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VISVESVARAYA TECHNOLOGICAL UNIVERSITY
"Jnana Sangama", Belagavi- 590 018
Repor
t on
Internship
Seminar “WIFI
DNC”
Submitted in partial fulfilment of the requirement for the 8th semester
BACHELOR OF ENGINEERING
in
ELECTRONICS AND COMMUNICATION ENGINEERING
by
NANDINI S 1RL20EC013
Under the guidance of
Mr. NANDISH N
Assistant Professor, Dept. of E&CE
DEPARTMENT OF ELECTRONICS & COMMUNICATION

ENGINEERING
R.L. JALAPPA INSTITUTE OF TECHNOLOGY

Kodigehalli, Doddaballapur – 561 203
2023-24
CERTIFICATE
This is to certify that Internship Seminar work entitled “WIFI DNC” by NANDINI S
(1RL20EC013) a bonafide student of R L JALAPPA INSTITUTE OF TECHNOLOGY
in fulfilment for the award of Bachelor of Engineering in ELECTRONICS AND
COMMUNICATION ENGINEERING of the VISVESVARAYA
TECHNOLOGICAL
UNIVERSITY, Belagavi during the academic year 2023-24. It is certified that all
corrections and suggestions indicated for Internal Assessment have been incorporated in the
Report deposited in the departmental library.
The internship Seminar report has been approved as it satisfies the academic
requirements in respect of Internship Seminar work prescribed for the said Degree.
Internal Guide HoD Principal

Prof. Nandish N Dr. Anil Kumar C Associate Dr. P Vijayakarthik
Assistant Professor Professor & Professor
Department of Head Department of ECE RLJIT
ECE
ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of people who made it possible. So with
gratitude, we acknowledge all those whose guidance and encouragement crowned out efforts
with success.
We would like to extend regards to Dr. P Vijayakarthik Principal, R L J I T, for all his
prolific support in all endeavours.
Our Special Thanks to Dr. Shivaprasad K M, Vice Principal, RLJIT for his guidance
in this complete endeavours.
We like to express our gratitude to Dr. M Sreenivasa Reddy, Director (Quality in
Academics and R&D) for his support and encouragement to complete our technical seminar.
We express our sincere thanks to Dr. Anil Kumar C. HOD, Department of Electronics
and Communication Engineering, RLJIT for his support and encouragement.
We express our sincere gratitude to Dr.Harish S. Seminar Coordinator,

Department of Electronics and Communication, RLJIT for his Support and guidance.
At this outset, we extend our gratitude to Prof. Nandish N, Assistant Professor,

Department of Electronics and Communication, RLJIT for her guidance at all stages of this
complete exercise.
We are thankful to all our faculties and the entire department ELECTRONICS AND
COMMUNICATION ENGINEERING for their cooperation and suggestion, without their
cooperation and suggestions our course would not have been a successful one.
Finally, we also thank our beloved parents for their blessing and love in our entire
endeavour.
Nandini S 1RL20EC013
(i)
CERTIFICATE
(ii)
ABSTRAC
Being India’s leading Defence equipment manufacturer, BEML Limited keeps the Indian Army
and other Defence forces abreast with state-of-the-art military equipment. The company
manufactures variants of heavy duty Tatra vehicles for all terrain operations including Bridge Layer,
Field Artillery Tractor, Medium and Heavy Recovery Vehicle, Pontoon Mainstream Bridge Systems,
Crash Fire Tenders, Mobile Mast Vehicle etc. BEML also supplies engineering Mine Ploughs, Tank
Transportation Trailers, Weapon Loading equipment, Armored Recovery Vehicle, Milrail Coaches
and Wagons apart from Aircraft Weapon Loading Trolley and Aircraft Towing Tractor. BEML plays
a stellar role in the country’s Integrated Guided Missile Also, BEML supplies equipment to Indian
Railways which include Integral Rail Coaches, Overhead Electric Inspection Cars(catenary
cars),Postal Vans, AC/DC Electric multiple units, Diesel EMUs, Utility Track Vehicles, Track
Laying Equipment, Broad-Gauge Rail bus, Treasury Vans, Spoil disposal Units etc.
The Company operates under three major Business verticals viz., Mining & Construction, Defence
and Rail & Metro. The three verticals are serviced by nine manufacturing units located at Bangalore,
Kolar Gold Fields (KGF), Mysore, Palakkad and Subsidiary - Vignyan Industries Ltd, in
Chikmagalur District.
BEML’s products are sold and serviced through its large Marketing Network spread all over the
Country and are exported to more than 67 countries. BEML's nationwide network of sales offices
enables buyers with ready access to its wide range of products. Also, the full-fledged service centers
and parts depots offer total equipment care, maintenance contracts and rehabilitation services. The
company has a dedicated R&D infrastructure and team in line with consistent policy of the company
to meet the technological demands through in-house R&D and strategic technical tie-ups with global
players.
(i
Table of Contents
ACKNOWLEDGEMENT (i)
CERTIFICATE (ii)
ABSTRACT (iii)
Table Of Contents
List of Figures
CHAPTER–1
INTRODUCTION
1.1 About the company 1
1.2 Vision and Mission 3
1.3 Products Manufactured 4
CHAPTER–2
WORK FLOW
2.1 Illustration (work flow model) 7
2.2 Quality and tool engineering 8
2.3 Stores 9
2.4 Purchase department 10
2.5 Production 10
CHAPTER-3
STUDY PROJECT ON WIFI DNC(DIRECT NUMERICAL CONTROL)
3.1 Communication between CNC machine and DNC using Ethernet cable 12
3.2 DNC Max software 14
3.3 The DNC system has been installed for the following CNC machines in plate shop 15
3.4 To install DNC in plate shop following are the points verified 21
CHAPTER-4
EARTH MOVERS DIVISION
4.1 Plate shop 23
4.2 Fabrication shop 24
4.3 Machine shop 26
4.4 Heat treatment shop 29
4.5 Gear shop 31
4.6 Assembly shop 33
4.7 Final testing 36
4.8 Defence hanger 37
CHAPTER-5
HP AND R&D
5.1 Hydraulics and power line 41
5.2 Research and development 42
CHAPTER-6
CONCLUSION 46
REFRENCE 47
List of Figures
Figure-1: BEML logo
Figure-2: Crawler
dozer Figure-3:
Excavators Figure-4:
Wheel dozer Figure-5:
Loaders Figure-6:
Dump trucks
Figure-7: Water sprinklers
Figure-8: Wifi DNC
Figure-9: communication between CNC machine and DNV machine using ethernet
cable Figure-10: Messer plasma cutting machine
Figure-11: Messer oxy fuel cutting machine
Figure-12: Flame cutting 6-Fanuc 01 MD
machine Figure-13: Flame cutting 8-Fanuc 18
MD machine Figure-14: Flame cutting 9-Fanuc
01 MD machine
Figure-15: Flame cutting 13-Fanuc 01 MD
machine Figure-16: CNC Tanaka flame cutting-01
machine Figure-17: Shearing machine
Figure-18: Straightening machine
Figure-19: CNC Turning machine
Figure-20: Shaping machine
Figure-21: Radial drilling
machine
Figure-22: Vertical milling and cylindrical grinding
machine Figure-23: Heavy duty boring machine
Figure-24: External
gearing Figure-25: Internal
gearing Figure-26: Tatra
Figure-27: ARRV
Figure-28: Bullet proof vehicles
(vii)
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CHAPTER - 1
INTRODUCTION
1.1 ABOUT COMPANY:

BEML Limited (formerly Bharat Earth Movers Limited) is public sector
undertaking under ministry of defence (Gov. of India) with headquarters in Bangalore.
BEML’s products meet the requirement sectors of economy viz. urban transportation,
construction and mining, defence equipment etc.
BEML was incorporated in 11th May 1964 and commenced its operations on 1st
January 1965 as the wholly owned company of Govt. of India under the administrative
control Ministry of Defence. After an initial divestment of 25% in 1992, the company’s
holding Progressively reduced and at present stands at 54% . BEML is now Asia’s
second largest manufacturer of earth moving equipment and also a major supplier of
state- of- the- art stainless steel metro cars to cities like Delhi and Bangalore and is ready
to take further plunge in this market.
BEML is ranked as “The Largest and Most Profitable Construction Equipment

Company” by Construction World –NICMAR, 2007 and has emerged in the forefront
of heavy engineering industry with a track record of growth and revenues for over four
decades. For its innovative management practices, the company has been awarded
“Golden Peacock Innovation Management Award”. BEML has also been rated as “The
Fourth Largest wealth Creator in the Country” by Dalal Street Magazine. BEML
Limited, a ‘Miniratna –Category- 1’ company, plays pivotal role and serves India’s core
sectors like Defence, Rail, Power, Mining and Infrastructure.
KGF unit is the main unit accounting for the manufacture and assembly of a wide array
of Earth- moving equipment such as bulldozers, mining shovels, loaders and
excavators. The Rail and metro coaches are made in Bangalore complex and Mysore
facility makes dumptrucks and diesel engines of various capacities for its captive
requirement. The new division at Palakkad turns out rail components and defence
equipment. The company plans to diversify into varied activities including underground
storage for petro- products, leasing and financial services and joint ventures abroad.
BEML’s products are exported to more than 25 countries. As a part of company’s
globalization strategy, the company
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Dept. of E&CE, RLJIT 2023-24 Page 1
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has its global reach by opening local companies at Indonesia and Brazil.
BEML operates on three major business verticals for associated equipment

manufacturing
• Mining and construction
• Defence
• Rail and Metro In addition to the above, there are three strategic business units (SBUs):
• Technology Division for providing end- to- end engineering solutions
• Trading Division for dealing in non- company products
• International Business Division for export of company products & services
Mining & Construction Business BEML Limited offers a comprehensive and diverse
range of mining machinery for both opencast and underground mines. BEML products
in this domain are: Electric Rope Shovels, Hydraulic Excavators, Bulldozers, Wheel
Loaders, Wheel Dozers, Dump Trucks, Motor Graders, Pipe Layers, Tire Handlers,
Water Sprinklers and Backhoe Loaders. Besides, BEML also manufacturers mammoth
Walking Draglines for cost- effective operations in the opencast mines.
Figure-1.1: BEML LOGO
Dept. of E&CE, 2023- Page 2 of 51

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1.2 VISION AND MISSION:

BEML’S VISION: To become a market leader, as a diversified Company, supplying
quality products and services to sectors such as Mining & Construction, Rail & Metro,
Defence & Aerospace and to emerge as a prominent international player.
BEML’S MISSION:
1. Improve competitiveness through collaboration, strategic alliances and joint
ventures, to sustain and enhance market share in product groups BEML operates.
2. Grow profitably by aggressively pursuing business and market opportunities in

domestic and international markets by pursuing at least 10% of sales in exports.
3. Adoption of state-of-the-art technologies and bring in new products through

Transfer of Technology and in-house R&D.
4. Continue to diversify and grow addressing new products and markets with turnover
from in-house R&D developed products at 60%.
5. Attract and retain people in a rewarding and inspiring environment by fostering

creativity and innovation with attrition levels less than 5%.
6. Offer technology and cost effective total solutions for enhanced customer
satisfaction

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1.3 PRODUCTS MANUFACTURED:
Being India’s leading Defence equipment manufacturer, BEML Limited keeps the
Indian Army and other defence forces abreast with state- of- the- art military equipment.
The company manufactures variants of heavy duty Tatra vehicles for all terrain operations
including Bridge Layer, Field Artillery Tractor, Medium and Heavy Recovery Vehicle,
Pontoon Mainstream Bridge Systems, Crash Fire Tenders, Mobile Mast Vehicle etc.
BEML also supplies engineering Mine Ploughs, Tank Transportation Trailers, Weapon
Loading equipment, Armored Recovery Vehicle, Milrail Coaches and Wagons apart from
Aircraft Weapon Loading Trolley and Aircraft Towing Tractor. BEML plays a stellar role
in the Country’s Integrated Guided Missile Development Project by supplying ground
support vehicles. The company has also created a world class test track at its KGF
complex to test Defence Equipment and vehicles. Rail and Metro Business In recent years,
BEML Limited has also forayed into manufacture and supply of high- tech metro trains
deployed for intra- city commuting. BEML is expanding its infrastructure to meet the
greater needs of metro projects coming up in the country. Also, BEML supplies equipment
to Indian Railways which include Integral Rail Coaches, Overhead Electric Inspection
Cars(catenary cars),Postal Vans, AC/DC Electric multiple units, Diesel EMUs, Utility
Track Vehicles, Track Laying Equipment, Broad- Gauge Rail bus, Treasury Vans, Spoil
disposal Units etc.
Products manufactured in K.G.F. complex are: (Assembly)

• Dozers
• Loaders
• Excavators
• ARRV and ARV
• Transmission of all vehicles
• Suspension Cylinders
Although the engines of all vehicles are produced at the Mysore complex, the
assemblies of earth movers are done in the K.G.F Complex. The company has 9
manufacturing units spread over the following locations:

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1. Kolar Gold Fields (KGF) Complex (around 100 Km from Bangalore) Earth
Moving Division, Rail Coach Unit II, Heavy Fabrication Unit and Hydraulic &
Power line Division.
2. Mysore Complex (around 130 Km from Bangalore) Truck Division and Engine
Division.
3. Bangalore Complex - Rail & Metro Division, Palakkad Complex and Vignyan
Industries, a subsidiary located at Tarikere (around 300 km from Bangalore) - Steel
Castings.
BEML’s nationwide network of sales offices enables buyers with ready access to its wide
range of products. Also, the full- fledged service centers and parts depots offer total
equipment care, maintenance contracts and rehabilitation services.
BEML Technology Division (www.bemltech.com) offers end- to end services and
solutions in areas of CAD, CAE, Testing and Technical Documentation. Design and
Development experience in CEMILAC (Centre for Military Airworthiness and
Certification) and ISO 9001:2008 certified environment, NABL certified test facility and
strategic alliances with global partners have ensured a competence comparable with the
best in the world. The company has a reputation for innovative products, Robust Designs
and excellent customer satisfaction. Trading Division Trade Division deals with non-
company products and commodities for captive requirements and also for customers
within the country and abroad.
MINING AND CONSTRUCTION BUISNESS:
Being India’s leading Mining & Construction Equipment manufacturer, BEML offers
a comprehensive and diverse range of mining machinery for both opencast and
underground mines.
BEML produces machines such as Hydraulic Excavators, Bulldozers, Wheel Loaders,

Wheel
Dozers, Dump Trucks, Motor Graders, Pipe Layers, Tyre Handlers, Water Sprinklers and
Backhoe Loaders. BEML has ventured into Underground Mining with products such as

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Side

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Discharge Loader, Under Ground Mine Cruiser, Load Haul Dumper and Granby Car.
BEML so far manufactured and supplied 6 numbers of walking draglines and 42 numbers
of Electric Rope Shovels (39 numbers of 10 cum shovels and 3 numbers of 20 cum
shovels).
BEML KGF complex is involved in manufacture of mining and construction products
FIG 2: CRAWLER DOZER FIG 3: EXCAVATORS
FIG 4: WHEEL DOZER FIG 5: LOADERS
FIG 6: DUMP TRUCKS FIG 7: WATER SPRINKLERS

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CHAPTER-2
WORK FLOW
2.1 ILLUSTRATION(WORK FLOW MODEL):

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2.2 QUALITY AND TOOL 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.
All the manufacturing units of the company have been certified for ISO9001- 2008
Quality Management System (QMS). The KGF Complex, Bangalore Complex and
Mysore Complex are certified for ISO 14001- 2004 Environmental Management System
(EMS). Also, the Bangalore Complex is certified for BS OHSAS 18001- 2007 OHSAS
Integrated Management system and Engine Division, Mysore complex is certified for
AS9100B Aerospace certification.
The manufacturing divisions are augmented with test facilities available at its R&D /
Technology Division. Laboratories at R&D, KGF and Mysore Complex are accredited to
National Accreditation Board for Laboratories (NABL) covering Calibration of Flow,
Pressure, Torque and Mechanical Measuring Instruments. The facilities include custom
made test tracks to evaluate the performance of equipment.
Tool engineering has under it

• Tool design
• Manufacturing of tools
• Planning
By using component drawing and process sheets, finds out work center 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.

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2.3 STORES:
• Receiving stores:
These receive materials through the gate pass, and are sent to the concerned departments.
• Project stores: These receive materials concerned to the production work.
• Non project stores:

These receive materials which indirectly help in the production work like weld rods etc.
• Stock control department:

This department will look after non production materials such as issuing of clothes,
medicines, books etc.
• Salvage stores:
These collect waste materials from shop side on corner of factory premises and are
stored for the further processing.
• Rejected stores:
These collect reject items from the various departments and send it for further action.
• The other stores are:

 Painting store
 Cylinder store
 Oil and diesel store.
Dept. of E&CE, 2023- Page 10 of

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2.4 PURCHASE DEPARTMENT:

The Purchase Department is decentralized and each section is responsible for
procurement of its requirement. It handles the central excise, customs and insurance of the
products that are procured from different vendors.
On every products manufactured, the manufacturer has to pay value tax and excise
duty(ED) which will be some percentage of cost of the goods. BEML pays both these
duties to the vendor. Since BEML also manufactures products which in turn will be taxed
upon it can credit the duty it had payed on products from the vendors. In case of imported
goods ED is called customs duty. Only after paying the customs can the components are
received by BEML. Products whose customs duty is not paid are called bonded goods.
These are kept in bonded warehouses and can be de bonded after payment of customer’s
duty.
This department also handles the insurance regarding the products. Every product that
enters the stores is ensured.
2.5 PRODUCTION :
Production at BEML is an integration of different workshops. Some process raw materials
while some assemble the parts into a dozer. Briefing about the entire process, the raw
materials reach the plate shop where they are bent/shaped/cut into specified shapes and
are welded together into a part like a bucket of an excavator. After the pre- assembly, the
parts move to the fabrication shop where the arms/buckets are further processed: fitted
and painted. The steering case and the track frame and mid frame are fabricated. In the
machining shop, the incompletely assembled parts are bored/drilled/milled for low end
and high- end assembly. Old machine shop is where the undercarriage chains are pinned
together. The parts after undergoing machining will be heat treated for case hardening as
they undergo a lot of stress in their lifetime. The parts are generally of mild steel and
various other steel varieties. So the Heat treatment shop is planned close to the machine
shop. Here, hardenings through furnaces/chemical hardening/induction hardening are
carried out. The furnaces for example the Push Type Open Furnace is used to harden the
complete product/part. The machine shop- 2 is a similar shop but this shop houses
advanced CNC machines for the same processes and most of the processes are automated.

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The gear shop as the name suggests produces gears that are used for the vehicle
movement. The

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refurbishment of gear boxes happens at the tool room. Servicing of products is also the
part of BEML. The gear drive of a vehicle usually has 3 gears as the speed is not a matter
of concern for the vehicles. The next shop where the parts move in are to the assembly.
The assembly happens at two stages: low- end and high- end. The low end is for low
capacity excavators/tractors/loaders. While the high- end is for heavier capacity vehicles
like the BE1800. The shop consists of equipment designed to handle heavy parts. The
defence hanger is where the Tatra trucks and recovery vehicles are assembled. The
Hydraulic and Power line division manufactures the transmission line, gear boxes and the
hydraulic apparatus. It consists of three major shops which are the two transmission shops
one each for manufacturing the parts and assembling them. The hydraulics shop is a hub
of hydraulic cylinders and hydraulic pump production. The power line shop assembles the
hydraulic apparatus and the transmission apparatus of almost all the products. The
company is now manufacturing the transmission of a Russian tank, hence revealing of the
standards and quality of the factory. The power line also manufactures the chassis of
High capacity dumper trucks that are assembled in the Mysore division. The division
also has a cutting and welding shop which is minimalistic but crucial for production. The
R & D cell is one of the most important division of the company. The
designing/protyping/quality are ensured and monitored here. There are accredited labs
that are functional. The fluid power lab, CAD center, hydraulics testing, material science
lab are some of the masterpieces. The engines/pumps are tested for loads or the hydraulic
cylinders are tested for their endurance or the frames/joints for their stress handling
capacities by running them through repeated cycles. The prototesting is where the
first/new design is implemented for validity. The detailed overview of all the shops is
summarized below:

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CHAPTER-3
Study Project on WIFI DNC [DIRECT
NUMERICAL CONTROL]
FIG 8: WIFI DNC
Wireless DNC is a form of wireless data transfer, known as Direct Numerical

Control, performed between a computer numerical control (CNC) machine and
the computer controlling it. These are very widely used in the automobile, engineering,
sheet metal and aeronautic industries. These machines are capable of producing different
parts. For each type of part, a sequence of instructions is needed. This list of instructions
is stored in a computer script, a computer file written in a programming language, such
as G-code. This script is commonly referred to as a part program. When a part is to be
produced this part program is uploaded to a CNC machine by RS-232 link.
Now this RS-232 link between a PC and CNC machine with software is called a DNC
system. In a typical machine shop floor, it is difficult to maintain the data cable. Hence
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wireless data transfer has come into existence. There are mainly two types of wireless
hardware units available in the market. One is using Bluetooth technology, while the
other uses Wi-Fi technology.
In case of Bluetooth, generally one pair of Bluetooth devices is used. One gets plugged
on a COM port of a PC or Laptop, and the other is connected to an RS-232 port of a
CNC machine. The wireless link is established with the required driver software. Once
this is established, the user can run their DNC software for data transfer. In most cases,
the file is sent from a remote PC to a selected CNC machine.
In Wi-Fi technology, a wireless link is established between a device called wireless
access point (generally near the PC) and a device called a wireless node, which is
interfaced to the CNC machine. There is one access point and multiple nodes. Each
wireless access point and wireless node has one IP address. This IP address must be of
the same domain name as the PC. Thus a wireless Ethernet link is created. The wireless
node has an RS- 232 port, which is connected to an RS-232 port of the CNC machine.
Driver software on the PC maps the RS-232 port of the wireless node as a virtual COM
port of the PC. Once this is done, the DNC software takes care of the two-way data
transfer.
3.1 COMMUNICATION BETWEEN CNC MACHINE

AND DNC USING ETHERNET CABLE:
our CNC machines have RS232 ports – SFA can connect them to your network with
Ethernet RS232 hardware. With our Wired & Wireless CNC Connect current devices or
our LAN Connect devices, you can leverage your IT infrastructure on the shop floor.
Replace the long RS232 runs of older style hubs, take advantage of your wireless
network & get rid of cables all together!
Using Ethernet allows multiple PCs the ability to access shop floor machines. Ethernet
can go longer distances, which keeps the RS232 connection short & provides more
reliable DNC communication. Wireless CNC Connect devices stay mounted to the
machine – confirm you have a dependable wireless signal, move your CNC machine, &
it is always connected to the DNC system.

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FIG 9: COMMUNICATION BETWEEN CNC MACHINE AND DNC USING

ETHERNET CABLE
3.2 DNC MAX SOFTWARE:

DNC-Max is the latest version of the most trusted CNC communication software on the
market. From its highly adaptable remote request and auto-receive to its advanced
client/server architecture, DNC-Max continues to be the software solution-of-choice.
DNC-Max provides end-to-end functionality designed to make every aspect of CNC
communications more reliable and efficient.
DNC-Max is for customers who demand performance, flexibility and reliability.

Whether your solution is for a small shop with a few CNCs or a corporate solution for
hundreds of machines in multiple remote facilities, DNC-Max is the proven solution.
DNC-Max meets or exceeds the functionality and flexibility of any other DNC
application on the market. DNC-Max is the obvious choice for any size CNC operation.
CNC Compatibility
DNC-Max is designed to be the complete DNC solution for all your CNC equipment. In
addition to standard Fanuc/Haas style controls DNC-Max includes the most
comprehensive support for Heidenhain, Mazak, Fagor, etc.
Hardware Compatibility

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DNC-Max works with off-the-shelf, industry standard RS-232 serial communications
hardware, including Ethernet and Wireless serial device servers, traditional card based
hardware, and existing legacy hardware.
CNC File Compatibility

Whether you set up your first system or you replace an existing system, the DNC
application you choose must be compatible with your data. DNC-Max eliminates the
need to update all your existing NC programs.
Ease of Use and Administration

File transfers, port monitoring and system administration are performed in a clean,
intuitive client/server interface. This is part of the system’s intelligent, solution driven
design.
3.3 THE DNC SYSTEM HAS BEEN INSTALLED FOR THE

FOLLOWING CNC MACHINES IN PLATE SHOP:
i) MESSER PLASMA CUTTING -WINDOWS BASED:

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FIG 10: MESSER PLASMA CUTTING MACHINE
Messer Cutting Systems has manufactured cutting-edge technology for the

metalworking industry worldwide for more than 100 years. We have perfected
machinery for straight and bevel plasma cutting to ensure the quality, reliability, and
efficiency of your cutting process.
Our straight and bevel plasma cutting machines are designed for peak durability and
quality, ensuring your business gets the most from your investment.
Following are key features of Messer Cutting Systems’ straight and bevel plasma cutters:
 Smooth surface edges.

 Precision quality cutting.
 Variety of cutting speeds and angles.
 Diverse material usage.
Key CNC Plasma Cutter Features:
 Low to high cut quality.

 Smooth, edge surface.
 Metallurgical perfect surfaces for welding.
 Medium heat input.
 High speed cutting.
 Hardening within the area of the HAZ.
 Wide range of material such as stainless steel, mild steel, and aluminum.
CNC Plasma Cutter Characteristics:
 Typical: ⅛ inch (3 millimeters) up to 3 inches (75 millimeters).

 Plate thickness: 1/32 inch (0.8 millimeters) up to 6 inches (150 millimeters) with
an 800 AMP plasma system with stainless steel or aluminum.
 PLASMACUTTINGAPPLICATIONS
Plasma cutting applications include reliably and precisely preparing metal
components, including aluminum and stainless steel used in automotive repair
and restoration shops, fabrication shops, industrial construction sites, and also
salvage and scrapping jobs.

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 While exploring CNC plasma cutting tables for use in your business, some key
factors to consider when making your purchase are the unit power requirements,
whether you need a portable or stationary unit and the amount and thickness of
metal to be cut.
ii) MESSER OXY FUEL CUTTING – WINDOWS BASED:
FIG 11: MESSER OXY FUEL CUTTING MACHINE
Oxyfuel cutting also referred to as oxyfuel flame cutting and oxyfuel gas cutting, is
the most economical process for cutting mild and low-alloy steel, even with weld
preparations involved. Oxyfuel cutting is regarded as one of the most important
production processes in the entire metal industry.
Over 100 years, Messer Cutting Systems has provided and developed leading-edge
technology for the global metalworking industry. We have perfected the design and
function of straight oxyfuel cutting machines and bevel oxyfuel cutting machines, which
deliver high-quality cuts, reliable service, and considerable savings to the cutting
process.
The Oxyfuel Cutting Process Involve

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Oxyfuel cutting is a combustion process using oxygen or a fuel gas flame. The heating
flame warms up the material to its ignition temperature. Next, an oxygen jet of at least
99.5 percent purity is blown onto the heated spot, oxidizing the metal. Burning metal
immediately turns to liquid iron oxide. This oxygen jet is the origin of the term “flame
cutting.”
The torch is then moved, and a narrow cutting slot, commonly called a kerf, is created.
The slag is removed from the kerf. The cut’s quality depends on the material’s surface
condition, cut velocity and thickness.
All low-alloy steel with a material thickness of as much as several inches can be cut
using this process. Despite the growing prominence of other cutting processes such as
plasma cutting and laser cutting, oxyfuel flame cutting remains a highly economical
process. When it comes to cutting heavy material thicknesses up to 35 inches (900
millimeters), oxyfuel flame cutting simply is unrivaled as a cutting process.
Oxyfuel cutting ensures reliable hole piercing and high cut quality. Component
production will be at their finished sizes without any need for further processing. For
weld seam preparations, V, Y, X and K bevels can be produced.
iii) FLAME CUTTING 6-FANUC 0I MD:
FIG 12: FLAME CUTTING 6-FANUC 0I MD MACHINE

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The product are controlled based on Japan's “Foreign Exchange and Foreign Trade
Law". The export from Japan may be subject to an export license by the government of
Japan. Further, re-export to another country may be subject to the license of the
government of the country from where the product is re-exported. Furthermore, the
product may also be controlled by re-export regulations of the United States
government. Should you wish to export or re-export these products, please contact
FANUC for advice. I. There are, however, a very large number of operations that must
not or cannot be performed, and if the manual contained them all, it would be enormous
in volume. It is, therefore, requested to assume that any operations that are not explicitly
described as being possible are "not possible". This manual contains the program names
or device names of other companies, some of which are registered trademarks of
respective owners.
iv) FLAME CUTTING 8-FANUC 18I MB:
FIG 13: FLAME CUTTING 8-FANUC 18I MB MACHINE

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v)FLAME CUTTING 9-FANUC 0I MD:
FIG 14: FLAME CUTTING 9-FANUC 0I MD MACHINE
vi)FLAME CUTTING 13-FANUC 0I MC:
FIG 15: FLAME CUTTING 13-FANUC 0I MC MACHINE

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vii) CNC TANAKA FLAME CUTTING - 0I MF:
FIG 16: CNC TANAKA FLAME CUTTING - 0I MACHINE
3.4TO INSTALL DNC IN PLATE SHOP FOLLOWING

ARE THE POINTS VERIFIED:
1. 3 Transmitters had been mounted on wall and pillar respectively.
2. 7 Transmitters had been mounted on CNV machines with antenna visible
condition.
3. Signal strength had been found satisfactory (3-4 points).
4. Computer with CIMCO DNC MAX software has been installed and running.
5. DNC max software with 7 port licence is enabled and working fine.
6. Program path of all CNC machines is configured to D:\NCPROGRAM on
CNC machine name respectively.
7. Expect FC-13 all CNC machines program transfer from pc us enabled.
8. FC-13 program call is proven from CNC (since it is RS232)
9. Existing program transfer provision like memory card/usb/code loader is still
on working condition without any changes on parameters on CNC on our
request .
10. Operational / maintenance training had been provided

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However if any trouble occurs in program transfer through DNC NETWORK System
BATOR TECHNOLOGIES should rectify and sort out the issues as earliest.

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CHAPTER-4
EARTH MOVERS DIVISION (EMD)
4.1 PLATE SHOP:
Electrical Orientation:
Supply is at 11Kv and the input is from the preceding shop. Two transformers operate
in parallel to supply the demands. Machines operate at 440V. The control cabin has 4
panels: input, T1, T2 and output to the next shop. The stepped down output of the
transformer is given to the bus bar across which various machines operate at their
tapping points. Protective measures include Circuit Breakers and MCB at each machine
input. Capacitor Bank is used to compensate the lag in pf in peak operation times
usually from
09.00 to and 13.00 to 14.30. From the bus bar chambers, lighting loads or any other
vital machine is supplied to, directly. Overhead rail is supplied from the bus through
brush contact and the two types of rails are cabin controlled and hanging controlled.
Separate grid layout and control is carried out.
Energy Fulfillments:
Wind energy harvesting happens at a plant in Shimoga and there are generators available
at the plant of capacity 3250KW and lesser. The electrical board charges industries at
Rs.7- 8 per unit. The supply by the board is based upon the assertive approximation of
energy proposed by the company required during the season. Suppose 2000KW is the
approximation, the company will be penalized for every energy extra unit consumed.
General faults occurring are Line to Line faults, line to earth, surges or human error.
Fuses and protective gears are, altogether, installed at 2 locations: at the bus bar tapping
and the other one at the machine supply. For DC operated machines, a motor coupled DC
generator is used at the machine location itself.
Mechanical Processes:
The main mechanical processes happening at the shop are:
Welding, Shearing, Drilling, Bending (3 Roller bender)
Cutting (Gas CNC and Plasma CNC {Pressurized jet}) for optimization in raw material
usage Pressing and shaping {750 Tons press which can bend plates of 70mm thickness)
Example machines:
Planar cooper machine which runs on DC. Used for pre welding preparations.
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Movable drilling machine: For swift and easy drilling

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FIG 17: SHEARING MACHINE
FIG 18: STRAIGHTENING MACHINE
4.2 FABRICATION SHOP:

The manufacturing facilities available in plate and fabrication shop are:
• CNC Flame Cutting Machines • CNC Plasma Cutting Machines.
• Plate Beveling.
• Plate Shearing.
• Rolling and Straightening Machines • Hydraulic Presses & PressBrake.
• Shot Blasting Machines.
• Heavy Duty Plano MillingMachines
Fabrication activities are spread over 4 shops, viz., Fabrication Shop, Dozer Fabrication

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Shop, Minor Fabrication Shop and Heavy Equipment Shop. The Following type of welding
is carried out in the shops.
• GMAW - Gas Metal Arc Welding

• FCAW - Flux CoredArc Welding
• GTAW - Gas Tungsten Arc Welding
• SAW - Submerged Arc Welding
• SMAW - Shield Metal Arc Welding
The company has a patent for its exclusive C0 2 welding. This is a low cost but
effective process although harmful for the environment as it produces a
greenhouse gas. This shop is where the arms and track frames are assembled.
The plates received from the plate shop are first pre welded for a setting and
then completely welded together. The steering cases are assembled and
checked for their dimension accuracies. The shop also has various lathe and
drilling machines for uninterrupted fabrication. The plates/parts may have to
undergo sand blasting to remove the rust accumulated on them. Vehicles that
come for maintenance have to have their weld removed which happens in the
gouging section of the shop.
Welding Fabrication and Associated Facilities:

 Auto and semi auto submerged Arc welding.
 CO2 welding sets of capacity of 400 AMPS.
 Thermal stress relievingfurnaces. ▪ Radiographic and

Ultrasonic tests on weldedstructures.
Under frame:
• Foil Roll welding machine for welding of corrugated sheets used for floor •
Corrugated rolling machine.
• Submerged Arc welding sets.
• Check & straightening machine for components.

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4.3 MACHINE SHOP:

EM Division is well equipped with latest facilities for manufacturing high quality
equipment as mentioned above. The current facilities are:
Machining Facilities
Different Varieties of
• CNC Horizontal Machining Centers.
• CNC Turning Centers.
• CNC Vertical Turret Lathes.
• CNC Milling Machines.
• CNC Heavy Duty Boring Machines.
• CNC Cylindrical Grinding Machines.
• CNC Universal Grinding Machine.
• CNC Wire Cut EDM.
• Heavy Duty Boring Machines ( SKODA, WMW and GLF )
• Heavy Duty Plano Millers.
• Vertical Turning Lathes • Radial Milling Machines.
• Surface Grinding.
• Internal Grinding.
• Cutting Machines.
The above mentioned machines and machining activities are spread across Machine
Shop- I, Machine Shop- II and Machine Shop III. These machines are arranged in all
combination of layouts catering to process type and product type in order to achieve
maximum output efficiency.
Most of the major assemblies require machines components which is performed here
CNC Turning Machining:- it is a computer numerically controlled lathe enclosed in a

casing. The work piece is held in place by the chuck. There is turret head which houses
different tools. For every turning operation a program is fed. During turning the screen in
the control panel indicates the instantaneous X and Z co- ordinates.

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FIG 19: CNC TURNING MACHINE
FIG 20: SHAPING MACHINE FIG 21: RADIAL DRILLING MACHINE

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FIG 22: VERTICAL MILLING AND CYLINDRICAL GRINDING MACHINES
FIG 23: HEAVY DUTY BORING MACHINE
• Some of the machines are manually controlled and some are CNC.
• Flexible Management System is being setup in this shop
• Setup should is flexible to change over palates of different series.

• Huge number of tools can be loaded on machine so that it can support all series.
• Rail carrier machine: for the movement of tools and components between
machines/ to take tool in and out, this reduces movement time. The robot which
serves this purpose ispeggi.

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• Automatic selection of programof different series is done so that it reduces the
chances offeeding wrong program.
• CNC machines enable a check on blunt tool and replace it.
• The Division is equipped with one of the best R&D Centers in Asia with modern
infrastructural and testing facilities. Also, the Division has one of the biggest
Machine Shops in Asia housing machine tools of different types and varieties with
dedicated product lines, Gear Shop, Fabrication Shops with latest welding
facilities including Robotic, Plate Preparation Shop and an exclusive Heavy
Equipment Shop to handle major fabrication of structures weighing up to 100 T.
Electrical Annexure:
All induction hardening use high frequency currents for heating using Eddy current
losses. This happens by stepping down the voltage to a desired level and then invert it
at desired frequency using IGBT based inverters. The movements of the arms of the
machine are regulated by the limits.
The motor speed control methods are not adopted by the industries as they are not very
economic.
Cyclo-convertersare used in low currentapplications. The outdatedtechnologies of CNC

control are Relay logic and Contact control logic. Presently, PLC is widely used.
The PLC has ladder logic embedded in it and the operators are unauthorized for changing
the codes.
The commonly used Over load relay play an important role in the safety of the machines.
4.4HEAT TREATMENT SHOP:

Furnaces:
• Sealed Quench Carburizing Furnaces.
• Carbo Nitriding Furnace
• Spray Quenching
• Low Tempering / High Tempering Furnaces.
• Gleason Press Unit.
• Controlled Atmospheric Furnace.
• Nitriding furnance

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Induction hardening machines:
• Single Shot IH Machine for all heavy Duty Gears.
• Tooth by Tooth Induction HardeningMachine.
• Radial Frequency Induction Hardening
• PLC Controlled Induction Hardening Machines for Track links
• CNC Vertical Shaft IH Machine.
• Roller Hardening Machine.
• Roller Shaft hardening Machine.
Compressors:
Ten Nos of 500 CFM and 2 Nos. 100 CFM Compressors operating at 6
Bar Pressure are installed in the Division. The generated Pneumatic Pressure is
well connected to all the Manufacturing and Assembly Shops through Leak
Proof Pipe Line Arrangement.
 The undercarriage section is a part of both machineshop and the heat

treatment as the process needs to be simultaneously heated.
 The induction heating equipment is used for case hardening for up to 3-

5mm of depth. Most furnaces use I²R heating principle. The interiors of
the furnaces are usually made of bricks or any other insulating materials.
The job after heating will be bathed in industrial brine or a polymer
based hardening agent.
 The testing of hardening is done by grinding over the surface. Other

heating techniques include ammonia furnace which heats ammonia to
500 C apparently hardening the job.
 For large parts, there is a pit type furnace in place. Also, the cooling will
be done in cooling pits which are usually 8 feet deep.
 The heating principle of eddy currents cannot be applied for tiny parts as
they make them become brittle and unfit for use. So, the plant has Radio
Frequency heating which heats the part using energized radio waves.
 There also a constant need for flow of cool water. So, there are induction
pumpsthat are used to pump water.

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 The bus bar tapings are taken underground in this shop as the furnaces are
spread all over the place. The furnaces are strategically placed for ease
and highest output efficiency.
 A sand blasting apparatus is used to remove rust from the parts.
 Maintenance of the furnaces is a vital routine in functioning of the shop.

The valves and hoses are regularly checked for leakage. And some
induction based heating machines needs to be operated for a fixed hours
per day.
Captive Power:
The Division is self Sufficientin Captive PowerGeneration. The following
Diesel Generatorsare installed in the Division to take care of the power
requirement during Power failures
4.5 GEAR SHOP:

• Gear Manufacturing Facilities:
• CNC Hobbing.
• CNC Shaping.
• CNC Gear Grinding.
• CNC Gear Shaving.
• CNC Gear Cutter Grinder • Vertical Broaching.
• Horizontal Broaching.
State-of-the-Art CNC Gear Grinding Machine from Hoffler Germany is

installed in the Shop and it has added new dimension to the Gear
manufacturing capabilities of EM Division. Gear Shop also houses a
Metrology Laboratory wherein Gear Testers of various make including the
latest CNC Profile Helix Gear Tester from Wenzel, Germany are available.
• The raw materials at the shop arrive as rings which needs to be shaped and the
teeth are to be shaped first. This is the first process here. There are various cutting
machines that do this based upon the thickness ofthe profile.

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• The shaped gears are to be shaved and grinded for smooth surfaces. This is done
by the grinding machine. The grinding machines usually use oil as lubricant as
well as the coolant. Most other process use oil and water mixture in the ratio 1:20
parts.
• The gear also needs to be drilled at relevant spots for later assembly and
alignment. So the shop also has drilling machines to serve the purpose.
• Broaching machines are used for internal gear cutting as there is no other efficient
way to do this.
• The gears manufactured here are generally spur hears. Helical gearsare generally
used for more efficient transmission. The gear shop has the hobbing machine for
an inexpensive way of cutting gears. The can be alternatively used for cutting
splines/sprockets/as a milling machine. The teeth are progressively cut by a
cutting tool called as hob.
• Gear shaving is also done for smoothening the gears to reduce the friction between
points of contact of teeth.
• The tool room is a vital part of the shop where the gears are aligned andare
assembled in the gearbox.
• The tool room also assembles the drive gear. The drive gear which transmits
power from the engine to the undercarriage chains have three gears for any typical
dozer or excavator. The underframe are provided with the slot to accompany the
idler pulley which along with the gear drive will form a loop for the chains. The
tensions in the chain are brought by the tiny idlers placed strategically al across
the underframe.
•
FIG 24: EXTERNAL GEARING. FIG

25:INTERNAL GEARING.

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4.6 ASSEMBLY LINE:

Diesel engine and transmission:
1. At the assembly line, the independently manufactured dieselengineand

transmissionjoin the mainframe. The engine is usually purchased completely
assembled as it is a complex systemwith machined componentsthat can be used
in manydifferentvehicularapplications. In fact, the engine (whichhas been
subjected to variousperformance tests)is certified to operate on arrival. The
engine mounts in the front of the bulldozer; however, it is connected to the
transmission, which sits in the back. The two are connected by a long shaft and
supported by couplings and bearings. The transmission is then connected to a
series of gears and differentials to comprise the rest of the power train. By
mounting on pads previously welded to the frame, the engine/transmission
assembly can be bolted directly to the base on the main assembly line.
Radiator and additional assemblies:
2. On the front of the bulldozer, an engine casing is mounted to support the

radiator and hydraulic lifting cylinders. The radiator, another finished assembly,
will then sit between the engine casing and mount to the front drive shaft.
Connections can then be made to attach water lines from the engine to the
radiator. Additional assemblies for the hydraulic, lubrication, cooling, and fuel
systems are also constructed at other locations and purchased as a finished
assembly ready to be fastened directly to the engine or base. These include
hydraulic lines composed of tubes, hoses, and fittings pre- assembled and
mounted on the engine or frame and connected to pumps, valves, tanks, and
cylinders, each of which can be brought to the main assembly line as a finished
component. Fuel, exhaust, hydraulic, and coolant lines also arrive ready for
assembly and mate to other finished components. Many of these components
and sub- assemblies must be inspected and approved for dimensional
compliance at an incoming inspection station prior to assembly.
Large component assembly:

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As the entireassembly of the frame, engine, transmission, and line groups
movealongthe main production line, larger assemblies and components are
brought in by overhead cranes, overhead conveyors. These components
include the cab, larger hydraulic cylinders, undercarriage components, and the
front blade.
1. The cab, which can also be purchased as a finished assembly, is usually
manufactured at a different facility and shipped for assembly. Usually
complete in its array of electronics and controls, the cab will be mounted on
steel blocks or pads located on the dozer frame. Aftermounting,
connectionswill be madeto the various controls, and powercan supplied to the
fully functioning cab.
3. Concurrent with the engine/transmission mounting, the undercarriage,

composed of tubular roller frames, drive sprockets, and bogey independent
suspension rollers, will be mounted on the frame and assembled to the drive
train. The axle assembly will turn the outer sprockets that rotate the track,
allowing the vehicle to maneuver. The sprockets, typically 2 ft. (61 cm) in
diameter, will fit into the track with case hardened teeth, which move the track
as they rotate. In many manufacturing operations, the undercarriage can be
machined, assembled, and painted in the same facility as the main assembly
line, but various smaller components like bearings and lubrication bushings
need to be outsourced to other facilities or outside contractors. The track, which
is often pre- assembled from machined steel links, can be fitted around the
drive sprockets, rollers, and front/back guide gears only after the
engine/transmission and undercarriage components are in place. The exhaust
stack, attached directly to the engine, is supported by brackets and flanges at its
base.
4. After the cab controls are connected to the engine and hydraulic systems,
prefabricated cowlings or body panels are mounted directly on the base frame
to cover the engine, transmission, radiator, and fluid lines. The body panels
are designed to fold back, making the inside of the dozer easily accessible for
regular maintenance. They are assembled into hinges already fastened to
structural supports. Tooling and storage compartments may also be built into

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the dozer once the lines have all been connected. Deck plates lie around the
cabin and are welded to support brackets.

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5. The front blade is attached to hydraulic cylinders, which can position the
blade at different angles of tilt. The cylinders, each comprised of a hardened
steel piston inside a honed cylinder, are attached at one end to engine casing
in the front of the bulldozer to move the blade vertically. Initially in the
assembly process, the cylinders are left unattached at the one end until the roll
formed steel blade is assembled, and then hydraulic lines can be fitted and
tightened. The lower end of the blade is attached at two joints with large steel
pins which rotate and tilt the blade with two more cylinders. Arms extending
from the undercarriage are attached to the blade and then are assembled along
with the other undercarriage components.
Final assemblies:
6. Once the dozer has been outfitted with its primary components, more hoses,
electrical lines, and fluid lines are attached at fitted connections. Items such as
the batteries, which are connected to the starter on the engine, lie underneath a
cowling in a compartment located near the engine. Lights, one of the last items
installed on the dozer, will be placed in a number of different areas and
connected to their power source. In addition, hand or guard rails and foot pegs
are bolted on the frame which complete main line assembly.
Paint:
7. Applied manually with spray guns, the final paint booth will deliver paint
to any area not blocked off with paper or plastic wrapping. The paint dries
quickly and the bulldozer will move to the next station where decals and
trim are applied by hand templates.
Fluids:
9.Various fluids are added, and the vehicle is then sent to a testing station
where the operationof all systemsis mechanically verifiedand recorded. The
vehicle is transported from the manufacturing site to a staging area for

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customization and shipping. The completed bulldozer is shipped on a flatbed
trailer and is ready for field operation upon arrival.
SAE 30, SAE 10 are generally used.
4.7 FINAL TESTING :

• All the vehicles undergo vigorous testing of up to 240 hours before the delivery.
The vehicle will be tested for all the operations it is designed to perform.
• Although individual parts are also tested choosing one from a lot of 25. The R &
D division tests the hydraulics/stress capabilities and endurance of each
component by randomly selecting from a lot of 25. The qualification in which will
lead to clearing of the batch of 25 components.
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.
• 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.
• Hose Endurance.
• Hydraulic Stress capacity.
• Hydraulic pump endurance.

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• R&D: EPTS (EnginePerformanceTest Standard)willhavebasicstandard valuesofa
perfect engine, which has to be compared with newly built engine to check its
values.
• For 5minutes run, tappet setting, run in, performance test and leak test EPT
standards are considered.
• Once engine and the gear box passes all these stages of testing, the batch is cleared.
• Universal Jointsare testedfor their stress/endurance by an apparatusthat imparts a
stress of about 200kg/cm2.
• The frames are also tested by simulating the forces on them for up to 3 months.
The resistance of the body to rolling over is also an important test.
• Impact testing: The hood is subjected to falling object of 40 and 75 kilograms. The
cabin must be capable of protecting the dummy operator of the falling object.
4.8 DEFENCE HANGOR:

• Being India’s leading Defence equipment manufacturer, BEML Limited keeps the
Indian Army and other defence forces abreast with state- of- the- art military
equipment.
• The company manufactures variants of heavy duty Tatra vehicles for all terrain
operations including Bridge Layer, Field Artillery Tractor, Medium and Heavy
Recovery Vehicle, Pontoon Mainstream Bridge Systems, Crash Fire Tenders,
Mobile Mast Vehicle etc.
• BEML also supplies engineering Mine Ploughs, Tank Transportation Trailers,
Weapon Loading equipment, Armored Recovery Vehicle, Milrail Coaches and
Wagons apart from Aircraft Weapon Loading Trolley and Aircraft Towing
Tractor.
• BEML plays a stellar role in the country’s Integrated Guided Missile
Development Project by supplying ground support vehicles.
• The company has also created a world class test track at its KGF complex to test
Defence Equipment and vehicles.
Some of the major projects that department has participated are mentioned below:
• Launch and recovery system of AEU- This system was developed in order to

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launch and retrieve the underwater submarine to the mother ship. The staffs from

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this department were present for the trials held. Today it is already in service with
the navy.
• Gas cooling system- The exhaust released by the vessel makes it an easy target
for enemy heat seeking missiles. Thus the navy wanted a system that will erase the
heat signal. This system runs on battery power and uses sea water for its
functioning as it is in abundance. It is mounted on the exhaust of the ship.
• AAV (active antenna array) unit- This antenna unit is mounted on a
reconnaissance aircraft and is used to prevent the enemy from jamming the
communication system. The bird hit test was conducted as well as the structural
analysis of the fixture.
• Tank repair vehicle- whenever tanks in the battlefield are damaged or become
immobile, these vehicles help to bring them back to safety.
• Sarvatra bridging system- often in the battlefield the tanks or any other army
vehicle may come across gorges, or small streams. In this case this bridging
system which can be temporarily constructed and de- assembled is used. It has
span of 75m.
• Arjun, T- 72 and T- 90 are one of the masterpieces that are assembled here and
tested. Although most of the defence vehicles are manufactured in Palakkad
complex.
• ARRV and ARV are tested for endurance and the retractable capacity of the
vehicles.
• ARMOURED RECOVERY VEHICLE WZT – 3 ARV WZT-3 is also
equipped with NSW 12.7 mm anti-aircraft gun, vehicle commander observation
device, drivers observation device, NBC protection, fire suppression system,
communication equipment, electric welding equipment, smoke grenade system,
load carrying platform, towing device, dozer blade and set of special devices and
tools.
HRV AV 15 – HEAVY RECOVERY VEHICLE
HRV AV 15 vehicle is designed to recover stuck-up, buried or overturned causalities of
armored or engineering vehicles. This has a recovery crane with lifting capacity of 15 tons
@ 2m radius with stabilizers. The recovery winch has a pull of 15 tons for effective length
of 150m. This vehicle is provided with all wheel drive for maximum traction, swinging
half axles for better cross country mobility, centralized tyre inflation, deflation system, self
recovery from front and rear, light dozing upto 250mm with dozer attachment. Cutting and

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Welding Equipment is provided for emergency use. It can tow rigid and suspended upto
11

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tons, tow trailers upto 15 tons in cross country and 65 tons on highways.
BEML – TATRA T816 6MWR 8T 10x10 VEHICLE BEML – TATRA T816 6MWR 8T
10x10 is a terrain vehicle with ABS system used for hauling long loads such as missile
transportation for Indian army with payload capacity of 19900 Kg. The equipment is
provided with hydraulically operated self- recovery winch and Air-conditioned cabin. The
vehicle is equipped with centralized tyre inflation system inside the cabin operated on the
move.
FIG 26: TATRA

Specifications
• Engine: ISM 440E 20, inline 6-cylinder, water-cooled, diesel direct injection,
turbocharger with intercooler, compliance with BHARAT STAGE – II (EURO-II)
Emission norms. Electronically controlled.
• Rated Power: 324 kW (434 HP) @ 1800 rpm
• Transmission: Automatic 6 Forward and 1 Reverse, electronically controlled
with torque differential between front and rear axles
• Axles: Swing half axles separately sprung.
• Suspension: Leaf spring on front 2 axles, Leaf spring with air bellows on middle
2 axles and air bellows with coil spring on rear most axle. First 2 axles and rear
most axle are provided with hydraulic shock absorber.
• Tyres: Tubeless tyre with bead lock, size – 16.00 R 20 XZL.

• Speed: 82 kmph max.

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FIG 27:ARRV
FIG 28:BULLET PROOF VEHICLE

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CHAPTER-5
HP AND R&D
5.1 HYDRAULICS AND POWERLINE

• The three subdivisions of the premisesare the transmissionshop, hydraulic shop
and the powerline shop. The transmission shop is where the machining of the
components are done which are a part of the transmission shaft or the transmission
line itself. Thereare approximately 1500 sub componentsinvolved in
manufacturing the gear box and transmission. Hence, the KGF complex is the hub
of transmission and hydraulics manufacturing of almost all the products.
• The transmission shop 1 will manufacture gears involved in transmission gear
drives. The drive assembly of dozer and BMP is also a part of the shop. The
componentsare generally of vehiclesunderrehabilitation while our visit. The gear
assembly of a normal dozer is with spur gears, but that of the Tatra is with the
helical gears to reducenoise.
• Generally, there are 5 forward and 1 reverse gear of the Russian tank. These are
aligned with idlers to reduce noise and vibration. The tanks also have a secondary
breaking system in case the main breaking system fails.
• The transmissionmoduleis the componentwhich convertsthe horizontal rotationof
the engine shaft to vertical motion (coveys it to the drive).
• The majoroperationsin the shop are gear cutting, turning, gear
alignment/assembly. The gearbox is filled with gear oil.
• Thereis also a grinding procedure,whichinvolves blowing pressurized air for
smoothening. The CNC lobby is installd with turning/milling machines.
• The hydraulics shop is for the assembly of cylinder pumps and oil pumps. The
gears will have been through various milling and grinding processes. The tiny spur
gears are of utmost importance in operation of the hydraulics system.
• The hydraulic suspensions are also a major production here. The piston and the
cylinder is separated by pressurized Nitrogen and other gasesfor maximum shock
absorption. Front and rear suspensions are two sub divisions here. Suspensions are
necessary for equipment protection from undesirable shocks.
• The shop receives the raw materialsfrom the cuttingand welding workshop
wherethe cylinder actually takes shape.
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• The powerline shop is for the assembly of cylinder and the transmission module.
• The cylinder which housesthe piston must have a smooth internal surface for easy
movement of the piston. This is done by the honing machine. The equipment is
grinded inside an oil bath.
• The piston will undergo induction hardening for it will be subjected to stress. The
stress which is developed in this heating process is simmered by post induction
heating at 500⁰C.
• The pistonand cylinderare pushed against each other. Thereis a smallopening at
the end of the cylinder for the pump inlet. The chassis assembly of the dumpers
also happens here. The chassis holds the transmission module and also protects it.
The transmission shaft rises from the transmission module to the engine.
• Heat treatmentshop is also installed in the divisionto makethe production
economic and versatile. Sand blasting module is also installed here.
• Gear boxes are tested and also the hydraulic apparatus which are painted later.
• Service of the products is a vital process. The following are the service facilities:
• Each office in the vast network, is headed by a senior level executive for product
support at pit-head / on-site, for Erection & Commissioning, Maintenance,
Troubleshooting, Condition Based Monitoring (CBM), Training, Total Support for
Mid- life Overhauling & Major Rehabilitation of Equipment to enhance the
equipment availability & productivity.
• The Product support packages include Annual Maintenance Contracts (AMC),
Annual Service Contracts (ASC), Maintenance and Repair Contracts (MARC) and
Guaranteed Availability & Spare Consumption Contract
BEML has established full- fledged ' Service Training Centers’ at KGF, Global
Service HQ - Nagpur and Mysore Complex for offering variety of programs,
scheduled round- the- year
5.2 RESEARCH AND DEVELOPMENT

Objectives:
• There are two major areas R&D and Product design.
• This is initial step of designing and building component.
• Software for designing 2D drawing auto CAED is used and for 3D proE is used.
R&D concerns with

“WIFI
• Designing new product.
• Improving existing product.
• Improving quality and reliability.
• Cost reduction.
• Theoutputof this department is CAED drawingwhichin turnis inputfor planning
department.
• ECN (Engineering Change Notice) will have any changes or updates to be done
on product.
• Based on the MPR raised by the concerned project groups and approved by the
Competent Authority, the Purchasegroupin R&D at Divisionscan issueenquiriesto
the partiesselected/identifiedby themonlyforprocurement ofinputsfornew,R&D
projects and indigenization, withinthe amount sanctionedby CMD/Board.
However, standard items already being procured / produced by division will
continue to be procured by the divisional purchase department. R&D can only go
for direct purchase of new and critical items on single tender basis to expedite
R&D projects.
LABS
Materials Science Lab:
The laboratories set the inspection standards and passing criteria for various test
procedures. It is also required to check that purchases satisfy the technical
requirements. They mainly conduct production oriented tests and to some extent
tests on the incoming materials to the factory as and when required by different
departments. Usually the vendor along with the products shows the test reports
conducted by him. It is generally accepted, but incase certain departments want it
tested again it is the function of these labs to conduct the specific tests and give the
result accordingly. Some of the tests conducted are mentioned below.
• Shear tensile test of spot weld- this test is carried out on a universal testing
machine. The specimen is placed between the grips as shown in the picture below.
The load is then applied gradually. The deflection is indicated by the dial gages.
The ultimate load taken by the specimen is noted.

“WIFI
• To check spot penetration of the weld- this test is conducted to check whether
the spot weld is penetrated deep enough through all the layers of the metal sheets.
• Crimping test- It is conducted to check the strength of joints of the electrical
cables. The cables are placed between the grips as shown in the picture. The
withstanding load is specified by the quality officials. A greater load is selected
and the load is gradually applied which is indicated by the pointer. The failure
load is noted and seen that it is above the specified load
• Hardness tests- Three hardness tests are conducted. They
are. Brinell hardness test.

Rockwell hardness test.
Micro hardness test.
• Chemical tests- these are used to detect the composition of various components.
Elements such as Cr,Mo,Ni,Mn,Fe,C,Si,P,Th.It is only lab in south India which
has got the facility of detecting the element thorium.
• Paint tests- to check the heat and corrosion resistance of the paint.
• Nondestructive tests
 Liquid penetrant test (to detect surface defects).
 Magnetic particle test (surface and sub- surface defects).
 Ultrasonic testing (internal defects).
 Radiography (X- ray & gamma).
 Digital paint film test.
• The Fluid Power lab tests the endurance of and the volumetric capacity of a
pump. Cylinder test for the load bearing capacity of the cylinder. The reference
cylinder is suppliedwith pressurized hydraulicoil which in turn impartsforce on
the test cylinder. The calibration of force simulation is done using sensors. Hose
testing is done by imparting 200bars of pressure on the test hoses in intervals of 1
second.

“WIFI
• Engine Testing: The engines are run in simulated natural conditions for their
endurance and the transmission modules are simulated with induction motors.
The engines are tested for any leakage/malfunction.
• Proto Testing: Any new prototype/design is first tested in the proto testing
centers before implementation/production.
• All the tests conducted are monitored using sensors and the output parameters are
finally presented in the computer based control output unit in terms of percentage

“WIFI
CHAPTER-6
Conclusion
BEML Limited has proved to be one of the modern templesof 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 overalla good learningand
rewardingexperience. This interactiongave me an insight and first-hand experience of
industrialscenario 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 for giving me an
opportunity to complete this internship.

“WIFI
REFERENCE:
1. https://www.bemlindia.in/
2. https://web.archive.org/web/20111014235441/http://bemlindia.com/vision_mission.p
hp https://www.bemlindia.in/Quality.aspx
3. https://www.bemlindia.in/product_profile_beml.aspx
4. https://web.archive.org/web/20111014235020/http://bemlindia.com/company_profile
.php
5. https://web.archive.org/web/20111014234630/http://bemlindia.com/kgf_earthmoving
.php
6. https://web.archive.org/web/20111014235123/http://bemlindia.com/kgf_hp.php

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

"Jnana Sangama", Belagavi- 590 018

DEPARTMENT OF ELECTRONICS & COMMUNICATION

R.L. JALAPPA INSTITUTE OF TECHNOLOGY

(1RL20EC013) a bonafide student of R L JALAPPA INSTITUTE OF TECHNOLOGY

in fulfilment for the award of Bachelor of Engineering in ELECTRONICS AND

COMMUNICATION ENGINEERING of the VISVESVARAYA

Report deposited in the departmental library.

Internal Guide HoD Principal

We express our sincere gratitude to Dr.Harish S. Seminar Coordinator,

At this outset, we extend our gratitude to Prof. Nandish N, Assistant Professor,

1.1 ABOUT COMPANY:

BEML is ranked as “The Largest and Most Profitable Construction Equipment

BEML operates on three major business verticals for associated equipment

Figure-1.1: BEML LOGO

Dept. of E&CE, 2023- Page 2 of 51

1.2 VISION AND MISSION:

2. Grow profitably by aggressively pursuing business and market opportunities in

3. Adoption of state-of-the-art technologies and bring in new products through

5. Attract and retain people in a rewarding and inspiring environment by fostering

Dept. of E&CE, 2023- Page 3 of 51

1.3 PRODUCTS MANUFACTURED:

Products manufactured in K.G.F. complex are: (Assembly)

Dept. of E&CE, 2023- Page 4 of 51

MINING AND CONSTRUCTION BUISNESS:

BEML produces machines such as Hydraulic Excavators, Bulldozers, Wheel Loaders,

Dept. of E&CE, 2023- Page 5 of 51

Dept. of E&CE, 2023- Page 6 of 51

BEML KGF complex is involved in manufacture of mining and construction products

FIG 2: CRAWLER DOZER FIG 3: EXCAVATORS

FIG 4: WHEEL DOZER FIG 5: LOADERS

FIG 6: DUMP TRUCKS FIG 7: WATER SPRINKLERS

Dept. of E&CE, 2023- Page 7 of 51

2.1 ILLUSTRATION(WORK FLOW MODEL):

Dept. of E&CE, 2023- Page 8 of 51

2.2 QUALITY AND TOOL ENGINEERING:

Tool engineering has under it

Dept. of E&CE, 2023- Page 9 of 51

• Project stores: These receive materials concerned to the production work.

• Non project stores:

• Stock control department:

• The other stores are:

Dept. of E&CE, 2023- Page 10 of

2.4 PURCHASE DEPARTMENT:

Dept. of E&CE, 2023- Page 11 of

Dept. of E&CE, 2023- Page 12 of

Dept. of E&CE, 2023- Page 13 of

FIG 8: WIFI DNC

Wireless DNC is a form of wireless data transfer, known as Direct Numerical

3.1 COMMUNICATION BETWEEN CNC MACHINE

Dept. of E&CE, 2023- Page 15 of

FIG 9: COMMUNICATION BETWEEN CNC MACHINE AND DNC USING

3.2 DNC MAX SOFTWARE:

DNC-Max is for customers who demand performance, flexibility and reliability.

Dept. of E&CE, 2023- Page 16 of

CNC File Compatibility

Ease of Use and Administration

3.3 THE DNC SYSTEM HAS BEEN INSTALLED FOR THE