SUMMER TRAINING REPORT  

  Hindustan Aeronautics Limited Lucknow, U.P. ( Duration: 30th may 2013 to 30th june 2013)

Submitted for partial fulfillment of the requirement for the award of the degree of  Bachelor of Technology In ELECTRONICS& COMMUNICATION ENGINEERING

SUBMITTED BY:

AKANSHA PATEL

Department of Electronics & communication engineering. BBDESGI.  Lucknow(U.P.)

ACKNOWLEDGEMENT

With deep sense of gratitude, first & foremost I express my profound thanks to Mr. S.P singh , Sr. Manager- Training for giving me this very opportunity to do my summer training in the Instrument  factory of H.A.L. Lucknow during the summer session- 2011. I would like to express my gratitude to Mr. Ram Awtar, Head of  Instrument factory, our training guide for the valuable guidance inspiration & enouragenment. Last but not the least, I also wish to acknowledge my indebtedness to the staff of H.A.L. without whose co-operation, this training would not have not been successful. The training at H.A.L. Lucknow was full of responsiveness & it gave me the rare opportunity to correlate the theoretical knowledge with the practical one. Being well known company of India & abroad, it gave me the opportunity to learn the work carried out here, got a glimpse of newenvironment & hard work of industrial unit.

 CONTENT 1.Preface

2. About H.A.L.

3. Mission of HAL. 4. Our Product 5. Airplane parts definitions 6. Major products of the H.A.L. Division 7. H.A.L. Accessories Division – Lucknow

8. Instrument Factory

  Clean room

  Assembly and test shop 2 & 3

  Electromagnetic rotating shop (E.R.M)

  Ground land navigation system shop (G.L.N.S)

 9.Gyroscope Properties.

 

10. Flight Data Recorder  11. Advanced Light Helicopter (ALH)15. 12. Conclusion

 PREFACE

Last few years have witnessed major changes in economic environment of our country. The industrial and economical policies have been liberalized .Indian industries have become globally competitive, giving boost to the young and small enterprises and thus arises the need of an efficient research and development department. I had done my part of training in INSTRUMENT DEPARTMENT of HAL LUCKNOW. The project I had worked on ALH department, SU30 department. There I had learned a lot of things about Helicopter and Fighter plane. This all, for me, was a memorable experience.

INTRODUCTION 

H.A.L was establised on 1 october 1964 by Seth Walchand hirachand with primary motive of production of Defence and civil aircraft.H.A.L lucknow , an accessories division was establised in 1970 with the primary objective of manufacturing systems and accessories for various aircraft and engines . 

HAL : SECTION 

Whole factory divided into following section .• Fuel factory• Mechanical factory• Instrument factory • SU-30 

FUEL FACTORY 

This factory is called so because all accessories related from fuel tank to engine are manufactured in this factory .Fuel factory also divided into following section• Machine Shop• Precise Machine Shop• Lapping Section 

MACHINE SHOP 

Here rough shape is given to raw materials . Machines available in machine shop are:• Simple Lathe machine• Electric discharge machining• Wire cut EDM• Milling Machine 

SIMPLE LATHE MACHINE 

A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting , drilling or deformation with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation . Important Parts of lathe machine are1. Headstock 2. tailstock3. spindle4. tool rest5. Bed 

MISSION OF HAL

To become a globally competitive aerospace industry while working as an instrument for achieving self reliance in design, manufacture and maintenance of aerospace defence equipment.

HAL has substantial progress in its current projects- Dhruv, which is advanced light helicopter. TEJAS IJT(intermediate jet trainer)

HAL PRODUCT PROFILE

SU 30 MKI

Twin seater, multi role, long run fighter.

MIG-27 M

Single seater tactical fighter.

EJECTION SEAT

The injection seat is installed to provide safe escape to the pilot from the aircraft while catapulting is affected with the help of a combined enjection gun.

Sukhoi Su-30 MKI

The Sukhoi Su-30MKI has been jointly-developed by Russia's Sukhoi Corporation and India's Hindustan Aeronautics Limited (HAL) for the Indian Air Force (IAF). It is a heavy class, long-range air superiority fighter aircraft.The Su-30 MKI is more advanced than the basic Su-30MK, the Chinese Su-30 MKK, and the Malaysian Su-30 MKM.The aircraft features state of the art avionics developed by Russia, India , Israel , France and South Africa which includes display, navigation,targeting and electronic warfare systems.MKI stands for "Modernizirovannyi Kommercheskiy Indiski" meaning "Modernized Commercial India".

General Features of Sukhoi 30 MKI

Sukhoi 30 MKI is a 4.5 generation fighter aircraft . Fifth generation planes are yet to come. Cost of single Su-30 MKI is $ 35 million or Rs 1.61 billionAs per deal between Russia’s Sukhoi Corporation and India’s HAL , in the first phase, components will be imported from Russia and only assembling will be done in India.In the second phase , there will be transfer of technology from Russia to

India , and then both manufacturing & assembling will be done in India. Various independent sources have claimed Su-30 MKI to be the most superior fighter plane in present World. 

Fuel Flow And Metering System In Sukhoi 30 MKI

Fuel capacity of Sukhoi 30 MKI: 12 ton or 12000Kg.There are 5 fuel tanks of which one is service tank or main tank. Service tank is centrally located is the most important one .Fuel from all other tanks pass through service tank before consumption. So in the end fuel remains only in the service tank.All the 5 tanks are so placed that the aircraft is aerodynamically balanced.

STRUCTURE

Fuel quantity & flow metering system can be subdivided into:Fuel Flow MeteringIt computes the total quantity of fuel available in aircraft.Uses impeller type of sensors.2. Fuel Quantity GaugingIt computes the quantity of fuel in the service tank.Uses capacitance type electronic sensors.3. Automatic ControlIt manages the sequence of fuel flow to/from various tanks during refueling and consumption.

FUEL QUANTITY GAUGING

Computes the quantity of fuel left in service tank. It is an electronic system based on the principle of variation o f capacitance with change in dielectric medium .It consists of uniform cylindrical shaped capacitor with thefuel acting as the dielectric.As the fuel gets consumed , the fuel is replaced by air as dielectric and there is a change in capacitance.So , the remaining fuel in the service tank can be calculated on the basis of variation in capacitance.Fuel quantity gauge is of utmost importance when

1. Only service tank is left with fuel.2. Flow metering system fails. 

AUTOMATIC CONTROL PORTION

Automatic control manages sequence of fuel flow to/from various tanks during refueling as well as consumption. The fuel from all the five tanks is taken in such a way that the aerodynamic balance of the plane is not disturbed. This is done with the help of automatic control system.Fuel from a certain tank is not taken all at once. After taking a certain quantity of fuel from one tank, the valve is closed and then fuel is drawn from another tank. So, the sequence of fuel flow from various tanks is decided by automatic control system.

Digital Light Indicator

It is an electronic display device in cockpit.It continuously displays fuel quantity of service tank.Semiconductor Relay Control Unit. It is a part of automatic control portion.It works as an amplifier and a switching device for the signals required for opening and closing of valves of various tanks in aircraft.

AIR PLANE PARTS AND DEFINITIONS AND THEIR FUNCTIONS

This page shows the parts of an airplane and their functions. Airplanes are transportation devices which are designed to move people and cargo from one place to another.Airplanes come in many different shapes and sizes depending onThe mission of the aircraft. The airplane shown on this slide is a turbine-power edairliner which has been chosen as a representative aircraft .For any airplane to fly, you must lift the weight of the airplane itself, the fuel, the passengers, and the cargo. The wings generate most of the lift to hold the plane in the air. To generate lift, the airplane must be pushed through the air. The jet engines, which are located beneath the wings, provide the thrust to push the airplane forward through the air. The air resists the motion in the form of aerodynamic drag. Some

airplanes use propellers for the propulsion system inst To control and

maneuver the aircraft, smaller wings are located at the tail of the plane. The tail usually has a fixed horizontal piece (called the horizontal lstabilizer) and a fixed vertical piece (called the vertical stabilizer). The stabilizers' job is to provide stability for the aircraft, to keep it flying straight. The vertical stabilizer keeps the nose of the plane from swinging from side to side, while the horizontal stabilizer prevents an up-and-down motion of the nose. (On the Wright brother's first aircraft, the horizontal stabilizer was placed in front of the wings. Such a configuration is called a canard after the French word for "duck").At the rear of the wings and stabilizers are small.

At the rear of the wings and stabilizers are small moving sections that are attached to the fixed sections by hinges. In the figure, these moving sections are colored brown. Changing the rear portion of a wing will change the amount of force that the wing produces. The ability to change forces gives us a means of controlling and maneuvering the airplane. The hinged part of the vertical stabilizer is called the rudder; it is used to deflect the tail to the left and right as viewed from the front of the

fuselage. The hinged part of the horizontal stabilizer is called the elevator; it is used to deflect the tail up and down. The outboard hinged

part of the wing is called the aileron; it is used to roll the wings from side to

side. Most airliners can also be rolled from side to side by using the spoilers. Spoilers are small plates that are used to disrupt the flow over the wing and to change the amount of force by decreasing the lift when the spoiler is deployed.

AIRCRAFT YAW MOTION

Inflight, any aircraft will rotate about its center of gravity, a point which is the average location of the mass of the aircraft. We can define a three dimensional coordinate system through the center of gravity with each axis of this coordinate system perpendicular to the other two axes. We can then define the orientation of the aircraft by the amount of rotation of the parts of the aircraft along these  principal axes. The yaw axis is perpendicular to the wings and lies in the plane of the aircraft centerline. A yaw motion is a side to side movement of the nose of the aircraft as shown in the animation. The yawing motion is being caused by the deflection of the rudder of this aircraft. The rudder is a hinged section at the rear of the vertical stabilizer.

AIRCRAFT ROLL MOTION

In flight, any aircraft will rotate about its center of gravity, a point which is the average location of the mass of the aircraft. We can define a three dimensional coordinate system through the center of gravity with each axis of this coordinate system perpendicular to the other two axes. We can then define the orientation of the aircraft by the amount of rotation of the parts of the aircraft along the principal axes. The roll axis lies along the aircraft centerline. A roll motion is an up and down movement of the wings of the aircraft as shown in the animation .The rolling motion is being caused by the deflection of the ailerons of this aircraft. The aileron is a hinged section at the rear of each wing. The

ailerons work in opposition; when the right aileron goes up, the left aileron goes down.

Their wings were wired together in such a way that the outer panels of each wing could be twisted relative to the inner panel. The twisting changed the local angle of attack of sections of the wing which changed the lift being generated by that section. Unequal forces on the wings caused the aircraft to roll. Many modern airliners use a spoiler to roll the aircraft. A spoiler is a plate that is raised between the leading and trailing edges of the wing. The spoiler effectively changes the shape of the airfoil, disrupts the flow over the wing, and causes a section of the wing to decrease its lift. This produces an unbalanced force with the other wing, which causes the roll. Airliners use spoilers because spoilers can react more quickly than ailerons and require less.  

Force to activate, but they always decrease the total amount of lift for the aircraft. It's an interesting trade! You can tell whether an airliner is using spoilers or Ailerons by noticing where the moving part is located. At the trailingedge, it's an aileron; between the leading and trailing edges, it's a spoiler.(Now you can dazzle the person sitting next to you on the plane!

 

MA   JOR PRODUCTS OF THE HAL DIVISION   –

The major products of the Division are:

  Undercarriage systems

  Wheels and Brake systems

  Hydraulic Systems

  Aircraft and Engine Fuel Systems

  Panel Instruments (Barometric and gyroscopic)

  Electric Power Generation and Control systems

  Environmental control systems.

  Flight Control Actuators

  Ground Support Equipment and test Rigs.

  M ain Customers :  I .Indian Air Force, Army, Navy, Coast Guard, BSFii. Defence R&D Laboratories and Deptt of Space;iii .Civil Aviation, State Govt., Ordnance Factories, Corporate Sectors;iv. Flying Academies & Educational Institutions;v. Airlines, Air Taxi, Air Cargo;vi. Overseas customers for civil and military applications.vii. Collaborators and Licensors.

 HAL ACCE SS ORIE S DIVI S ION - LUCKNOW  Hindustan Aeronautics LimitedAccessories Division Lucknow 226 016IndiaThe Division was established in 1970 with the primary objective of manufacturing systems and accessories for various aircraft, helicopters and engines with a view to attain self-sufficiency in this field in the country. The Division started with the manufacture of hydro-mechanical accessories and instruments under license for Marut and Kiran aircraft. This was followed by license manufacture of accessories for MiG-21 aircraft, Cheetah/Chetak helicopters, Dornier and other defense applications. Additionally repair and overhaul of Lucknow manufacture d accessories as well as those fitted on directly purchased aircraft, such as Mirage and Sea Harrier was undertaken. At present, it is manufacturing, repairing and overhauling more than 800 different types of systems and accessories under license. The range of items cover units for hydraulics, engine fuel system, environment control system, pressurization system, gyroscopic instruments, barometric instruments, electrical system items, undercarriages, and electronicitems. The number of licensors exceeds twenty.

H.A.L. accessory division, Luknow is divided into three main factories namely

1. Mechanical Factory

2. Instrument Factory

3. FuelFactory

INSTRUMENT FACTORYThis factory deals with the testing and assembly of electronics instruments used in aircraft e.g. Altimeter, RMI, Gyro-magnetic compass , black box etc. This INSTRUMENT FACTORY is further divided into four units which are as follows:

  CLEAN ROOMS

  ASSEMBLY AND TEST SHOP 2 & 3

  ELECTRO ROTATING MACHINES

  GROUND LAND NAVIGATION SYSTEM SHOP (G.L.N.S 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 adverse effect on their functional efficiency. The required specification for the instruments assembled and tested are different .so Clean room is further subdivided into three units.

Assembly and test shop 2 & 3 The major products of H.A.L. are fighter aircrafts. An aircraft comprises of many small units or accessories, which play significant role in their

successful flight. any fault, may lead to an catastrophic end. Here comes the role of assembly and test unit .it forms an integral part of any manufacturing unit. The main instrument were KCN-2 compass system, flight data recorder, gyro magnetic compass, fuel gauging system, radio magnetic indicator, millivoltmeter  temperature indicator.  

 

Electromagnetic rotating shop (E.R.M) In the E.R.M department of the instrument factory the assembly and testing 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 takes 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 is of Russian origin and jaguar aircraft is of France origin.

Gyroscope

A gyroscope is a device for measuring or maintaining orientation, based on the principles of momentum. The device is a spinning wheel or disk whose axle is free to take any orientation. This orientation changes much less in response to a given external torque than it would without the large angular momentum associated with the gyroscope's high rate of spin. Since external torque is minimized by mounting the device in gimbals, its orientation remains nearly fixed, regardless of any motion of

the platform on which it is mounted. Gyroscope works in situations when using magnetic compass is not possible at all (as in Hubble telescope). Due to higher precision it is used to maintain direction in tunnel mining.

 

Description

 Within mechanical systems or devices, a conventional gyroscope is a mechanism comprising a rotor journal to spin about one axis, the journals of the rotor being mounted in an inner gimbals or ring, the inner gimbals being journal for oscillation in an outer gimbals which in turn is journal for oscillation relative to a support. The outer gimbals or ring is mounted so as to pivot about an axis in its own plane determined by the

support. The outer gimbals possesses one degree of rotational freedom and its axis possesses none. The inner gimbals are mounted in the outer gimbals so as to pivot about an axis in its own plane that is always perpendicular to the pivotal axis of the outer gimbals.The axle of the spinning wheel defines the spin axis. The inner gimbals possess two degrees of rotational freedom and its axis possesses one. The rotor is journal to spin about an axis which is always perpendicular to the axis of the inner gimbals. So, the rotor possesses three degrees of rotational freedom and its axis possesses two. The wheel responds to a force applied about the input axis by are action force about the output axis.The behavior of a gyroscope can be most easily appreciated by consideration of the front wheel of a bicycle. If the wheel is leaned away from the vertical so that the top of the wheel moves to the left, the forward rim of the wheel also turns to the left. In other words, rotation on one axis of the turning wheel produces rotation of the third axis. A gyroscope flywheel will roll or resist about the output axis depending upon whether the output gimbals are of a free- or fixed- configuration.

ADVANCED LIGHT HELICOPTER (ALH) Advanced Light Helicopter is a multirole, multimission 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 and capability to operate in hot & humid environment are the key design features.

CONCLUSION   After four week of my training ,I found that H.A.L is a leading manufacturer of fighter planes and they also work with new technology .H.A.L lucknow accessories division makes different product which are needed in planes .For better performance ,the formed product are sent to quality control department .the product are properly checked then they are sent for assembly.