Project Report of BEL

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

1

CERTIFICATE TO WHOM SO EVER IT MAY CONCERN This is to certify that Mr. NITIN DHINGRA bearing Roll No. 2306218 Department of Electronics &

communication

Research , Mithapur , Ambala

Engineering , Ambala

college

of engineering & applied

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.

2

ABS TRACT

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.

3

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 CHAPTER- 1

DESCRIPTION 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

5

PAGE No.

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.

6

REVIEW

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 of-the-art

State-

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 7

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

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 8

HISTORY SINCE 1954 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

9

1996

Joint venture with Multitone and GEMS

1994

ISO-9001 Accreditation

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.

1985

1983

Madras & Panchkula Units, Broadcast & TV, Digital Communication Equipment Divisions, Vacuum Interrupters

(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

MA NUFACTURING UNITS

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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: 12

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: 13

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.

14

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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B.E.L PANCHKULA – A VITAL LINK

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 WORK 16

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.

18

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. 19

7. P & S (Plant and Services)

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) 20

•

FINANCE – Department for the sanction of money

•

PAYROLL – It deals with the salaries of the employees.

•

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, XRAY 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 22

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

23

VHF frequency range of 30 - 88 MHz 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. 24

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

25

modem. At the receiver end, the encrypted data stream is demodulated / decrypted and the original speech is synthesized. The user can switch between clear and secure mode during the Same call.

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

4. SECURE UHF HANDHELD RADIO (LUP 291): 26

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.

27

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 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

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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.

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:29

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: 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.

30

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:-

•

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.

31

AUTOMATED ASSEMBLY INSPECTION (AAI):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.

32

Testing and inspection :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. 33

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

AMF

34

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.

35

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

36

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. 37

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 38

- 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.

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RESULTS AND DISCUSSIONS

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.

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

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.

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BIBLIOGRAPHY

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

References THE MAIN WEBSITE: www.bel-india.com

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