INDIAN TELEPHONE

INDUSTRY

SANTOSH PATEL
[ SUMMER TRANNING-
EVALUATION]
MECHANICAL
INDIAN TELEPHONE INDUSTRY, LIMITED
RAEBARELI
1.Products / Services :-
ADSL, HDSL, GPON, BTS(GSM), TWIN TRX, Wi-MAX etc.
2.Company Profile :
ITS A TELECOM GIANT OF INDIA SINCE 1949 AND MEANT TO
CATER THE WHOLE NATIONS NEED IN TELECOM SECTOR.
IT IS THE LEADING MANUFACTURER OF SMPS BASED POWER
PLANT, ADSL, HDSL, GPON, BTS(GSM), TWIN TRX, Wi-MAX etc.

Raebareli Manufacturing unit was setup in 1973 and boasts a world-class

infrastructure. Presently, this unit manufactures GSM network equipments and
CDMA handsets. ITI Raebareli has taken a leap to enter broadband equipment G-
PON and WiMAX. This unit is India's first telecom equipment manufacturer to
conduct field trial of G-PON technology in India, and is all set to rollout India's first
lot of G-PON equipment.

3.Establishment Year :- 1949.

4.Firm Type :- Public. Ltd.

5.Nature of Business :- Manufacturer

6.Level to Expand :- International
 PRODUCTION
BASE TRANS-RECEIVER STATION (BTS):-

Base Trans-Receiver Station (BTS) “BTS A-9100”, is radio frequency mobile

communication product based on GSM technology. It is a set of equipments
that facilitates wireless communication between user equipment (UE) and a
network. A BTS in general consists of Trans-receiver module, Antenna
Network Combiner, Controller (SUMA) & Alarm Extension System (XIBM).
It is a self contained unit for transmitting / receiving signal for mobile
communication.

Types of BTS:
1. Indoor BTS
2. Outdoor BTS
3. Dual Band BTS
4. Twin TRX BTS

BASE TRANS-RECEIVER STATION SHELTER

 Shelter is a portable Sealed cabin made up of sandwiched insulated

panels with polyurethane as filler material between galvanized pre-
coated steel sheet.
 Floor is made up of 19mm thick marine plywood and is covered with
PVC antistatic flooring.
 MS tube is reinforced inside floor panel for higher floor load capacity.
 Secondary slanting roof is provided to protect primary roof from direct
sunlight and rainwater.
 Door is fixed with heavy-duty hinges. It is equipped with hydraulic
closer & three way locking arrangement.
 Shelter is installed on suitable base frame of galvanized I-beam
supported on concrete pedestal.
 ITI LIMITED Rae Bareli is manufacturing Prefabricated Shelter for
housing of BTS & its accessories used in Telecom Mobile Service.

PRODUCT RANGE

The following three types of shelter of internal dimensions (all in mm) are being manufactured:
Type I : 3000 L x 2000 x W x 2500 H
Type II : 4000 L x 3500 x W x 3000 H
Type III : 5000 L x 3500 x W x 3000 H
 ROOF TOP TOWER

PRODUCT RANGE

Square Lattice Type of RTT(as per GR) : - 10M, 15M, 20M Height.
Triangular Type RTT(SERC) : - 9M, 12M, 15M & 18M Height.

TECHNICAL SPECIFICATION

 Square Lattice type of RTT are manufactured as per GR No.

GR/TWR-09 FEB. 2004
 Design of triangular type RTT is duly approved from Structural
Engineering Research Center (SERC), Chennai.
 All members of RTT are made up of structural steel as per IS2062
Grade A & hot dip Zinc galvanized as per IS 4759.
 It can carry 6 Nos. GSM/WLL Antenna & 3 Nos. 0.6M dia
Microwave Antenna.
 Basic design of RTT is for wind speed 200 Km/h. It can survive wind
velocity up to of 210 km/h for short duration.

TRANSCEIVER

 Alcatel's new Twin TRX radio transceiver doubles the capacity of 
existing equipment, while occupying the same space in the rack.
 The new Twin TRX is particularly  adapted for densely populated
urban areas, with a maximum capacity  of 24 TRX per Base Station
cabinet.
 Twin TRX transceivers can be installed in the full range of  Alcatel's
indoor and outdoor BTS.

CDMA (Code Division Multiple Access)

 CDMA (Code Division Multiple Access) is a digital wireless technology to
provide mobile communication. CDMA works by converting speech into
digital information, which is then transmitted as a radio signal over a wireless
network.  CDMA uses a unique code to distinguish each different call.  The
receiving device is instructed to decipher only the data corresponding to a
particular code to reconstruct the signal.  This enables many subscribers to
share the same frequency band and, at the same time, without any cross talk
or interference.

CDMA WLL technology provides option of limited as well as full mobility to

the customers.  This helps to provide faster last mile connectivity, where
laying of cables is difficult.

SMPS

FEATURES

• Low cost & light weight

• Controls up to three LVD
• Hot plug-in rectifiers
• Fan cooling
• Temperature compensated battery charging
• Intelligent battery health monitoring
• Wide AC Input range
• RS485 Compatible (Remote Monitoring)
Infrastructure available at Rae Bareli Unit
Electronic Assembly-Versatility with Quality
At ITI Rae Bareli, the electronic assembly lines have been established in air-conditioned, dust-
free world class assembly hangars (approx 15,000 sq.m. air-conditioned area). Each of these
lines is multi-purpose and are well equipped for all types of P.C.B. assemblies, system
assemblies, system wiring and system integration and system burn-in at elevated temperature
(150 sq.m. area). We can make any type of PCB Assemblies, system assemblies/ Integration by
developing dedicated Testers/software to meet the customer's specific needs.

Surface Mount Technology(SMT)

An exclusive facility dedicated to Surface Mount Technology (SMT) offers Pick & Place Europlacer
a total solution for a wide range of SMT production. We have two most
modern zero defect SMT lines which are capable of handling complex and
fine pitch components with great accuracy. The SMT lines are supported by
latest and advanced BGA rework station. The manufacturing facility is also
equipped with latest and accurate connector fixing machines which provide
total solution for SMT art of work.

Pick & Place Machine FUJI, Japan EUROPLACER, France

Speed 94,000 cph 54,000 cph Pick & Place Fuji

Accuracy +/- 0.05 mm +/- 0.06 mm

PCB Size (mm) 50 x 50 to 457 x 356 60 x 60 to 460 x 500

PCB Thickness (mm) 0.3 to 4.0 0.5 to 4.5

Component Size (mm) 402 to 45 x 150 x 25.4  201 to 50 x 50 x 15

Feeder Capacity 440 of 8 mm & 20 tray 237 of 8 mm & 30 tray  

Lead 0.3 mm Lead 0.4 mm  

Min. Pitch
Ball 0.25 mm Ball 0.3 mm

Screen Printer DEK Horizen 2i DEK Horizen 2i

Screen Size 29 inches 29 inches

Accuracy 0.3 mm pitch 0.3 mm pitch

In-Circuit Tester
The state of art In-Circuit Tester TS 128 from Teradyne, USA, is
capable of highly reliable and accurate quality test for complex PCB
assemblies. It can test upto 3840 test points on any size of PCB with
facility of DSM programming and Boundary Scan. It provides excellent
diagnostic accuracy because closed-loop, low-impedence driver remains
accurate even under fault conditions. It has the highest-capacity in-
circuit test solution available in the market.

Mechanical manufacturing infrastructure

Rae Bareli has modern mechanical manufacturing infrastructure
consisting of latest CNC Punching, CNC Bending, Crimping and
Pneumatic Riveting setup with conveyorised Powder Coating Line,
Electroplating Plant and welding (MIG/ARC/GAS/SPOT) facilities,
supported by Tool Room. We can produce a variety of items like
Cabinet, Rack, pressed components, formed components, welded
assemblies required for Telecom, Power, Automobile, Defence and
other sectors
CNC Punch Press AMADA

CNC Press Brake AMADA, Godrej

Hydraulic Press Brakes LVD 300T & 400T

Shearing Machine LVD & Boutilion

Conveyorised Phosphating and Powder

Powder Coating
Coating Line

Electroplating Facilities Zinc Plating and anodizing

Injection Moulding MachinesBillion, Arburg

Powder Coating Line

Conveyorised Powder Coating Line
Powder coating booth with multi-cyclone recovery unit

back to back type side cutout : 850 x 900 mm

Roll out mechanism for spray booths
Auto sieving, recycling & mixing unit
Electrically heated convection type curing oven
 MANUFACTURING DEPARTMENT

1. Cabinet and Rack Manufacturing.

2. Pressed and Formed Sheet Metal Components.

3. Plastic Moulded Components.

4. Electroplating and Powder Coating Facilities.

5. CNC Department.

6. MIG/MAG/ Co Welding.
2

7. Tool Room.
1.PRESS MACHINES:
Press Machines work on the Air Copressor System.Compressor is run by
electrical motor and make the air compressed. Punch makes the stroke
happen using this compressed air.Depending upon the weight as 25
tonne,80 tonne &120 tonne, the press machines are used to punch a
definite thickness of metal.Every press machine is equipped with apunch
and a die. So on the press machines PUNCHING and PIERCING
operations can be done easily. An 80 tonne press machine has the
capacity to punch in 13.5 mm thick plate.
 Punch and Die for a Press Machine

2.LATHES:
Lathes were using three types of chuck on the basis of need of time and
accuracy in which the job is to be done:
1.Three-Jaw chuck:

This is also known as self centic chuck as it maintains its centre itself
when workpiece is mouted on it.It is very easyto mount and less time
consuming.
2.Four-jaw chuck:
It is time consuming but provides the facility to hold big jobs and its
holdness is very strong.It takes time in maintaining the centre.
3.Collet chuck :
Collets are very small chucks and are used to hold very small jobs.
These can hold the jobs even less than 1mm diameters.

3.MILLING:
A milling machine (also see synonyms below) is a machine tool used to
machine solid materials. Milling machines are often classed in two basic
forms, horizontal and vertical, which refers to the orientation of the main
spindle. Both types range in size from small, bench-mounted devices to
room-sized machines. Unlike a drill press, which holds the workpiece
stationary as the drill moves axially to penetrate the material, milling
machines also move the workpiece radially against the rotating milling
cutter, which cuts on its sides as well as its tip. Workpiece and cutter
movement are precisely controlled to less than 0.001 in (0.025 mm),
usually by means of precision ground slides and leadscrews or
analogous technology. Milling machines may be manually operated,
mechanically automated, or digitally automated via computer numerical
control (CNC).
The milling cutters used in ITI are as follows:
4.Grinding Machine
A grinding machine, often shortened to grinder, is a machine tool used for
grinding, which is a type of machining using an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece
via shear deformation.
The grinding machine consists of a power driven grinding wheel
spinning at the required speed (which is determined by the wheel’s
diameter and manufacturer’s rating, usually by a formula) and a bed
with a fixture to guide and hold the work-piece. The grinding head can
be controlled to travel across a fixed work piece or the workpiece can be
moved whilst the grind head stays in a fixed position. Very fine control
of the grinding head or tables position is possible using a vernier
calibrated hand wheel, or using the features of numerical controls.

MEASURING INSTRUMENTS

 Vernier Caliper(Digital dial gauge)

 Micrometer(Outside,dics type)
 Three point inside micrometer
 Bevel protractor
 Slip gauge
 Vernier height gauge
 Height master
 Riser block
 Lever Type Dial,Plunger Type dial
 Magnetic stand with V-block
 Filler gauge
 Radius gauge
 Thread gauge
 Dial bore gauge
 Plug pin gauge
  Profile projector
 Ring Gauge
 Spirit level
 Lever gauge
 Combination square set

TOOL ROOM EQUIPMENTS

 Precision lathe
 High speed lathe
 Cylindrical grinding
 Profile projector
 Zig grinding machine
 Zig boring machine
 Bench
 repairing
 Universal milling & boring
 Cnc milling
 Cnc wire cut
 Cnc zig boring & milling
 Surface grinding machine
 Turning machine
 Milling machine
CNC wire cut
CNC wire cut also known as cnc wire cut edm which is working
base on electro sparking principle. If there is a load, the wire edm
will moving slowly towards the electrical conductive workpiece.
The wire will be energize and create electrical spark between the
wire cut cnc machine and workpiece. The electrical spark created
between the wire and workpiece will erode some small amount of
workpiece and flush away by the deionized water to form the
spark gap between the wire and the workpiece. The electrical
sparking process will stop if reach the required depth.

The spark gap size can be controlled as small as 0.0127mm.

Workpiece made from cnc wire cut

If there is no load the machine will run only one cycle until the
required depth and stop.
Electrical discharge machining or EDM

Introduction

Electrical Discharge Machining (EDM) is a widespread technique used in manufacturing

industry for high precision machining of all types of conductive materials such as metals and its
alloys of any hardness which are difficult to machine with traditional techniques. EDM process
find application in various fields such as the automotive, medical, aerospace, electrical and
electronic industries.

Principles of EDM

EDM uses two oppositely charged electrodes namely a machining electrode and a work-piece,
and then bring these electrodes closer in dielectric fluid. As the electrodes get close enough,
insulation breaks down and a spark will occur, resulting temperature to reach about 12000
degrees Celsius which will melt and vaporize the material. The discharges that reveal the “spark”
create the crater-like surface by removing the material. The electrode and work-piece never
touch each other, and a small gap is maintained at all times. The electrical discharge machining
proceeds through repetition of the above phenomenon tens to hundreds of thousand times a
second.

Importantly there are few parameters need to consider in EDM are material removal rate,
accuracy and surface finish. The colour degradation, change in micro hardness and heat affected
zone of the material after the EDM are also important for the majority of the EDM applications.

Basically there are two types, namely die-sinking EDM and wire-cut EDM.

Die-sinking EDM

Die-sinking EDM is a non-traditional manufacturing process and will be used for making
negative impression of the electrode on the work-piece. The machining will done in the dielectric
submerged condition. Generally machining electrode will be of Copper and Graphite and work-
piece will be of any conductive material and their alloys.

Today’s most of the die-sinking EDM applications require multiple passes to get the desired
accuracy and surface finish on the machined parts. This is done by applying different
combination of machining parameters like current, voltage, discharge on/off time etc. which are
automatically precisely controlled by computer with the help of preset conditions database.

                                       

    

Wire-cut EDM

In Wire-cut EDM, a moving thin wire will be used as machining electrode and deionised water
as dielectric fluid, the conductive material will be cut using thin wire which follows the
programmed path.
Even for Wire-cut EDM, most of their applications require multiple passes of the wire to get the
desired accuracy and surface finish on the machined parts. This is done by applying different
combination of machining parameters like current, voltage, discharge on/off time etc. which are
automatically precisely controlled by computer with the help of preset conditions database.

profile projector

What is a profile projector? Also known as an optical comparator,

or even called a shadowgraph, a profile projector is an optical
instrument that can be used for measuring. It is a useful item in a
small parts machine shop or production line for the quality control
inspection team. The projector magnifies the profile of the
specimen, and displays this on the built-in projection screen. On
this screen there is typically a grid that can be rotated 360
degrees so the X-Y axis of the screen can be aligned with a
straight edge of the machined part to examine or measure. This
projection screen displays the profile of the specimen and is
magnified for better ease of calculating linear measurements. An
edge of the specimen to examine may be lined up with the grid
on the screen. From there, simple measurements may be taken
for distances to other points. This is being done on a magnified
profile of the specimen. It can be simpler as well as reduce errors
by measuring on the magnified projection screen of a profile
projector.
The typical method for lighting is by diascopic illumination,
which is lighting from behind. This type of lighting is also called
transmitted illumination when the specimen is translucent and
light can pass through it. If the specimen is opaque, then the
light will not go through it, but will form a profile of the specimen.

Measuring of the sample can be done on the projection

screen. A profile projector may also have episcopic illumination
which is light shining from above. This useful in displaying bores
or internal areas that may need to be measured.
If you have a need for a profile projector or optical comparator,
please contact us today. We have several lines available,
including versions with manual micrometers or newer versions
with digital readouts and digital micrometers for accurate and fast
microscope measuring.

Lathe:-

A lathe (pronounced /ˈleɪð/) is a machine tool which spins a block

of material to perform various operations such as cutting,
sanding, knurling, drilling, or deformation with tools that are
applied to the workpiece to create an object which has symmetry
about an axis of rotation.
Lathes are used in woodturning, metalworking, metal spinning,
and glassworking. Lathes can be used to shape pottery, the best-
known design being the potter's wheel. Most suitably equipped
metalworking lathes can also be used to produce most solids of
revolution, plane surfaces and screw threads or helices.
Ornamental lathes can produce three-dimensional solids of
incredible complexity. The material is held in place by either one
or two centers, at least one of which can be moved horizontally to
accommodate varying material lengths. Examples of objects that
can be produced on a lathe include candlestick holders, cue
sticks, table legs, bowls,baseball bats, musical instruments
(especially woodwind instruments), crankshafts and camshafts.
Surface grinding
Surface grinding is a widely used process of machining in which a
spinning wheel covered in rough particles cuts chips of metallic or
non metallic substance making them flat or smooth.
Process
Spark out is a term used when precision values are sought and
literally means "until the sparks are out (no more)". It involves
passing the workpiece under the wheel, without resetting the
depth of cut, more than once and generally multiple times. This
ensures that any inconsistencies in the machine or workpiece are
eliminated. As with any grinding operation, the condition of the
wheel is extremely important. Diamond dressers are used to
maintain the condition of the wheel, these may be table mounted
or as the first image shows, mounted in the wheel head where
they can be readily applied.
Lubrication
Lubricants are sometimes used to cool the workpiece and wheel,
lubricate the interface, and remove swarf. It must be applied
directly to the cutting area to ensure that the fluid is not carried
away by the grinding wheel.
FF FLOW OF WORKING PROCESS
FFFFFFFFLOW OFFFFGKIF
The Powder Coating Plant Process
Powder coating has today established itself as the most effective
means of metal surface finishing. It has replaced liquid painting
and various methods of electroplating due to the many
advantages this process offers …
_ Substantial improvement to chemical corrosion
_ Substantially improved resistance to mechanical abuse – better
scratch resistance, abrasion resistance and
mechanical wear and tear
_ Cleaner process for improved environment
_ Faster process for better productivity through the paint-shop
_ Requires less skills for high quality coatings
_ Guarantees uniform and consistent results
_ Substantially improved aesthetics for higher sales value of the
finished product
_ Requires lower energy per Meter2 of surface coated
_ Requires lesser care in storing and packing due to the
toughness of the coat
_ Is cost-effective
Powder coating is a simple process requiring minimal skill and
training. The articles to be coated are first cleaned of all foreign
matter from the surface. Mild steel components need to go
through a phosphate conversion coating. Aluminum components
go through a chromate conversion coating. This, known as
pretreatment, is employed for improved bonding of the powder coat
to the material being coated to provide a longer life to the coat.

PRETREATMENT SYSTEM – consisting of tanks or tubs containing

chemicals or water in which the
articles are dipped to clean and prepare the surface for powder
coating. The size of the tanks depends on the
size and quantity of articles to be coated. The specific process
depends on the metal make-up of the article.
AIR COMPRESSOR – fitted with appropriate filters provides clean
and dry compressed air to the powder coating
system. A 3HP or a 5HP air compressor is normally adequate for
a batch coating system using 1 coating
Machine. Conveyorized systems with multi-gun application may
require a larger capacity air compressor.
POWDER SPRAY SYSTEM:
(also known as the powder coating machine) – is considered
the heart of the powder paint shop. Normally an electrostatic
powder spray system is used. This sprays electrostatically
charged powder into the spray booth where the articles to be
coated are hung. Electrostatic forces provide a uniform and
consistent coating quality. Major strides have been made in the
design of these machines offering major benefits to the user.

POWDER COATING BOOTH WITH RECOVERY SYSTEM – in which

the actual powder coating is carried out. The efficiency of
recovery of oversprayed powder for reuse decides the economics
of powder coating. The efficiency of overall retention of
oversprayed powder decides the pollution-free worthiness of the
system. There are two types of powder recovery booths – Filter
Cartridge type and the Hyper Cyclone type.
CURING OVEN – in which the powder coated articles are placed for
10 to 15 minutes at the recommended
temperature for the powder to melt, polymerize, fuse and cure
into the final finish of high aesthetic appeal with
strong mechanical and chemical properties.
.
CNC:

Name Of CNC Machine:- AMADA

Specification of Machine:-
Machine specifications

Press Model name :- LC-2510NT

Press capacity :- 20 Metric tone

Tool Storage:- 45 Stations

Max Sheet Thickness :- 3.2mm

Max Sheet Mass :- 50 kg at f1
150 kg at f4
Y-axis travel :- 1270mm
X-axis travel :- 2500mm
Pusshing accuracy :- ±0.1mm

Numerical control (NC) refers to the automation of machine tools that

are operated by abstractly programmed commands encoded on a storage
medium, as opposed to manually controlled via hand wheels or levers, or
mechanically automated via cams alone. The first NC machines were
built in the 1940s and '50s, based on existing tools that were modified
with motors that moved the controls to follow points fed into the system
on punched tape. These early servomechanisms were rapidly augmented
with analog and digital computers, creating the modern computer
numerical controlled (CNC) machine tools that have revolutionized the
manufacturing process.

In modern CNC systems, end-to-end component design is highly automated using

computer-aided design (CAD) and computer-aided manufacturing (CAM)
programs. The programs produce a computer file that is interpreted to extract the
commands needed to operate a particular machine via a postprocessor, and then
loaded into the CNC machines for production. Since any particular component
might require the use of a number of different tools-drills, saws, etc.-modern
machines often combine multiple tools into a single "cell". In other cases, a
number of different machines are used with an external controller and human or
robotic operators that move the component from machine to machine. In either
case, the complex series of steps needed to produce any part is highly automated
and produces a part that closely matches the original CAD design.