore ( present LPE Division)

1954 Incorporation of BEL

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MANUFACTURING UNITS

In 1954 with a factory of Jallahali, Bharat Electronics grew into nine units, spread all over the India.

The locations & products of the units are given below:-

1. BANGALORE:

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This is also called BG Complex. Jallahali unit which is the mother unit is now a part of this complex.

This is the biggest unit with approx. 10000 employees working here. Among the products

manufactured here, the important ones are:

a. Military Communications

b. Naval Systems

c. Radars

d. Telecom & Broadcasting Systems

e. Electronic Components

2. GHAZIABAD:

This is the second unit which was setup in 1974, &approx. 2500 employees are working here. The

products manufactured here are:

a. Radars

b. Antennae

c. SATCOM(Defence)

d. Microwave Components

3. PUNE:

To diversify further one more branch was added in 1979 & this was in pune. In this branch around

700-800 employees are working here.

The product profile includes:

X-Ray Tubes

Batteries

Electro Optics

4. MACHLIPATNAM:

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There was one Andhra Scientific Company, which was a sick unit. This was taken over by BEL & is

called ASCO unit in 1983.The product includes:

Optical Products

Medical Electronics

5. TALOJA:

This is an industrial place near Mumbai. This unit makes:

a. Shelters for Electornic Equipment

b. Train Actuated Warning System

c. Electornic Equipment Assembly

6. PANCHKULA:

Panchkula & Kotdwara were proposed simultaneously by the Government in 1985. It was proposed to

setup one unit each in Haryana & Uttar Pradesh. But the place in U.P. for setting up a unit could not be

decided while at Haryana, it was decided & hence this unit started earlier. This unit manufactures only

Tactical Communication Equipment.

7. KOTDWARA:

This is a unit in Garhwal district of U.P. This manufactures radio relay, multiplex equipments &

exchanges etc.

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8. CHENNAI:

The eighth unit of BEL was established in Chennai. This unit manufactures:

a. Tank Electronics

b. Optical Fire Control Systems

9. HYDERABAD:

This is another unit of BEL which manufactures electronic warfare equipments.

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In September 1982, the government approved proposal of Bharat Electronics Limited for the establishment of two equipment factories.

One of these was to be located in Haryana. Subsquently, Panchkula was selected as location in Haryana and approximately 23 hectare of land was given free of cost to B.E. by govt. of Haryana in Industrial Area, Phase-III in 1983. The establishment of the Panchkula unit, with an investment of Rs.248 million, marks an important milestone in growth Plans of B.E. for augmenting its manufacturing facilities and capacities.

The construction work commenced in 1984 and the main Production and services buildings were occupied in 1987 .B.E.L in 1984 set up temporary facilities in hired sheds. Production of VHF Transrecievers from these sheds commenced in 1985. Professional grade communication has been BEL’s primary business and the Panchkula unit contributes significantly towards this area with the production of radio communication equipments. The wireless set STARS-V being manufactured here is largely used by the armed forces .It was used recently in OPERATION VIJAY in KARGIL .BEL firmly believes in quality products and has proved itself by getting and retaining the ISO-9002 certificate since more than 4 years.

TRAINING WORK16

B.E.L PANCHKULA – A VITAL LINK

ORGANISATION

BEL Panchkula has different divisions which are further divided into departments:-

1. D & E (Development and Engineering)

D & E (DEVELOPMENT & ENGINEERING) – It is to design the project, make the

modifications to prepare design and related documents.

D & E CRYPTO – It is for designing of secure communication.

TIC (Technical Information Centre) – TIC is a library for designing purpose.

DRG OFFICE – It is the Drawing office.

2. MKTG (Marketing Division)

Sales – It is to prepare ESO equipment source order.

FGS (FINISH GOODS STORE) – After finishing the project it is sent to FGS for final

packing.

TL (Technical Literature) – It is the booklet with the project having the instructions

PR (Public Relation) – It deals with public relations.

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3. MFG (Manufacturing)

WA (Work Assembly)- there are different types of work assembly i.e. PCB assembly,

Module assembly, Final assembly.

WF (Work Fabrication) – It is the department for the mechanical work.

AMF (Advanced Manufacturing Facilities) – Advanced machines are used in the

manufacturing of the projects as SMT(Surface Mounted Technology), it is an automatic

system to mount the item on the PCB

PE (Production engineering) – It is for the installation of the new machinery.

PPC (Production, Planning and Control) – In this the work is planned.

SC (Sub Contract)

4. MS/HRD (Human Resources Department)

HRD – It is the training centre.

EDP (Electronic Data Processing) – It is the network system for copy. It is also for the

enquiry of an item.

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5. MM (Material Management)

It is the management of the materials.

ISM (Integrated Store Management).

PUR (Purchase department) – This department purchases the materials.

HS (Holding Store) – It has different bins that hold

Items after inspection.

IGS (Incoming Good Store).

MC (Material Contract)

6. PA (Product Assurance)

Testing – Products are tested by different tests.

C Test (Cipher Test) – It is the test for the secrecy.

PS (Product Support) – It is done after sale services.

SELF CERT (Self Certification) – it is the department which visits the place where work

is going on.

7. P & S (Plant and Services)

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It is the department for providing the services to company. Services are water supply,

electrical supply, transport, horticulture.

8. P & A (Personnel & Administration)

SECURITY – this department look after the security of the company premises and the

residential townships.

PERSON. (Personnel) – In this department the recruitment of employees is done.

ESTD. (Establishment) – It is to use manpower in different areas.

MEDICAL – Medical facilities are also available.

CRECHE

CANTEEN

WELFARE

9. F & A (Finance and Account)

FINANCE – Department for the sanction of money

PAYROLL – It deals with the salaries of the employees.

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BUDGET – It is made for one year.

ACCOUNTS – It is the record of the money.

AUDIT – Survey of the systems.

10.QM (Quality Management)

ISO (International Standards Organization) – It is to sell our products in the international

market.

6∑ - It is the statistical technique for maintaining Quality.

TES (Test Equipment and Support) – Calibration or

Measuring of instruments.

QCC (Quality Control Circle) – In this department there is group of employees who

discuss the problems, find out its solution and present it to manager.

QCC (Quality Control Circle) – In this department there is group of employees who

discuss the problems, find out its solution and present it to manager.

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PRODUCTS MANUFACTURED

The products of BEL are mainly focused on defence purposes but later on BEL also started

manufacturing some commercially useful items also. The major products include communication

devices which provide secure mode of communication. Also the major products include RADARS, X-

RAY tubes, and TRANSRECEIVERS etc. BEL has been involved in providing state of art

communication equipment to the Indian Army, be it hand held mobile radios and terminals, ground

based systems, air borne and even ship borne equipments.

The communication Equipments developed here cover HF, VHF, UHF, and V/UHF frequency bands.

The most important project of BEL under the communication equipments is STARS-V which provides

secure mode of data transfer. In STARS-V, the data to be transferred is first encrypted using a

microprocessor which could be read only by a similar device with same coding. Now the latest

technology of the frequency hopping is being implemented which is a very useful tool in making a

secure data transfer system.

BEL manufactures a lot of products which are very difficult to list but some of the major products are

given below:

o Integrated circuits and micro circuits

o HF & broadcast equipment

o Radars

o STARS-V

o SECTEL

o CNR

o HUD

o ACME MK II

o Space guiding equipments

o Airborne GPS receiver

o PRIME

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o SECURE FAX

o SECURE TELEPHONE

o

PRODUCTS :-

1. STARS-V (SECURE TACTICAL ARMY RADIO SYSTEM)

STARS-V (Secure Tactical Army Radio System - VHF) is a family of fixed frequency and frequency

hopping radio sets available in 5W and 25W power output configurations. The radios provide

communication in voice clear, voice secure and data modes. They can be controlled from a remote

location upto 2 km. All front panel controls (except ON/OFF) are extended using 2 wire cables to a

Remote Control Unit (RCU) at the remote location. Intercom operation between radio set and RCU is

also provided. The radio set can be configured for fully automatic rebroadcast operation. It is also

possible to setup rebroadcast over two wires for voice clear mode only. External data interface is

provided on the front panel to facilitate data communication with suitable modem

The radios are fully modular in construction. They are designed to perform in conformance to MIL 461

class of EMI/EMC specifications.

STARS-V radios find use in Manpack as well as vehicular applications for providing voice and data

communications in VHF frequency range of 30-88 MHz

VHF frequency range of 30 - 88 MHz

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2320 channels with 25 KHz spacing

1W/2W/5W/25W power outputs in different models

250 hops per sec for FH radios

In built GPS

32 preset crypto keys + 1 manual key

BITE up to module level

Built-in data modem

Complaint to MIL 461 EMI specifications

Manpack / Vehicular roles

2. CNR (COMPOSITE NET RADIO)

VHF Transrecievers (CNR) is a software controlled frequency hopping radio (Transmitter and Receiver)

in the VHF frequency band of 30 – 88 MHz the design of the radio is based on Digital Signal Processor

(DSP) technology making use of Direct Digital Frequency Synthesis (DDFX). The radio works in

Anti-jam frequency hopping and fixed frequency modes with built-in high grade digital secrecy. The

radio supports both Voice and Data communication in clear as well as secure mode.

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Radio is based on DSP technology

Frequency range of 30-88 MHz with 25 KHz channel spacing

Supports 2320 channels with 10 preset channels and 10 hop sets

Scan and BITE facility

Automatic re-broadcast facility

Direct serial data interface (RS-232C)

Modular construction

3. SECTEL (SECURE TELEPHONE)

Secure Telephone is a compact, full duplex digital Subscriber End Secrecy Device (SESD) providing highest

grade of secrecy on normal telephone lines. It replaces subscriber’s normal telephone instruments. It can

operate over any standard voice channel of telephone networks like DOT hired miltrunk single link circuits and

STD channels. It operates from 230 V AC mains using AC-DC adapter. Key management is supported by Fillgun.

Speech is digitized using Linear Predictive Coding (LPC) technique and digitally encrypted by a highly complex

crypto algorithm which ensures highest grade of secrecy. The encrypted speech is transmitted over the

telephone line using a Full Duplex QAS modem. At the receiver end, the encrypted data stream is demodulated

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/ decrypted and the original speech is synthesized. The user can switch between clear and secure mode during

the

High-grade speech secrecy

Full duplex transmission in Secure and Clear mode

Data rate 2.4 kbps full duplex

Memory dialing of 10 stored numbers

Multi-function keypad for different functions

Simple connectivity over standard two wire telephone lines

2 x 16 character LCD display to show the status

Same call.

4. SECURE UHF HANDHELD RADIO (LUP 291):

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LUP 291 is a UHF handheld radio with inbuilt high grade digital secrecy. The radio set is state – of –

the art design, compact and light weight. Interface is provided for Headgear and Crypto key loading.

The operator interface is user friendly with minimum number of controls. The radio set is provided

with helical and magnetic mount antennas. The radio set has in-built mic and speaker. VOX headgear

is also available as optional accessory for hands free operation.

Continuous Tone coded squelch(CTCSS)

RF Power Output : 5W /1 W (selectable)

Various programmable features like Scan, CTCSS frequency selection, Power Save, Password etc.

Inbuilt Powerful Diagnosis feature (BITE)

TX Inhibit (Sulk ) , Clone , Erase and Whisper facilities

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7.2 V Primary & Secondary batteries

Antennas : Helical and magnetic mount

Complaint to MIL 461 EMI specs

Optional accessories: Battery charger, Headgear,

Handset, Fillgun/ Programmer etc.

Frequency range 403 - 470 MHZ

Channel Spacing 12.5 /25 kHz

Built –in high grade Crypto

32 Preset crypto keys + 1 manual key

Selective call facility

16 Preset frequencies

5. DBC (DUAL BATTERY CHARGER):-

DBC stands for dual battery charger. It is used to charge the battery which is used in VPS set. DBC is

designed in such a way that it can charge two batteries at a time. It can work with AC as well as DC

input also. It’s working range is 0°C to 40°C.. It is also shockproof.

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Can charge two batteries at a time

Temp range- 0°C -40°C

Can work with AC as well as DC input

Display for voltage indication

LED’s used to indicate charging, discharging and overcharging

Fuse used to prevent it from very high input voltage

Controller card Is used

Product group:-

Production, planning and control:-

This sub-department forms the most important section among the others present because it forms the

‘backbone’. Right from the beginning till the end of the production of a particular set, the

responsibility lies in the hands of this section, it mainly performs three functions namely:-

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Scheduling

Launching

Control

The market section takes the order from the customer and gives the equipment stock order to PPC. The

management servicing department prepares the work order and gives it to PPC. Now PPC makes the

list of each component involved in product. This is called “Scheduling”.

Next function that comes is launched PPC prepares shop order and engineering documents such as

drawings. This function is called “Launching”.

Now comes material control. Here the PPC keeps track of production i.e. the purchase

requisition is given to purchase department and sub-contact department. The purchase now comes to

the IGS (Inwards Goods Section) where it is tested in IGI. The pieces that are okayed are then stored in holding

stores.

ASSEMBLY SECTION :-

As the name suggests, in this department all the components are mounted on PCB’s. These PCB’s are

then sat properly in the complete set. It is divided into three sections:-

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PCB assembly section

Coil winding section

Final assembly section

This set reaches the final assembly section only after they pass all the tests, done in the inspection

department.

AUTOMATED ASSEMBLY INSPECTION (AAI):-

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When the components have been mounted on the PCB’s, then the prepared PCB’s are brought to AAI.

In AAI electrical test is done on each individual component, this is very important department because

it ensures that quality of BEL standards is maintained.

An automated machine known as In Circuit Tester does the checking. The maker of the machine is

GEN RAD- 2372 Ckt. Firstly the drawing of Ckt. is made. Every path, connected branches of two

components it gives the no. manually. This no. has to be fed in the program by entering through the

keyboard to the In Circuit Tester. When all the numbering has been done, a program is fed into the

machine. There is a monitor present for viewing the entire process being done. The machine bites its

own numbers known as hybrid numbers. These numbers give information about wiring connections to

be done during the checking of PCB. A casting (made of needles) of the base of the PCB is made.

To one end of the casting the PCB is placed, such that one end of the needle holds the junction point

( where the components are soldered to the PCB ), while the other end of the wire is connected to a

particular nail where no. matches with the hybrid number given by the machine itself .

At a time only one PCB is tested.

When a PCB is placed over the needle with the help of vacuum it is tightened to the casting. It should

be noted that a very important advantage of using this machine is that testing of an individual

component is done in such a way that it is guarded from the surrounding components. By the term

guarding it means that the testing takes place as if only particular component is present. This is

advantageous because the other components do affects the testing.

The in circuit tester checks the value of all individual components. It checks whether the

particular component has been done without error. It is a master of fine second in which the in circuit

tester checks a PCB containing hundreds of components.

If not for the presence of machine, it would have been impossible to check the PCB’s manually.

It really pays its cost, which is an approximately rs. 60 lakhs.

Testing and inspection :-

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AAI mentioned above is by itself apart and inspection section, but due to its imp. As mentioned

above it is a separate section in PG-I. Inspection is done in every stage of PCB namely at:-

Module stage

Sub-assembly

Final stage

It is done after the environmental testing and before sending for testing. The most important

parameters that are to be followed during the inspection are as follows:-

1) The values of the various components

2) The visible characteristics of various active devices

3) Various interconnections

4) Whether the BEL standards are maintained or not

Testing is very important in the production. In PG-I manufacturing of STARSV is the main job.

Testing of STARSV is done in two main stages only.

PCB level testing

Main testing

PCB level testing takes place in many stages. Firstly, the PCB’S are kept in chamber with a temp. of

+50°C and -30°C. This is done to check the stability of characteristic of PCB as well as its

components. This process is done for approx. 80 hours. This is called ageing process.

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The PCB that passes out of the ageing process are then brought out in the block to put them through

test jigs. These test jigs provide perfect environment In terms of signals that actual set will face in the

field.

In testing, product is subjected to adverse condition to check the reliability of product under condition

defence forces will use.

The PCB is sent to assembly section back and they come out clear from test jigs. Now in assembly

section all components are packed finally. These packed sets are now sent for main testing. The main

testing includes many tests.

The first test is BUMP TEST. This is done to check the resistance of set against mechanical bumps and

vibrations.

Next is THERMAL SHOCK test to check the adaptability of set to sudden change in temperature.

Thermal shocks are given. The sets are subjected to temp. Range of 40°C-70°C.

LEAKAGE TEST is done to check the set for any leakage. In this the radio set is immersed in water.

The air is filled inside set through a nozzle at a pressure of 3 PSI. if air bubbles appear , set is sent for

repairing. There is a spatial section in testing by the name CIPHER. Here the encryption part of PCB is

enabled and checked. Entry in this section is strictly restricted for anyone, apart from authorized

personnel.

PRODUCT SUPPORT:-

In this department customers come and see the product. They are also provided the facility to check the

set with help of instruments. Characteristics of set are provided to them in addition to knowledge of

working environment

A M F

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The Advanced manufacturing facility uses the surface mounting technology (SMT) which is used for

making the sizes if the circuits are very small. This technology is Used in the mobile phones. It is

meant for fully automatic processes.

The surface mounting technology has got some disadvantages also that the process involved are

irreversible and the components are costly.

THE SMT LINE

The various stages involved in the SMT in sequence are called the SMT line. The stages involved are:-

Figure 1 SMT LINE

THE SMT LINE INCLUDING PICK AND PLACE

1. Loader: The PCB is loaded by using equipment known as loader. The PCBs are loaded into the

stacks called as magazines.

2. Screen printer: In this stage, the PCB is printed by solder paste in edges. This serves as the joint

between the components and the PCB such that it holds the components on the PCB.

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3. Pick & Place Machine: It is fully automatic machine costing around 5 crores. It picks up the

component & places it on to the PCB as per the program fed into the machine. Its construction

consists of the two gantries:-

Figure 2 Gantries

DIFFERENT TYPES OF THE NOZZLES USED IN THE REVOLVER HEAD

Gantry 1: Here, the placement of the components takes place with the help of revolver head. The

revolver head picks 12 small components upto 18mm of size at a time, with the help of nozzles. The

machine creates the Vaccum between the nozzle and the component, hence, picking the component.

The size of the nozzles differs with the size of the components.

Gantry 2: In gantry 2, the placement of fine pitch components takes place. Here, the revolver head

consists of 2 nozzles, therefore, picking up 2 components at a time the speed 3500 cph.

Its speed ranges upto 17000 components per hour (cph).The components that can be worked by this

machine are:-

chip components at 13500 cph

fine pitch components at 3500 cph

4. Reflow oven – This is a machine that is used to create modeling between the components and the

PCB. It is 5.5 mts long & it is made in Germany. There are 6 heating zones provided in it. Melting

temperature of solder paste is 230-240 degrees Celsius. This temperature cannot be achieved by simple

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means, so the heating zones are provided which do this work. There is a zone called the active cooling

zone that is to bring down the temperature from 240 degrees Celsius to room temperature.

5. AOI (Automatic Optical Inspection) –This machine checks if the placement of the components on

the PCB is correct or not. It inspects the PCB optically. The optical inspection is done by

Solid state

OCR (Optical character Resonator) that recognizes the letters.

OCV (Optical character verificator) that verifies the character about its size.

6. Buffer Stacker – The defective PCB boards are stored here.

7. Flipping Machine – It flips the PCB through various sections. It works like a ‘bypass machine’. If

the PCB boards have to be mounted by the components on both the sides, here, the PCB is flipped.

8. Unloader – Here, the machine unloads the PCB.

SALIENT FEATURES OF SMT LINE

1. Mounts Flip Chip BGA (Ball Grid Array) , MELF (Metal Electrode Filament ) , CSP (Chip Square

Package) , Fine Pitch Components upto 12mil.

2. Can mount components on both sides of the PCBs.

3. Handles component sizes from 0.6mm * 0.3mm (0201) to 85mm * 85mm.

4. Placement Accuracy 45 um at 6sigma.

5. PCB size from 500mm * 450mm to 70mm * 70mm.

6. Feeder Capacity: Tape/Reel/Stick (180mm * 8mm) or (135mm * 8mm) & 70 types of Matrix trays.

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7. Built-in 2D inspection facility of solder paste print area.

8. Automatic Optical Inspection Facility.

SALIENT FEATURES OF PICK AND PLACE MACHINE

1. PCB size handled: max. – 580mm, min. - 50mm.

2. Edge Clearance of PCB – 3mm.

3. Component handling capacity:

- 0201 size to 85mm * 85mm.

- BGA, MELF, Mini-MELF, CSP.

- Fine pitch component upto 12 mil

4. Placement Speed:

- Chip components – 13500 cph

- Fine pitch components – 3500 cph

5. Feeder Capacity:

- 180mm * 8mm tape feeder

6. Accuracy of placement:

- 45 um at 6 sigma for fine pitch components.

7. Tape size:

- 8mm to 64mm

8. Feeder Types:

- Tape feeder

- Stick feeder

- Matrix Tray feeder

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- Bulk feeder

9. Portability of CAD Data into machine.

10. Off-Line feeder preparation.

11. Automatic Vaccum sensing of nozzles.

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WAVE SOLDERING MACHINE

Wave soldering machine consists of the PCB carrier stand, which can hold 10 PCBs at a time. This

stand moves over the conveyer belt whose speed is 60 – 80 cm/sec. The flux used for soldering is

Rosion R8. The thinner is added to the flux so as to make the flux thinner. The next component in this

machine is air knife where the excess flux is removed. Next comes the pre-heater zone. It consists of 6

per-heaters. The temperature for the first 2 heaters is 100 degree Celsius, for next two pre-heaters the

temperature is 140 degree Celsius, and the temperature for last two chambers is 180 degree Celsius.

The box containing the solder is called the solder bath, which has the capacity of 400kg. The

temperature of the solder bath is 250 – 270 degree Celsius. While the solder is heated up inside the

solder bath, the pump arrangement provides for the hot solder to flow. The solder nozzle then produces

a solder wave. After the solder bath, the conveyor belt is set on the angle of 4 – 7 degrees. This

machine costs around 30 lakhs. This machine also consists of the sensors which sense the green mask

as well as the spot mask on the PCB such that the solder does not stays on it. The waste material of the

machine is known as dross. The solder temperature is continuously controlled by the PID controller

and its thermo couples.

In short, the description of the process is as follows:

To arrest the air pollution by fume emission from wave soldering machine.

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WAVE SOLDERING MACHINE AND ITS ADVANTAGES

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PCB CLEANING MACHINE

Figure 3 PCB CLEANING MACHINE

When the PCB is to be cleaned manually, iso –propyl alcohol is used. PCB

Cleaning machine uses the solvent. It consists of 2 tanks. Tank 1 consists of

HC EL20 (hydrocarbon) in addition to HFE 71 (hydro fluoro ether). HFE 71 is an expensive solvent,

i.e., Rs. 5000/L. The capacity of Tank 1 is 60L, with

60% of HCEL20 and 40% of HFE 71. Tank 2 consists of HFE 71, its capacity

Being 75L. The movable Trans can lift upto 30 kg of the load that is to be fed into the machine for

cleaning. The temperature of operation is 65 degrees Celsius. The refilling of tanks takes place through

Tank 2.

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OTHER MACHINES AT AMF DEPARTMENT

1. Component Lead Bending Machine : Used for bending of leads of resistors and capacitors.

2. IC Lead Straighten Machine : Used for straightening of IC leads.

3. PCB Cutting Machine : Used for cutting the rough edges of PCBs.

4. Burn-In Chamber (Oven): Baking of PCBs take place. This is done for the efficient soldering

of the PCBs. Temperature Range:

-5 degree Celsius above ambient to 150 degree Celsius. Its

Performance is as per ISO 9000.

RESULTS AND DISCUSSIONS

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The industrial training at B.E.L. has given me an exposure of the activities of a defense unit. This being a large organization deals with wide spectrum of technologies.

During my training in B.E.L, I came to know about different range of products , ranging from communication equipments to hardware to software equipments and it goes in every strata of society like it is now usually used in police training academies .

APPLICATIONS OF PRODUCTS :-

1. STARS- V- These radios are used in Manpack as well as vehicular applications for

providing voice and data communications in VHF frequency range of 30-88 MHZ.

2. CNR – This radio works in Anti – jam frequency hopping and fixed frequency modes

with built –in high grade digital secrecy.

3. SECTEL- Here the encrypted speech is transmitted over the telephone line using a

FULL Duplex QASK modem. At the receiver end, the encrypted data stream is

demodulated / decrypted and the orinal speech is synthesized. The user can switch

between clear and secure mode during the same call.

4. SECURE UHF HANDHELD RADIO – this radio set is provided with helical and magnetic

mount antennas. The radio set has in –built mic and speaker. VOX headgear is also

available as optional accessory for hands free operation.

5. DBC- It is to charge the two batteries at the same time which is used in VPS set. It can

work with AC as well as dc input also .It is also shockproof.

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The six weeks of summer training at BEL, PKL unit generated a lot more interest in my subject.

It made me more aware of the scope of Electronics & Communication Engineering. It has also made

me appreciative of an industrial work environment.

Undergoing training on the indoor substation has helped me integrate conceptual knowledge with real

life application. I was fortunate to have personal guidance from experienced professionals who took

been interest in explaining the working details of various equipments.

I feel that without this opportunity, my own understanding of this subject and also the motivation to

acquire more knowledge would have remained incomplete.

Well, regarding future scope I think my training has given me enough motivation and an exposure that I will try to join defence services or get linked up with the defence of the country.

FUTURE PLANS

BHARAT ELECTRONICS Plans to introduce world class Products with state – of – the – art technologies, in the near future.

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FUTURE DEVELOPMENTS PLANS

Super Bright White LEDs for home lighting

Thermal imagers.

Complimentary bipolar process technology using self aligned double poly.

SiGe heterojunction Bipolar Transistor (for high Ft).

SOI Technology.

BiCMOS technology.

Double sided detectors.

BIBLIOGRAPHY

THE MAIN RESOURCES OF THE WORK WERE THE PERSONS OF HRD DEPT.

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&

References

THE MAIN WEBSITE: -

www.bel-india.com

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