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Internship report on 'STABILIZER UNIT' in BMP-II SARATH at Ordnance factory medak


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This document contains detailed report on stabilization unit in BMP-II SARATH based on the observations done during my internship at Ordnance factory medak.

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Internship report on 'STABILIZER UNIT' in BMP-II SARATH at Ordnance factory medak

  1. 1. INTERNSHIP REPORT ON BMP-II SARATH STABILIZER UNIT at ORDNANCE FACTORY MEDAK Ministry of Defence, Government of India By Under AMRUTH CHINTHALA MR. P. MANMADA RAO B Tech, ECE AWM (IOFS), FA Duration: 1-06-2016 to 30-6-2016 Submitted to VARDHAMAN COLLEGE OF ENGINEERING (AUTONOMOUS) Accredited by NAAC with ‘A’ Grade, NBA, ISO 9001:2008 Certified Kacharam, Shamshabad – 501 218. DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING
  2. 2. ACKNOWLEDGEMENT Being Electronics and Communication Engineering student, exposure to industry will help to think in new horizons and understand the subject in-depth. Moreover being in country’s prestigious ORDNANCE FACTORY MEDAK is just dream come true for any aspirant. I would whole-heartedly thank Prof. Y. Pandu Rangaiah Sir, HOD ECE for permitting me to undergo internship. I always owe my sincerely respects to P. Manmada Rao Sir, AWM (IOFS) for directing me to take STABILIZER UNIT as area to study at ODF. Ordnance Factory Institute of Learning (OFIL) has always been a strong supporter for the students to learn at ODF. This section will not be complete unless I thank Mr. Murthi Sir, FA for explaining the unit from scratch. I will be in depth to Mr.Srinivasulu Sir, JWM for introducing me to Ordnance factory, Medak. I also feel gratitude towards Dr. J V R Ravindra sir for his constant support and all the kind employees of the factory who gave me lift to travel inside the factory. Last but not least, I could not complete this internship without cooperation from my family, for whom I could not compensate in any means in my lifetime. Content inside this report is solely based on the study at ORDNANCE FACTORY MEDAK during my internship. Amruth Chinthala
  4. 4. INDIAN ORDNANCE FACTORIES Indian Ordnance Factories are the oldest and largest industrial setup functioning under the Department of Defence Production of Ministry of Defence. The Ordnance Factories form an integrated base for indigenous production of Defence hardware and equipment, with the primary objective of self-reliance in equipping the armed forces with state-of- the-art battlefield equipment. It is engaged in research, development, production, testing, marketing and logistics of a comprehensive product range in the areas of air, land and sea systems. OFB comprises of one Headquarters (HQ), forty-one Ordnance Factories, nine Training Institutes, three Regional Marketing Centres and four Regional Controllerates of Safety, which are spread all across the country. It is often called the "Fourth Arm of Defence", and the "Force behind the Armed Forces" of India. It is amongst the top fifty defence equipment manufacturers in the world. 18 March is celebrated as the Ordnance Factories' Day. CORE COMPETENCIES: Weapons Small, Medium and Large Calibre Weapons & Mortar Equipment Ammunition, Explosives & Propellants Small, Medium and Large Calibre Ammunition, Mortar Bombs, Signalling and related stores, Rockets & Aerial Bombs, Fuzes, Explosives, Chemicals & Propellants Military Vehicles Trucks, Mine protected and Special Security Vehicles Armoured Vehicles Tanks & its variants, Armoured Personnel Carrier(APCs) & Engines Instruments & Optical devices Night & Day Vision Sights & Instruments Parachutes Brake Parachutes, Man dropping & Supply dropping Parachutes Troop comfort & General Stores Tentage, Clothings, Personal equipment, Bridges, Boats, Cables etc. VALUE OF PRODUCTION (Rs in crore) 2011-12 2012-13 2013-14 2014-15 12390.72 11984.00 11234.00 11364
  5. 5. ORDNANCE FACTORY MEDAK Ordnance factory, Medak is one of the 41 Ordnance Factories under Ordnance Factory Board, Ministry of Defence, and Government of India. On 19th July, 1984 by the then Prime Minister, Late Smt. Indira Gandhi laid the foundation to establish the factory for indigenous production of Infantry Combat Vehicles (ICVs), at Yeddumailaram in Medak District. The first chariot of Medak rolled out of the portals of Ordnance Factory, Medak in the year 1987. The requirement of Army for Infantry Combat Vehicles has been totally met by Ordnance Factory Medak. It has a wide range of modern state-of-art facilities like, Investment Steel Casting and Aluminium Foundry, CNC oriented Light Machining, Heavy Machining and Assembly lines. We are modern Hi-Tech Engineering factory with more than 2000 Nos. of machines covering a wide variety of sophisticated Technologies. Viz, 5 and 3 axis CNC Machines, Thermo Pressing Technology, Foam Filling Technology, Welding Technology and Surface Treatment Technology. It has a wide range of modern state-of-art facilities like, Investment Steel Casting and Aluminium Foundry, CNC oriented Light Machining, Heavy Machining and Assembly lines. We are modern Hi-Tech Engineering factory with more than 2000 Nos. of machines covering a wide variety of sophisticated Technologies. Viz, 5 and 3 axis CNC Machines, Thermo Pressing Technology, Foam Filling Technology, Welding Technology and Surface Treatment Technology. Ordnance Factory, Medak accredited with ISO 9001-2000, ISO -9002, EMS(ISO 14001-2004) certification and also has accredited Metallurgical Laboratory under NABL. Area Acres Factory Area 607 Estate Area 1691 Testing Track 593 Railway Siding 132 Total Area 3023
  6. 6. BMP II SARATH BMP-2 SARATH (Chariot of Victory) – Indian license-produced variant of the BMP-2,built by Ordnance Factory Medak. The first vehicle, assembled from components supplied by KBP, was ready in 1987. By 1999, about 90% of the complete vehicle and its associated systems were being produced in India. It is estimated that by 2007, 1,250 vehicles had been built. All the parts used for BMP II SARATH is manufactured at different places across the country and worldwide. All the units are bought to Ordnance Factory Medak and assembled at Vehicle Assembly (VA) section and the whole vehicle undergoes rigorous tests at FINAL ASSEMBLY (FA) section. Once the vehicle passes all the tests under prescribed norms by Director General, Quality Assurance (DGQA), it is commissioned to the destination. This organisation is more than hundred years old and provides Quality Assurance (QA) cover for the entire range of Arms, Ammunitions, Equipments and Stores supplied to Armed Forces. SPECS: CAPACITY Driver, Commander, Gunner and 7 Crew FUEL CONSUMPTION 92 L / 100KM AUTOMATIC GUN 30 mm calibre Slow Mode: 200-300 rounds/min Rapid Mode: 550 rounds/min Firing Range: 4km CO-AXIAL GUN 7.62 mm calibre 700-800 rounds/min Firing Range: 4km ATGM LAUNCHER 4km COMMUNICATION R174-TADIRON SET COMMUNICATION RANGE 30KM NAVIGATION GPK 59
  7. 7. SOME OF THE VEHICLE PART MANUFACTURERS:  Periscopes at Ordnance Cable Factory, Chandigarh  Gunner and Commander Hatch Plates at Ordnance Factory, Kanpur  Shock Absorbers Gem Precision Tool (P) Ltd in Coimbatore Escorts Limited in Faridabad  Radio Sets by Tadiron, Israel ELECTRONICS IN BMP II SARATH: Electronics plays a vital role in making BMP II highly combatable. Electronics is used in  Gun stabilization movement  Tank Intercom System  Instant fire detection and suppression  Advanced land navigation system Major electronic parts are manufactured by Bharat Electronics Limited, Government of India, and Ministry of Defence. GRAPHIC MODEL OF BMP II SARATH
  8. 8. INTRODUCTION TO STABILIZER Stabilizer is an all-electric drive system intended to stabilise the armament mounted on infantry fighting vehicle (BMP II) in traverse and elevation when firing at ground targets on the and at halt. Stabilizer provides the semiautomatic traverse and elevation laying when engaging aerial targets at halt. The commanders traverse target designation, make it possible for the commander and operator to operate twin gun mount. Stabilization unit is fitted inside the turret of BMP II SARATH. SYSTEM LAYOUT: Following units are common for both Traverse and Elevation controls:  Control Unit  Control Panel  Converter  Power supply Filter STABILIZER ELEVATION DRIVE CONTROL TRAVERSE DRIVE CONTROL ELEVATION DRIVE RATE GYRO AMPLIFIER ELECTRIC MOTOR TRAVERSE DRIVE RATE GYRO AMPLIFIER ELECTRIC MOTOR TARGET DESIGNATION DEVICE
  12. 12. DESCRIPTION OF UNITS IN STABILIZER POWER SUPPLY FILTER: Filter is designed to minimise the noise in 27V vehicular mains during operation. It consists of reverse polarity protection circuit for protection. CONVERTER: It converts 3 phase 36v, 400Hz AC voltage to feed other units like amplifier, control unit, rate gyros and target designation device. It is made up of permanent magnetic rotor. RATE GYRO: When the gun position is changed during vehicle movement, rate gyro produces electric signal proportional to angular rate of the turret on which gun is mounted. It consists of: 1. Gyrometer 2. Transducer 3. Gimbal Base 4. Torsion wire ELECTRIC MOTORS: Two electric motors are present in stabilization unit. One for traverse and other for elevation. BEL PRODUCTS FOR BMP II SARATH
  13. 13. CONTROL PANEL: Control Panel is used to monitor the Stabilizer from the operator side, either gunner or commander. It is operated by setting DRIVE toggle switch to ON position. It takes 6-20 seconds to get energized. It consists following switches on control panel.  ELEV  TRAV  AUTO or AIDED At a particular point only one, either gunner or commander can operate their control panels. Control can be toggled between commander and gunner using DRIVE toggle switch. LED’s referring ELEV, TRAV, and AUTO or AIDED is ON only on the current operator’s control panel. AMPLIFIER: Amplifier converts control signal supplied from control panel into pulse width modulated signal and amplifies such it can actuate the motor. DC signal PW Modulated signal Two H-bridged amplifiers are used for elevation and traverse motors to actuate based on input control signals. Amplifier consists of:  Voltage stabilizer  Inhibit signal generator  Rectifier and  Pulse width modulator Voltage Stabiliser: It generates stabilized voltage of 15V DC. Inhibit signal generator: It is used to minimise back load current amplitude. It consists of operational amplifier and comparison circuit. Rectifier: Rectifier generates DC voltage. It consists of diode bridges and ripple capacitive filters. Pulse width modulator: This converts DC signal applied to PWM modulator to pulse modulated signal. It consists of saw tooth waveform generators, operational amplifiers, compensators and transistor voltage amplifiers. Actual components used in amplifiers are furnished in next section. AMPLIFIER
  14. 14. COMPONENTS USED IN AMPLIFIER (BY OBSERVATION) IN INHIBIT SIGNAL GENERATOR:  LM709AH – Operational amplifier  RESISTORS  DIODES  CAPACITORS PULSE WIDTH MODULATOR  RLR32C – metal film military grade resistor  RESITORS  ZENERS  CAPACITORS VOLTAGE REGULATORS  2N3055 – general purpose transistors  CAPACITORS  RESISTORS  DIODES PULSE AMPLIFIERS  4 PULSE AMPLIFIERS, each consists of 2N6437 All electronic components used are military grade which can withstand temperatures from -45 to 85 (in Celsius). LM709AH 2N3055 ZENER DIODE
  15. 15. CONTROL UNIT: Control unit intended to sum up, convert and amplify the elevation and traverse drive control signals and switch circuits for operation of stabilizer. Control unit consists of  Voltage stabilizer  Time relay  Integrators (T, E)  Summing Amplifiers (T, E)  Voltage Amplifiers (T, E) VOLTAGE STABILIZER: It produces DC voltage of +15V as measured relative to the centre tap. TIME RELAY: Used to introduce time delay of 4-20seconds when the stabilizer is activated. SUMMING AMPLIFIER: It is designed to sum up the signals from the integrator, current transducer and rate gyro. It consists of interrupters, two amplifiers built round operational amplifier. TARGET DESIGNATION DEVICE: It is designed to generate electric signal corresponding to error angle between commander periscope’s line of sight in azimuth and the gun position. When commander observes a target, he can use target designation device to immediately turn the turret and align the gun with commander’s periscope line of sight. TURRET OUTER-VIEW ATGM LAUNCHER SMOKE CYLINDERS GUNNER HATCH COMMANDER HATCH
  16. 16. ATGM LAUNCHER ATGM stands for anti-tank guided missile weapon system that can be mounted on a vehicle to destroy the enemy targets. ATGM launcher kit activates only if the gun position comes to halt because if gun position does not come to halt or 0 degree position in elevation, missile launched from ATGM launcher hits the gun. MISSILE IS LAUNCHED FROM AN ATGM LAUNCHER SMOKE CYLINDERS When an enemy detects the ICV, the operator inside the vehicle fires smoke cylinder so that a cloud of smoke is created so that it makes difficult for the enemy to target the vehicle, in mean time vehicle gets escapes from the area. SMOKE DISCHARGED FROM 902B CYLINDERS
  17. 17. WORKING OF STABILIZATION UNIT Stabilizer is not a single unit. It is an assembly of many units that work together and with synchronisation to minimise the miss-position of the gun after the vehicle undergo jerks. ELEVATION DRIVE AND TRAVERSE DRIVE: When there is a jerk and position of the gun is changed, elevation drive rate gyro deflects and produces electric signal proportion to rate of change (or) deflection rate(𝑑∅/𝑑𝑡), where ∅ is angle of deflection from its initial position. This is an ac signal and it is passed to the integrator. Integrator converts input signal from gyro and control panel to output signal which is proportional to the integral of input signal. It converts ac signal into dc signal and switches the further circuits for operation. This signal is applied to summing amplifier and then to voltage amplifier. The amplified signal is given as an input to Pulse width modulator which converts DC voltage signal into pulse voltage signal whose pulse width is proportional to voltage at modulator input. WHY PULSE WIDTH MODULATOR IS USED? By changing pulse width, we are changing average voltage applied to next unit. i.e., electric motor armature winding. Based on the width of the pulse supplied to motor, motor actuates. If width is motor, motor is actuated more and if it is less, it actuates less. Pulse width modulator has a saw tooth wave form generator. Its working is diagrammatically shown below. This is a simulation for ac input. The same holds good for a DC signal. Output pulse width is based on the comparison between saw tooth signal and input dc signal.
  18. 18. The pulse signal from the modulator is amplified by power amplifier and supplied to Electric Motor armature winding. The motor moves the gun to compensate for the hull deflection so that gun is correctly aimed to the target. For anticipated performance: Output signal from gyro and signal proportional to the speed to the speed of the motor (obtained by summing the current feedback and voltage feedback signals) are used. For quality of transient process: Signal proportional to the motor speed entering summing amplifier together with the signal of the current transducer serves for the stability of elevation drive. The gyro signal entering the summing amplifier through rejection filter is tuned to the natural frequency of oscillations of rate gyro. The current transducer signal, proportional to the current induced by the electric motor armature, is applied to summing amplifier. The amplified and converted summation signal is fed to the electric motor. The above whole description is common for both elevation and traverse drive. So, separate description is not produced here.
  19. 19. COMMUNICATION SYSTEM IN BMP II SARATH Communication set in BMP II SARATH helps the combatants inside the vehicle to communicate with each other, other vehicles in the troop and also with other directing teams within 30km range. Communication set inside the SARATH is manufactured by TADIRAN. TADIRAN is an Israeli company and communication radio sets are imported. TADIRAN RADIO SET Radio set can be operated in levels based on power:  LOW ---- 0.25 W to 5W (less than 10km)  MEDIUM ---- up to 25W (10 to 12km)  HIGH ---- up to 50W (up to 25km) It can be operated in three modes:  CLEAR  SECURE  ANTI JAMMING – normal, advance Priorities can be set during talks:  LOW  MEDIUM  HIGH This radio set accommodate up to 80 channels to communicate. 2 antennas are present for 2 sets. ERS button erases the whole data of saved channels etc., within tens of seconds.
  21. 21. CONCLUSION During my internship period from 1-6-2016 to 30-6-2016, I have witnessed many new technologies at Ordnance factory. It ranged from mighty Infantry Combat Vehicles to well- equipped Tank electronics laboratory. It was like a learning jungle for an electronics enthusiast like me. I studied about the core electronics application in the tank, STABILIZER. These 30 days at Ordnance factory helped me a lot to understand about the STABILIZER to a better level. Yet, there are many things to learn at Ordnance factory in the field of electronics, I was happy with the content I grasped during this time span. I feel very proud to be with a mighty organisation like Ordnance factory Medak which manufactures ICVs to meet the needs of the Indian Army. Discipline and Punctuality are the two things that anyone can learn at the factory. I hope that I behaved according to the code of conduct and this internship will help me to achieve great heights in my career and understand the importance of planning, discipline and punctuality.