“Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced...

Dr. G N DayanandaChief Scientist & Head

Centre for Societal Missions & Special TechnologiesChairman, Societal Cluster

CSIR-National Aerospace Laboratories, Bengaluru-560017

“Polymer Composites for SocietalApplications”

School on Mechanics of Reinforced Polymer CompositesKnowledge Incubation for TEQIP, IIT-K, Jan. 22-25, 2017

Outline

• Societal Missions @ NAL

• HANSA

• Renewables - focus on wind

• Radomes

• Autoclaves

• Micro Air Vehicles

Contents are the Property of National Aerospace Laboratories, Bangalore

HANSASARAS

C-NM5LCA Tejas

Participation of CSIR-NAL inAircraft Programmes NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

CSIR NAL’s Aircrafts

Slybird

Hansa CNM – 5

Black KiteLCAContents are the Property of National Aerospace Laboratories, Bangalore

Societal Missions @ NAL

Contents are the Property of National Aerospace Laboratories, Bangalore

Centre for Societal Missions & SpecialTechnologies – Primarily Composites Research

Airborne Radomes Wind Turbine Ground Based Radomes

Autoclaves UAVs / MAVsImpregnation Machine

Contents are the Property of National Aerospace Laboratories, Bangalore

0°

90°

+45°

-45°

+45°

-45°

90°

0°

±45°

0°/90°

±45°

0°/90°

0°/90°

±45°

±45°

0°/90°

Symmetric & Balanced Composite laminates

Quasi-isotropic Laminateusing Uni-directionalLaminae

Quasi-isotropic Laminate usingBi-directional woven Laminae

Contents are the Property of National Aerospace Laboratories, Bangalore

Continuous Fibre Reinforced laminated Composites

Contents are the Property of National Aerospace Laboratories, Bangalore

Sandwich Composite Constructions

Foam Core Sandwich Honeycomb Core Sandwich

Face Sheet / Skin

CoreAdhesive Bond

Contents are the Property of National Aerospace Laboratories, Bangalore

Short Fibre

Discontinuous Reinforcements in Composites

Particulate

Contents are the Property of National Aerospace Laboratories, Bangalore

Hansa-3 Aircraft Program

Contents are the Property of National Aerospace Laboratories, Bangalore

Materials :• Epoxy Resin Systems• PVC Foam Cores• Glass Fabrics• Carbon Tapes

Processes :• RT Vacuum Bag Moulding• Carbon Tape Impregnation• Post Curing• Thermoforming• Adhesive Bonding

Material Characterisation :• Mechanical• Thermal• Hygrothermal• Design Data Generation

• NDT• Static Testing• Analysis• Flight Testing

QUALIFICATION/ CERTIFICATION

(JAR-VLA , AUW < 750Kgs.)

All Composite Aircraft - HANSA

Contents are the Property of National Aerospace Laboratories, Bangalore

LCRA (Feb. ‘87) HANSA-2 (Nov. ‘93)

HANSA-3 Proto-I (Nov. ‘96) HANSA-3 Proto-II (May ‘98)

LCRA to HANSA-3

Contents are the Property of National Aerospace Laboratories, Bangalore

First effort was to “WET” hands in building and flying aircraft LCRA built from plans and raw materials procured from USA First flight : February 1987 First hand experience with foam – fiber glass construction Flown for 259 hours Flying as UAV at ADE

Light Canard Research Aircraft (LCRA)

Contents are the Property of National Aerospace Laboratories, Bangalore

Set up Flight Experiments Division 11 June, 1988 to manage HANSA project Participation of many scientific divisions of NAL First flight of HANSA-2 : 23 November, 1993 LCRA technology was adopted Re-engined with a higher power engine - HANSA-2RE AUW was 868 kg 116 hours of flying Improvements required in fuselage shape & performance – HANSA - 3

Hansa-2

Contents are the Property of National Aerospace Laboratories, Bangalore

First flight of HANSA-3 prototype-1 : 25 November, 1996 Improved fuselage shape Airframe with sandwich construction technology Continental Engine with 125 HP AUW was 800 kg Improvement required in weight reduction - HANSA – 3 PT-2

Hansa-3 PT-1

Contents are the Property of National Aerospace Laboratories, Bangalore

First flight of HANSA-3 prototype-2 : May, 1998AUW achieved 750 kgRotax Engine with 100 HPAircraft was certified by DGCA on 1st Feb’2000Certified under JAR-VLA via FAR23 CategoryDay / Night VFR operations

Hansa-3 PT-2

Contents are the Property of National Aerospace Laboratories, Bangalore

Fibre glass composite structureRotax 914 F3 turbo-charged engine

100 BHP continuous115 BHP max.

Constant speed propeller

Certified under JAR-VLA forday / night VFR operationsLightning protected

PerformanceStall speed with flaps : 48 KIASMax. cruise speed : 115 KTASMax R/C : 650 ft / min.Endurance : 4 hTake-off distance : 450 mLanding distance : 600 m

Specifications of Hansa-3

Contents are the Property of National Aerospace Laboratories, Bangalore

Side by side seating, neat cockpit,very good visibility

Conventional instruments &modern Nav-Com units

Dual flight controls with excellentcontrol harmony

Turbo-charged engine withconstant speed propeller

COCKPIT

Rotax 914 F3 engine

Features of Hansa-3

Contents are the Property of National Aerospace Laboratories, Bangalore

Extensively tested and documented (for its class)

Fuselage test rig

Engine mount test rig

Wing test rig

Features of Hansa-3 Continued..

Contents are the Property of National Aerospace Laboratories, Bangalore

Innovative vacuum bag moldingtechnique process for fabricationof airframe

Maintenance and repair of glassfiber composite structure

Design of composite aircraftstructures & integration of smallaircraft

Lightning protection scheme

Structural testing of components

Type certification for civil use

Technologies Developed

Contents are the Property of National Aerospace Laboratories, Bangalore

Hansa-3 Fabrication in a Nut ShellNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Renewables - focus on wind

Contents are the Property of National Aerospace Laboratories, Bangalore

Present

Antarctica Past

Recent Past

300 kWWTS

500 kWWTS

Kethanur,TNKethanur

Kanyakumari, TN

WindResource

Assessment

A Legacy in Renewable Energy

Kethanur, TN

Contents are the Property of National Aerospace Laboratories, Bangalore

The Trade Winds:

Steady northeast/southwest

winds between equator and

horse latitudes.

EQUATOR

30°N

60°N

30°S

60°S

Some weather(wind) characteristics of atmosphere

Wind Patterns differfrom one continentto the other.

Vast differences :American/European toIndian sub-continent.

WITHOUTCORIOLIS EFFECT

WITHCORIOLIS EFFECT

Easterlies

Westerlies

NortheastTrades

SoutheastTrades

Doldrums

Westerlies

Easterlies

Contents are the Property of National Aerospace Laboratories, Bangalore

Major Surface weather characteristicsP Cell

F Cell

H Cell

L L L L L

H H H H

H H H H

H

H

EquatorITC

Trade Winds

Subtropical HighPressure Belt

Prevailing WesterliesPolar Front

Polar Westerlies

Contents are the Property of National Aerospace Laboratories, Bangalore

Small Wind Solar Hybrids at

Center for Societal Missions & SpecialTechnologies- CSMST

National Aerospace Lab, Bengaluru

Wind-Solar Hybrid (WiSH) System PT1

Targeted for low wind regimes in tropics

28

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

29

NALCSIR

Wind-Solar Hybrid (WiSH) System PT2

Contents are the Property of National Aerospace Laboratories, Bangalore

Composites

RenewableEnergy

Controls

Aerodynamics

Indigenous Wind Turbine Rotor

Contents are the Property of National Aerospace Laboratories, Bangalore

500 kW2

3

1

421 VC

PD

overallP

50 kW

5 kW

Roto

r Dia

met

er, m

NAL’s Small Wind turbine Rotor Systems

NAL’s Effort

0.5 kW

North America& Europe

Design Wind Speed ~ 2 X Annual Average Wind Speeds(Source : Large Wind Turbines, Eric Hau)

10000

1000

100

10

1

0.1 0 2 4 6 8 10 12 14 16Design Wind Speed, m/s

Contents are the Property of National Aerospace Laboratories, Bangalore

Fundamental Equation of Wind PowerWind Power depends on air:• Volume• Velocity• Density

Kinetic Energy definition:• KE = ½ * m * v2

Power is KE per unit time:• P = ½ * m. * v2

Mass flow rate• dm/dt = A * v

• Power ~ cube of velocity• Power ~ air density• Power ~ rotor swept area A = r2

• P = ½ * A * v3

m = dm/dt mass flux

V

A

Contents are the Property of National Aerospace Laboratories, Bangalore

Design Methodology for NALWIN

Aerodynamic analysisby GH-Bladed

Wind TurbineConfiguration, Airfoil

selection, AerodynamicDesign for operating

conditions

Load Matchingusing different

methods

TowTesting

FieldTesting

Systemperformance

studies

Fabrication and off-line structural testing

Quantification ofMass & stiffness

properties of blades

Structuralanalysis using

NASTRAN for thestress & stiffness

based design

Aeroelastic analysisusing GH – Bladed

NALWIN

Contents are the Property of National Aerospace Laboratories, Bangalore

Aerodynamic Design & Analysis

Twist Distribution

Analysis by GH-Bladed CAD Model of the blade

Chord Distribution

Twist

Chor

d

Radius RadiusContents are the Property of National Aerospace Laboratories, Bangalore

Structural Design and Analysis

CFRP Structural Design and Analysis of the blade using Hypermesh –NASTRAN

Moulds

FE Model

Blade c/s and composite layupscheme

Blade Fabrication Scheme

Stress Distribution

Contents are the Property of National Aerospace Laboratories, Bangalore

Composite Blade ManufacturingTechnology

Tooling Development• NC machined Master

• Carbon composite (CFRP) Blade fabrication• Novel light weight coreless carbon composite blade

•Room temp. vacuum bag moulding process• Weight of the blade ~950 gms

• Split composite mould

Contents are the Property of National Aerospace Laboratories, Bangalore

Static Deflection Testing of Blade& Dynamic Balancing of Rotor

Dynamic Balancing of RotorStatic Deflection Testing of BladeContents are the Property of National Aerospace Laboratories, Bangalore

Tow Testing at HAL Airport, Bengaluru

Simulate

Wind speeds

up to 20 m/s

Contents are the Property of National Aerospace Laboratories, Bangalore

Tow-Testing of Wind Turbine

Contents are the Property of National Aerospace Laboratories, Bangalore

Unique features of NALWIN

Indigenously developed rotor blade system

Furling for overspeed protection.

Eco-friendlier composite CFRP rotor blade system

Suitable for Indian low wind speed regimes.

Contents are the Property of National Aerospace Laboratories, Bangalore

Development of 1 kW Wind SolarHybrid (WiSH) system

Contents are the Property of National Aerospace Laboratories, Bangalore

System Configuration

InverterBatteriesDump Load

AC Load

Solarcharge

controller

WindTurbine

controller

NALWIN Solar PVPanels

CSIR-NAL

CSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

WiSH System Specification

Type : Horizontal AxisNo. of blades : 3 Nos. / 4 Nos.Blade material : CFRPRated Power : ~ 1000W @ 12 m/sOperating wind speed : 3 – 18 m/sRotor diameter : 2.05 mDirectional control : Tail vaneOverspeed protection : Furling & Dump loadGenerator : Multi-pole Permanent

MagnetDrive train : Direct driveTower : Guyed tilt down typeTower height : > 20m (site specific)

Integrated with 500 W Solar PV Panels

Contents are the Property of National Aerospace Laboratories, Bangalore

As a Roof Top Application

Wind Turbine

Solar PV Panel

Contents are the Property of National Aerospace Laboratories, Bangalore

Field trials of Wind Solar Hybrid systems atRenewable Energy Park , NAL

Wind Turbine

Solar Panel

Wind Turbine

Solar Panel

Smart Structures BuildingCSIR-NAL

Field trials at NAL Campus, Kodihalli,Bengaluru

Contents are the Property of National Aerospace Laboratories, Bangalore

Press Release on WiSH System

The New Indian Express,May 16, 2014

The Hindu, May 24, 2014

46

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

NAL-Win @Jyoti Nivas CollegeKoramangala Bengaluru

Wind Turbine :- 900 WDate of Installation :- 26-05-2016

Contents are the Property of National Aerospace Laboratories, Bangalore

NAL-Win @ Vivekananda Institute of TechnologyKumbalagudu- Bengaluru

Wind Turbine :- 900 WSolar :- 500 WDate of Installation :- 17-09-2016

Contents are the Property of National Aerospace Laboratories, Bangalore

Networking with Private Players

AerodynamicDesign

MechanicalDesign

CompositeProcess Electrical &

Electronics

Battery(COTS)

Wind Turbine Rotor

Charge Controllercum Inverter

Outdoor Kiosk

Solar PV Panels

JMJ SwitchGears

ARES

49

NAL

Contents are the Property of National Aerospace Laboratories, Bangalore

Summary Solar/Wind energy programs should not be pursued

in isolation or indiscriminately.

A holistic approach to energy needs taking intoaccount all available regional resources is the need ofthe hour.

Integration of renewable energy to grid is a challengeand must be properly addressed.

Storage of energy is an area that needs to bedeveloped.

Promoting indigenous technology and associatedeco-system is the key to growth.

Contents are the Property of National Aerospace Laboratories, Bangalore

Renewable Energy Initiative for EducationalInstitutions

A 1 kW class NALWIN wind turbine system is installed at Jyothi NivasCollege, Kormangala, Bengaluru. Another 1 kW class WiSH system is installed at Vivekanada Institute ofTechnology, Bengaluru. 4 Nos. of WiSH system are under installation at CSIR-IMMT,Bhubaneswar under the CSIR 800 Banner Program.

NALWIN Wind Turbine atJyothi Nivas College

NALCSIRWiSH System at

VKIT

Contents are the Property of National Aerospace Laboratories, Bangalore

South West Monsoon Winds

Contents are the Property of National Aerospace Laboratories, Bangalore

Largest IndigenousWind Turbine

300 kW Wind Turbine(2004)

100 W Savonius WindTurbine, Antarctica (2000)Water Pumper

WP – 2 WindTurbine (1959 – 64)

Sail Wind Mill(1975)

300 W 3- bladedaero-generator (1993)

2 kW 3- bladedSAMIRA Wind

turbine (1987-89)

A legacy ofexperience inR&D of WindTurbines since

1959

500 kW WindTurbine (2008)

History of NAL’s wind turbine activity

Contents are the Property of National Aerospace Laboratories, Bangalore

55

Wind ResourceAssessment

500 kWWTS

600 +400 WWindSolar

HybridSystem

Wind Turbine Development

300 kWWTS

Wind Solar HybridSystem

CSIR-NAL's mission – To translate aerospacetechnologies for societal applications

Contents are the Property of National Aerospace Laboratories, Bangalore

Portable wind batterycharger-Sankalp – remote field

Antarctica- 36 W. 56

CSIR-NAL’s Wind Energy Activities at Antarctica

• Exploitation of wind energy• Power supply to the communication

repeater station & for remote fieldexperiments

NAL’s Savonious Wind battery charger atVittaiah peak, Maitri, Antarctica – 75 W

Contents are the Property of National Aerospace Laboratories, Bangalore

Radomes

Contents are the Property of National Aerospace Laboratories, Bangalore

Airborne Radomes

Jaguar Nose Radomes (11 Nos.) for HAL/Indian Air Force (IAF)

Material system: E-glass BD fabric & elevated temp. epoxy matrix

Manufacturing Technology: Contoured fabric preforms & closedmould

pressure assisted Resin InjectionTechnology

(RTM)

Current Status: Transfer of Technology (ToT) to HAL completed formanufacture of 60-70 Nos. of radomes

JAGUAR Nose RadomeNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Material : Composite(E-GlassFabric & HighTemp. EpoxyResin)

Shape : StreamlinedType : MonolithicLength : 965.50 mmBase dia.(OD): 522.61 mmWeight : 13.5 kgs.

Jaguar Radome SpecificationsNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Conical Preforms for Air-Borne Radomes(Contour varying in 3-Dimensions)

Fighter AircraftJacquard wovenconical seamless

preform(Varying contourfrom base to tip)

Contents are the Property of National Aerospace Laboratories, Bangalore

Static Load Test Vibration Test

Lightning Test

Testing of Jaguar Radome

EM Test

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Material system: E-glass BD fabric & RT epoxy matrixManufacturing Technology: Honeycomb core sandwichconstruction with RT vacuum bag moulding technologyWeight : 3.5 Kgs.End use: CSIR-NAL’s SARAS prototype

Nose Radome for CSIR-NAL built 14 seater civilian aircraft

SARAS Nose RadomeNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

• Composite components made from prepregs and Autoclave moulding• Over 30% composite in Air Frame• Use of UD carbon Prepregs

Reinforcements in SARAS AircraftNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Total Direction Finder Radome for TU-142M Aircraft

Total Direction Finder Radome - TU142Aircraft

Material system: Quartz BD fabric & high temp. epoxy matrixManufacturing Technology: Contoured fabric preforms and closedmould pressure assisted resin injection technology (RTM)Weight : 95 gms.Supplied : 16 nos.End use: DRDO/ IAF

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Ground based RadomesPrinciple of construction is based on Platonic Solids

TruncatedIcosahedron

Dodecahedron

Soccer Ball

DWR

X-Band

(GoldbergPolyhedron)

12 Pentagons+ 20 Hexagons

12 Pentagons

NALCSIREuler char. formula for Polyhedra = V(60) - E (90) + F(32) = 2

Euler char. formula for Polyhedra = V(20) - E (30) + F(12) = 2

Contents are the Property of National Aerospace Laboratories, Bangalore

Trial Assembly At BEL,Bangalore

66 Panels, 3700 fasteners

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Mark-I (146 panels)

Material system: E-glass BD fabric and RT cured epoxy matrix

Manufacturing Technology: PU Foam core sandwich construction with RTVBM

End use: Indian Meteorological Department (IMD) /ISRO

Current Status: ToT to BEL completed for manufacture of 30 Nos. of radomes

Installed at Bhuj, Gujarat

Mark-II (66 panels)NALCSIR

13 m Dia DWR Mark-II Radome

Installed at Satish Dhawan SpaceCentre, SHAR – ISRO, Sriharikota

Contents are the Property of National Aerospace Laboratories, Bangalore

Mark-I (146 panels)

Material system: E-glass BD fabric and RT cured epoxy matrix

Manufacturing Technology: PU Foam core sandwich construction with RTVBM

End use: Indian Meteorological Department (IMD) /ISRO

Current Status: ToT to BEL completed for manufacture of 30 Nos. of radomes

Installed at Bhuj, Gujarat

Mark-II (66 panels)NALCSIR

13 m Dia DWR Mark-II Radome

Installed at Satish Dhawan SpaceCentre, SHAR – ISRO, Sriharikota

Contents are the Property of National Aerospace Laboratories, Bangalore

1. BEL, Bangalore 2. Bhuj, Gujarat 3. Cherrapunji, Meghalaya, NE

4. SHAR, Sriharikota 5. Odisha 6. Port Blair

6

13 m Dia DWR Mark-II RadomeNALCSIR

SPECIFICATIONS

1. Dia. : ~13 m

2. Surface Area : 514 m2

3. Operating frequency : 2.7 - 2.9 GHz

4. Design wind speed :250 – 300 kmph5. Construction : Sandwich Composite

Panel1

5

Installed

2

To be Installed

4

6

Contents are the Property of National Aerospace Laboratories, Bangalore

13m Doppler Weather Radome TOTto BEL, Navi Mumbai

• Hands on training to BEL team onprocessing of composite panels atNAL

.• Shipped all tooling, moulds, fixtures.

• Assisted in setting up facility &initial trial runs.

Inauguration of the facilityon 1st Nov. 2013

CherrapunjiNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Material system: E-glass BD fabric and RT cured epoxy matrix

Fabrication Methodology: PU Foam core sandwich construction with RTVacuum bag moulding technology

Total Number of Panels: 11 nos.

Installation location: NARL, Tirupati.

4.2 m dia X-Band RadomeNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Customised Narrow width fabric in Radome panels

4.2 m Diameter X- Band Radome

Housings for WeatherRadars

Radome Panel

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Autoclaves

Contents are the Property of National Aerospace Laboratories, Bangalore

Cooking anAircraft Airframe? NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

CSIR-NAL embarked on the development of autoclaves(when they were in the embargo list) in the earlyeighties to meet the requirements of indigenization ofmilitary and civil aircraft programs.

• First indigenous autoclave commissioned in 1986

• First state of the art computer controlled indigenousautoclave commissioned in 1994

• Largest aerospace autoclave in the countrycommissioned in 2009

Aerospace Autoclave Dev. Initiation at NALNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

CSIR-NAL embarked on the development of autoclaves(when they were in the embargo list) in the earlyeighties to meet the requirements of indigenization ofmilitary and civil aircraft programs.

• First indigenous autoclave commissioned in 1986

• First state of the art computer controlled indigenousautoclave commissioned in 1994

• Largest aerospace autoclave in the countrycommissioned in 2009

Aerospace Autoclave Dev. Initiation at NALNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

• High-performance, advanced prepreg polymericcomposite aircraft structural components

• Large and complex shapes that meet thestringent weight and quality requirements

• Obtaining high degree of reliability and consistencyin composite products

Investments in autoclaves are considered to bestrategically important in the aerospace industry

Autoclave Processing/ Manufacture for:

The challenge is to develop robust, ruggedindigenous autoclave technologies (that can safelyand reliably process prepreg based expensivepolymeric composites) with wide vendor base andsuit Indian conditions.

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Autoclave Design - Drivers

• High reliability

• Space Optimization

• Fail-Safe operation

• Safety of Charge & Personnel

• Power failure management

• Modularity

• Upgradability

• Ease of Maintenance

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Range of Autoclave Process Parametersat CSIR - NAL

Sl.No.

Parameter Range Can Cater to

1. Temperature 25 - 350°CPrimary load structuresof military and civilaircraft, Hightemperature enginerelated components,Satellite structures,Leading edges of spaceshuttles,rockets etc.,

2. Pressure 1 - 15 bar

3. Length 1- 9 m

4. Diameter 0.6 - 4.5 m

5. Volume 0.2 - 140 m3

On an average over 200 cures/year performed at NAL

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Typical Autoclave cure cycleNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

82

a = MOULD b = RELEASE AGENT APPLIED TO MOULDc = LAY UP d = BLEEDER e = BREATHERf = POROUS RELEASE FILM g = PRESSURE PADh = BAG

Typical Autoclave Molding BaggingScheme NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Industrial Grade, High Temperature and HighPressure Indigenous Autoclaves

Mark IMark II

Mark IV

Mark III Mark 0

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

N2 Gen.plant

Eco-system development- Autoclaves

PressurisedBlower motor,Asian – B’lore

ReservoirsPioneer,Meerut

CoolingPaharpur

Vacuum- Indfos

Indcon andVayutech, Delhi

Autoclave shell, H.E.- UCE,Mumbai

Heaters- Escorts,Faridabad

Control valves – L&TChennai

Electrical Control & Inst. SystemDATASOL, Bangalore

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

85

Three tier layout ofSubsystems NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Innovative Features

HeaterDistribution

•Fool Proof door safety device•Quick Lock Rotating Door•Optimized Door Handling Scheme•Variable Area Heat Exchanger•Evolved Forced Circulation System•Pressurized Blower Motor•Auto, Semi-Auto & Manual mode• Accurate temp. cont. ± 1°C• Temp. uniformity ± 2°C• Open Control Architecture• Fail Safe & Fault Tolerant

Fool proof door locksafety device

Four bar steering mech.-Optimized Door Movement

Variable AreaHeat Exchangerat rear end

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Using Visual studio that supports high levelprogramming such as OPC (Object linking and enablingfor Process Control), MODBUS driver, multi threading,socket programming & low level programminginstructions. Interface with number of process instruments (7nos)

through ‘virtual com’ ports in the computer Main and Hot standby computer architecture PLC software to cater for a novel Heater Power Steering

Logic, pressure sensitive variable speed blower, safetyrequirements, sequential and automatic starting andshutdown control, interlocks etc

In-house Software for Autoclave Cure ControlNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

6Orders completed5 Orders under execution

Enquiries from Strategic sectorEnquiries from Societal sector

MIT

VSSC

HAL,ADE,ISAC

ASL

DMRL

IITK

DMSRDEMKU

Godrej

OF

Autoclave OrdersExecuted, ongoing

&Bids submitted

IITKharagpur.

6 orders won againstInternational

Bidding

Revenue generatedby PPP

about 31 croresof rupees

RPP

IIT B

IIT Guwahati

Contents are the Property of National Aerospace Laboratories, Bangalore

3D- Model of Lab scaleAutoclave

3D- Model of Lab scaleAutoclave

900mm dia& 1000mmworking length, 210DegC,7 Barg

Contents are the Property of National Aerospace Laboratories, Bangalore

Lab Scale Autoclave for IIT Kanpur

Successfully commissioned and handed overon 25.03.14

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Lab scale autoclave for MIT, Manipal, Mangalore

Successfully commissioned andhanded over on 26.08.14

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Longest Autoclave – 3D Model4m dia., 15m length, 10 bar

Mandrel -15 Tons

Crab

Unique Mandrel rotating mechanism

Trolley

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Autoclave Shell Fabrication in progressat UCE, Mumbai

4m Dia x15 m LengthLongest Autoclave in Indian Aerospace Sector

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Longest Autoclave designed and Developed byNAL

• Optimised flange design using FEA•Unique Mandrel rotating mechanism,•Hydrotest @ 20 barg with strain monitoring

Contents are the Property of National Aerospace Laboratories, Bangalore

Upgradation of Vertical Autoclave forVSSC, Comp. Mfr. Divn., Vattiyoorkavu

Top half of autoclave shell

CONTROLPANEL

Supply and warrantycompleted on 27.04.2014

Specifications:Working Dia. : 4mWorking Height :1.5mMax. Pressure : 7 bargMax. Temp : 200º C

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Autoclave User’s Meet, 3rd Sept. 2013NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Press Coverage: On Lab scale autoclaveVijay Karnataka

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

NAL’s Microwave Hybridized Autoclave

• Working Dimensions:Ø0.8m X 1.5m lengthTemp: 425 Deg CPres : 15 Barg

• Autoclave shell designedwith multiple Microwaveports and rotating platform.

• Fabrication is in progress.

Study of EM field & temperaturedistribution for Autoclave

ambients.

Microwave ports

Rotating platform

Significant EnergySavings Likely

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Desk top Autoclave forcomposites processing

• Compact, affordableautoclave for

educational& Research Institutions

• Fits in a space of 1.5cubic metre

• Working temperature :200 Deg C

• Working pressure : 7barg

• Works on single phase ,32 A power source

Contents are the Property of National Aerospace Laboratories, Bangalore

Micro Air Vehicles

Contents are the Property of National Aerospace Laboratories, Bangalore

Lightweight MAV Airframes; How ‘light’ can itbe?

MaterialDensity(kg/m3) Weight

(grams)

Air 1.2 10Solimide® 6.3 46Rohacell® 32 245PU foam 42 322

Skin StiffenerConst. - 1600

Approx. VolumeOf 1.6 m wing spanSlybird : 0.00768m3

Building an MAVusing only airmolecules !!!

Air Molecules

Contents are the Property of National Aerospace Laboratories, Bangalore

Micro Air Vehicles @ NAL

Sl.No. MAV Wing span

class (mm)Weight(gms.)

AirframeWeight

Endurance(min.)

A. Microbeacon 150 120 15 15B. Black Kite 300 292 50 35C. Pushpak 450 730 280 45D. Suchan 1600 3600 1800 55-75

A B C D

1600

mm

From the NAL MAV Stables

Contents are the Property of National Aerospace Laboratories, Bangalore

Structural Concepts for Airframes…Contd

Black Kite Pushpak

Suchan

Contents are the Property of National Aerospace Laboratories, Bangalore

Suchan 1.6 m MAV

Wing span : 1.6mLength : 1.3mWeight : 3.6 kgs (str. wt: 1.8 kgs.)Endurance : 45-60 minutes

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Features Modular construction Light weight Materials design

Crashworthy features Snapping longerons in

fuselage By design

Mounting for electronicsCOTS items

Stiff CFRP Wing-Fuselage Interface

Fuselage Trolley

‘Suchan’ 1.6 m MAVNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Modular wing of MAV-Exploded view

CSIR-NALCSIR

• Completed more than 100 landingsContents are the Property of National Aerospace Laboratories, Bangalore

MAV - Pushpak

Wing span : 450 mmLength : 550 mmWeight : 730gms. (str. wt: 300 gms.)Endurance : 40 min

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

MAV - Micro Beacon

Wing span : 150 mmLength : 160 mmWeight : 145 gms (str. wt: 25 gms.)Endurance : ~30 min

NALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

Before droop After droop

Lateraldroop line

Inclineddroop lineLE droop (morphing) of black kite MAV

Morphing 300mm Black Kite MAVNALCSIR

Contents are the Property of National Aerospace Laboratories, Bangalore

110

Acknowledgements

1. Sri J J Jadhav, Director, CSIR – NAL

2. Director General, CSIR

3. Team CSMST @ CSIR – NAL

4. Team C-CADD

5. Team ACD

6. Dr. U N Sinha.

7. Flosolver Team, NAL

Thank You