AIRCRAFT PRODUCTION FACTORY
Avionics setup of PAC known as Avionics Production Factory (APF) was initially established as the Radar Maintenance Centre (RMC) in 1983 for overhaul / rebuild of ground based radar systems. In 1989, its capability was enhanced to handle avionics along with ground based radars.
Today APF, with its state of the art facilities, can undertake production of different types of avionics as well as commercial electronics equipment while ensuring high quality standards as per requirements of Aerospace Standard AS9100 Rev C.
The factory has produced number avionics systems like Grifo-7 and KLJ-7 airborne radars, radar warning receivers, Identification of Friend or Foe (IFF), Digital Audio Video and Crash Recorders, various mission computers and navigation systems. Most of these systems have been co-produced in collaboration with Chinese and Western manufacturers.
The factory has also produced various commercial products such as PAC PAD called Takhti-7, PAC notebook and e-book reader.
The avionics production facility at APF can be divided into six major segments: Design & Development, Avionics Integration, Production Line, Testing Line, Specific System Department and Environmental Stress Screening facilities.
APF can undertake design and development of avionics systems based on user requirements and provide complete solution from initial concept to product support throughout its service life. The prototype avionics systems are designed using Computer Aided Design and Simulation tools.
The prototype systems also undergo Electromagnetic Interferrence (EMI) / Electromagnetic Compatability (EMC) and environmental qualification. Systems developed at APF have qualified and are flying on fighter aircraft. The developed system prototypes are functionally tested and integrated in the Dynamic Simulation and Integration Laboratory known as DSI. This facility can also undertake integration of Off The Shelf (OTS) systems with an avionics suite.
APF has developed core integration technology for meeting new requirements as well as upgrades / modifications / retrofits in existing aircraft. The systems are validated through Hardware In the loop ground testing in simulated environment and are subjected to flight trials before final qualification. After successful qualification, serial production is undertaken utilizing semi automated and automated machines.
APF is a Qualified Production Vendor for various companies and its Generic Production Line employs stuffing of surface mounted and through hole electronic components on bare printed circuit boards. PCB stuffing is a multi-stage process involving PCB inspection, cleaning and drying before these are ready for components installation. The processed bare boards are then passed through automated assembly line which installs the components. Few components like connectors etc are however installed manually.
The assembly line is configured to adapt to production of any type of PCBs. The completed PCBs are inspected using Optical and X-ray inspection systems for faults before being passed for testing. The standard of workmanship during complete production process conforms to requirements of IPC 600 and 610 D standard.
Stuffed PCBs are passed to Generic Testing Line for in-circuit and functional testing. These PCBs are powered on and tested to ensure serviceability of individual components and complete functioning of PCBs. The testers are adapted for testing any electronic assembly.
The testing facility is generic and comprises of sophisticated test stations.APF has the expertise to develop complete testing solutions including development of software programs and mechanical adaptations for testing of electronic assemblies.
When PCBs have been stuffed with components and tested, these undergo conformal coating before being fed to Specific System Department.
Here these shop repairable units (SRUs) alongwith other components, electrical & mechanical wiring and harness assemblies are put together as a Line Replaceable Unit (LRU) for final testing of system. Since the processes require unique procedures for each system, there are separate assembly and testing areas for every system.
Once a system is ready, it is passed over for Environment Stress Screening where these systems are exposed to practical military environment, with the help of thermal climatic chambers and shakers. The aim of this strenuous testing is to ensure that the equipment conforms to actual aircraft environment as per requirements of Military Standard 810 D. The systems that pass through this process are guaranteed to perform reliably when put into operation.
Avionics Production Factory (APF) also provides life cycle support for these airborne avionics systems. Factory employs are skilled manpower with years of experience in repairs. The facilities are equipped with latest test and measurement equipment and repairs are undertaken as per international quality standards to ensure original equipment manufacturer specifications.
APF also carries out overhauling/refurbishment of low level and high level ground based radars. The facilities available with APF are electronics modules repairs & testing, Cables and harness repair and manufacturing which includes RF, Signalling and power cables, Antenna structural repair and testing, Trouble shooting and repair of hydraulic systems, Gear testing facility and radar vehicle overhauling. Overhauling gives a new life to the radars and are considered fit for operations for another life of 8 to 10 years.
The factory has so far overhauled more than 90 MPDR and TPS series of radars. APF has come a long way to acquire the knowledge and skills in the field of quality production and repair of avionics equipment and overhaul of ground based radars and looks forward to enhance this capability further to achieve the excellence.