Embed Size (px)
DESCRIPTION
ELECTRONICS DEPARTMENT SUMMER TRAINING REPORT FROM HAL LUCKNOW
Citation preview
(HAL FOUNDER)
Hindustan Aeronautics Limited has blossomed into a major player in the global aviation arena,
and today is among the elite Navratna companies. The history of Indian aircraft industry can be
traced to the foundation of Hindustan Aircraft Limited at Bangalore in December 1940 in
association with the erstwhile princely state of Mysore and late Shri Seth Walchand Hirachand,
an industrialist of extra-ordinary 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
Aeronautics India Limited and Aircraft Manufacturing Department Kanpur to form HAL on 1-
october-1964.
Today HAL has got 18 production divisions & 9 research & design centers spread out in
7 different locations in India. Its product track record consists of 12 types of aircraft from in
house R & D and 13 types by license production. 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 project like Dhruv –
Advanced Light Helicopter (ALH), Tejas-Light Combat Aircraft (LCA), Intermediate Jet Trainer
(IJT) & Summer training various military and civil upgrades. The deliveries of Dhruv were
Page | 1
affected to Indian Army, Navy, Air force & Cost Guards in March 2002, in its first year of
production which is a unique achievement. The Government of India decided to set up a factory
Lucknow Division in 1969 to undertake License manufacture of accessories an instrument for
Hindustan Fighter HF-24 and Hindustan jet trainers HJT-16, aircrafts. The factory building is
ready by October 1973 and full fledged manufacturing of the accessories to cover Ajeet,MIG-
BIS Aircrafts, aero engines and Helicopters.
HAL Accessories Division Lucknow was established in 1970 with primary objective of
manufacturing systems and accessories for varies aircrafts and engines. At present it is turning
out over 1100 different types of accessories. The division manufactures various systems viz.
Hydraulics; engine Fuel systems, Air-conditioning Pressurization, Gyro and Barometric
Instruments, Electrical system items Undercarriage, Electronic items all under one roof to meet
the requirements of the aircrafts, helicopters and engines being produced by HAL.
HAL has played a significant role for India’s space program in the manufacturing of
satellite launch vehicle like PSLV (Polar Satellite Vehicle), GSLV (Geo Stationary Launch
Vehicle), IRS (Indian Remote Satellite) & INSAT (Indian National Satellite).
HAL has joint ventures companies BAEHAL, Software Limited & Indo- Russian
Aviation Limited (IRAL),Snecma-HAL Aerospace Pvt Ltd. Apart from these, other major
diversification project & industrial marine gas turbine & airport services. Several co-production
& joint ventures with international participation are under consideration.
HAL’s supplies / services are mainly to Indian Defense services, Coast Guard & Border
Security Force. Transport Aircraft & Helicopters have also been supplied to Airlines as well as
State Government of India. The company has also achieved a foothold in export in more than 30
countries, having demonstrated its quality & price competitiveness.
Page | 2
DIVISION
Page | 3
Page | 4
MISSION-“To 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.) Instrument accessories.
In addition, the division also manufactures the wide variety of ground support equipment
like Ground Power Unit, hydraulic trolley, weapon loading 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.
Page | 5
Page | 6
SYSTEM LAYOUT
Head of HAL Lucknow division is General Manager. The factory is divided
into five sub Divisions:
· Instrument factory
· Mechanical factory
· Fuel factory
· Design and Development
· Sukhoi-30
INSTRUMENT FACTORY
This is further divided into two shops
1. Assembly shop
2. Manufacturing 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. NGL Shop
2. Smiths shop
3. Gyro shop
4. Press Shop
Page | 7
Following systems or instruments are manufactured in Instrument factory.
1. Barometric instrument
2. Gyroscopic instruments
3. Electrical and Electronics equipments
4. Fuel gauging systems
5. 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.
STANDARD CLEAN ROOMS CONDITIONS
TEMPERTURE: - 15 to 25 ℃HUMIDITY: - 45 TO 55%
DUST COUNT: - Less than 100,000 for class C shop(unmonitored)
Less than 100,000 for class B shop
Less than 10,000 for class A shop
Page | 8
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 helicopters during the late 1970,s in
Lucknow Division.
The current products of HAL are-
DO-228
Kiran MK II
HPT-32
Cheetah
Chetak
MIG-21
MIG-27
Jaguar
Engine Test beds
Radars
There are some new products-
ALH
LCA
HTT-35
Industrial/marine Gas Turbine
Modern Instruments
GSE
The division today has prime name in the Aviation market and various international companies
are interested to join hands it for future purpose. The division has also made steady progress in
Page | 9
the area of export.
Page | 10
Page | 11
Page | 12
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 units, AC/DC Electrical system, Actuators.
Land navigation system
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 system
Booster pumps, main and Reheat Fuel systems, Nozzle Actuators.
Page | 13
SERVICES
MANUFACTURE & OVERHAUL OF AIRCRAFT
The division has manufactured more than 700 Aircraft & 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 challenge future task such as manufacture of SU-30 MK 1 & Advanced Jet Trainer.
CUSTOMER SERVICES
The division has established full fledge infrastructure, facilities & system for ensuring optimum
level for customer’s satisfaction on the products & services rendered. The major area includes
Overhaul/ Repair of Rotable
The Division takes up over/repair of entire range of Electrical, instrument, Mechanical &
Armaments Rotables. Supply of Spares & other.
Ground support equipments and rigs
Ground power unit, hydraulics trolley and power packs, dedicated test Rigs, custom-
build Fuel/ Hydraulics Test rigs.
Site Repair
The Division undertakes site repair of Aircraft at IAF bases by deputing site repair teams.
Defect Investigation/Failure Analysis
The aggregate which was received on premature withdrawal from the units are studied & the
causes for defects /failures are investigated. Repetitive cases are taken up for in the depth study
& modifications are incorporated in the unit to minimize the recurrence of such defects/failures
in future.
Product Training
The Division has positioned Service Engineers at various IAF bases to closely liaise and
to access the requirement of the customer. Based on the feedback received from Service
Engineers, the division renders adequate support for fully exploiting the products.
Page | 14
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 divided into: -
NGL Shop
Smiths shop
Gyro shop
Press Shop
Following systems or instruments are manufactured in Instrument factory.
Barometric 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 the order and it approved by the authorities the planning of steps for preparations are to be layer by authorities now assembly of the material is done and stored in stored. Now these are collected as required and experts prepare unit. Now the important step comes of testing. Testing is done under specified conditions and assurance is done in all respect then certificate is raised of being tested. Now the last step comes of proper packing and storing. These are supplied to costumer under followed terms and conditions.
Page | 15
PRODUCT FLOW CHART
Request of costumer
Planning of steps
Assembly of material
manufacturingnof units
Testing of under for conditions
collecting and proper packing of unit
Page | 16
ADVANCED LIGHT HELICOPTER
Advanced Light Helicopter(ALH) is a multi-role, multi-mission helicopter designed & developed
by HAL. The design of this 5.5 ton class, twin-engine helicopter incorporates several state of the
art technologies. Extensive use of composites high cruise speed, long range & endurance,
excellent high altitude performance & capability 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 roles 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.
Endurance: - 4 hrs.
Hover in ground effect: - 1500 m.
Hover out of ground effect: - 1000m.
Leading Particulars: -
Overall length: - 15.87 m.
Overall height: - 4.91 m.
Width: - 3.91 m.
Empty weight: - 2500 kg.
Fuel capacity: - 1100 kg.
Maximum takeoff weight: - 5500 kg.
Maximum under slung weight: - 1500 kg.
Maximum height: - 2500 HT.
Page | 17
ROLES: -
Military Role (Unarmed): -
Hellebore attack.
Reconnaissance
Logistic support
Casualty evacuation
Air observation post
Military Role (Armed): -
Anti tank
Close air support
Anti submarine warfare
Anti surface vessel warfare
Civil Role: -
Commuter/ VIP
Search & rescue
Disaster relief
Air ambulance
Offshore operation
Salient Features: -
Ergonomically designed cockpit
Extensive use if composites, reduced radars signature
Large cabin volume
Ballistic damage tolerant
Greater system redundancy
Provisions for weapons hard points
Twin engine with fully authority digital electronic control
Page | 18
Adequate safety margin for single engine operation
Four axis automatically flying control system
Crash worthy crew seats, under floor and fuel tank
Hinge less main rotor & bearing less tail rotor
Excellent handling qualities at low as well as high speeds
Low maintenance cost & high fuel efficiency
Skid version & retractable wheel version available
Page | 19
ALH PROBES
Auxiliary Tank Probe : -
The Auxiliary Tank (AT) probes are a part of fuel system of ALH. It is installed from the top of
the tank. The AT probes is for gauging fuel content.
The units consist of following main sub-assemblies: -
Tube assembly – consisting of gauging & level sensing.
Card assembly gauging – it consist of gauging circuit.
Electronic assembly – it consist of receptacle & interconnection wires connected to card
and tube assembly.
Electrical Characteristics: -
I/P Characteristics: -
Electrical 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 content. It is also has built in low
level warning sensors which is electrically isolated 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 fuel, this probe is always immersed in fuel.
Page | 20
The unit consists of following sub assemblies –
1) NET FLANGE HEAD ASSEMBLY: - It consist of reference frequency, sensing circuit,
receptacle, interconnection – wires, connecter to card & hold cup assembly.
2) HOLD CUP ASSEMBLY: - It consists of sensing probes.
Page | 21
G-METER
The indicating G – METER provides visual indication of acceleration experienced along the
vertical axis of ALH.
The dial presentation comprises three co–centric pointer moving over a linearly divided
scale. The front pointer indicates the instantaneous acceleration & the middle and read pointers
indicate the maximum positive & negative accelerations respectively. This unit provided with a
resting knob 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 damage candling & transit.
Weight: - 425 gm (max).
NVG (Night Vision Gauge).
TEMPERATURE SWITCH
Temperature switch is used in ALH to close on electrical circuit. When the temperature in the
area surrounding its sensor reaches a predetermined value. The unit senses the oil temperature of
the transmission system.
It works on vapour pressure action & consists of bulb containing Ethyl Alcohol due to
sufficient changes on temperature. The organic liquid vaporizes & builds up pressure within a
closed 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.
Gear box oil temperature senses.
Ensure temperature is within 115 ± 4 °C (max), 110 ± 4 °C (min).
Warning switch cockpit.
Page | 22
PRESSURE SWITCH
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 (max).
Operating range: - 0 to 25 bar.
Functions: -
Pressure switch senses the oil pressure 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
bellows assembly is being fixed leak proof to pipe union with the help of sealing washer &
sealing nut. When an external pressure is applied to bellow assembly through 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.
Page | 23
OUTSIDE AIR TEMPERATURE GUAGE
Outside Air Temperature Gauge is a panel mounted instrument & indicates the outside
temperature. The sensor portion of the instrument protrudes outside the cockpit & senses the
outside air temperature.
Leading Particulars: -
Name: - Outside Air Temperature Gauge.
Weight: - 150 gm (max).
Size: - 56 * 155 mm.
Accuracy: - ± 1.5 °C.
Operating Temperature Range: - - 45 °C to + 75 °C.
Storage Temperature: - - 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 temperature indicator. The heart is a bimetallic sensor wound in a
helical form. One end of the metallic sensor is clamped rigidly & the other end is connected to a
steel rod, on the other end of the rod, a pointer is connected which move over a linear dial to
indicate the temperature senses by the metallic sensor. Thus assembly is housed in a tube and
cup – type case.
Page | 24
RADIO MAGNETIC INDICATOR
RMI is a panel mounted (from front) air-borne instruments which provides the pilot
following function-
Heading of aircraft.
Relative bearing of radio station.
Deviation from a set course.
Additional heading error proportional to sine of the angle between heading & course set
pointer.
Physical Specification: -
Name: - Radio magnetic indicator.
Size: - 83 * 83 * 202025 mm.
Weight: - 1200 gm (max).
Location: - Cockpit instrument panel.
Power Supply: -
a) 5V ± 0.5 dc.
b) 26V ± 10 % V, 400 Hz, single phase a.c.
Page | 25
AIR SPEED INDICATOR
ASI is designed to provide continuous indication of the speed of an A/C. The instrument
is basically a differential air pressure gauge consisting of a twin capsule assembly connected via
suitable linkage & gearing to pointer which moves over a circular diameter calibrated in km/hr.
when installed the interior at the capsule is connected by a capillary tube to A/C pilot pressure
line while the exterior of the capsule is open to static pressure via the A/C static system. The
pointer indicator on a dial which is calibrated 30-400 km/hr.
When the pilot & static pressure applied to the capsule are equal, the pointer remains in
null position. 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:
AC master box
DC master box
Filter Transformer Unit
Alternator Control and Protection Unit
Auxiliary Tank Probe
Radio Magnetic Indicator
Page | 26
AC MASTER BOXES
INTRODUCTION:–
Excluding the two alternators and protection unit and static inverter,
primary AC distribution system consists of following boxes:
1. AC Master Box – 1
2. AC Master Box – 2
3. 115 V AC Emergency Bus Relay
4. 26 V AC Emergency Bus Relay
AC Master Box –1 consist of three phase main bus – 1(115 V), 1-Ø emergency bus – 1 & 2 (115
V), 1-Ø main bus – 1 (26 V). 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.
With AC ground power in & selected in the cockpit, external power control card
validates incoming ground power and automatically energizes the external power contactor 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.
Page | 27
AC master box –2 is similar in construction and function to AC MBX –1. This box dose
not includes external power contactor & control cards. However it has non-essential bus along
with its contactor, this bus is powered from the main bus –2 only when the
alternators are running.
All the power O/P of different buses is protected with thermal
circuit breakers, which are provided in both master boxes.
Page | 28
AC MASTER BOX-1
AC master Box used in ALH distributes AC electrical power to different three phase
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= 266± 5.0 mm
Width = 240± 5.0 mm
Height = 120± 5.0 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)
Input AC power supply –
115 V ac (nominal)
108 V ac to 118 V ac (normal)
100 V ac to 125 V ac (abnormal)
Power consumption – 5 KVA
Page | 29
FUNCTIONS –
Under normal operation ACMBX – 1 distribute ac power. But in the case when
alternator–1 fails then ac power is distributed to different loads through ACMBX –2 from
alternator –2.
During normal operation (both alternator running) complete system is powered from
alternator –1 and ACMBX –1 distribute ac power to different electrical system of ALH.
External power control card (EPC) inside AC Master Box controls the energization of
external power contactor to allow correct quantity of external AC power to be transmitted
to electrical system.
Page | 30
AC MASTER BOX-2
AC Master Box –2 (AC MBX – 2) used in Advanced Light Helicopter Distribute ac
electric power to different three phase loads as per requirement when alternator –1 is failed. It is
used in conjunction with two alternators, two ACPU’s and static inverter.
LEADING PARAMETERS –
Name – AC Master Box –2
Weight – 5.0 kg max.
Dimensions –
Length=266± 5.0 mm
Width =240± 5.0 mm
Height =120± 5.0 mm
Input DC power supply –
28 V dc (nominal)
22 V dc to 29 V dc (normal)
20 V dc to 31.5 V dc (abnormal)
Input AC power supply –
115 V ac (nominal)
108 V ac to 118 V ac (normal)
100 V ac to 125 V ac (abnormal)
Power consumption – 5 KVA
Page | 31
FUNCTIONS –
Under normal operation ACMBX –1 distribute ac power. In the case when alternator –1
failed then ac power is distributed to different 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. Under voltage protection test (in normal & environmental condition)
3. Over/Under frequency
4. Vibration test
5. Functional test.
Page | 32
DC MASTER BOX
INTRODUTION –
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. 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 Ground Power Unit (GPU).
FUNCTIONAL DESCRIPTION
DC Master Box distributes the complete dc power generation. It contains the main bus
through which dc power is directed to the overhead panel through circuit breakers for dc power
distribution.
During 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 single on-
board internal battery through a normally closed battery contactor. Provision has been made for
receiving the dc external power during ground operation through an external power receptacle.
The external dc power supply is transferred to main bus through N.O. contactor, which is
switched on by External Power Card (EPC). The EPC switches the external power contactor ON
only if the applied voltage is within specified limit & of correct polarity and therefore protects
the dc system from over-voltage conditions. As long as external power is connected to the
Helicopter (External Power Contactor is closed), battery should remain disconnected.
Page | 33
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 ground: 6 KW
2. Types of O/P Buses:
Main Bus – 200 A at 28 V DC through
-100 A circuit breaker: 1 no.
-50 A circuit breaker: 2 no.
-3 A circuit breaker: 2 no.
3. Capacity:
-Capacity of unit (Main Bus): 200 A at 28 V DC
-Overloading: 150% (300 A) for 2 min & 200% (400 A) for 5 sec
4. Protection Function –
External Power control :
External Power Control (EPC) card housed inside the DC Master
Box provides the following functions when external power is
selected to the Helicopter.
a) Over voltage protection: At 30.5± 1 V with a fixed time delay of 0.4± 0.1 sec.
b) Reverse polarity protection: External Power fails to connect itself to the system
if the polarity of the external power is reversed.
Page | 34
FAILURE MODES –
There may be multiple failure modes for each functioning. Design has been found to meet the
basic criterion for external system: -
a) Single fault at a time should not affect the normal flight. This has been designed
as MINOR failure. This may also be called as CONTROLLED FAULT, which
may be corrected by appropriate design safety device or special automatic/manual
procedure. Hence, one fault at a time should only lead to MINOR failure.
b) Double fault occurring simultaneously should not lead to an emergency situation
and may be counteracted by emergency action. Hence, two faults simultaneously
should only lead to MAJOR failure.
c) 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.
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 grounding/reference lines used in the unit are connected to a common negative
point used 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 suppressors and
freewheeling diodes are also used in PCB circuit design.
The length of the leads/wires is kept as short as possible and multi-strand wires are used
to reduce eddy current effects.
Page | 35
ALTERNATOR CONTROL & PROTECTION UNIT
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 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.
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.
Overloading: - 150 % for 5 min, 200 % for 5 sec.
Nominal Speed: - 1200 RPM.
Maximum Speed for Regulation: - 12600 RPM.
Minimum Speed for Regulation: - 11400 RPM.
Over Speed: - 15000 RPM.
Frequency at 12000 RPM: - 400 Hz.
Page | 36
FILTER TRANSFORMER UNIT
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 no. 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 Description: -
The FTU is enclosed in an aluminum box & having natural cooling. The heat sink fins made on
two side walls are capable to provide the sufficient heat conduction generated from four power
transistors. The basic electronics of this unit utilizes the conventional sine wave oscillator &
push pull power amplification principle. The unit provides single phase 26 V RMS, 400 Hz O/P
synchronized with phase AB of AC power. The unit is capable of 130 % of FLUFF. The unit is
having built in protection against O/P over voltage, O/P under voltage. The unit also provides a
single under above faulty condition.
The total circuit is spited into 3 main functional parts: -
Power supply.
O/P voltage control & its phase synchronization.
Protection.
Power Supply: -
Three phase power 200 VLL, 400 Hz available from A/C is being fed to step down I/P
transformer. The three phase bridge rectifier rectifies the O/P of the I/P transformers. The
Page | 37
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 received at control card. The phase AB of A/C ac supply is fed to I/P of
synchronization 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
chassis. 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 distortion 26 V RMS, 400 Hz O/P
is available at the connector.
The O/P T/F has voltage feedback winding. A sine wave proportional to main O/P is being
rectified & filtered 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 increases, 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 is
available at the O/P of the unit.
Page | 38
PROTECTIONS
1) PHASE ERROR PROTECTION:-
The O/P sine wave & I/P phase AB available at the secondary of the phase synchronizing
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 directly 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 comparator 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 specified 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
circuit & O/P becomes high after a specified time delay & thus unit O/P falls to zero & the
aircraft load gets transferred to the second FTU.
2) O/P UNDER VOLTAGE:-
The d.c. voltage proportional to the O/P a.c. voltage is fed to the comparator which
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 comparator becomes high, which in turn
makes O/P of the latching cum time delay circuit to high, after fixed time delay, & the unit
tripped off & the aircraft load is transferred to another FTU.
3) O/P OVER VOLTAGE:-
The a.c. voltage induced across the feedback winding of the O/P transformer is rectified
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 exceeds the threshold limit of O/P over voltage,
the O/P of the comparators becomes high, 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 transferred
to the another FTU.
Page | 39
4) O/P OVERLOAD:-
The a.c. voltage is proportional to the O/P current is achieved by the current transformer.
The voltage is rectified & filtered to obtain the d.c. voltage proportional 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 latching cum delay circuit to high after a fixed time delay & the unit is tripped off
& the aircraft load is transferred to another FTU.
Page | 40
FLIGHT DATA RECORDER (FDR) OR BLACK BOX
Flight data recorder system is fitted in aircraft for recording of flight parameters 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 during any miss-
happening. Though it is called Black Box, as data are being recorded on film and cannot be seen
easily by everyone.
It mainly consist of-
1- Information storage system
2- Matching mechanism
3- Cassette
4- Transducers for various parameters.
Purpose &working
Flight data recorder system records automatically 6 continuously changing parameters
(altitude, engine speed, aircraft speed, vertical acceleration, and horizontal acceleration and turn
angle of stabilizer) imposed on 3 continuously variable 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 flight conditions.
Inner structure consists of a light beam source and plane mirrors. 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. Now, when light beam passes the beam, it is
reflected by plane mirror and when this falls on galvanometers mirrors, and get light gets
reflected in six parts and falls on film forming different wave shapes.
Page | 41
INTRODUCTION TO SU-MKI AIR CRAFT
1. Aircraft SU-30MKI is a multipurpose twin seated supersonic fighter designed to destroy
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 surface targets within tactical and
operational depths under heavy noise conditions as well.
2. To destroy aerial targets, a provision is made for employment of all angle medium-range
missiles (active, semi-active radar and infrared guided missiles) and short-range missiles (infra-
red guided missiles) capable of high target hit probability.
3. To destroy ground targets, use is made of unguided bombs, guided bombs and missiles.
The aircraft is also equipped with a rapid-fire gun mount with caliber of 30mm.
4. The aircraft is also intended for training, acquisition (perfection) of skills in flying
techniques, air navigation and combat employment including participation in group combat
actions.
Main Features
Fuselage: The fuselage of SU-30MKI aircraft is an integrated aerofoil body that provides
40% of aircraft’s total lift. The fuselage is built up of three sections; Nose sections, tall
section and wing center section.
Fuselage Nose 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.
Page | 42
Wing Center Section: It is the main load carrying structure of the aircraft. It provides
attachment points for landing 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 part 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 attached at the trailing edge, which operate as
ailerons and flaps. The leading edge flaps are located all along outer wingspan to improve
the aerodynamic characteristics.
Air intakes : The engine air intakes are under slung and provided with ramp 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 operated 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 provided with wheel steering system.
Flight Controls: The aircraft longitudinal control is achieved by synchronous deflection
of stabilizers, lateral control by differential deflection of stabilizers and flaperons and
directional control by rudders. Fly by wire system operates all the control surfaces. Fore
plane or canard is introduced for providing larger stability and Maneuverability at higher
angle of attack and subsonic speeds. Wing leading flaps also act as lift augmenting 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 independent systems i.e.:
First or Left hydraulic system and Second or Right hydraulic system.
(a) Hydraulic oil used:AMG-10/OM-15
(b) Hydraulic tank capacity: 15.8 liters (each system)
(c) Left hydraulic system capacity: 40 liters
(d) Right hydraulic system capacity:40 liters
(e) System operating pressure: 280+15 kgf/cm2
Page | 43
Fuel System: The ac carries fuel in five metallic fuel tanks, which can be refueled in air
also. On ground the ac can be refueled in two modes i.e. basic and full: in case of
emergency the fuel can be dumped in air. The capacity of fuel tanks is as follows.
o Tank No. 1: 3260 kg
o Tank No. 2: 4160 kg
o Tank No. 3: 1060 kg
o Tank No. 4: 350 kg
o Tank No. 5: 650 kg
o Total : 9480 kg
Pneumatic System: There are three independent pneumatic systems. All the system
bottles are charged with nitrogen to a pressure of 200-15 kgf/cm2
a) Canopy Pneumatic Control System: It ensures 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 extends the landing gears in case the
first hydraulic system fails. The bottle capacity 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 capacity is 3 liters.
Page | 44
Page | 45
MARKETING STRATEGIES
Marketing is the relation between costumer and organization. When the customer
contacts the organization then it is seen that the request is of our capability or not. If not then
regret order is send. Else request is judged under various points of cost, terms and conditions,
time duration etc. and the decided conditions are send to the customer now if the customer agree
then order is placed for further 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.
Marketing mainly includes two units of marketing. They are Civil and Export. It mainly
deals with the defense requirements, but besides this there are many other costumers in India and
outside India.
MARKETING
Civil Export
ISRO, Sahara Airlines, kingfisher, Oman UA, England, Romania,
JET airways, etc. Zimbabwe, Srilanka, etc.
CIVIL - In civil unit it mainly deals with the costumers of India only. They are different airlines and research organizations, army, navy, coast guard, air force, etc. They may contact for repairing of parts and for requirements of parts.
EXPORT - In this unit there are mainly customers of foreign are the airways of England, Oman, UA, etc. There are very strict rules for the trade between these organizations. These foreign organization look to HAL as a faithful organization. When customer contacts HAL then there are predefined steps to be followed by the organization.
Page | 46
These can be described in chart as—
FLOW CHART FOR MARKETING PROCESS
Page | 47
DIVERSIFICATION
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) during 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) soared to Rs.1,743.60 crores, which is an increase of 54.88%
over the previous year's performance.
The highlights are given below:
Rupees in Crores
Particulars 2005-06 2006-07 Growth over Previous Year
Sales 5342 7783 45.69%
VOP 5916 9202 55.54%
Profit before tax 1126 1744 54.88%
Profit after tax 771 1149 49.03%
Gross Block 1694 2081 22.85%
Page | 48
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 organization
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, Planning, Decision
making, Co-ordination etc. These golden experiences help the student to sharpen his/her
professional as well personal skills. After being the training student of HAL a particular
department is assigned to study.
This department helps in all possible ways to guide the functions, working process, units
prepared of the organization. One can learn a lot if he takes the proper interest.
Page | 49
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 pilot’s .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 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, 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.
Page | 50
REFERENCE
Magazines of HAL
Manuals of departments:
LAB MANUAL 1: - ADVANCED LIGHT HELICOPTER.
LAB MANUAL 2: - DC MASTER BOX [WORKING].
LAB MANUAL 3: - AC MASTER BOX [WORKING].
LAB MANUAL 4: - ACPU [WORKING].
LAB MANUAL 5: - FTU [WORKING].
Internet
Page | 51
