ROTATION PROGRAMME

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

1) TEST EQUIPMENT & AUTOMATION

2) P.C.B FABRICATION
3) QUALITY CONTROL (WORKS)
4) WORKS ASSEMBLY
5) MAGNETICS
6) MICROWAVE LAB
7) ENVIRONMENTAL LAB
8) P&S ELECTRICAL
9) MANAGEMENT SERVICES

During the rotation period of three weeks I had to go to various departments, listed
above to get some introduction about the work that is being done in that particular
department. The co-operative staff at various department made the learning process
very interesting, who allowed me to know more about the company in a very short time.
The various departments are now given in detail.
 TEST EQUIPMENT & AUTOMATION
This department deals with the various instruments used at BEL. There are
three hundred equipments and they are of sixteen types.

Examples of some test equipment are:

• Oscilloscope (C.R.O)
• Multimeter
• Signal Analyzer
• Logical Pulsar
• Counters
• Function Generator etc.

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

Test equipment and automation laboratory mainly deals with the equipment that is
used for testing and calibration.

Examples of some test equipment are:

• Oscilloscope
• Multimeter
• Signal Analyzer
• Logical Pulsar
• Counters etc.
 This section calibrates and maintains the measuring instrument mainly used for
Defense purpose.

A Calibration is basically testing of equipment with a standard one. It is done with the
help of standard equipment should be of some make, model and type.

The national physical laboratory (NPL) New Delhi provides the standard values
yearly. BEL follows International Standard Organization (ISO) standard. The test
equipment is calibrated either half yearly or yearly.

After testing, different tags are labeled on the equipment according to the
observations.
• GREEN ---O.K, Perfect
• YELLOW --- Satisfactory but some trouble is present

• RED --- Cannot be used, should be disposed off.

The standard for QC, which are followed by BEL are:

• WS 102
• WS 104
• PS 520
• PS 809
• PS 811
• PS 369
Where, WS = Workmanship & PS = Process Standard

After the inspection of cables, PCB’s and other things the defect found are given in
following codes.
• A --- Physical and Mechanical defects.
• B --- Wrong Writing
• C --- Wrong Component / Polarity
• D --- Wrong Component / Mounting
• E --- Bad Workmanship/ Finish
• F --- Bad Soldering
• G --- Alignment Problem
 • H --- Stenciling
• I --- Others (Specify)
• J --- Design & Development

After finding the defect, the equipment is sent to responsible department which is
rectified there.
 PRINTED CIRCUIT BOARD (P.C.B.)

INTRODUCTION

As the name suggests, printed circuit board refers to a board on which a circuit
is imprinted. The circuit appears as copper tracks on non-conducting surface. Here the
surface or the board is a glass epoxy sheet with copper coating on either both sides or
on one side only. The board material is not restricted to glass epoxy only, it can be any
hard surface (non conducting) with copper coating. In some cases we use Teflon sheets
also.

Earlier the designed circuit was made with the components, which were
connected to each other by means of wire. This created a lot of confusion and
difficulty in case there were any repairs or rework to be done. It was very difficult
to track any connection by simply looking at it and doing a repairing job was a
hard and tedious process. This was made easy by the arrival of P.C.B.’s as they
had the entire circuit printed on them. This made the circuit neat, easily
understandable, simpler and free from zigzag network of wires. With the use of
P.C.B’s large circuits can be realized on a small piece of board. They have
revolutionized the field of electronics as the electronic goods are getting reduced
in size and also their life and reliability are increasing.

Generally the P.C.B’s can be categorized in three forms viz.:

SINGLE SIDED P.C.B.

Board having circuit pattern on one side.

DOUBLE SIDED P.C.B.

Board having circuit pattern on both sides.

MULTI LAYERED P.C.B.

Board having many layers of circuits.
 QUALITY CONTROL (WORKS ASSEMBLY)

According to some laid down standards, the quality control department ensures
the quality of product. The raw materials and components etc. purchased are inspected
according to the specifications by I.G. department. Similarly Q.C. work department
inspects all the items manufactured in the factory. The fabrication department checks all
the fabricated parts and ensures that these are made according to the part drawing,
painting, plating and stenciling etc are done as per BEL standards.

The assembly inspection department inspects all the assembled parts such as
PCB, cable assembling, cable form, modules, racks and shelters as per latest
documents and bel standards.

The mistakes in the PCB can be categorized as-

1. D & E mistakes
2. Shop mistakes
3. Inspection mistakes

The process card is attached to each PCB under inspection. Any error in the PC is
entered in the process card by certain code specified for each error or defect.

After a mistake is detected, following action are taken:

1) Observation is made
2) Object code is given
3) Division code is given
4) Change code is prepared

5) Recommended action is taken.

 WORKS ASSEMBLY

This department plays an important role in the production. Its main function is to
assemble various components, equipments and instruments in a particular procedure. It
has been broadly classified as:
• WORK ASSEMBLY RADAR e.g.:INDRA-2, REPORTER
• WORK ASSEMBLY COMMUNICATION e.g.: EMCCA, MSSR, MFC
o EMCCA: EQUIPMENT MODULAR FOR COMMAND CONTROL
APPLICATION
o MSSR: MONOPLSE SECONDARY SURVEILLANCE RADAR
o MFC: MULTIFUNCTIONAL CONSOLE

The stepwise process followed by work assembly department is:

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

The documents issued to the assembly are:

KS: Key Sheet
PL: Parts List
CL: Connection List for cable form
WL: Wiring List for modules
WD: Wiring Diagram
GA: General Assembly Diagram
SD: Schematic Diagram
Material receive

Preparation
This is done before mounting and undertakes two procedures.

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

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

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

Wave Soldering
These are done in a machine and solder sticks on the entire path, which are
tinned. Wave soldering machine consists of following parts

1. Conveyor
2. Fluxer
3. Heater
4. Flux Cleaner
Touch up
This is done by hand after the finishing is done.

Inspection
This comes under quality work.

Heat ageing
This is done in environment lab at temperature of 40 degree Celsius for 4 hrs and
three cycles.

Lacquering
Lacquering is only done on the components, which are not variable.
 MAGNETICS

This department is making all types of transformers and coils that are used in
various equipments. This department basically consists of four sections:

1. Planning section
2. Mechanical assembly section
3. Moldings section
4. Inspection

The D & E department gives the following description – numbers of layers, numbers
of turns /layers, types of winding, gapes in core, insulation between layers, ac/dc
impedance, dielectric strength, electrical parameters and earthing.

The various types of transformer being made are:

1. Open type transformer

2. Oil cooling types transformer
3. Moulding type transformer
4. PCB moulding type transformer

The transformer is mechanically assembled, leads are taken out and checking of
specification is done.

Winding machines are of three types:

1. Heavier one – DNR for 0.1 to 0.4 mm diameter.

2. LC control machine
3. Torroidal machines having 32 operations from winding to mechanical assembly.

The various types of windings used are: -

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

Two types of cores used are:

1. E-type for 3-phase

2. C-type for signal phase

Various procedures involved in the manufacture of transformers are; -

1. Formers of glass – expoxy

2. Winding
3. Core winding
4. Varnishing
5. Impregnation- various varnished coils are heated, than cooled, reheated and put
into vacuum. Then air is blown to remove the humidity.
6. Moulding-araldite mixed with black dye is used to increase mechanical as well
as electrical strength. Moulding is done at 120 degrees centigrade for twelve
hours.
7. A RDB compound is used for leakage production. Oil is boiled at 70 to 80
degrees under vacuum conditions to remove air bubbles. After this the cols
are dipped in varnish and core is attached.
8. Painting
9. Mechanical assembly
10.Termination
11.Testing: dielectric testing is done at 50 kv voltage applied for a minimum of one
minute. During inspection, the following characteristics are checked: -
• Turn ratio

• DC resistance ofor each coil

• Inductance
• No load voltage
• Leakage
 MICROWAVE INTEGRATED CIRCUITS

Frequencies greater than 1 GHz are termed as Microwaves. Microwave

Integrated Circuit used extensively in production of subsystems for Radar and
Communication equipment constitutes a very important part of technology for these
systems are generally imported. Owing to the crucial and building block nature of the
technology involved, BEL is currently setting up a modern MIC manufacturing facility at
a planned expenditure of Rs. 2 crore. When in full operation this facility will be the main
center for the MIC requirements of all the units of the company.

The manufacturing facility of hybrid microwave components available at BEL

Ghaziabad includes facility for preparation of substrates, assembly of miniaturized
components on substrates, bonding and testing. Testing of these microwave
components viz. Directional couplers, Waveguides, low noise amplifiers, phase shifters,
synthesis etc. involve scalar as well as vector measurements. For this state of the
network, analyses are used. Various losses such as return loss, bending loss, Insertion
loss are measured and testing is done in a way to minimize these losses. The testing of
microwave components is done with the help of various radio and communication
devices. Phase and magnitude measurements are done in this section. Power
measurements are done for microwave components because current and voltage are
very high at such frequencies. Different type of waveguides is tested in this department
like rectangular waveguides, circular waveguides. These waveguides can be used to
transmit TE mode or TM mode. This depends on the user’s requirements. A good
waveguide should have fewer losses and its walls should be perfect conductors. In
rectangular waveguides the distortion is minimum. Circular waveguides are used where
the antenna is rotating.

MICROWAVE LAB
This section undertakes:

1. Manufacturing of films and microwave components to meet internal

requirements.
 2. Testing of low power antenna for which test-site is about 100 Km from
the factory at sohna

The main component testing in this department is:

• Oscillators
• Amplifiers
• Mixers
• Radiation elements (e.g. Feeders)
• Microwave components (e.g. Isolators, circulators, waveguides etc.)
• Filters (e.g. LPF, BPF, Uniplexers, and Multiplexers etc.)

The instruments used for this purpose are as follows:

1. Filters
2. Isolators
3. Reflectors
4. Network Analyzers
5. Spectrum Analyzers

6. Amplifiers and Accessories

• Adaptor
• Attenuator
• Coupler
• Mixer
• Detector

Parameters of component that are being checked are listed below:

• Frequency response
• Noise figure
• VSWR
• Directivity and coupling
• Power measurements
 ENVIRONMENTAL LAB

Various tests are conducted in the environmental lab in BEL in order to ensure
reliability. Reliability is defined as the probability of a device performing its purpose
adequately for the period intended under the given operating condition. In a given
reliability is given as

R= R1 * R2 * R3……….

The standards available here are:

• JSS55555- Joint services specifications (Military Standard of India)

• MII Standards – U.S Military standers

• QM333 – Civil Aviation and police

FIRST ARTICELS TEST (FAT)

The tests are performed on the prototype. If these tests are successful then the
mass production is taken up.

ACCEPTANCE TEST PROCEDURE (ATP)

This sets on the extent to which a test is to be conducted and also decides what
tests should be conducted.

There are three types of tests: -

Class A Test:
All types of regular production go through these tests i.e. 100% production
goes through class A test.
Class B Test:
These are quality assurance and reliability tests. Only 10%of the equipment
goes through these tests. They include quality control, electrical tests and some
environmental tests.

Class C Test:
These tests are carried out on only 1%of the components. All the environmental
tests are carried. if any failure is seen ,the component must be re designed .also the
customer must be supplied with modified goods. This test comes in picture only for
the good bulk in production only.

These tests are carried out according to the customers requirements i.e. it
depends upon the customer that which test is to be performed from the following
tests under the above categories: -

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

Thermal Shock Test

There are two chambers, which are at temperature of –40 degree C and +70
degree C. The equipment is kept for 1 hr. in cold chamber and is immediately
transferred to hot chamber where it is kept for 1 hr. This is repeated for 6 cycles and
instrument suffers a temperature change of 110 degree C.

High Temperature Operate and Storage

The instrument is kept at 50 degree C for 50 hours and is kept ON. It is then kept
at 70 degree C in OFF state.

Low Temperature Operate and Storage

The instrument is kept at 0 degree C for 15 hours in OFF state and operated for the
next 1 hr. It is then kept at –40 degree C in OFF state for 16 hrs.

Altitude Test
The instrument is kept at 0 degree C and 10000 ft. of air pressure for 15+1 hours
(OFF + ON). Then instrument is kept at –40 degree C and 5000 ft. of air pressure for 16
hours (OFF).

Bump / Vibrations Test

In bump test instrument is given 300 bumps of height 1 inch. Vibration test includes
vibrations in x, y, z directions of frequency 5 to 500 Hz. With a disp. of + 6 mm and
acceleration of 1.5 – 2g. It is done for 2 hrs. in each direction.
Salt Spray Test
The instrument is placed in salt spray chamber for two days. The solution to be
sprayed is 5% salt solution. In some cases 20% salt solution is also made.

Tropical Exposure Test

The instrument is kept at 25 degree C and 95% humidity and then this condition is
changed to 35 degree C and 95% humidity in 3 hrs. This condition is kept for 12 hrs.
and then again changed to 25 degree C and 95% humidity in 3 hours where it is kept
for 6 hrs. This cycle can be repeated for 7, 14, 28, 56 times.

Rain Test
The instrument is placed in artificial rain for 10 hours and its performance is checked.

Humidity Test
The instrument is kept in a chamber having 95% humidity for 15 + 1 hrs. (OFF+ON).
And performance is checked in last 1 hr.

Dust Test
The instrument is placed in a dust chamber for 2 hrs.

Transportation Test
The instrument is kept in a vehicle, which is made to run 40 kms. at a speed of 15
km/hr. on rough road .Then vehicle is run for 400 kms. on plane road with no fixed
speed.
Shock Test
The instrument dropped from a height of 3 ft. This test is rarely performed.

Burn in Test
The instrument is turned ON for 100 hours and tested for performance every 24
hours with everything turned ON.
 P & S (ELECTRICAL)

The main task of this department is to supply power to the all production units,
administrative block and other parts of the factory.

This department is arranged into one main station and five sub stations at different
locations in the company. The power is received from the Uttar Pradesh Vidyut Board
through 33 kV power line at the main station. At the main station the power is stepped
down to 11 kV using 33/11 KV step down transformer. The main station is provided air
circuit breakers (ACB), oil circuit breaker (OCB).

There are two transformers at the main station. Out of these two only one is used
at a time and second one is standby transformer i.e. it is operated in case when first
transformer does not work properly.

There are five sub stations at BEL, which receive the power from main station at
11kV and stepped down to 433 V for the use of various machines in the factory. The
transformers being used at various sub stations are of rating 1600 KVA. These sub
stations provide power to different divisions of the factory. Like the main station these
stations are also provided with OCB’s etc.

In case of power failure there are two generators, which can supply the power to
production divisions only, and some other important sections. These generators are
imported from Czechoslovakia and are of Ascorda make. These generators are air-
starting type and consume 400 Liters/Hr. of diesel each. Each generator is having 6
cylinders. These are of capacity 860 kV and each generator generates 400 V at 50Hz.
This voltage is stepped up by a transformer to 11KV and supplied to the sub stations.
 MANAGEMENT SERVICES

Industrial Engg. Deptt. Deals with management service in BEL Kotdwar.

Management services include safety, planning etc.

Management Services in BEL KOTDWAR

• P
lanning and MIS

• I
ndustrial Engg.

• F
acilities and technology development

• S
afety Department

Activities of Planning and MIS

• P
reparation of different plans.

• M
IS reports / presentation

• W
ork orders

• M
anufacturing cost estimates

• S
ub contract rate fixing

• L
ayout planning.
Activities of Industrial Engg.
• W
ork-study.

• L
TT / OTC booking.

• M
achine utilization reports.

• I
DLE time reports.

• S
hop order accounting.

• I
ncentive scheme.

• P
roductivity measurement and monitoring.

• O
rganizational charts.

• M
anpower records.

• C
apacity assignment / Load balance charts.

• S
uggestion scheme

Activities of Facility and Technologies Development

• P
reparation of capital budget.
 • I
mplementation of capital budget for current year.

• T
o hold machinery committee meeting

• T
o keep record of existing facilities

• T
o update and advise management for technological advances

Activities of Safety Department

• Safety propagation (Posters, slogans, bulletin, competitions)

• Safety incentive scheme

• Development of safety stewards

• Plant safety inspection

• Safety committees

• Assessment / Procurements of personal safety equipments.

• Implanting safety training.