VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“Jnana Sangama”, Belagavi-590018, Karnataka

An Internship Report
On
“BEML LIMITED, Organizational study”
Submitted in partial fulfillment of the requirements for the award of the degree of

Bachelor of Engineering
In
ELECTRONICS AND COMMUNICATION ENGINEERING
For the Academic Year 2022-23
Submitted By
AMRUTHA J S : 4AD20EC004

Under the Guidance of

Mrs. JUSLIN F
Assistant Professor
Department of ECE

13th Kilometer, Mysore – Kanakapura – Bangalore Road,

Mysore – 570 028, Karnataka
Phone: +91-821-25 93 335
 ATME College of Engineering, Mysuru
13th Kilometer, Mysuru – Kanakapura – Bangalore Road, Mysuru – 570 028

DEPARTMENT OF ELECTRONICS ANDCOMMUNICATION

ENGINEERING

CERTIFICATE
Certified that the Internship work entitled “BEML LIMITED, Organizational study” carried
outby AMRUTHA J S [4AD20EC004] students of ATME College of Engineering, Mysuru
in partial fulfillment for the award of Bachelor of Engineering in Electronics and
Communication Engineering, of the Visvesvaraya TechnologicalUniversity, Belagavi during
the year 2022-23. It is certified that all corrections/suggestions indicated for Internal
Assessment have been incorporated in the Report deposited in the departmental library.
The Internship report has been approved as it satisfies the academic requirements in respect of
Internship work prescribed for the said Degree.

Name & Signature Name & Signature

Guide HOD

Internship Viva-Voce

Name of the Examiners Signature with date

1.
2.
 DEPARTMENT VISION AND MISSION
 To develop highly skilled and globally competent professionals in the field of
Electronics and Communication Engineering to meet industrial and social requirements
with ethical responsibility.

MISSION
 To provide State-of-art technical education in Electronics and Communication at
undergraduate and post-graduate levels, to meet the needs of the profession and society and
achieve excellence in teaching- learning and research.
 To develop talented and committed human resource, by providing an opportunity for
innovation, creativity and entrepreneurial leadership with high standards of professional ethics,
transparency and accountability.
 To function collaboratively with technical Institutes/Universities/Industries, offer
opportunities for interaction among faculty-students and promote networking with alumni,
industries and other stake-holders.

Program Specific Outcomes (PSOs)

At the end of Graduation the student will be able,

 To have the capability to understand and adopt the technological advancements with the usage
of modern tool to analyze and design embedded system or processes for variety of applications.
 To work effectively in a group as an independent visionary, team member and leader having
the ability to understand the requirement and develop feasible solutions to emerge as potential
core or electronic engineer.
 ACKNOWLEDGEMENT
We would like to express our immense gratitude to Dr. A K Murthy, Principal, ATMECE,
Mysuru for his timely help and inspiration during the tenure of the course.

We would like to express our deep gratitude to Dr. L Basavaraj, Professor and Head,
Department of Electronics and Communication Engineering, ATMECE, Mysuru for his timely co-
operation while carrying the Internship work. His friendliness made us learn more.

We would like to express our sincere thanks to the Internship guides Mrs. Juslin F, Assistant
Professor, Department of Electronics and Communication Engineering, ATMECE, Mysuru for their
guidance, encouragement and suggestions that helped us a lot in completion of the internship.

We also extend our sincere thanks to the Internship coordinator Mrs. Chethana K S and Dr.
Shalini Hanok, and all the faculty members, Department of Electronics and Communication
Engineering, ATMECE, Mysuru who have encouraged us throughout the course.

Last but not the least, we express our heartfelt gratitude to Almighty, our parents for their love
and blessings that helped us complete the Internship work successfully
 TABLE OF CONTENTS
Chapter No. Title Page No.
Chapter 1 INTRODUCTION
1.1 About the Company 02
1.2 About the Software and tools 05
1.3 Objectives of the Internship 06
Chapter 2 Programmable Logic Controller(PLCs)
2.1 Introduction to PLCs 07
2.2 PLCs programming in Electronics 08
2.3 Salient features 10
Chapter 3 TASKS PERFORMED DURING THE
INTERNSHIP
3.1 Various Sensors used in Manufacturing 14
3.2 R&D Department 16
3.3 BH205E 18
3.4 Computer-aided design(CAD) 19

Chapter 4 REFLECTION NOTES

4.1Application 21

CONCLUSION
REFERENCES
 Organizational study at BEML limited, Mysuru

CHAPTER 1

INTRODUCTION
1.1 About the Company
BEML Limited, formerly known as Bharat Earth Movers Limited, was established in May
1964 as a Public Sector Undertaking with the primary objective of manufacturing Rail
Coaches & Spare Parts and Mining Equipment at its Bangalore Complex. Over the years,
the company has undergone partial disinvestment, and as of now, the Government of India
retains 54 percent of the total equity, while the remaining 46 percent is held by the public,
financial institutions, foreign institutional investors, banks, and employees.

The company operates through 9 manufacturing units strategically located across different
regions. The Kolar Gold Fields (KGF) Complex, situated approximately 100 km from
Bangalore, houses the Earth Moving Division, Rail Coach Unit II, Heavy Fabrication Unit,
and Hydraulic & Powerline Division. The Mysore Complex, located around 130 km from
Bangalore, is home to the Truck Division and Engine Division. The Bangalore Complex
encompasses the Rail & Metro Division, while the Palakkad Complex and Vignyan
Industries, a subsidiary situated at Tarikere (around 300 km from Bangalore), and
specialize in Steel Castings.

BEML has established a nationwide network of sales offices, ensuring convenient access
to its diverse range of products for buyers. Additionally, the company's full-fledged service
centers and parts depots play a crucial role in providing comprehensive equipment care,
maintenance contracts, and rehabilitation services.

With an eye on the future, BEML formulated its VISION – 2013, aiming for an ambitious
growth rate of 12% CAGR to achieve a turnover of over Rs. 5,000 Crores by 2013-14,
coinciding with BEML's Golden Jubilee year. Looking ahead, the company is poised to
surpass the Rs. 5,000 Crore mark in the next two years and is actively working towards
reaching the Rs. 10,000 Crore milestone by 2016-17. To support this growth trajectory,
BEML is diligently preparing the necessary infrastructure to meet its ambitious targets.

Vision of the Company

“Become a market leader, as a diversified company, supplying quality products and
services to Defense & Aerospace, Mining & Construction, Rail & Metro and to emerge as
a prominent international player.”

Company Product & Services

The products manufactured at Truck Division are:
 Mining & Construction
1. Dump Trucks (Mechanical Drive)
2. Dump Trucks (Electrical Drive)

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3. Water Sprinkler
 Motor Grader Defense
1. Tatra 6x6 (Euro II)
2. Air Craft Weapon Loader
 Others
1. Air Craft Towing Tractor
2. Air Craft Towing Tractor with Ground Power Unit

Various Dump Trucks are as Follows:

1. BH205-AC
2. BH150E3
3. BH100
4. BH60
5. BH40
6. BH35-2

 Water Sprinklers
1. BWS28-2
2. BWS70

PATENTS
 Field programmable gate array module based Unified Electronic Controller for off-
highway dump truck
 New GMAW / CO2 welding process improvement for better weld quality &
mechanical strength
 Multi-Functional vehicle Data Recorder
 Forged Design Tooth Point for Backhoe Loader
 Tooth Point assembly for Walking Dragline Buckets
 A Control System for an Automatic Power shift Transmission
 Radio Control System for Clutch Control Geared Dozer
 A system for induction hardening of concave profile components
 An exhaust after treatment system for an engine
 Wheel steering control system
 Accelerated fuel filling system

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1.2 About the Software and tools
The software and tools used are as follows:
1. Machine Tools:
Lathes
Milling machines
Drilling machines
Grinding machines
2. Welding and Cutting Tools:
Welding machines (MIG, TIG, arc welders)
Cutting torches
Plasma cutters
3. Automation Tools:
Programmable Logic Controllers (PLCs).
Robotics and robotic arms.
4. Computer-Aided Design (CAD) Software:
Used for creating detailed 2D and 3D models of products and components.
5. Multimeters:
Used for measuring voltage, current, and resistance in electrical circuits.
6. Oscilloscopes:
Essential for visualizing and analyzing electronic signals over time.
7. Signal Generators:
Produce electronic signals for testing and calibration.
8. Power Supplies:
Provide controlled electrical power for testing and powering electronic circuits.
9. Soldering Stations:
Used for soldering components onto printed circuit boards.
10. Digital Calipers:
Measure dimensions of electronic components and circuits.
11. Logic Analyzers:
Help analyze digital signals in complex electronic systems.
12. Function Generators:
Generate different waveforms for testing electronic circuits.
13. Electronic Workbenches:
Equipped with tools and instruments for assembly, testing, and troubleshooting.

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14. Circuit Board Inspection Tools:
Magnifying lamps and microscopes for detailed inspection of circuit boards.
15. ESD (Electrostatic Discharge) Protection Tools:
Prevent damage to sensitive electronic components during handling.
16. Programming and Debugging Tools:
In-circuit programmers and debuggers for microcontrollers and other programmable
devices.
17. Environmental Test Equipment:
Tools for testing electronic equipment under various environmental conditions
(temperature, humidity, etc.).
18. Network Analyzers:
Used for analyzing the performance of communication networks.
19. Automated Test Equipment (ATE):
Systems designed for testing electronic components and systems automatically.

Benefits of tools
1. Efficiency and Productivity:
Automation tools, such as Automated Test Equipment (ATE) and robotic systems,
contribute to increased efficiency and faster production rates.
CAD and CAM software streamline the design and manufacturing processes, reducing time
and effort required for product development.
2. Precision and Accuracy:
Testing and measurement tools like oscilloscopes and multimeters ensure precise
measurements, helping to identify and rectify issues in electronic components.
Automated testing equipment provides accurate and repeatable testing procedures,
minimizing errors.
3. Quality Control:
Tools like Automated Optical Inspection (AOI) systems and environmental test
chambers contribute to rigorous quality control by identifying defects and ensuring
products meet specified standards.
In-circuit testers and quality management software help maintain high product quality by
identifying faults early in the manufacturing process.
4. Cost Savings:
CAD and CAM software assist in optimizing designs and reducing material waste,
contributing to cost savings in the manufacturing process.
Automated testing reduces the need for manual labor in testing processes, potentially
reducing labor costs.
5. Reliability and Consistency:

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Robust testing and measurement tools contribute to the reliability of electronic components
and systems by ensuring that they meet specified performance criteria.
Automated assembly tools help maintain consistency in product assembly, reducing
variability and enhancing overall reliability.
6. Innovation and Design Optimization:
Electronic design automation (EDA) software facilitates innovation by providing tools
for designing and simulating complex electronic systems.
Prototyping equipment allows for the testing and optimization of designs before full-scale
production, reducing the risk of costly errors.
7. Safety and Compliance:
Testing equipment, such as EMC testing tools, helps ensure that electronic products
comply with safety standards and regulatory requirements.
Environmental testing tools assist in evaluating product performance under various
conditions, contributing to safety and reliability.
8. Time-to-Market Reduction:
CAD and CAM tools, along with rapid prototyping capabilities, can accelerate the
product development cycle, reducing time-to-market for new products.
9. Skill Enhancement and Training:
Tools such as service training centers equipped with the latest technology enable
employees to enhance their skills and stay updated on new developments in electronics
manufacturing.
10. Customer Satisfaction:
Ensuring the quality and reliability of electronic products through rigorous testing
contributes to customer satisfaction and trust in the brand.

1.3 Objectives of the Internship

Practical Application of Academic Knowledge:
Provide students with an opportunity to apply theoretical knowledge gained in their
academic studies to real-world electronics projects and challenges.
Hands-On Experience:
Enable students to gain practical, hands-on experience with the tools, equipment, and
technologies used in electronics manufacturing and engineering.
Skill Development:
Enhance the technical skills of students in areas such as circuit design, testing,
troubleshooting, and electronic system integration.
Exposure to Industry Practices:
Expose students to the day-to-day operations and practices of a leading electronics
manufacturing company, giving them insights into industry standards and best practices.

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Collaboration and Teamwork:
Cultivate teamwork and collaboration skills by involving interns in multidisciplinary
projects that require effective communication and cooperation with colleagues.
Networking Opportunities:
Provide opportunities for interns to interact with professionals, engineers, and experts in
the electronics industry, helping them build a professional network.
Problem Solving:
Challenge interns with real-world problems encountered in electronics design,
manufacturing, or testing, encouraging them to develop innovative solutions.
Understanding of Manufacturing Processes:
Expose students to the entire lifecycle of electronics manufacturing, from design and
prototyping to testing, quality control, and production.
Professional Development:
Provide opportunities for interns to develop their professional skills, including time
management, project planning, and effective communication.
Industry Awareness:
Increase awareness among interns about the challenges and opportunities in the electronics
industry, helping them make informed career decisions.

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CHAPTER 2

Programmable Logic Controllers(PLCs)

Introduction to PLC

A Programmable Logic Controller at the core is an industrial computer with a high

degree of reliability capable of running a program without interruption in a 24/7/365
environment.
Programmable Logic Controllers were created as a cost effective alternative to relay-
based systems a few years after transistors become more commonplace. A
Programmable Logic Controller at the core is a computer with a high degree of
reliability capable of running a program without interruption in a 24/7/365
environment.
A Programmable Logic Controller is typically the hardware that will control the
process. In case you're wondering, a PLC looks like a box filled with electrical circuits
similar to your desktop computer. A PLC is typically housed in what's called an
electrical enclosure in order to protect it from the harsh environments they may
control. For the context of discussion, it's not uncommon to reference to PLCs as the
entire plant floor control system as they're always tied to sensors, motors, switc hes,
valves, etc.

Allen Bradley PLC Block

PLC Programming in Electronics

An electrician within a production facility is typically an invaluable asset for the

company. This individual would know the visible as well as the invisible components
of the production floor. An electrician typically requires formal training to ensure safe
behavior within a medium voltage environment. This training may take place outside

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or within the company. However, a licensed electrician typically requires formal
education and an apprenticeship program.
Electricians range in skill. Some are capable of working with electrical systems only
while others are capable of programming PLCs, field devices, and even network
infrastructure. In addition to working safely, electricians are trained in tools such as
a multimeter, oscilloscope, wire crimping, megohmmeter, and more.
Electricians are valuable assets in operations, engineering, and maintena nce
departments. Their hours range from an average 8 hour day to 12-hour shifts
depending on business needs. Electricians who know PLC Programming would
typically have a better work environment, higher flexibility, and a higher hourly rate.

Most Popular PLC Brands

 Allen Bradley by Rockwell Automation

 SIMATIC by Siemens
 AC500 by ABBABB

PLC Used in various departments of the Company

Automated Assembly Lines: PLCs control the sequencing of assembly tasks, ensuring
that components are added in the correct order and at the right time. This helps in
streamlining production and minimizing errors.
Machine Control: PLCs are used to control the operation of heavy equipment such as
bulldozers, excavators, and dump trucks. They regulate parameters such as speed,
direction, and hydraulic functions, optimizing performance and ensuring safe
operation.
Quality Control: PLCs can be integrated with sensors and vision systems to perform
quality checks during production. They can identify defects or deviations from
specifications and trigger corrective actions or stoppages if necessary.
Material Handling: PLCs control conveyor systems, robotic arms, and other material
handling equipment, facilitating the movement of components and finished products
throughout the manufacturing facility.
Energy Management: PLCs monitor energy consumption and optimize the usage of
resources such as electricity, water, and compressed air, helping BEML reduce
operational costs and environmental impact.
Maintenance and Diagnostics: PLCs collect data on equipment performance and
health, enabling predictive maintenance strategies to be implemented. They can also
provide diagnostic information in case of faults, aiding in troubleshooting and
reducing downtime.

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2.1 Salient Features
Manufacturing Capabilities:
BEML is known for its manufacturing capabilities, producing a wide range of products
such as earthmoving equipment, rail coaches, mining equipment, and other heavy
machinery.
Technological Expertise:
BEML is recognized for its technological expertise in engineering and manufacturing
heavy equipment. The company often incorporates advanced technologies into its products.
Quality Standards:
The company adheres to high-quality standards in its manufacturing processes to ensure
the reliability and durability of its products.
Government Collaboration:
BEML, being a PSU (Public Sector Undertaking), often collaborates with the government
on various projects, especially in defense and infrastructure development.
Nationwide Network:
BEML has a nationwide network of sales offices, service centers, and parts depots, ensuring
that its products are widely accessible and supported.
Electronics Manufacturing:
BEML's facility in Mysore may be involved in the manufacturing of electronic components
or systems used in heavy engineering equipment.
Embedded Systems Development:
If BEML incorporates electronic control systems in their machinery, the electronics
department may be involved in the development and programming of embedded systems.
Circuit Design and Simulation:
Electronics engineers at BEML may engage in circuit design and simulation using
computer-aided design (CAD) tools to ensure the functionality and efficiency of electronic
components.
Testing and Quality Assurance:
The electronics department is expected to have robust testing procedures and quality
assurance measures to ensure the reliability and performance of electronic components.
Control Systems Integration:
If applicable, the electronics department may be involved in integrating control systems
into the heavy machinery manufactured by BEML.
Safety Standards Compliance:
The electronics department is likely to adhere to safety standards and regulations, especially
if the electronic systems are used in critical applications such as defense or transportation.
Maintenance and Support:
The electronics team may be involved in providing maintenance support for electronic
components throughout their lifecycle.

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Cybersecurity Measures:
In the context of embedded systems and connectivity, the electronics department may
implement cybersecurity measures to protect electronic systems from potential threats.
Training and Skill Development:
BEML's electronics department may provide training programs and skill development
opportunities for its employees to keep them updated on the latest technologies and industry
practices.
Continuous Improvement Initiatives:
The electronics team may participate in continuous improvement initiatives, aiming to
enhance the efficiency, reliability, and performance of electronic systems.

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CHAPTER 3
3.1 VARIOUS SENSORS USED IN MANUFACTURING
Sensors for lubrication systems are measuring devices that record filling levels, flow rates,
but also e.g. piston movements. This helps you to monitor the function of individual system
components or the entire system. The signals recorded by the sensors and transmitted to
the controller provide important data to better understand the condition of a machine or
system. Sensors are therefore key components of digitization. An evaluation of the data
supplied by sensors via AI allows intelligent process optimization. This enables increases
in productivity, reduction of downtimes and saves considerable costs.

 Types of sensors
 Fill level sensor
 Oil-streak sensor
 Oil flow sensor
 Oil flow monitor
 Aerosol monitor
 Humidity sensor
 Piston detector

 Applications
 Machine tools
 Heavy industry
 Agricultural machines
 Construction machines

Pulse meter IPM

For digital flow monitoring in oil circulation systems. IPM is a digital pulse metering panel
to monitor flow rates in oil circulation systems. It can be operated combined with flow
meters or flow limiters. The intuitive IPM touch display allows field configuration and
individual parameters for up to 45 lubrication points. IPM offers an excellent upgrade
possibility for existing oil flow monitoring systems having pulse feed or static signals.

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Gear Wheel indicator SFZM

For precise flow rate monitoring in oil circulation systems. The SFZM gear wheel indicator
is an oil flow monitoring device. It offers robust flow monitoring of lubrication points even
under harsh environmental conditions. Its gear wheel measuring principle is based on the
flow limiter technology. SFZM flow meters have a compact design and have small
installation dimensions. At the same time, they allow a wide range of flow rates from 0,09
l/min to 8,0 l/min. This allows the use in a wide variety of applications. SFZM gear wheel
indicators can also be used as monitoring device for self-adjusting circuits.

Pressure Sensor DSC1

Analogue and digital pressure switch. DSC1 pressure switches are electronic pressure
switches with integrated digital display for relative pressure measurement. They are used
primarily for pressure monitoring. Depending on the design, they also can assume control
functions. Pressure switch points, pressure indication, and the switching logic can be
configured and programmed easily. The values are displayed as 4-digit alphanumeric
characters, at the same time there is an alternating display (red / green) to indicate the
switching status. DSC1 can be operated with both hysteresis and window functions and the
mode can be set separately for each switching output.

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Ultrasonic Sensor

Analogue and digital versions for lubricant reservoirs over five litres. SKF’s Ultrasonic
sensors – available in analogue and digital versions – improve fill-level monitoring on
pump reservoirs with lubricant capacities of over five litres. They use ultrasonic waves to
provide non-contact measurement of the distance to the lubricant surface, making them
virtually maintenance-free.

GS4011/GS6011 Oil-streak sensor

Analogue and digital versions for lubricant reservoirs over five liters. SKF’s Ultrasonic
sensors – available in analogue and digital versions – improve fill-level monitoring on
pump reservoirs with lubricant capacities of over five liters. They use ultrasonic waves to
provide non-contact measurement of the distance to the lubricant surface, making them
virtually maintenance-free. Both analogue and digital versions use a two-color. LED
system to indicate fill level, allowing reliable and convenient monitoring.

GS300 Flow sensor

Flow sensors keep an eye on the flow of oil from a metering point to the lubrication point,
metering out a small amount of oil for only a short period of time. They are suitable for

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intermittent, centralized lubrication systems e. g. with piston metering devices, metering
elements, injection oilers, oil and air centralized lubrication systems.

Pressure sensor DSC2

Digital pressure switch with hysteresis and window function mode. DSC2 sensors are
electronic pressure switches with an integrated digital display for relative pressure
measurement. They are used primarily for pressure monitoring Depending on the design,
they also can assume control functions. Pressure switch points, pressure indication and the
switching logic can be configured and programmed easily. The four-digit, digital display
that indicates switching with LEDs DSC2 can operate in switching point, hysteresis and
window function modes. The switching mode can be programmed separately for each
output.
3.2 R&D Department
The journey of Research and Development (R&D) activities in the divisions of KGF,
Mysore, and Bangalore commenced during the mid-70s, reflecting a commitment to
technological advancement and indigenous innovation. Initially focusing on technology
absorption and indigenization, these endeavors gradually expanded to encompass the
design and development of products and aggregates, marking a pivotal shift towards self-
reliance and innovation.
A significant milestone was achieved in 1984 with the establishment of a fully equipped
R&D Centre in KGF, representing a substantial investment of INR 50 crores. Over the
years, this center underwent continual upgrades, evolving into one of India's largest
development hubs. Recognized by the Department of Science & Technology, Government
of India, the R&D centers in KGF, Mysore, and Bangalore have become instrumental in
fortifying the Earthmover and related industries in the nation.

The R&D division boasts state-of-the-art facilities for design, simulation, and testing,
supported by dedicated laboratories in key areas such as Fluid Power, Power Train,
Structural Engineering, and Material Science. Equipped with a CAD Center and staffed by
highly qualified engineers specializing in advanced fields like mechanical design, engine

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technology, structural engineering, material science, fluid power, and electronics, these
centers possess extensive experience and technical prowess.

Through their relentless pursuit of innovation, the R&D centers have made significant
contributions to the development of machinery and aggregates. Their efforts have not only
fostered technological self-sufficiency but also propelled the growth of indigenous
industries, thereby reinforcing the nation's industrial landscape. By leveraging their
expertise and resources, these centers continue to drive advancements in design,
performance, and efficiency, thereby shaping the future of the sector.

The evolution of R&D activities in KGF, Mysore, and Bangalore divisions stands as a
testament to the organization's unwavering commitment to innovation and excellence.
From humble beginnings focused on technology absorption to becoming beacons of
indigenous technological prowess, these centers have played a pivotal role in shaping
India's industrial landscape. As they continue to push the boundaries of innovation, their
impact on the Earthmover and related industries remains profound, ushering in a new era
of growth and prosperity.

THE PRODUCTS DEVELOPED BY ELECTRONICS GROUP ARE:

Unified Electronic Controller: One of the flagship products developed by the Electronics
Group is the Unified Electronic Controller, a sophisticated system designed to streamline
the management of various vehicle functions. This controller integrates transmission
control, payload monitoring, and vehicle health monitoring into a single unit, offering
unparalleled efficiency and reliability.

Multi-Functional Vehicle Data Recorder: The Multi-Functional Vehicle Data Recorder

represents another groundbreaking innovation, serving as a comprehensive data acquisition
and analysis tool. This recorder captures a wide array of vehicle parameters, facilitating in-
depth analysis of vehicle performance, usage patterns, and operational efficiency.
Radio Control Dozer: The Radio Control Dozer showcases the group's expertise in remote
control technology, enabling operators to remotely manipulate the dozer's movements with
precision and ease. This innovative solution enhances operator safety and productivity,
particularly in hazardous or inaccessible environments.
Portable Equipment Weighing System: Designed for versatility and convenience, the
Portable Equipment Weighing System provides accurate weight measurements for various
types of equipment on the go. This portable solution offers flexibility and efficiency,
allowing users to monitor load distribution and comply with weight regulations effortlessly.
Transmission Controller: The Transmission Controller represents a breakthrough in
transmission management, offering precise control over gear shifts and optimizing
performance for different operating conditions. This controller enhances vehicle efficiency,
durability, and overall driving experience.
Programmable Digital Display: Equipped with advanced diagnostics and data storage
capabilities, the Programmable Digital Display offers real-time monitoring of vital vehicle

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parameters. This user-friendly interface provides operators with valuable insights into
vehicle status, facilitating proactive maintenance and troubleshooting.
Payload Monitoring System: The Payload Monitoring System ensures accurate and reliable
monitoring of payload weight, enabling operators to optimize load distribution and
maximize vehicle efficiency. This system enhances productivity while minimizing the risk
of overloading and associated safety hazards.
LCD Display Centralized Monitoring System: The LCD Display Centralized Monitoring
System offers centralized monitoring and control of vehicle functions, incorporating
enhanced diagnostics and data storage capabilities. This intuitive system provides operators
with comprehensive insights into vehicle performance, enabling proactive maintenance and
efficient operation.

TECHNOLOGY:
SOFTWARE:
 Pro-E, Autodesk Product Design and Manufacturing collections (PDMC), Autodesk
Inventor Professional, Solidworks software packages for 3D modelling.
 ANSYS Mechanical CFD Enterprise for FEM Analysis/Fluid-Flow Analysis and
Optimization.
 KissSoft and KissSYS software for gear calculation and simulation.
 ADAMS for Kinematics and motion Analysis of systems.
 AutoCAD for 2D drafting.
 UltraArc Robot Offline Programming Simulation for Arc Welding application.
 Visual Studio .NET, Visual Studio (Basic, C++, FoxPro) for application software
Development.
 Adobe CS suit and Adobe Acrobat editing tools.

IN-HOUSE DEVELOPED SOFTWARE:

 BemlKam: Nesting of drawing profiles & production scheduling for CNC machines at
Plate shop.
 Pipe bending: To create automated production drawings of pipes by a novice user.
 Gear design: Gear geometry for Internal and External Spur and Helical Gear pair.
Contact & Bending Stress for Spur and Helical Gear pair. Addendum modification
coefficient. Gear Inspection parameter.
 Vehicle Performance Simulation: Predicts vehicle performance for various operating
condition considering engine and hydraulic torque converter matching.
 Library management Software: Library management through interactive user friendly
screen.
 Torque Converter Design: Torque Converter Performance Prediction Software.

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3.3 BH205E

Performance:
High power diesel Cummins / MTU engine and world renowned General Electric for
electric drive, provide smooth consistent grade ability and acceleration performance.
Productivity:
High power to weight ratio gives ample reserve power for increased engine life. More target
area, higher volumetric capacity and a low loading height ensures high productivity.
Reliability:
Diesel-electric power module with few wearing parts offer more durability and high
availability.
Serviceability:
Low maintainability and repair ability index makes easy serviceability.
Maneuverability:
Power steering with wide steering angle, results in short turning radius.
Comfort:
Ideally located spacious deluxe cabin, easy to read and easy to reach instrument panel and
operation switches, large tinted glass windows with excellent visibility for increased
operator's comfort.
Safety:
Features include emergency power steering, electrical dynamic retarding with continuously
rated blown grids and all hydraulic caliper disc brakes meet relevant safety standards.
Specific details about the technology and innovation incorporated into the BEML 205E
electric excavator may not be readily available without consulting BEML's official
documentation or specifications, I can provide you with some general insights into the types
of technology and innovation commonly found in modern electric excavators.
Battery Technology:
The BEML 205E likely utilizes state-of-the-art battery technology to store and deliver
electrical energy to power the excavator's electric drive system. This could include high-
capacity lithium-ion batteries or other advanced battery chemistries designed for durability,

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energy density, and fast charging capabilities.
Advanced Controls:
Modern electric excavators often feature advanced control systems that leverage sensors,
actuators, and onboard computers to optimize machine operation and efficiency. These
control systems may incorporate features such as automated digging cycles, adaptive load
sensing, and intelligent power distribution to maximize productivity while minimizing
energy consumption.
Telematics and Connectivity:
The BEML 205E may be equipped with telematics and connectivity capabilities that enable
remote monitoring, diagnostics, and fleet management. This could include GPS tracking,
real-time performance data transmission, and predictive maintenance algorithms to
proactively identify and address potential issues before they lead to downtime.
Operator Assistance Systems:
To enhance operator productivity and safety, the BEML 205E might include various
operator assistance systems such as ergonomic cab design, intuitive control interfaces, and
integrated cameras or sensors for improved visibility and situational awareness.
Environmental Considerations:
In line with environmental regulations and sustainability goals, the BEML 205E may
incorporate features designed to minimize environmental impact, such as energy-efficient
operation, reduced noise levels, and emissions-free operation.
Modularity and Upgradability:
To accommodate evolving customer needs and technological advancements, the BEML
205E could be designed with modularity and upgradability in mind, allowing for the
integration of future technology enhancements and component upgrades as they become
available.

3.4 Computer-Aided Design(CAD)

CAD (Computer-Aided Design) software is integral to the manufacturing of heavy

vehicles, including those produced by companies like BEML Limited. Here's how CAD
software is specifically utilized in this context:
Design and Engineering: CAD software allows engineers to create detailed 2D drawings
and 3D models of heavy vehicles, such as trucks, bulldozers, and excavators. Engineers can
design individual components, assemblies, and entire vehicles within the software,
incorporating precise measurements and specifications.
Prototyping and Iteration: CAD software enables manufacturers to rapidly prototype and
iterate vehicle designs. Engineers can quickly modify designs, test different configurations,
and evaluate performance virtually before committing to physical prototypes. This iterative
process helps optimize vehicle designs for efficiency, safety, and functionality.

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Integration with Simulation: CAD software often integrates with simulation tools to
perform virtual testing and analysis of heavy vehicle designs. Engineers can simulate
various scenarios, such as structural stress testing, aerodynamics analysis, and vehicle
dynamics simulations, to assess performance under different conditions.

Collaboration and Communication: CAD software facilitates collaboration among design

teams, engineers, and other stakeholders involved in the manufacturing process. Design
files can be easily shared, reviewed, and annotated within the software, allowing for
seamless communication and feedback exchange.
Manufacturing Documentation: CAD software generates manufacturing documentation,
including detailed drawings, bills of materials (BOMs), and assembly instructions. These
documents provide precise specifications for production processes, ensuring consistency
and accuracy in manufacturing heavy vehicles.
Customization and Configuration: CAD software enables manufacturers to customize
heavy vehicle designs to meet specific customer requirements or adapt to different market
demands. Engineers can easily modify designs to incorporate new features, accommodate
different payloads, or optimize for specific applications.
Cost and Time Savings: By leveraging CAD software, manufacturers can significantly
reduce the time and costs associated with traditional design and prototyping methods. The
ability to design, simulate, and iterate digitally minimizes the need for physical prototypes
and accelerates the overall product development cycle.

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CHAPTER 4: APPLICATIONS

 MAJOR ASSEMBLY:
60ton and above dumpers, graders and water sprinklers are assembled in this shop. For
purpose of load distribution sometimes 60ton dumpers are also assembled. Vehicles
assembled are BH100, BH6OM, WS70, BG605, BG405 and BG825.
There are 3 bays in this shop which are specifically reserved for dumpers, Graders and
water sprinklers each Engine, transmission and fuel tank sub assembly are set up in this
shop. Every equipment under goes 20hrs of test drive.

 Tool Engineering:
This department comes under engineering services
Tool engineering has its under
 A Tool design
 Manufacturing of tools
 Planning
By using component drawing and process sheets, finds out work centre and then particular
tool is given to concerned shop.
If required meeting is done with operators of machines for procurement of tools.
Also by this meeting they take operators views and generate the final drawing.
Tools like spanner, cutting tools etc. follow consumption based activity and consider 3years
of consumption and plan.
This department uses JVS technology tO maintain tool history.
They contact purchase department for re ordering or ordering of tools tools and and to put
in the stores.
Main motto of this department is to increase productivity with decrease in cost.

 QUALITY ENGINEERING:
BEML Limited views Quality improvement as a business strategy and hence remains
proactive in the areas of product and service quality. At BEML, a Corporate Quality Policy
emphasizing Total Quality Management ensures that quality system adopted results in
products, services and processes that meet stringent standards and requisite performance
criteria. A separate Quality Department spearheads the thrust towards Total Quality
Management.

 FINAL TESTING:
There are several steps followed in testing process
Oil charging
Test bed
 Oil temperature test
 Water temperature test
 Oil pressure test
 Water pressure test
Five minutes of engine run which detects any abnormality.

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 Organizational study at BEML limited, Mysuru
Tappet setting is done.
Run In: one hour running of engine where complete checking is done.
By setting engine to more power and maximum torque performance.
Testing is done
 Leak test
 Engine air leak test
 Water leak test
 Oil leak test
 Diesel leak test
 Painting is done
Final assembly is done

 R&D:
EPTS (Engine Performance Test Standard) will have basic standard values of a perfect
engine, which has to be compared with newly built engine to check its values.
For 5 minutes run, tappet setting, run in, performance test and leak test EPT standards are
considered. Once engine passes all these stages of testing it is dispatched.

 MAINTENANCE:

 ELECRICAL
 Common electrical service
 Power system maintenance
 Machine tools, welding sets, flame cutting machines and robots
 Crane's, telephone lines, AC'S

 MECHANICAL:
 Machine tools.
 Air compressors.
 Canteen equipment such as boilers.

 CIVIL & LANDSCAPING:

 Civil construction & maintenance
 V Housekeeping the landscape
 Water supply & sanitary
 Liaoning with KIADB, BWSSB etc.

 PLANNING:
 Supply parts for entire plant maintenance department.
 Liaoning with all department for timely receipt of materials.
 Material Information System.

 SAFETY:
 Factory safety and Liaoning with inspectors of the factory.

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CONCLUSION

This interaction gave me an insight and first-hand experience of industrial scenario outside
the institute curriculum. In addition, the exposure gave me the practical knowledge into the
overall functioning of the organization, human behavior in industry and also helped us co-
relate theoretical concepts of classroom and practical approach to industrial production.
The entire duration of four weeks in BEML was professionally managed by all the
responsible persons I came across, very informative and I have no doubt, it will retain its
significance when I embrace my professional careers as an engineer. In doing so, I
gratefully acknowledge the large heartedness of this institution for giving me an
opportunity to complete this internship.
BEML Limited has proved to be one of the modern temples of engineering in India
and no doubt the company is no less than their competitors in the private sector. As I have
experienced, there is no shortage of expertise, talent, professionalism and dedication of the
workforce towards accomplishing the tasks and targets in meeting delivery of products to
its various customer segments. It was a privilege to be a part of this esteemed organization
as an intern and I am fortunate to have the exposure across most of the departments and its
industrial functioning. It was in overall a good learning and rewarding experience.
This interaction gave me an insight and first-hand experience of industrial scenario
outside the institute curriculum. In addition, the exposure gave me the practical glimpses
into the overall functioning of the organization, human behavior in industry and also helped
us co-relate theoretical concepts of classroom and practical approach to industrial
production.
I gratefully acknowledge the kind heartedness of this institution forgiving me an
opportunity to complete this internship.

REFERENCES

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1. https://www.bemlindia.com
2. https://youtu.be/FcmyOXyK4Q4?si=RNyvOGlhYNgoPJv9
3. https://www.google.com
4. https://www.scribd.in
5. Roths well W. J (2010). Effective Succession Planning, Ensuring Leaders Continuity
and Building Talent from within, 4th edition, American Management association, New
York.

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