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INDUSTRIAL TRAINING IN BHARAT ELECTRONICS

LIMITED

INTRODUCTION

Bharat Electronics Limited is a state owned electronics company with about nine factories and few regional offices in India.

It is owned by the Indian Government and primarily manufactures advanced electronic product for the for the Indian armed forces.

BEL is one of the eight PSUs under ministry of defense, Government of India.

It have been earned the Government’s Navaratan status in June, 2007.

HISTORY

Bharat Electronics Limited was setup at Banglore, India by the Government of India under the ministry of defense in 1954 to meet the specialized electronic needs of the Indian defense service.

Over the years it has grown into a multi-product, multi-technology and multi-unit company.

Starting with manufacture of a few communication equipment in 1956, BEL went to produce receiving valves in 1961, Germanium semiconductor in 1962 and radio transmitter for AIR in 1964.

In 1966 BEL setup a RADAR manufacturing facility for ARMY. Manufacturing of transmitting tubes, silicon devices and Integrated Circuits starts in 1967.

PCB manufacturing facility was established in 1968.

In 1970 manufactures of Black and White TV pictures tube, X Ray tube and microwave tube started.

Motto and mission Values

Quality Technology & InnovationTo be a market leader in

defense electronics & in other chosen field and products.

Putting customer first. Working with transparency, honesty

and integrity. Trusting and respecting individuals. Fostering team work. Striving to achieve employee

satisfaction. Encouraging flexibility and

innovation. Proud of being a part of

organization.

CORPORATE MOTTO, MISSION AND VALUES

Manufacturing units

BANGALORE (KANARATAKA) BEL started its production activities in Bangalore on 1954 with 400W high frequency (HF)

transmitter and communication receiver for the Army. Since then, the Bangalore Complex has grown to specialize in communication and Radar/Sonar Systems for the Army, Navy and Air-force.

GHAZIABAD (UTTER PRADESH) The second largest Unit at Ghaziabad was set up in 1974 to manufacture special types of radar for

the Air Defence Ground Environment Systems (Plan ADGES). The Unit provides Communication Systems to the Defence Forces and Microwave Communication Links to the various departments

of the State and Central Govt. and other users.PUNE (MAHARASHTRA)

This Unit was started in 1979 to manufacture Image Converter Tubes. Subsequently, Magnesium Manganese-dioxide Batteries, Lithium Sulphur Batteries and X-ray Tubes/Cables were added to the product range. At the present the Laser Range Finders for the Defence services.

CONTD……

MACHILIPATNAM (ANDHRA PRADESH)The Andhra Scientific Co. at Machilipatnam, manufacturing Optics/Opto-electronic equipment was integrated with BEL in 1983. the product line includes passive Night Vision Equipment, Binoculars and Goggles, Periscopes, Gun Sights, Surgical Microscope and Optical Sights and Mussel Reference Systems for tank fire control systems. The Unit has successfully diversified to making the Surgical Microscope with zoom facilities.

PANCHKULA (HARYANA)To cater the growing needs of Defence Communications, this Unit was established in 1985. Professional grade Radio-communication Equipment in VHF and UHF ranges entirely developed by BEL and required by the Defence services are being met from this Unit.

CHENNAI (TAMIL NADU)In 1985, BEL established another Unit at Chennai to facilitate manufacture of Gun Control Equipment required for the integration and installation and the Vijay anta tanks. The Unit is now manufacturing Stabilizer Systems for T-72 tanks, Infantry Combat Vehicles BMP-II; Commander’s Panoramic Sights & Tank Laser Sights are among others.

CONTD…..

KOTDWARA (UTTER PRADESH)

In 1986, BEL STARTED A unit at Kotdwara to manufacture TelecommunicationEquipment for both Defence and civilian customers. Focus is being given on the requirement of the Switching Equipment.

TALOJA (MAHARASHTRA)For the manufacture of B/W TV Glass bulbs, this plant was established in collaboration with coming, France in 1986. The Unit is now fully mobilized to manufacture.

HYDERABAD (ANDHRA PRADESH)To coordinate with the major Defence R&D Laboratories located in Hyderabad, DLRL, DRDL and DMRL, BEL established a Unit at Hyderabad in 1986. Force Multiplier Systems are manufactured here for the Defence services 20’’ glass bulbs indigenously.

SERVICES OF BHARAT ELECTRONICS LIMITED

DEFENCE PRODUCTS:- Naval System Military Communication Equipment Radars Tele Communication & Broadcasting Services Opto Electronics Electronic Warfare Tank Electronics

NON-DEFENCE PRODUCTS:- Electronic Voting Machine Solar Products DTH

ROTATION PROGRAM

Under this we are introduced to the company by putting us under a rotation program to various departments. The several departments where I had gone under my rotational program are:

Test Equipment and Automation P.C.B. Fabrication Quality Control Works-Radar Work Assembly- Communication Magnetics Microwave lab

TEST EQUIPMENT AND AUTOMATION

This department deals with the various instruments used in BEL. There are 300 equipments and they are of 16 types.

Examples of some test equipments are: Oscilloscope(CRO) Multimeter Signal Analyzer Logical Pulsar Counter Function Generator etc.

Mainly the calibration of instruments is carried out here. They are compared with the standard of National Physical Laboratory (NPL).

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

CONTD…..

The national physical laboratory (NPL), New Delhi provides the standard values yearly. BEL follows International Standard Organization (ISO) standard. The test equipments are 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 – Can’t be used, should be disposed off.

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 

PCB FABRICATION

P.C.B. stands for Printed Circuits Board. It’s an integral part of the Electronics equipment as well as all the components are mounted on it. It consists of the fiberglass sheet having a layer of copper on both sides.TYPES OF PCBs

Single Sided Board : Circuits on one side. Double Sided Board : Circuit on Both side. Multi-layer Board : Several layers are interconnected through hole

metallization.

Raw material for PCB’s

Most common raw material used for manufacturing of PCBs is copper cladded glass epoxy resin sheet. The thickness of the sheet may vary as 1.2, 2.4 and 3.2mm and the standard size of the board is 610mm to 675mm

CONTD…..

There are three types of solder marking done in BEL:

Wet solder mask: Due to some demerits this method is totally ruled out. The demerit was non- alignment, which was due to wrong method applied or wrong machine.

Dry pin solder mask: Due to wastage of films about 30% this method is also not used now.

Liquid photo imaginable solder mask (LPISM): In this first presoaking is at 80 degree Celsius for 10 to 20 minutes. Next, screen preparation is done. The board is covered by a silk cloth whose mesh is T-48. The angle to tilt of the board is 15 degree to 22.5 degree.

QUALITY CONTROL

According to some laid down standards, the quality control department ensures the quality of the product. The raw materials and components etc. purchased and inspected according to the specifications by IG department. Similarly QC 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 departments inspects all the assembled parts such as PCB, cable assembly ,cable form , modules , racks and shelters as per latest documents and BEL standards .

The mistakes in the PCB can be categorized as: D & E mistakes Shop mistakes Inspection mistakes

CONTD…..

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 actions are taken: Observation is made. Object code is given. Division code is given. Change code is prepared. Recommendation action is taken

WORK 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 –II, REPORTER. WORK ASSEMBLY COMMUNICATION e.g. EMCCA, MSSR, MFC. EMCCA: EQUIPMENT MODULAR FOR COMMAND CONTROL

APPLICATION. MSSR: MONOPULSE SECONDARY SURVEILLANCE RADAR. MFC: MULTI FUNCTIONAL CONSOLE.

CONTD…..

The stepwise procedure followed by work assembly department is: Preparation of part list that is to be assembled. Preparation of general assembly. Schematic diagram to depict all connections to be made and brief idea about all components. Writing lists of all components.

MAGNETICS

MAGNETICSIn this department different types of transformers and coils are manufactured , which are used in the various Defence equipments i.e. radar , communication equipments.

This department basically consists of three sections : 1.) PRODUCTION CONTROL :- Basic function of production control is to plan the production of transformer and coils as per the requirement of respective division (Radar and Communication). This department divided into two groups :a) Planning and (b) Planning store . 

(2.) WORKS (PRODUCTION) :- Production of transformers and coils are being carried out by the works departments.

CONTD….

3.) QUALITY CONTROL :- After manufacturing the transformer/coils the item is offered to the inspection department to check the electrical parameters(DCR , No load current , full load current , dielectric strength , inductance , insulation resistance and mechanical dimension as

mentioned in the GA drawing of the product. The D&E department provides all the information about manufacturing a coil and the transformer.The various types of transformers are as follows :

Air cored transformers Oil filled transformers Moulding type transformers P.C.B Mounting transformers

CONTD…..

Steps involved in the process of manufacturing of transformer/coils:

  Preparation of former : Former is made of plastic bakelite comprising

a male and female plates assembled and glued alternately to form a hollow rectangular box on which winding is done.

  Winding : It is done with different material and thickness of wire. The

winding has specified number of layers with each layer’s having a specified number of turns. The distance between the two turns should be maintained constantly that is there should be no overlapping. The plastic layer is inserted between two consecutive layers.

MICROWAVE LABORATORY

Microwave lab deals with very high frequency measurements or very short wavelength

measurements. 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. The power measurements being done in microwave lab are in terms of S- parameters. Mainly the testing is done on coupler and isolators and parameters are tested here.

There are two methods of testing: Acceptance Test Procedure(ATP) Production Test Procedure(PTP)

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