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505 Army Base Workshop
1. INDIAN INSTITUTE OF TECHNOLOGY
DELHI
Department of Mechanical Engineering
MET 420 Summer Internship
505 Army Base Workshop
Avnish Gaur (2010ME20769)
Industry Supervisor: Lt. Col. Harsh Agarwal
2. About the Workshop
Overhauling of Tank T-72, T-90, Scania, Tatra, Bridging
Equipment.
The tank is an industry in itself. There are a lot of parts or
assemblies are in a tank. India imports the battle tanks from
Russia so assemblies and parts are made there.
Imported tanks from Russia 30-40 yrs. ago are repaired,
reclaimed here and then send back to the army and this saves
a lot of money of our govt.
When tank’s life deteriorated to the much extent, then giving
a new life is the overhauling.
3. Tank
• Three main requirements are Mobility, Firing
Power and Protection.
• In T-72, capacity for 3 people. Commander, Driver
and Gunner.
• Gunner is responsible for laying the gun.
• Driver drives the tank, and also serves as day to
day mechanic.
• The commander is responsible for commanding
the tank. The commander is provided with all
round vision devices rather than the limited ones
of the driver and gunner.
9. Project
• Study and analyse the Gun Stabilization
System and suggest some improvements to it.
• This is the heart of the Gun Control
equipment (which itself is the most important
component of a Tank) and is responsible for
stabilizing the turret and gun of the tank.
• Create a testing jig to test the electronic parts
of the Gun Stabilization System during time of
emergency.
10. Study of Gun Stabilization System
Gun Control
Equipment
Stabilization
System
ALG Unit
Auto Loading Gun Unit
11. Gun Control Equipment
• One of the 4 components of the Tank Control
System.
• It has 2 components which together performs
the job to enable remote and targeting of
guns against tanks, aircraft, and shore targets.
• It performs the same task as a human gunner
firing a weapon, but attempts to do so faster
and more accurately.
14. Problem Statement
• Can we test the electronic parts of stabilization
system of tank without completely disassembling it?
• There are some dedicated testing jigs in the workshop,
which require the tank to be completely disassembled
for testing.
• But suppose, there is some emergency problem during
a war, or we want to figure out the exact location of
the problem.
• In the current scenario, we would have to send the
tank to the workshop and completely disassemble it.
• Only if we have a small portable device which can be
quickly plugged in to find the root of the problem.
16. Portable Testing Jig
• Also called Built-in testing Equipment (BITE)
• A built-in test equipment (BITE) or built-in
self-test (BIST) is a mechanism that permits a
machine to test itself.
• The main purpose of BITE is to reduce the
complexity, and thereby decrease the cost and
reduce reliance upon external (patternprogrammed) test equipment.
17. Components of Stabilization System
Elevation Unit
• This unit is responsible
for the vertical
movement of the gun.
• It comprises of
Elevation Booster (like
PWDM in Traverse
unit), Actuating
Cylinder (elevates the
gun) and Gun.
18. Components of Stabilization System
Traverse Unit
• This part of Stabilization
System rotates the
Turret through 360o.
• It consists of PWDM
(Pump with Dry Motor),
High Torque Motor and
Turret.
19. Components of Stabilization System
K-1 M Box
• Heart of stabilization
system.
• It is also called the First
Distribution Box.
• K1M box is the most
important component of
stabilization system.
• It contains all the relays,
microcontrollers, ICs of
the system, and
manages all the input
and output signals.
20. Components of Stabilization System
LAT (Linear Acceleration
Transmitter)
• Its function is to
maintain the balance of
turret in fixed position
during jerks and pit
holes, and provide gun
enough power to
maintain its position
during tilted paths.
21. Components of Stabilization System
GSD (Gun Setting Device)
• Its function is to bring the gun at 4.50 and freeze it
until new round of ammunition is loaded.
• Whenever commander presses a button of
particular ammunition, GSD ensures the gun
comes to a position of 4.50 and holds it there till
the ammunition is loaded, and then releases it.
22.
23. Working of Stabilization System
• K1M Box is responsible for all the inputs and outputs. It receives
input signal if Commander presses button to load ammunition, or
driver rotates the turret, etc. and performs the desired action.
• To rotate the turret, K1M Box sends electrical signal to PWDM and
it converts the electrical signal to corresponding hydraulic force.
• High Torque Motor uses the signal sent by PWDM to rotate the
turret
• Similar process is followed in the elevation side which is responsible
for the vertical movement of Gun.
• The Elevation Booster receives the electrical signal and converts it
to corresponding hydraulic force.
• The Actuating Cylinder expands or retracts and varies the elevation
of gun.
• Battery supplies 24V DC supply to Convertor which converts it to
40V AC supply at 500 hz frequency, and supplies it to K1M box.
26. T-72 Range Finder
Gunner’s Range Finding Unit TPD-249
• 1000m-4000m
• Sets the gun on the target.
• The unit combines the properties of an optical Gyro
stabilized sight whose field of view is stabilized in
elevation, and of a monocular stereoscopic range
finder.
Δ-D Mechanism
• Maintains the gun on target despite the movement of
tank.
27. ΔD mechanism
• Consists of techno-generator and the cosine
potentiometer.
• Together they form a feedback mechanism, and keep
the gun on target.
• In automatic mode of operation, when the gun is laid
on a ranged target, the gun should remain laid even if
there are range variations due to the movement of
own tank (provided the target doesn’t move).
• At the time of ranging, the range arrow of the gunner’s
ranging sight would be coinciding with the target.
28. ΔD mechanism
• When tank moves from its position ‘A’ to a new position ‘B’ through
a distance ‘D’, the technogenerator generates a proportionate
voltage corresponding to the distance ‘D’ moved by the tank and
feeds it as input to the cosine potentiometer.
• When the gunner traversed the turret through the angle ‘Ɵ’, the
output of cosine potentiometer is the cosine function of the input
voltage and a DC voltage is accordingly fed to the range motor
located inside the sight unit.
• The range motor rotates and causes the range scale to rotate
proportional to the voltage generated by the technogenerator and
cosine potentiometer.
• Rotation of range motor alters the line of sight. This variation of LOS
moves the gun to a new position, therefore super elevation of gun
changes, which caters for the increase/decrease in range
automatically.
29. Working of Testing Jig
Parameters for testing
• DC voltage supply 24v and AC 40v
• High Tension voltage should be 300V DC
• Gyro signal range: 0-10v
• LAT signal range: 0-10v
• GSD signal: 24v should be the output
• Compensator output: 0-450mV both side up &
down.
30. Working of Testing Jig
DC/AC Supply Checking
• The DC range should be around 22-28 V.
• The AC range should be around 38-44 V.
• In case of any error, the possible reason could be
that convertor is damaged.
LAT Signal
• Range should be around 0-10V.
• It is checked on W2 12th pin.
31. Working of Testing Jig
Compensator
• Range should be 0-450 mV.
• Checked on W6 (pin 39 with 2, 3 shorted) for up
• Checked on W6 (pin 39 with 4, 5 shorted) for down
GSD Signal
• 24 V optimum
• Checked on W2 19th pin.
• In case of error, electromagnet might be damaged.
32. Working of Testing Jig
Traverse Output
• Optimum Range 6V-35.5 V
• Checked on W6 (pin 14 with 23, 24 shorted) for left
• Checked on W6 (pin 14 with 25, 26 shorted) for right
• In case of any error, change amplifier power
Elevation Output
• Optimum Range 6V-35.5V
• Checked on W6 (pin 17 with 10, 11 shorted) for up
• Checked on W6 (pin17 with 12, 13 shorted) for down
• In case of any error, change amplifier power
33. Issues at ABW
• Improper infrastructure and tools.
• Unorganized.
• Missing coordination between ground level
employees and officers.
• Lacking innovation.
• No training or personal improvement culture.
• Low investments lead to poor quality of
service, which hampers the defence.
34. Supply of Materials
Demand of
workers
If not
OSS (Ordinance
Store Section)
COD (Central
Ordinance Depot)
If available
Goods
If available
Local Purchase or
Manufacturing
Ordinance Factory
If not
35. Ordering New Material
Section In-charge
Overall In-charge
Lt. Col. Harsh
Agarwal
Quotation Call
Main Control
Officer
Product Manager
Companies will bid
Lowest bid wins
Takes approximately
36 months
36. Need of the moment
Innovation
Challenge &
Improvement,
Deming’s 14 pts.
Motivation at the ground
level. Work culture. Show
them success.
Basic tools and infrastructure.
Motivated team of leaders Ex.
CEO, CTO, Colonel, Commander
