MADE by

Avinash Kumar Singh

Sameer Kr Gautam
Tarun Kumar
ABOUT HAL



Type
State-owned
enterprise
Industry
Aerospace and
defence
Founded
1940 (in 1964,
company took on
current name)
Headquarters
Bangalore,
Karnataka, India
Chairman Ashok Nayar
Products
Aerospace
equipment
Military aircraft
Communication &
Navigation
equipment
Space systems
Revenue
US$2.35 billion (FY
2007)
Employees 30,000
HISTORY OF HAL
> Hindustan Aeronautics Limited (HAL) came
into existence on 1st October 1964. The
Company was formed by the merger of
Hindustan Aircraft Limited with Aeronautics
India Limited and Aircraft Manufacturing Depot,
Kanpur
Late Mr. Seth Walchand Hirachand set up
Hindustan Aircraft Limited at Bangalore in
association with the erstwhile princely State
of Mysore in December 1940
The Government of India became a
shareholder in March 1941 and took over the
Management in 1942.
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HAL- PRESENT SCENARIO
MISSION OF HAL
To become a global player in the aerospace
industry

> Hindustan Aeronautics Limited is the largest
PSU under the Department of Defense Production
and is a Navaratana Company.
> Presently ranked 34
th
among the global defense companies
>HAL is one of the largest aerospace companies in Asia with
its annual turnover to be running above US$ 2 billion.
> It has several facilities throughout India including
Nasik, Korwa, Kanpur, Koraput, Lucknow, Bangalore
and Hyderabad.
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SERVICES OF HAL
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ACCESSORIES DIVISION
HAL LUCKNOW
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HAL LUCKNOW
Established in 1970 with the primary objective of
manufacturing systems and accessories for various
aircraft and engines and attain self sufficiency in this
area
Presently turning out over 1100 different types of
accessories
Started with manufacturing various Systems and
Accessories-Hydraulics, Engine Fuel System, Air-
conditioning and Pressurization, Gyro & Barometric
Instruments, Electrical System items,
Undercarriages, Electronic items all under one roof to
meet the requirements of the aircraft, helicopters and
engines being produced by HAL
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PRODUCTS OF HAL LUCKNOW
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 units, AC/DC Electrical
system, Actuators.
Land navigation systems
Microprocessor controller
Under carriage, wheels and breaks
Hydraulic system and power control
Pumps, Accumulators, Actuators, Electro-Selectors, Bootstrap Reservoirs
and various types.
Environmental control system
Pneumatics and oxygen system, cold air unit, water Extractors, valves.
Ejection system-Ejection Seats, Release Units
Engine fuel control systems
Booster pumps, main and Reheat Fuel systems, Nozzle Actuators

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BASIC AERODYNAMIC FLIGHT
THEORY
AERODYNAMICS-
The word comes from two Greek words:
>Aerios = concerning the air.
>Dynamis = meaning powerful
Aerodynamics is the study of objects in
motion through the air and the forces
that produce or change such motion
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BASIC FLIGHT THEORY
FOUR BASIC FOURCES IN FLIGHT-
Lift- The upward force
Thrust- The forward force
Weight/Gravity- Gravity the
Downward force
Drag- The rearward force
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The Four Forces of Flight
The four forces act on the airplane in flight and also
work against each other.
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THE FOUR FOURCES
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WHAT IS WEIGHT ???
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Weight counteracts lift.
The earths gravity pulls down on
objects and gives them weight.
Newtons 1
st
Law Applies
WHAT IS DRAG ???
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WHAT IS LIFT ???
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HOW LIFT IS GENERATED???
Newtons Laws of Motion and Bernoullis
Principle are used to explain lift.
Bernoulli Bernoullis Principle states
that, as air speeds up, its pressure goes
down.
He focused his studies on the curvature of
the wing, and the differing air pressure
over the top and bottom of the wing.
Newton Newtons Third Law states
that for every action there is an equal
and opposite reaction.
He focused his studies on the deflection of
air or fluid on an object and its reaction.
(Newtons 3
rd
Law)
To explain the lift phenomena we have to
understand the meaning of Aerofoil
structure

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AEROFOIL
An Aerofoil is a device that gets a
reaction from air moving over its
surface. When it is moved through the
air it produces lift. Wings, horizontal
and vertical tail surfaces and propellers
are all examples of aerofoil
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EQUATION INVOLVED IN FLIGHT
THEORY
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WHAT IS THRUST ???
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SIMPLIFIED AIRCRAFT MOTION
BALANCED FORCES
In order for an airplane to
fly straight and level, the
following relationships must
be true:


Thrust = Drag
Lift = Weight
This is called
Straight and
Level Flight
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SIMPLIFIED AIRCRAFT MOTION
UNBALANCED FORCES
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AXES OF MOVEMENT OF ANY
AIRCRAFT
Axis of Roll
(Longitudinal Axis)
Axis of Pitch
(Lateral Axis)
Axis of Yaw
(Vertical Axis)
Axis of Rotation:-
Intersect at the centre
of gravity The axes of
movement of any
aircraft are basically
imaginary lines about
which the aircraft may
rotate about while
flying
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EXPLANATION OF ALL AXES
The Longitudinal Axis-
This is an imaginary line running length wise
through the micro-light from bow to stern.
Movement around this axis is called rolling.
The Vertical Axis-
This is a line through the centre of gravity going
downwards and at right angles to the longitudinal
axis. Movement around this axis is called yawing
The Lateral Axis-
This is sometimes called the pitch axis. This is
the line through the centre of gravity and running
span wise from wing tip to wingtip and at right
angles to the longitudinal axis. Movement around
this axis is called pitching

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VARIOUS MOTIONS AROUND THE
AXES
Yawing along vertical axis
side to side motion
Pitching along lateral axis
up and down motion
(nose up and nose down)
Rolling along longitudinal
axis rolling motion
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Pitch Around the Lateral Axis

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Roll Around Longitudinal Axis

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Yaw Around the vertical Axis

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AIRFRAME UNITS
Propeller
Power-plant ( jet engine)
Cockpit
Engine cowl
Fuselage
Wings
Stabilizers-Horizontal
stabilizer and Vertical
stabilizer
Flight control surfaces-
ailerons, rudder, flaps,
spoilers, elevators, slats
Landing gear-nose
landing gear and main
landing gear
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AIRFRAME UNITS
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FUSELAGE (BODY)
The body of the
airplane that all the
other parts are
attached to.
Can be made of
many different
substances such as
aluminum or wood
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WINGS
The part of the plane
that creates lift and
controls roll.
Has a rounded
leading edge and
tapered trailing edge
which helps create
lift.
The wing design
uses Bernoullis
Principle.

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PROPELLER
Uses the principle of a
wing to create thrust to
move the airplane
forward.
Can have different
number of blades on
propeller.
Design is similar to an
airfoil

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POWERPLANT (JET ENGINE)
Turns the
propeller at high
RPMs to
increase thrust
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ENGINE COWLING
Cover to protect the
engine and make
the plane
aerodynamic
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COCKPIT
Place where the
pilot controls the
airplane.
The airplane
control, gauges,
and indicators
are held here.
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MAIN LANDING GEAR
A frame with
wheels that allow
the plane to take-
off and land.
Some airplanes
have retractable
landing gear.

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NOSE LANDING GEAR
The front landing
gear when the
plane has three
wheels to land.

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HORIZONTAL STABILIZER
Horizontal with
the fuselage.
Helps airplane
maintain level
flight
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VERTICAL STABILIZER
Vertical to the
horizontal
stabilizer.
Helps to airplane
maintain level
flight
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FLIGHT CONTROL SURFACES
AILERONS
ELEVATORS
RUDDER
FLAPS
SPOILERS
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AILERONS
AILERON- The ailerons form
a part of the wing and are
located in the trailing edge of
the wing towards the tips.
The control stick is
connected by means of wires
or hydraulics to the wings
ailerons. By turning the stick,
the pilot can change the
positions of the ailerons
Located at the top of the
trailing edge of the wings.
Controls rolling.
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ELEVATORS
Elevators are the
movable control surfaces
hinged to the trailing edge
of the horizontal
stabilizer. The control
stick is connected by
means of wires or
hydraulics to the tail
sections elevators.
In line with and behind the
horizontal stabilizer.
Controls pitching.

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The rudder is a moveable
control surface attached to the
trailing edge of the vertical
stabilizer. The foot pedals are
connected by means of wires or
hydraulics to the rudder of the
tail section. The rudder can also
be used in controlling a bank or
turn in flight.
Provides side to side control of
airplane.
Controls yawing.

RUDDER
Located near at the
trailing edge of the wing
near the fuselage.
Change the shape of wing
Increase Lift and Drag
Used on takeoff and
landing
The Flaps increase lift
FLAPS
SPOILERS
Spoilers are located in
the outer third of each
wing. When deployed
a spoiler kills the lift
over that portion of the
wing while the other
wing retains full lift and
induces roll.
They basically do the
job of spoiling the lift.
Hence can be
supposed as a braking
system for any aircraft
HAL ACCESSORIES DIVISION
LUCKNOW
INSTRUMENT FACTORY

CLEAN ROOMS
ASSEMBLY AND TEST SHOP 2 & 3
ELECTRO -ROTATING MACHINE
SHOP

CLEAN ROOM
In Clean room those
subunits are assembled
and tested that are
sensitive to dust,
temperature and humidity.
All these parameters
are kept under
control because these
can have an adverse effect
on their functional
efficiency.
The required
specification for the
instruments assembled
and tested are different


ASSEMBLY AND TEST SHOP 2 AND 3

The major products of H.A.L. are fighter aircrafts.
An aircraft comprises of many smaller units or
accessories, which play significant role in their
successful flight .
Any fault, may lead to a catastrophic end. Here
comes the role of assembly and test unit .it
forms an integral part of any manufacturing unit.
The main instruments are KCN-2
compass system, flight data recorder, gyro-
magnetic compass, fuel gauging system,
radio magnetic indicator, DNDU (day and night
dimmer unit), GPPU (ground power protection
unit).
ELECTRO-MAGNETIC ROTATING SHOP

In the E.R.M department of the instrument
factory the assembly and testing is done of
the dc Starter Generators, AC Generator
system, constant speed alternator, regulators,
inverter of the Russian and French origin.

These products are basically those products
which take the principle of the
electromagnetic rotating which can
be elaborated as follows i.e., electrical energy
is converted into mechanical energy or vice
versa. These products are of mig-21 & mig-27
aircrafts which are of Russian origin and
jaguar aircraft of France origin.

INSTRUMENT SYSTEMS OF AN
AIRCRAFT

Instrument Systems:-
Just as in a car, there are instruments that monitor the
engine, and instruments that monitor the drive. So in
aircraft too there are certain instruments that monitor the
flight. The groups of instrument systems are mainly-

FUEL SENSING/ GUAGING PROBES SYSTEM
FLIGHT INSTRUMENTS
PITOT-STATIC INSTRUMENTS
GYROSCOPIC INSTRUMENTS
AIRCRAFT ELECTRICAL SYSTEMS
FUEL CONTENT GUAGING SYSTEM
The function of F.C.G is based upon the
principle that the capacitance of two
concentric tubes (cylindrical in shape) is
different when there is air in between and
when there is aviation fuel present in
between them, it acts as a dielectric in
between the gap.
The capacitance increase or decrease as
the level of fuel changes in the gap. This
change in capacitance is measured by
meter.
This system is also known as Fuel low
level warning sensors system as it gives
emergency signal on lowering of fuel
level within the tank
FLIGHT INSTRUMENTS
These instruments basically help in controlling and
monitoring the flight parameters.
PITOT-STATIC INSTRUMENTS-
Pitot-static instruments are those that basically work on the
principle of Pitot and static pressure.
STATIC PRESSURE-Static pressure is the pressure that is
simply the aircrafts surrounding pressure.
PITOT PRESSURE- Pitot pressure is the pressure that
comes into scenario when aircraft flies and goes forward. It
is generally the front pressure that acts against the body of
the aircraft.
The three basic Pitot-Static instruments mainly assembled in
the instrument panel of a cockpit are-
Airspeed Indicator, Altimeter and Vertical Speed Indicator
PITOT-STATIC SYSTEM
Airspeed Indicator (ASI)
Static and Pitot pressure principle based source
Also known as Mach meter
Measure the difference between static pressure and static
pressure (impact pressure)
Shows speed through air (not over ground)
Shows Indicated Airspeed (IAS) in Knots or Miles Per Hour
(MPH, older system)
Aneroid capsule connected to pitot pressure. Case
connected to static pressure. Aneroid capsule inflates with
more airspeed, moving dial clockwise. Static pressure in
case corrects for altitude.
Pitot pressure pushes against a diaphragm inside the
airspeed indicator, which will then be able to expand or
contract accordingly. This linear movement of the diaphragm
is then translated into needle movement.
ASI
ASI WORKING
CONCEPT OF
DIAPHRAGM AND CAPSULE
DIAPHRAGM-Two capsule units together
make one diaphragm.
CAPSULE-It is the heart of the large no
of instrument for aircraft .It simply
consists of two diaphragm of beryllium
and copper material for
better handling capability. We first cut the
two pieces of
circular shape from the sheet and then
make them as like bowl
shape and then joint both the capsules
and thus diaphragm is
generated.

Airspeed Markings
Green Arc
Normal Range (Lower limit = Vs)
Yellow Arc
Caution Range (Lower limit = Vno)
Red Line
Never Exceed Speed (Vne)
White Arc
Flaps Range (Lower limit = Vfe)
Altimeter

ALTIMETER
Shows height in feet
Measures pressure of outside air (drops with
altitude)
Aneroid capsules (like balloons) inside are
set to standard pressure. As altitude
changes, capsules expand and contract,
moving needle on dial.
Static pressure is taken as only input
Manufacturer seals the aneroid wafer(s) at a
specific pressure. As the static pressure fills
in the area around these sealed wafers, they
will be able to contract or expand
accordingly.
As the aircraft moves into lower pressure a
climb is indicated
As the aircraft moves into higher pressure a
descent is indicated

Altimeter Operation
Air moves out
Air moves in
Wafers expand
0
1
2
3
4
5
9
8
7
6
Wafers contract
0
1
2
3
4
5
9
8
7
6
0
1
2
3
4
5
9
8
7
6
Air moves out
Air moves in
Wafers expand
0
1
2
3
4
5
9
8
7
6
Wafers contract
0
1
2
3
4
5
9
8
7
6
0
1
2
3
4
5
9
8
7
6
Vertical Speed Indicator
Indicates speed up or
down (rate of
climb/descent) in feet per
minute (FPM)
Static pressure enters
aneroid capsule and case. But
pressure in case delayed.
Capsule registers difference in
pressure (as descent or climb)
on dial.
What does a VSI show?
Climbs
Descents
Level Flight
GYROSCOPIC INSTRUMENTS
GYROSCOPE-
A Gyroscope is an
accurately balanced
flywheel having a mass and
freedom of in one or more
axis which crossed on a
point at right angle to each
other and having the
property of RIGIDITY &
PRESSION


RIGIDITY- It is the ability of a gyroscope
to resist any freedom with tends to
change the direction of spin axis
Rigidity depends upon-
Speed of gyro(in RPM)
Mass of the gyro(rotor)
The radius of gyro
rotor/motor.
PRECESSION-It is the angular change
in the direction of plane of the spin of the
rotor resulting from the application of
external torque. The ratio of precession
depends upon-
The magnitude of applying
torque.
Rotor speed which is directly
proportional to the applied
torque
and inversely proportional
to the rotor speed.

ALTITUDE INDICATOR
Only instrument that gives
immediate and direct
indication of the airplanes
pitch and bank attitude.

Gives the rolling and
pitching information.

Also known as the Artificial
horizon/ Vertical gyro/ Gyro
horizon.

HEADING INDICATOR
Also known as the
Directional Gyro (DG)

Displays magnetic heading
without magnetic compass
errors.

Senses rotation about the
aircrafts vertical axis.
Gives the yawing
information.

TURN CO-ORDINATOR (RATE GYRO)
Rate and Rolling
information is achieved
by this.

Slip and Skid
parameters are
determined

INSTRUMENT PANEL
ALTERNATOR CONTROL AND
PROTECTION UNIT (A.C.P.U)
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 frequency, over load
& feeder fault conditions.
Under these faulty conditions, the unit disconnects
the alternator from AC electrical system by de
energizing the contractor & field.

A.C MASTER BOX
Excluding the two alternators and protection unit and static inverter,
primary AC distribution system consists of following boxes:
AC Master Box 1
AC Master Box 2
115 V AC Emergency Bus Relay
26 V AC Emergency Bus Relay
During normal operation (both alternator running), complete system 1
is powered from alternator
1.In case of fault on alternator 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 disconnected
from alternator 2. In case of both alternator fails to supply power to
AC main buses, emergency
buses of system 1 are powered from static inverter.
In the Aircrafts, 2 AC MASTER BOX are present, if one of them gets fail
then other works.

D.C MASTER BOX
DC Master Box is a part of dc power generation and
distribution system for re-engine Cheetah Helicopter.
It is designed for use with an independent
starter/generator mounted on the engine accessories
gearbox, and is interfaced with GCPU, battery, 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 single battery (Ni-Cd 40
Ah) will get connected to the main bus & supply
power to the emergency loads
FILTER TRANSFORMER UNIT
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 no. of
FTUs 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).

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 building a whole range of aircraft helicopters and jet
trainers. Besides, the company manufactures aircraft components,
overhauls fighter planes and trains future pilots .its success in the design
and development of light combat aircraft Tejas and advanced light
helicopter Dhruv has won admiration. HAL is the backbone of Indias 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, design &
development of aircrafts.

The project is based on the instruments that are used in the manufacture of
the various aircrafts. A deep knowledge of these instruments is crucial in
the perfect design & manufacture of the aircrafts. The project will benefit
those who have interest in the instrument & will provide the reader with the
deeper knowledge of the topic.

FLY SAFE.!!!!!

THANK YOU
THANK YOU