HAL Report

2011
HAL Hindustan Aeronautics Limited

TRAINING REPORT
MADE BY:
ANUPRIYA GUPTA 0712231018 EC-FINAL YEAR
ON
Prepared by ±
Anupriya Gupta
Electronics & Communication Engg. SRMCEM , Lucknow
Summer training Page 2
CERTIFICATE
Certified that Anupriya Gupta has done a training in Instrument factory (ALH dep
artment) of HAL and has presented in this report for the award of Bachelor of Te
chnology from Gautam Buddh Technical University(GBTU),Lucknow. The training repo
rt embodies the original work and studies carried out by the student himself and
the content do not form the basis for the award of any degree to the candidate
or to anybody else.
Ms PUSHPANJALI SINGH
Faculty (Training incharge) Dept of Electronics & Communication Engg
Prof
S. C . TEWARI
Head of Electronics Wing Dept of Electronics & Communication Engg
Date:
Date:
With deep sense of gratitude, first and foremost express my profound thanks to M
r.Rajnish Kumar Agnihotri chief Manager ALH for giving me this opportunity to do
my summer training in Instrument department of Hindustan Aeronautics Limited, L
ucknow during the summer session 2010. Being renowned company of India & abroad,
it gave me the opportunity to learn the work carried out here, got a glimpse of
new environment & hard work of industrial unit. Mr. A. K. Sharma Chief Engineer
.of ALH I was posted under his guidance. He was very helpful during my training.
I also wish to acknowledge my indebtedness to the staff of HAL without whose co
operation; this training would not have been successful.
Anupriya
Gupta
Preface
Training has misinterpreted by most of us as a platform for project performation
. Industrial training in true sense has been included in curriculum to make the
student well versed with the technical procedure of various industries, the basi
c criteria for management of various resources in a company or industry.
The educational institution sole aim by industrial training is to improve the te
chnical knowledge and to have a hand on experienced to make them realistic in th
inking, to understand the procedure for manufacturing keeping mind the minute de
tail which will benefit the customer like no learning is proper without implemen
tation.
Doctors, Lawyers, hotel management student surely hold a upper hand. Its because
right from the second year of their graduation the are made to face the world a
nd their problems with a tender mind. In due course of time slowly but steadily
they, develop a competitive attitude and have a definite plan and aim as they co
mplete their graduation.
Unlike the pitiable engineers like us who are completely isolated from industry.
Therefore their should be industry institutions made compulsory for every engin
eering institutes.
BRIEF HISTORY/INTRODUCTION OF INDUSTRY/ORGANIZATION ORGANISATIONAL CHART SYSTEMS
/PLANT LAY OUT PRODUCTS &SPECIFICATIONS/ACTIVITES/SALIENT FEATURES PRODUCT FLOW
CHART/PROCEDURES CHRONOLOGICAL TRAINING DAIRY (WEEKLY DETAILS OF OBSERVATION/STU
DIES IN DIFFERENT SECTIONS) PRODUCTION PROCESSES/PROJECT/CONSTRUCTIONAL/STRUCTUR
AL DETAILS MARKETING STRATEGIES DIVERSIFICATIONS SUGGESTIONS CONCLUSIONS REFEREN
CES
(HAL FOUNDER)
Hindustan Aeronautics Limited has blossomed into a major player in the global av
iation arena, and today is among the elite Navratna companies. The history of In
dian aircraft industry can be traced to the foundation of Hindustan Aircraft Lim
ited at Bangalore in December 1940 in association with the erstwhile princely st
ate of Mysore and late Shri Seth Walchand Hirachand, an industrialist of extra-o
rdinary vision. Govt. of India became one of its shareholders in March 1941 and
took over the management in 1942. Hindustan Aircraft Limited was merged with Aer
onautics India Limited and Aircraft Manufacturing Department Kanpur to form HAL
on 1-october-1964. Today HAL has got 18 production divisions & 9 research & desi
gn centers spread out in 7 different locations in India. Its product track recor
d consists of 12 types of aircraft from in house R & D and 13 types by license p
roduction. HAL has so far produced about 3352 aircraft (which include 11 type of
indigenous design), 3583 engines & overhauled over 8141aircraft & 27267 engines
. HAL has engaged & succeeded in number of R & D programs for both the military
and civil aviation sectors. Substantial progress has been made in the current pr
oject like Dhruv ±Advanced Light Helicopter (ALH), Tejas-Light Combat Aircraft (LC
A), Intermediate Jet Trainer (IJT) &
various military and civil upgrades. The deliveries of Dhruv were affected to In
dian Army, Navy, Air force & Cost Guards in March 2002, in its first year of pro
duction which is a unique achievement. The Government of India decided to set up
a factory Lucknow Division in 1969 to undertake License manufacture of accessor
ies and instrument for Hindustan Fighter HF-24 and Hindustan jet trainers HJT-16
, aircrafts. The factory building is ready by October 1973 and full fledged manu
facturing of the accessories to cover Ajeet,MIG-BIS Aircrafts, aero engines and
Helicopters. HAL Accessories Division Lucknow was established in 1970 with prima
ry objective of manufacturing systems and accessories for varies aircrafts and e
ngines. At present it is turning out over 1100 different types of accessories. T
he division manufactures various systems viz. Hydraulics; engine Fuel systems, A
ir-conditioning Pressurization, Gyro and Barometric Instruments, Electrical syst
em items Undercarriage, Electronic items all under one roof to meet the requirem
ents of the aircrafts, helicopters and engines being produced by HAL. HAL has pl
ayed a significant role for India¶s space program in the manufacturing of satellit
e launch vehicle like PSLV (Polar Satellite Vehicle), GSLV (Geo Stationary Launc
h Vehicle), IRS (Indian Remote Satellite) & INSAT (Indian National Satellite). H
AL has joint ventures companies BAEHAL, Software Limited & IndoRussian Aviation
Limited (IRAL),Snecma-HAL Aerospace Pvt Ltd. Apart from these, other major diver
sification project & industrial marine gas turbine & airport services. Several c
o-production & joint ventures with international participation are under conside
ration. HAL¶s supplies / services are mainly to Indian Defense services, Coast Gua
rd & Border Security Force. Transport Aircraft & Helicopters have also been supp
lied to Airlines as well as State Government of India. The company has also achi
eved a foothold in export in more than 30 countries, having demonstrated its qua
lity & price competitiveness.
Divisions
MISSION-³To become a global player in the aerospace
industry ¶·
HAL LUCKNOW (ACCESSORIES DIVISION)
The manufacturing range of this division can be grouped under three categories:
1.) Mechanical and hydro-mechanical accessories, 2.) Engine Accessories 3.) Inst
rument accessories. In addition, the division also manufactures the wide variety
of ground support equipment like Ground Power Unit, hydraulic trolley, weapon l
oading trolley ,Test equipment etc. The Aerospace & equipment research & design
Centre is involved in the design and development of hydraulic pumps, actuators,
wheels and brakes etc.
Organizational chart
Chairman Managing Director General Manager AGM(Fuel) DGM Chief Manager Senior Ma
nager Manager Deputy Manager Engineer AGM(Design) DGM Chief Manager Senior Manag
er Manager Deputy Manager Engineer AGM(Instrument) DGM Chief Manager Senior Mana
ger Manager Deputy Manager Engineer AGM(Mechanical) DGM Chief Manager Senior Man
ager Manager Deputy Manager Engineer
Employees
Employees
Employees
Employees
SYSTEM LAYOUT Head of HAL Lucknow division is General Manager. The factory is di
vided into five sub Divisions: y y y y y Instrument factory Mechanical factory F
uel factory Design and Development Sukhoi-30
INSTRUMENT FACTORY This is further divided into two shops 1. Assembly shop 2. Ma
nufacturing shop
Assembly shop is divided into: 1. SHOP 1 2. SHOP 2 3. SHOP 3 4. SHOP 4 5. ALH
Manufacturing shop is divided into: 1. 2. 3. 4. NGL Shop Smiths shop Gyro shop P
ress Shop
Following systems or instruments are manufactured in Instrument factory. 1. 2. 3
. 4. 5. Barometric instrument Gyroscopic instruments Electrical and Electronics
equipments Fuel gauging systems Ground level navigation systems
All the above products are manufactured in specially designed rooms called clean
rooms. Following conditions are essential for the clean rooms for production. S
TANDARD CLEAN ROOMS CONDITIONS TEMPERTURE: - 15 to 25 oC HUMIDITY: - 45 TO 55% D
UST COUNT: - Less than 100,000 for class C shop(unmonitored) Less than 100,000 f
or class B shop Less than 10,000 for class A shop
PRODUCTS
Initially production of accessories was planned for Marut and Kiran aircrafts in
1972 which later expanded to include accessories for MIG-21 series and helicopt
ers during the late 1970,s in Lucknow Division. The current products of HAL are D
O-228 Kiran MK II HPT-32 Cheetah Chetak MIG-21 MIG-27 Jaguar Engine Test beds Ra
dars There are some new products ALH LCA HTT-35 Industrial/marine Gas Turbine Mod
ern Instruments GSE
The division today has prime name in the Aviation market and various internation
al companies are interested to join hands it for future purpose. The division ha
s also made steady progress in the area of export.
PRODUCT PROFILE 1950s & 1960s
BASANT
AJEET
JAGUAR *
HPT-32
MIG 21 M
HS 748
HTT-34
KIRAN Mk II
CHEETAH*
1970s & 1980s
BASANT AJEET JAGUAR *
HPT-32
MIG 21 M
HS 748
HTT-34
KIRAN Mk II
CHEETAH*
1990s to Date
MIG-27M IJT * HAWK - AJT *
DO ² 228 *
LANCER * SU-30MKI*
LCA *
ALH (DHRUV)*
* Current products
Products of HAL Lucknow division
Instruments Sensors, Gyros Flight instruments, electrical indicators, Fuel Gauge
probes, Gyros, sensors and Switches Electrical power generation and control AC/
DC Generator, Control and protection units, inverters, Transformers Rectifier un
its, AC/DC Electrical system, Actuators. Land navigation system Microprocessor c
ontroller Under carriage, wheels and breaks Hydraulic system and power control P
umps, Accumulators, Actuators Reservoirs and various types. Electro-Selectors, B
ootstrap
Environmental control system Pneumatics and oxygen system, cold air unit, water
Extractors, valves. Ejection system Ejection Seats, Release Units Engine fuel co
ntrol system Booster pumps, main and Reheat Fuel systems, Nozzle Actuators.
MANUFACTURE & OVERHAUL OF AIRCRAFT The division has manufactured more than 700 A
ircraft & overhauled more than 1300 Aircraft in last 3 decades. Having state-of-
the-art technology & facilities, the division is fully geared up to take the cha
llenge future task such as manufacture of SU-30 MK 1 & Advanced Jet Trainer.
The division has established full fledge infrastructure, facilities & system for
ensuring optimum level for customer¶s satisfaction on the products & services ren
dered. The major area includes Overhaul/ Repair of Rotable The Division takes up
over/repair of entire range of Electrical, instrument, Mechanical & Armaments R
otables. Supply of Spares & oth Ground support equipments and rigs Ground power
unit, hydraulics trolley and power packs, dedicated test Rigs, custom- build Fue
l/ Hydraulics Test rigs. Site Repair The Division undertakes site repair of Airc
raft at IAF bases by deputing site repair teams. Defect Investigation/Failure An
alysis The aggregate which was received on premature withdrawal from the units a
re studied & the causes for defects /failures are investigated. Repetitive cases
are taken up for in the depth study & modifications are incorporated in the uni
t to minimize the recurrence of such defects/failures in future.
Product Training
The Division has positioned Service Engineers at various IAF bases to closely li
aise and to access the requirement of the customer. Based on the feed back recei
ved from Service Engineers, the division renders adequate support for fully expl
oiting the products.
Product flow chart
The instrument factory is divided into Assembly shop Manufacturing shop Assembly
shop is divided into: SHOP 1 SHOP 2 SHOP 3 SHOP 4 ALH Manufacturing shop is divi
ded into: NGL Shop Smiths shop Gyro shop Press Shop
Following systems or instruments are manufactured in Instrument factory. Baromet
ric instrument Gyroscopic instruments Electrical and Electronics equipments Fuel
gauging systems Ground level navigation systems
Process of product preparation follows certain steps. When the customer places t
he order and it approved by the authorities the planning of steps for preparatio
ns are to be layer by authorities now assembly of the material is done and store
d in stored. Now these are collected as required and experts prepare unit. Now t
he important step comes of testing. Testing is done under
specified conditions and assurance is done in all respect then certificate is ra
ised of being tested. Now the last step comes of proper packing and storing. The
se are supplied to costumer under followed terms and conditions. Product flow ch
art Request of costumer Planning of steps
Assembly of material
Manufacturing of units
Testing of unit under for conditions
Collecting and proper packing of unit
Advanced Light Helicopter is a multi-role, multi-mission helicopter designed & d
eveloped by HAL. The design of this 5.5 ton class, twin-engine helicopter incorp
orates several state of the art technologies. Extensive use of composites high c
ruise speed, long range & endurance, excellent high altitude performance & capab
ility to operate in hot & humid environment are the key to design features. ALH
has been designed for both civil & military application in large variety of role
s overland & sea. Performance: Maximum cruise speed at maximum load: - 250 km/hr
. Maximum rate of climb: - 10 m/sec. Range with 20 min reserve: - 650 km. Endura
nce: - 4 hrs. Hover in ground effect: - 1500 m. Hover out of ground effect: - 10
00m. Leading Particulars: Overall length: - 15.87 m. Overall height: - 4.91 m. W
idth: - 3.91 m. Empty weight: - 2500 kg. Fuel capacity: - 1100 kg. Maximum takeo
ff weight: - 5500 kg. Maximum under slung weight: - 1500 kg. Maximum height: - 2
500 HT. ROLES: Military Role (Unarmed): Hellebore attack. Reconnaissance Logisti
c support Casualty evacuation Air observation post
Military Role (Armed): Anti tank Close air support Anti submarine warfare Anti s
urface vessel warfare Civil Role: Commuter/ VIP Search & rescue Disaster relief
Air ambulance Offshore operation Salient Features: Ergonomically designed cockpi
t Extensive use if composites, reduced radars signature Large cabin volume Balli
stic damage tolerant Greater system redundancy Provisions for weapons hard point
s Twin engine with fully authority digital electronic control Adequate safety ma
rgin for single engine operation Four axis automatically flying control system C
rash worthy crew seats, under floor and fuel tank Hinge less main rotor & bearin
g less tail rotor Excellent handling qualities at low as well as high speeds Low
maintenance cost & high fuel efficiency Skid version & retractable wheel versio
n available
Auxiliary Tank Probe: The probes (AT) are a part of fuel system of ALH. It is in
stalled from the top of the tank. The AT probes is for gauging fuel content. The
units consist of following main sub-assemblies: y Tube assembly ± consisting of g
auging & level sensing. y Card assembly gauging ± it consist of gauging circuit.
y Electronic assembly ± it consist of receptacle & interconnection wires connected
to card and tube assembly. Electrical Characteristics: I/P Characteristics: Ele
ctrical supply ± for gauging 5V dc (nominal) Current consumption ± for gauge 2.5 mA
with 5 mA o/p load. Supply Tank Probe: Probe is a part of a fuel system of ALH.
It is installed from the bottom of the tank. The s-probe is gauging the fuel con
tent. It is also has built in low level warning sensors which is electrically is
olated from fuel content sensing circuit Reference Sensor Probe: The probe is a
part of the fuel system of ALH. It is installed from the bottom of the tank. The
RS Probe transmits the reference frequency which is normally stable but varies
slightly to assist the computer to compensate the changes excepted in other fuel
gauging probe. O/P due to the change in temperature or variation in grade of fu
el, this probe is always immersed in fuel. The unit consists of following sub as
semblies ± 1) NET FLANGE HEAD ASSEMBLY: - It consist of reference frequency, sensi
ng circuit, receptacle, interconnection ± wires, connecter to card & hold cup asse
mbly. HOLD CUP ASSEMBLY: - It consists of sensing probes.
2)
The indicating G ± METER provides visual indication of acceleration experienced al
ong the vertical axis of ALH. The dial presentation comprises three co ± centric p
ointer moving over a linearly divided scale. The front pointer indicates the ins
tantaneous acceleration & the middle and read pointers indicate the maximum posi
tive & negative accelerations respectively. This unit provided with a resting kn
ob to reset the pointers to align with the main pointer. The unit has a locking
facility to lock the mass of unit when installed, to prevent the unit from damag
e candling & transit. Weight: - 425 gm (max). NVG (Night Vision Gauge).
Temperature switch is used in ALH to close on electrical circuit. When the tempe
rature in the area surrounding its sensor reaches a predetermined value. The uni
t senses the oil temperature of the transmission system. It works on vapour pres
sure action & consists of bulb containing Ethyl Alcohol due to sufficient change
s on temperature. The organic liquid vaporizes & builds up pressure within a clo
sed chamber. The high vapour pressure compresses a below assembly, which is turn
operates a snap ± action micro switch. The unit is normally open type switch. Gea
r box oil temperature senses. Ensure temperature is within 115 4 °C (max), 110 4 °C
(min). Warning switch cockpit.
The pressure switch is for use in ALH to close an electric circuit of the system
when the pressure falls below a predetermined value. Leading Particulars: Name:
- pressure switch. Electric supply: - 28V dc. Current consumption: - 500 mA (ma
x). Operating range: - 0 to 25 bar. Functions: Pressure switch senses the oil pr
essure of the auxiliary gear box of the transmission system. Operation: The unit
uses the below assembly as a pressure sensing element. The upper end of the bel
lows assembly is being fixed leak proof to pipe union with the help of sealing w
asher & sealing nut. When an external pressure is applied to bellow assembly thr
ough the pipe union, bellow assembly compresses & its free end moves toward up &
it operates as a micro switch. The micro switch opens an electric circuit when
the pressure of the system rises above predetermined value.
Outside Air Temperature Gauge is a panel mounted instrument & indicates the outs
ide temperature. The sensor portion of the instrument protrudes outside the cock
pit & senses the outside air temperature. Leading Particulars: Name: - Outside A
ir Temperature Gauge. Weight: - 150 gm (max). Size: - 56 * 155 mm.
Accuracy: - 1.5 °C. Operating Temperature Range: - - 45 °C to + 75 °C. Storage Tempera
ture: - - 65 °C to + 75 °C. Response Time: - 3 min. Supply: - 5V dc. Current: - 150
mA (max). Storage Life: - 10 years. Operation: The unit is bimetal type temperat
ure indicator. The heart is a bi metallic sensor wound in a helical form. One en
d of the metallic sensor is clamped rigidly & the other end is connected to a st
eel rod, on the other end of the rod, a pointer is connected which move over a l
inear dial to indicate the temperature senses by the metallic sensor. Thus assem
bly is housed in a tube and cup ± type case.
RMI is a panel mounted (from front) air-borne instruments which provides the pil
ot following function Heading of aircraft. Relative bearing of radio station. Dev
iation from a set course. Additional heading error proportional to sine of the a
ngle between heading & course set pointer.
Physical Specification: Name: - Radio magnetic indicator. Size: - 83 * 83 * 2020
25 mm. Weight: - 1200 gm (max). Location: - Cockpit instrument panel. Power Supp
ly: - a) 5V 0.5 dc. b) 26V 10 % V, 400 Hz, single phase a.c.
ASI is designed to provide continuous indication of the speed of an A/C. The ins
trument is basically a differential air pressure gauge consisting of a twin caps
ule assembly connected via suitable linkage & gearing to pointer which moves ove
r a circular diameter calibrated in km/hr. when installed the interior at the ca
psule is connected by a capillary tube to A/C pilot pressure line while the exte
rior of the capsule is open to static pressure via the A/C static system. The po
inter indicator on a dial which is calibrated 30-400 km/hr. When the pilot & sta
tic pressure applied to the capsule are equal, the pointer remains in null posit
ion. When differential pressure is applied, the capsule will expand or contract
accordingly. The resultant movement of the free side of the capsule assembly is
transmitted by the linkage to rotate the rocking shaft & then causes the sector
gear temperature range operation: 45°C to +71°C. Storage: - -54°C to + 85°C.
THE MAIN PARTS OF ALH ARE:
1. 2. 3. 4. 5. 6. AC master box DC master box Filter Transformer Unit Alternator
Control and Protection Unit Auxiliary Tank Probe Radio Magnetic Indicator
INTRODUCTION ± Excluding the two alternators and protection unit and static invert
er, primary AC distribution system consists of following boxes: 1. 2. 3. 4. AC M
aster Box ± 1 AC Master Box ± 2 115 V AC Emergency Bus Relay 26 V AC Emergency Bus R
elay AC Master Box ±1 consist of three phase main bus ± 1(115 V), 1-J emergency bus ±
1 & 2 (115 V), 1-J main bus ± 1 (26 V). During normal operation (both alternator r
unning), complete system ± 1 is powered from alternator ± 1. In case of fault on alt
ernator ±1, all the buses of system ±1 are connected to alternator ±2, with alternator
±1 in failed condition, in the event of short circuits. On a main bus ±1, it goes d
isconnected from alternator ±2. In case of both alternator fails to supply power t
o AC main buses, emergency buses of system ±1 are powered from static inverter. Wi
th AC ground power in & selected in the cockpit, external power control card val
idates incoming ground power and automatically energizes the external power cont
actor to supply ground power to all buses of system ±1 & system ±2 through main bus ±1
of system ±1. The external power control card inside AC master box ±1 controls the
energization of external power contactor to allow correct quality of external AC
power, as to be transmitted to the electrical system. AC master box ±2 is similar
in construction and function to AC MBX ±1. This box dose not includes external po
wer contactor & control cards. However it has non-essential bus along with its c
ontactor, this bus is powered from the main bus ±2 only when the alternators are r
unning. All the power O/P of different buses is protected with thermal circuit b
reakers, which are provided in both master boxes.
AC master Box used in ALH distributes AC electrical power to different three pha
se loads as per requirement. It is used in conjunction with two alternators, two
ACPU and static inverters. LEADING PARAMETERS ± Name ± AC Master Box ±1 Weight ± 5.5 kg
max. Dimension ± Length= 266s5.0 mm Width = 240s5.0 mm Height = 120s5.0 mm
Input DC power supply ±
28 V dc (nominal) 22 V dc to 29 V dc (normal) 20 V dc to 31 V dc (abnormal) 115
V ac (nominal) 108 V ac to 118 V ac (normal) 100 V ac to 125 V ac (abnormal)
Input AC power supply ±
Power consumption ± 5 KVA
FUNCTION ± Under normal operation ACMBX ± 1 distribute ac power. But in the case whe
n alternator ±1 fails then ac power is distributed to different loads through ACMB
X ±2 from alternator ±2.
During normal operation (both alternator running) complete system is powered fro
m alternator ±1 and ACMBX ±1 distribute ac power to different electrical system of A
LH. External power control card (EPC) inside AC Master Box controls the energiza
tion of external power contactor to allow correct quantity of external AC power
to be transmitted to electrical system.
AC Master Box ±2 (AC MBX ± 2) used in Advanced Light Helicopter Distribute ac electr
ic power to different three phase loads as per requirement when alternator ±1 is f
ailed. It is used in conjunction with two alternators, two ACPU¶s and static inver
ter.
LEADING PARAMETERS ± Name ± AC Master Box ±2 Weight ± 5.0 kg max. Dimensions ±Length=266s5
.0 mm Width =240s5.0 mm Height =120s5.0 mm Input DC power supply ± 28 V dc (nomina
l) 22 V dc to 29 V dc (normal) 20 V dc to 31.5 V dc (abnormal) Input AC power su
pply ± 115 V ac (nominal) 108 V ac to 118 V ac (normal) 100 V ac to 125 V ac (abno
rmal) Power consumption ± 5 KVA FUNCTION ± Under normal operation ACMBX ±1 distribute
ac power. In the case when alternator ±1 failed then ac power is distributed to di
fferent loads through ACMBX ±2 from alternator ±2. No external power card is used AC
MBX ± 2 as used in AC MBX.
TESTS ± 1. Over voltage protection test (in normal & environmental condition) 2. U
nder voltage protection test (in normal & environmental condition) 3. Over/Under
frequency 4. Vibration test 5. Functional test.
INTRODUTION ±
DC Master Box is a part of dc power generation and distribution system for re-en
gine Cheetah Helicopter. It is designed for use with an independent starter/gene
rator mounted on the engine accessories gearbox, and is interfaced with GCPU, ba
ttery, and external power source and control panel of DC power generator to the
loads through its main bus. In the event of failure of starter/generator, the dc
master box will activated the battery contactor, through which the on-board sin
gle battery (Ni-Cd 40 Ah) will get connected to the main bus & supply power to t
he emergency loads. DC External Power Receptacles (EPR) is provided at the port
side of the Helicopter with EPC in DC master box to supply the dc power from Gro
und Power Unit (GPU). FUNCTIONAL DESCRIPTION DC Master Box distributes the compl
ete dc power generation. It contains the main bus through which dc power is dire
cted to the overhead panel through circuit breakers for dc power distribution. D
uring normal operation, the total dc power from starter/generator is brought to
the main bus through Normally Open (N.O.) contactor, which is controlled by GCPU
.
In case of failure of starter/generator, the dc power will be available from a s
ingle on-board internal battery through a normally closed battery contactor. Pro
vision has been made for receiving the dc external power during ground operation
through an external power receptacle. The external dc power supply is transferr
ed to main bus through N.O. contactor, which is switched on by External Power Ca
rd (EPC). The EPC switches the external power contactor ON only if the applied v
oltage is with in specified limit & of correct polarity and therefore protects t
he dc system from over-voltage conditions. As long as external power is connecte
d to the Helicopter (External Power Contactor is closed), battery should remain
disconnected. FUNCTIONAL REQUIREMENTS ± 1. Input sources for DC Master Box: Starter
/generator along with GCPU: 6 KW Battery (Ni-Cd): 40 Ah External power source on g
round: 6 KW 2. Types of O/P Buses: Main Bus ± 200 A at 28 V DC through 100 A circui
t breaker: 1 no. 50 A circuit breaker: 2 no. 3 A circuit breaker: 2 no. 3. Capacit
y: Capacity of unit (Main Bus): 200 A at 28 V DC Overloading: 150% (300 A) for 2 m
in & 200% (400 A) for 5 sec 4. Protection Function ± External Power control: Exter
nal Power Control (EPC) card housed inside the DC Master Box provides the follow
ing functions when external power is selected to the Helicopter. a) Over voltage
protection: At 30.5s1 V with a fixed time delay of 0.4s0.1 sec.
b) Reverse polarity protection: External Power fails to connect itself to the sy
stem if the polarity of the external power is reversed.
FAILURE MODES ± There may be multiple failure modes for each functioning. Design h
as been found to meet the basic criterion for external system: a) Single fault a
t a time should not affect the normal flight. This has been designed as MINOR fa
ilure. This may also be called as CONTROLLED FAULT, which may be corrected by ap
propriate design safety device or special automatic/manual procedure. Hence, one
fault at a time should only lead to MINOR failure. Double fault occurring simul
taneously should not lead to an emergency situation and may be counteracted by e
mergency action. Hence, two faults simultaneously should only lead to MAJOR fail
ure. Triple faults occurring simultaneously may lead to an emergency situation.
This may also require PILOTS immediate action for emergency condition. This type
of fault has been called as CRITICAL failure.
b)
c)
PRECAUTIONS FOR EMI/EMC CONTROL ± The following precautions have been taken during
design and development stage of DC Master Box to control EMI/EMC All the ground
ing/reference lines used in the unit are connected to a common negative point us
ed inside the unit and then being brought out through connector pins of 16 AWG.
The chassis of the unit is kept isolated from the grounding points to avoid the
return currents to flow through the Helicopter structure. The bonding points are
provided on the unit at the mounting points.
All contactors are used with coil having surge suppressors. Transient suppressor
s and free wheeling diodes are also used in PCB circuit design. The length of th
e leads/wires is kept as short as possible and multistrand wires are used to red
uce eddy current effects.
INTRODUCTION: Alternator Control & Protection Unit regulates the alternator O/P
voltage within specified limit under various rated load & speed conditions. The
unit is having built in protections against over/under voltage, over/under frequ
ency, over load & feeder fault conditions. Under these faulty conditions, the un
it disconnects the alternator from AC electrical system by de ± energizing the con
tractor & field.
The unit will be interfaced with the alternator having characteristics: Type: -
3 ± phase star connection. O/P Power: - 5 kVA. Voltage: - 115/200 V, 400 Hz. Overl
oading: - 150 % for 5 min, 200 % for 5 sec. Nominal Speed: - 1200 RPM. Maximum S
peed for Regulation: - 12600 RPM. Minimum Speed for Regulation: - 11400 RPM. Ove
r Speed: - 15000 RPM. Frequency at 12000 RPM: - 400 Hz.
INTRODUCTION The Filter Transformer Unit (FTU - 01) is for Jaguar aircraft which
gives single phase 26 V, 400 Hz low distortion O/P, synchronized with phase AB
of the three ± phase 200 VCC O/P, 400 Hz aircraft power source. The unit is being
operated from three phase 200 VCC, 400 Hz aircraft power source. There are two n
o. of FTU¶s in one A/C. in case of failure of one unit (FTU), the entire A/C load
will be automatically transferred to another healthy unit (FTU). Functional Desc
ription: The FTU is enclosed in an aluminum box & having natural cooling. The he
at sink fins made on two side walls are capable to provide the sufficient heat c
onduction generated from four power transistors. The basic electronics of this u
nit utilizes the conventional sine wave oscillator & push pull power amplificati
on principle. The unit provides single phase 26 V RMS, 400 Hz O/P synchronized w
ith phase AB of AC power. The unit is capable of 130 % of FLUFF. The unit is hav
ing built in protection against O/P over voltage, O/P under voltage. The unit al
so provides a single under above faulty condition. The total circuit is spited i
nto 3 main functional parts: Power supply. O/P voltage control & its phase synch
ronization. Protection. Power Supply: Three phase power 200 VLL, 400 Hz availabl
e from A/C is being fed to step down I/P transformer. The three phase bridge rec
tifier rectifies the O/P of the I/P transformers. The rectifier O/P is filtered
through capacitor & a dc voltage of amplitude of approx. 26 V is available. This
dc voltage is used to bias the circuit within the unit & also to provide the O/
P power. A new reference i.e. 0 V is generated within the unit & w.r.t.0 V. The
+ VCC & VCC are generated to provide the biasing to the circuit.
O/P Voltage & Phase Synchronization: A three phase oscillator consisting of IC¶s &
associated resistors & capacitors produce 3 ± phase sine wave, 120 degrees apart
to each other. The sine wave available is in phase with the sine wave signal rec
eived at control card. The phase AB of A/C ac supply is fed to I/P of synchroniz
ation T/F. The O/P of T/F is step down & is fed to the control card, so the sine
wave available is always in phase with AB of A/C ac power. The sine wave O/P is
followed by pre ± amplifier is followed by the driver transistor mounted on chass
is. The T/F drives the class ± B push pull amplifier. The O/P available at the O/P
T/F is filtered through a filter consisting L & C. After filtration a low disto
rtion 26 V RMS, 400 Hz O/P is available at the connector. The O/P T/F has voltag
e feedback winding. A sine wave proportional to main O/P is being rectified & fi
ltered through capacitor in the control card. As unit O/P voltage decreases, the
amplitude of the square wave increases, hence the amplitude of the sine wave in
creases, hence the amplitude of the sine wave increases, which in turn increases
the O/P voltage & vice ± versa, so a regulated voltage within permissible range i
s available at the O/P of the unit.
The O/P sine wave & I/P phase AB available at the secondary of the phase synchro
nizing T/F are converted into square wave & fed to PLL. The O/P of the PLL is a
pulse whose width varies with phase difference b/w two square waves. The O/P of
PLL is followed by LPF. A smooth DC is at the O/P of LPF whose amplitude is dire
ctly proportional to the width of the pulse. The DC voltage available at the O/P
of the LPF is compared with a fixed reference voltage by the comparator. The co
mparator O/P is low as
long as the phase error b/w O/P of the unit & I/P phase AB is less than the spec
ified value. When the phase error exceeds the specified limit, the comparator of
the O/P becomes high. The high signal is fed to the latching cum time delay cir
cuit & O/P becomes high after a specified time delay & thus unit O/P falls to ze
ro & the aircraft load gets transferred to the second FTU.
The d.c. voltage proportional to the O/P a.c. voltage is fed to the comparator w
hich compares this d.c. voltage to find a reference voltage. If the O/P voltage
becomes lower than the O/P under voltage threshold level, then the O/P of the co
mparator becomes high, which in turn makes O/P of the latching cum time delay ci
rcuit to high, after fixed time delay, & the unit tripped off & the aircraft loa
d is transferred to another FTU.
The a.c. voltage induced across the feedback winding of the O/P transformer is r
ectified by bridge rectifier & filtered to obtain the d.c. voltage is fed to the
comparator which compares the fixed reference voltage. If the O/P voltage excee
ds the threshold limit of O/P over voltage, the O/P of the comparators becomes h
igh, which in turn males the O/P of the latching cum time delay circuit to high,
after fixed time delay the unit is tripped off & the aircraft load is transferr
ed to the another FTU.
The a.c. voltage is proportional to the O/P current is achieved by the current t
ransformer. The voltage is rectified & filtered to obtain the d.c. voltage propo
rtional to the O/P current. The d.c. voltage is compared by a comparator with a
fixed reference voltage. If the O/P becomes higher than the specified limit, the
O/P of the comparator becomes high, which in turns makes the O/P of the latchin
g cum delay circuit to high after a fixed time
delay & the unit is tripped off & the aircraft load is transferred to another FT
U.
Flight data reorder system is fitted in aircraft for recording of flight paramet
ers on aero photo film and preserving it in normal as well as in crash condition
. This box is dark orange in color to give bright contrast for easy search durin
g any mishappening. Though it is called Black Box, as data are being recorded on
film and cannot be seen easily by everyone. It mainly consist of1- Information
storage system 2- Matching mechanism 3- Cassette 4- Transducers for various para
meters.
Purpose &working
Flight data recorder system records automatically 6 continuously changing parame
ters (altitude, engine speed, aircraft speed, vertical acceleration, and horizon
tal acceleration and turn angle of stabilizer) imposed on 3 continuously variabl
e parameters, and timer line to indicate the time on black and white aero photo
film and preserve it in normal and crash condition for study and analysis of fli
ght conditions. Inner structure consists of a light beam source and plane mirror
s. There are six sets of galvanometer is a plane mirror. These galvanometers are
placed in magnetic field. When the signals are send to galvanometers the coils
moves due to magnetic effect, making the mirror move in different directions. No
w, when light beam passes the beam, it is reflected by plane mirror and when thi
s falls on galvanometers mirrors, and get light gets reflected in six parts and
falls on film forming different wave shapes.
1.
Aircraft SU-30MKI is a multipurpose twin seated supersonic fighter designed to d
estroy air target in free space and against the earth background both by day and
at night under visual and adverse weather conditions and to engage ground and s
urface targets within tactical and operational depths under heavy noise conditio
ns as well. To destroy aerial targets, a provision is made for employment of all
angle medium-range missiles (active, semi-active radar and infrared guided miss
iles) and short-range missiles (infra-red guided missiles) capable of high targe
t hit probability. To destroy ground targets, use is made of unguided bombs, gui
ded bombs and missiles. The aircraft is also equipped with a rapid-fire gun moun
t with caliber of 30mm. The aircraft is also intended for training, acquisition
(perfection) of skills in flying techniques, air navigation and combat employmen
t including participation in group combat actions.
2.
3.
4.
Main Features Fuselage: The fuselage of SU-30MKI aircraft is an integrated aerof
oil body that provides 40% of aircraft¶s total lift. The fuselage is built up of t
hree sections; Nose sections, tall section and wing center section. Fuselage Nos
e Section: It is an all-metal semi monologue construction. It includes nose cone
, two cabins, nose LG well and equipment compartment. For planes or canards and
attached to the last frame of this section. Wing Center Section: It is the main
load carrying structure of the aircraft. It provides attachment points for landi
ng gears, outer wings, fuselage nose section, and fuselage tail section and air
intakes. Fuselage Tall Section : It comprises of air ducts, air Intakes and two
engine compartments interconnected by an intermediate
compartment. Horizontal stabilizers and vertical fins are attached to the rear p
art of fuselage tail section Outer Wings: Outer wings are an integrated part of
the fuselage, trapezoidal in shape and swept back by 420. The flaperons are atta
ched at the trailing edge, which operate as ailerons and flaps. The leading edge
flaps are located all along outer wingspan to improve the aerodynamic character
istics. Air intakes: The engine air intakes are under slung and provided with ra
mp panels the air intakes are closed by protective screen to prevent the ingress
of foreign objects. Landing Gear: The aircraft has tricycle type landing gear o
perated by first hydraulic system. Only the main wheels are provided with brakes
, and the brakes are operated by hydraulic pressure. The nose landing gear is pr
ovided with wheel steering system. Flight Controls: The aircraft longitudinal co
ntrol is achieved by synchronous deflection of stabilizers, lateral control by d
ifferential deflection of stabilizers and flaperons and directional control by r
udders. Fly by wire system operates all the control surfaces. Fore plane or cana
rd is introduced for providing larger stability and Maneuverability at higher an
gle of attack and subsonic speeds. Wing leading flaps also act as lift augmentin
g device at greater angle of attack. The fly by wire system operates canards and
leading edge flaps automatically. All control surfaces are operated by both the
hydraulic systems. Hydraulic system: The hydraulic system comprises of two inde
pendent systems i.e.: First or Left hydraulic system and Second or Right hydraul
ic system. y (a) y (b) y (c) y (d) y (e) Hydraulic oil used: AMG-10/OM-15 Hydrau
lic tank capacity: 15.8 liters (each system) Left hydraulic system capacity: 40
liters Right hydraulic system capacity:40 liters System operating pressure: 280+
15 kgf/cm2
Fuel System: The ac carries fuel in five metallic fuel tanks, which can be refue
led in air also. On ground the ac can be refueled in two modes i.e. basic and fu
ll: in case of emergency the fuel can be dumped in air. The capacity of fuel tan
ks is as follows. Tank No. 1: 3260 kg Tank No. 2: 4160 kg Tank No. 3: 1060 kg Ta
nk No. 4: 350 kg Tank No. 5: 650 kg Total : 9480 kg Pneumatic System: There are
three independent pneumatic systems. All the system bottles are charged with nit
rogen to a pressure of 200-15 kgf/cm2 a) Canopy Pneumatic Control System: It ens
ures opening, closing and sealing operation of canopy, jettisoning of canopy in
case of emergency and pressurization of alcohol tank used for canopy anti-icing.
The bottle capacity is 8 liters. b) Emergency Extension of Landing Gears: It ex
tends the landing gears in case the first hydraulic system fails. The bottle cap
acity is 9 liters. c) Emergency Extension of Refueling probe: It extends the air
-to-air refueling probe in case the second hydraulic system fails. The bottle ca
pacity is 3 liters.
Marketing is the relation between costumer and organization. When the costumer c
ontacts the organization then it is seen that the request is of our capability o
r not. If not then regret order is send. Else request is judged under various po
ints of cost, terms and conditions, time duration etc. and the decided condition
s are send to the customer now if the customer agree then order is placed for fu
rther process. Firstly HAL had only defense sector as the only customer, but now
it has decided to expand it capabilities to earn more and more profit. Marketin
g mainly includes two units of marketing. They are Civil and Export. It mainly d
eals with the defense requirements, but besides this there are many other costum
ers in India and outside India.
Marketing
Civil (ISRO, Sahara Airlines, kingfisher kingfisher, JET airways, etc.)
export (Oman, UA, England, Romania, Zimbabwe, Srilanka, etc.)
y CIVIL- In civil unit it mainly deals with the costumers of India only. They ar
e different airlines and research organizations, army, navy, coast guard, air fo
rce, etc. They may contact for repairing of parts and for requirements of parts.
y EXPORT- In this unit there are mainly customers of foreign they are airways o
f England, Oman, UA, etc. There are very strict rules for the trade between thes
e organizations. These foreign organization look to HAL as a faithful organizati
on. When customer contacts HAL then there are predefined steps to be followed by
the organization.
These can be described in chart as²
CUSTOMER
Approved proposal
RFQ/RFP MARKETING
ENQUIRY REVIEW
Techno/commerci al proposal
Preparation (export evolution, pricing committee, etc.)
Vetting (finance) Approval (competent authority)
FLOW CHART FOR MARKETING PROCESS
Hindustan Aeronautics Limited (HAL) has cruised past the Rs.7,500-crore mark for
the first time with a sales turnover of Rs.7,783.61 crores ($1.82 billion) duri
ng the Financial Year 2006-07, The Value of Production has also gone up by 55.54
% to Rs. 9,201.88 crores, while the Profit of the Company (Profit Before Tax) so
ared to Rs.1,743.60 crores, which is an increase of 54.88% over the previous yea
r's performance.
The highlights are given below:
Rupees in Crores Particulars Sales VOP Profit tax before 2005-06 5342 5916 1126
771 1694 2006-07 7783 9202 1744 1149 2081 Growth over Previous Year 45.69% 55.54
% 54.88% 49.03% 22.85%
Profit after tax Gross Block
SUGGESTIONS
It is matter of great prestige to be a part of well& highly organized Navaratna
organization, HINDUSTAN AERONAUTICS LIMITED. After being a part of such organiza
tion one has the chance to learn a lot about a successful organization. Besides
this it also imparts the opportunities to strengthen the particular¶s professional
skills. Atmosphere of organization teaches one the characters of Focusing, Plan
ning, Decision making, Co-ordination etc. These golden experiences help the stud
ent to sharpen his/her professional as well personal skills. After being the tra
ining student of HAL a particular department is assigned to study. This departme
nt helps in all possible ways to guide the functions, working process, units pre
pared of the organization. One can learn a lot if he takes the proper interest.
Conclusion
The joy of flying has fascinated the human race for centuries. Defense avionics
major &Navratana PSU Hindustan Aeronautics Limited (HAL) is in the business of b
uilding a whole range of aircraft helicopters and jet trainers. Besides, the com
pany manufactures aircraft components, overhauls fighter planes and trains futur
e pilot¶s .its success in the design and development of light combat aircraft Teja
s and advanced light helicopter Dhruv has won admiration. HAL is the backbone of
India¶s air defense and continues to occupy the strategic importance reflecting a
new pace of growth. Today the faster growing sector is the aviation sector & is
likely to be a boon for the entire job market. It deals with the manufacture, d
esign & development of aircrafts. The project is based on the instruments that a
re used in the manufacture of the various aircrafts. A deep knowledge of these i
nstruments is crucial in the perfect design & manufacture of the aircrafts. The
project will benefit those who have interest in the instrument & will provide th
e reader with the deeper knowledge of the topic.
Reference
Magazines of HAL
Manuals of departments:
LAB MANUAL 1: - ADVANCED LIGHT HELICOPTER. LAB MANUAL 2: - DC MASTER BOX [WORKIN
G]. LAB MANUAL 3: - AC MASTER BOX [WORKING]. LAB MANUAL 4: - ACPU [WORKING]. LAB
MANUAL 5: - FTU [WORKING].
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2011

HAL Hindustan Aeronautics Limited

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