BABU BANARSI DAS

INSTITUTE OF TECHNOLOGY
GHAZIABAD

REPORT ON
SUMMER TRAINING
AT
HINDUTAN AERONAUTICS
LIMITED
LUCKNOW

SUBMITTED TO: SUBMITTED BY:

K.L.PURSNANI VINDHYAVASHANI UPADHYAY
H.O.D BRANCH: EC
ELECTRONICS & COMMUNICATION 4TH YEAR
DEPARTMENT 0703531113
 PREFACE

Training has misinterpreted by most of us as a platform for project performation.

Industrial training in true sense has been included in curriculum to make the student well
versed with the technical procedure of various industries, the basic criteria for
management of various resources in a company or industry.
The educational institution sole aim by industrial training is to improve the
technical knowledge and to have a hand on experienced to make them realistic in
thinking, to understand the procedure for manufacturing keeping mind the minute detail
which will benefit the customer like no learning is proper without implementation.
Doctors, Lawyers, hotel management student surely hold an upper hand. It’s
because right from the second year of their graduation they are made to face the world
and their problems with a tender mind.
Unlike the pitiable engineers like us who are completely isolated from industry.
Therefore there should be industry institutions made compulsory for every engineering
institute.
 ACKNOWLEDGEMENT

I am thankful to HINDUSTAN AERONAUTICS LIMITED for providing me

an opportunity to get an insight and practical experience in the operation, control and
manufacturing of aircraft accessories.

I am extremely grateful to MR. MANOJ SRIVASTAVA (TRAINING

MANAGER) under whose guidance this summer training was conducted successfully. I
feel highly indebted to all the senior HAL officials who extended me a constructive help
in the technical field along with enriching me with valuable practical tips in the operation
of the accessories.
I gratefully acknowledge all the engineers/staff who gave us their valuable
time, encouragement, constructive criticism for familiarizing us with all technical aspects
of the HAL aircraft.

Sincerely,

PUSHPENDRA SINGH GANGWAR

B.TECH 4TH YEAR
BRANCH-EI
 TABLE OF CONTENTS

• HISTORY OF HAL
• MISSON OF HAL
• RESEARH AND DESIGN CENTRES
• DIVISION OF HAL
• EMLPOYEE HIERARCHY
• ACCESSORIES DIVISION LUCKNOW
• SERVICES OF HAL
• AIRCRAFT&HELICOPTER WITH INDIAN NAME
• ACCESSORIES OF HAL LUCKNOW AIRCRAFT
• ALTIMETER
• FUEL SENSING PROBE
• HORIZON GYRO
• DIRECTION GYRO
• CAPSULE
• TEMPERATURE SWITCH
• PRESSURE SWITCH
• DC MASTER BOX
• A/C ELECTRIC DISTRIBUTION BOX (ACBX)
• FTU (FILTER TRANSFORMER UNIT)
• ALTERNATOR CONTROL AND PROTECTION UNIT
• AIR SPEED INDICATOR
• TACHO TRANSMETER
• TACHOMETER INDICATOR
• FLIGHT DATA RECORDING SYSTEM

• AWARDS FOR ACHIEVEMENTS

 HISTORY OF HAL

Hindustan Aeronautics Limited (HAL) came into existence on 1st October 1964. The
Company was formed by the merger of Hindustan Aircraft Limited with Aeronautics
India Limited and Aircraft Manufacturing Depot, Kanpur.

The Company traces its roots to the pioneering efforts of an industrialist with
extraordinary vision, the late Seth Walchand Hirachand, who set up Hindustan Aircraft
Limited at Bangalore in association with the erstwhile princely State of Mysore in
December 1940. The Government of India became a shareholder in March 1941 and took
over the Management in 1942.

Today, HAL has 19 Production Units and 9 Research and Design Centres in 7 locations
in India. The Company has an impressive product track record - 12 types of aircraft
manufactured with in-house R & D and 14 types produced under license. HAL has
manufactured over 3550 aircraft, 3600 engines and overhauled over 8150 aircraft and
27300 engines.

HAL has been successful in numerous R & D programs developed for both Defense and
Civil Aviation sectors. HAL has made substantial progress in its current projects:

• Dhruv, which is Advanced Light Helicopter (ALH)

• Tejas - Light Combat Aircraft (LCA)
• Intermediate Jet Trainer (IJT)
• Various military and civil upgrades.
Dhruv was delivered to the Indian Army, Navy, Air Force and the Coast Guard in
March 2002, in the very first year of its production, a unique achievement.

HAL has played a significant role for India's space programs by participating in the
manufacture of structures for Satellite Launch Vehicles like

• PSLV (Polar Satellite Launch Vehicle)

• GSLV (Geo-synchronous Satellite Launch Vehicle)
• IRS (Indian Remote Satellite)
• INSAT (Indian National Satellite)

HAL has formed the following Joint Ventures (JVs):

• BAeHAL Software Limited

• Indo-Russian Aviation Limited (IRAL)
• Snecma HAL Aerospace Pvt Ltd
• SAMTEL HAL Display System Limited
• HALBIT Avionics Pvt Ltd
• HAL-Edgewood Technologies Pvt Ltd
• INFOTECH HAL Ltd

Apart from these seven, other major diversification projects are Industrial Marine Gas
Turbine and Airport Services. Several Co-production and Joint Ventures with
international participation are under consideration.

HAL's supplies / services are mainly to Indian Defence Services, Coast Guards and
Border Security Forces. Transport Aircraft and Helicopters have also been supplied to
Airlines as well as State Governments of India. The Company has also achieved a
foothold in export in more than 30 countries, having demonstrated its quality and price
competitiveness.
 HINDUSTAN AERONAUTICS LIMITED
The Mission

“To become a global player in the aerospace industry”

Hindustan aeronautics limited (HAL) is a “Navratna” Defence Public Sector Unit

and is presently ranked 34th among the global defense companies. It has witnessed steady
Growth over the years and achieved a turnover of 2 BUSD in 2007-08 (Rs.8625 Cr).

Founded in 1940 and now fully owned by the Government of India, HAL is the
Premier aerospace industry in Asia. There are 19 Production Divisions and 9 R& Centers
Spread across the country. The product portfolio, emanating both from indigenous in-
house design and license production , meets almost all the requirement of Indian Defence
Services through Fighter aircraft, Trainer aircraft and Helicopters.

Major products currently in the production range are SU-30MKI, Jaguar, Hawk,
Dornier 228, Dhruv (Advanced Light Helicopter – ALH), Cheetal and Chetek
helicopters.
The Limited Series Production of the Light Combat Aircraft (LCA), Intermediate jet
Trainer (ijt) have commenced and the Light Combat Helicopter (LCH) which is in an
Advanced stage of development will be inducted into service shortly.

CORE BUSINESS

Affirming its commitment to the Defense Services and to achieve strategic self reliance
in the Aerospace Sector in the country, HAL’s core business activities comprise:-
• Design, Development and Production of Fixed Wing aircraft (Fighters, Trainers
& Transport) and Helicopters, their Engines, Avionics & Accessories.
• Life Cycle customer support through Maintenance, Repair & Over hall of
Aerospace products.
• Manufactures of Structures and Integrated systems for space launch vehicles &
satellites.

The Company is launching new design & development projects on Fifth Generation
Fighter Aircraft, Multi-role Transport Aircraft, Light Utility Helicopter, Medium Lift
Helicopter, Turboprop Trainer and UAVs to meet the future requirement of our Defense
Services.
 FINANSIAL PERFORMANCE

The year 2007-08 was a year of growth, achievement and recognition for the
Company. During the year HAL registered all time record turnover of Rs.8625.33 crs.
registering a 10.82% growth over the previous financial year. The profit for the year was
Rs.2164.23crs. as against Rs.1743.60 crs. in the previous year. The net worth of the
Company has gone up from Rs.2084.99 crs (in 2006-07) to Rs.3326.53 crs (in 2007-08).

HAL has attained the status of a Zero Debt Company during 2007-2008.

Return to the Government on the investment in HAL is steadily on the increase with the
highest Dividend of Rs.327 crs. (271%) paid for the year 2007-2008.

HAL MANAGEMENT ACADEMY(HMA)

HMA is a premier centre of learning having qualified faculty members and equipped with
all required training facilities. It regularly conducts series of training programmers from
entry level to senior executives of the company to facilitate continued enhancement of
their managerial skills and leadership qualities. It has embarked on a journey to enable
personal and professional development of executives of the company belonging to all
functions, through re-designing the required framework, establishing of processes and
making available opportunities for a sustained learning and development, spanning their
entire career.HMA has an ambitious vision to go beyond training and enable executives
of HAL to unleash their potential and enrich their professional and personal lives.

BANGALORE COMPLEX

AIRCRAFT DIVISION

• The product profile of the Division presently includes Jaguar aircraft HAWK-
Advanced jet trainer, PTA (Lakshya).

• The Division exports high precision aircraft components and sub-assemblies like
Airbus A320/A321 Forward Pax Doors, Boeing 777 Up lock Box assembly, B737
cargo conversion and other structural work packages.
ENGINE DIVISION

• Engine Division is presently engaged in manufacture of Adour MK 871, Adour

MK811, Garrett TPE 331-5, Artouste IIIB & PTAE engines.

• The division also undertakes repair and overhaul of TM 333-2B2, Adour MK 811,
Adour MK 804E, Garrett, Dart, Gnome, Orpheus, Artouste IIIB.

• The Division also has taken up new TPE 331-12 engine programmed for export.

OVERHAUL DIVISION

• The present activities of Overhaul Division includes Major servicing of Kiran MK

I/IA , Kiran MK II, Jaguar Strike& Trainer and Major inspection of Mirage 2000
Fighter & Trainer , Overhaul & repair of Lycoming engines (HPT-32 & Islander)
Overhaul and repair / servicing of accessories.

• The Divisions also renders services to IAF aircraft at its various bases in
Yelahanka (Avro and AN-32), Tambaran (Kiran MK1/1A and HPT -32), Pune
(Jaguar), Ambala (Jaguar), and Gorakhpur (Jaguar).

AEROSPACE DIVISION

• The division undertakes production of Light Alloy Structures for the Polar
Satellite launch Vehicle (PSLV) , Geo-Stationary Launch Vehicle (GSLV MkII),
Indian Remote Sensing Satellite (IRS) , Indian National Satellite (INSAT) and the
structures & welded tank for the Cryogenic upper stage of GSLV MkII.
• The Division has taken up full equipping & integration of the strapon boosters for
GSLV MkII and also manufacture of all structures & tank ages for a larger GSLV
Mk III Vehicle with enhanced capabilities.

FOUNDRY & FORGE DIVISION

• The division undertakes development & manufacture of Aluminum and

Magnesium base alloys and indigenous development of castings and forgings in
ferrous and Non ferrous alloys, rolled rings, brake pads and rubber products for
critical applications for the Aeronautics, Space & Defense industries.
• The Division has the Central Materials & Processes Laboratory which undertakes
development of Materials, Castings, and Forgings & New Processes.
AIRPORT SERVICES CENTRE

• Presently Airport Services Centre is providing the technical services of Air

Traffic Control, maintenance of runway and navigation / landing aids and various
other allied services at HAL airport.

INDUSTRIAL &MARINE GAS TURBINE (IMGT) DIVISION

• The major activities of IMGT Division presently are manufacture of LM 2500

(Marine) engines and repair / overhaul of Industrial Avon, Allison & LM 2500
(Industrial) engines.

LCA-LSP

• A dedicated LCA-LSP Unit has been set up to handle LCA-Tejas Limited Series
production as well as series production.
 RESEARCH AND DESIGN CENTRES

In the year 1951, when HT-2 the first indigenously designed primary trainer made its first
flight, it heralded the era of Research & Design at HAL This aircraft served as the back
bone of IAF's training fleet for more than three decades.

Subsequently, HAL's R&D capabilities have grown from strength to strength and have
been harnessed to achieve greater heights of self reliance. The Advanced Light Helicopter
- ALH (DHRUV) is the latest new generation helicopter designed and developed by HAL.
It is under production since 2002. The test flights on Technology Demonstrators (TD-I
and II) and Prototype Vehicles (PV-1 and 2) of Light Combat Aircraft - LCA (Tejas) are
progressing satisfactorily. The Intermediate Jet Trainer (IJT) is undergoing test flights.

In addition, HAL has successfully completed many systems updates and integration tasks.
HAL has 9 Research & Design Centres engaged in the design and development of combat
aircraft, helicopters, aeroengines, gas turbines, engine test beds, aircraft communication
and navigation systems and mechanical system accessories.

The indigenously upgraded MiG-27M aircraft has received Initial Operation Clearance
(IOC) and the first batch of aircraft has been delivered. First flight test on Jaguar Nav
WASS upgraded aircraft with indigenously developed mission computer with weapon
delivery capabilities has been carried out and retromod of fleet has been taken up.

Equipped with the latest facilities, the company is backed by high profile, highly skilled
manpower with an impressive track record of more than five decades of rich experience in
all disciplines of aeronautics.
 DESIGN COMPLEX
AIRCRAFT R & D CENTRE (ARDC)

• ARDC has full spectrum of expertise in all facets of aircraft design, prototype
manufacturing and extensive testing facilities backed by a rich in-service
experience of more than five decades.

On-going projects include indigenous design & development of intermediate jet trainer.
(IJT) & Light Combat Aircraft (LCA). Upgrade of Jaguar, Sea Harrier aircraft is also
being undertaken by the division.

AIRCRAFT WING R & D CENTRE (RWRDC)

• RWRDC undertakes full range of design tasks for civil & military helicopters. It
has extensive facilities for design & development, testing & analysis of structure/
transmission system / integration of engine / avionics as well as accessories.

• RWRDC is the nodal agency for successful design & development of Dhruv-
Advanced Light Helicopter (ALH) for wide range of military & civil applications.
On- going projects include Weapon System Integration on ALH & development
of Light Combat Helicopter (LCH).

ENGINE TEST BED R&D CENTRE (ETBR&DC)

• ETBR&DC is involved in design & development of small engines& Engine Test

Beds.

HELICOPTER DIVISION

• The division undertakes production of Advanced Light Helicopter (Dhruv).

HELICOPTER MRO DIVISION

• A dedicated MRO Division has been created to address product support, spares,
maintenance & services for Dhruv helicopter.

BARRACKPORE DIVISION

• The division undertakes manufacture & overhaul of Cheetah (SA-315 Lama),

Chetak, Lancer, Cheetal and Chetan helicopters.
COMPOSITE MANUFACTURING DIVISION

• A dedicated division has been created for manufacture of composite structures of

aircraft & helicopters (like ALH & LCA), apart from export programmes.

MIG COMPLEX

AIRCRAFT MANUFACTURING DIVISION, NASIK

• The Division is currently engaged in manufacture of SU-30 MKI aircraft, spares

of MiG1 series & MIG 27M aircraft.

• The division is also involved in manufacture/repair /overhaul of undercarriages

for ALH, LCA and Mirage-2000.

AIRCRAFT OVERHAUL DIVISION,NASIK

• The Division is engaged in repair/overhaul and upgrade of MiG-21 aircraft

variants/MiG-27M aircraft and their aggregates & rotables.

AIRCRAFT UPGRADE RESEARCH & DESIGN CENTRE (AURDC), NASIK

• AURDC is engaged in mid-life upgrade of various types of Russian origin

aircraft, Design & Development support to MiG-27 & Su-30 MKI.

• The centre has got rich experience in aircraft upgrades, Life extension
programmes, Indigenization of aircraft materials and components, Training in
aircraft systems and technologies, aircraft publications etc.

ENGINE DIVISION, KORAPUT

• Present activities of Koraput Division include manufacture of RD33 engines for

MiG-29 aircraft and overhaul of R-11/R25 engines for MIG-series aircraft, R-29B
engines for MiG-27M aircraft and RD-33 engines for MiG-29 aircraft.
 • The division also undertakes development & manufacture of forgings & castings
for aeronautical & industrial applications.

• Co-located Gas Turbine R&D Centre deals with design improvement of Russian
Engines.

SUKOI ENGINE DIVISION , KORAPUT

• A separate Division has been set up for manufacture and overhaul of AL 31FP
engine for SU-30MKI aircraft.

AEROSPACE COMPLEX

ACCESSORIES DIVISION, LUCKNOW

• THE Division undertakes manufacturing of Hydraulic SYSTEM, Wheel & Brake

system , Environmental control system, Engine fuel control system, Flight control
system , panel instruments- Gyroscopic, Barometric & Electro-Mechanical,
Electrical systems, Fuel Management system & oxygen System for the various
aircraft & helicopters of Indigenous, Western & Russian origin.

• The Division is also manufacturing a wide range of Ground support and Handling
equipment.

• The Co-located Aerospace System & Equipment Research & Design Center
(ASERDC) has developed expertise in the areas of hydraulic pump, actuators,
wheels & brakes, turbo-coolers, fuel content gauging, electrical systems &
rotating machines.

AVIONICS DIVISION , HYDRABAD

• Presently, the product profile of the Division includes Communication

Equipment, Radio Navigation Systems , Air borne Radar equipment , On-board
Computers etc,
• Flying on various aircraft & helicopters of indigenous, Western & Russian origin.
AVIONICS DIVISION, KORWA

• The Division’s manufacturing range includes Internal Navigation System,

Attitude & Heading Reference System, Air Data Computer, Head-up Display
(HUD), Weapon Aiming Computer, Laser Ranging System, Flight Data Recorder,
Multi-Function Display (MFD), and Digital Map Generator (DMG).

TRANSPORT AIRCRAFT DIVISION (TAD), KANPUR

• Currently, the activities of TAD-Kanpur Division include manufacturing and

overhaul of DO-228 aircraft in addition to overhaul of HS-748 and HTP-32
aircraft and their rotables.

• HAL Detachment Agra, attached to TAD-Kanpur, is involved in servicing of the

AN-32 aircraft.

EMPLOYEE HIERARCHY
 CHAIRMAN

MANAGERIAL DIRECTOR

GENERAL MANAGER

ADDITIONAL GENERAL
MANAGER

DEPTI GENERAL MANAGER

CHIEF MANAGER

SENIOR MANAGER

MANAGER

ASSISTANT MANAGER

ENGINEER

ASSITANT ENGINEER
Accessories Division of HAL was established in 1970 with the primary objective of
manufacturing systems and accessories for various aircraft and engines and attains self
sufficiency in this area. Its facilities are spread over 94,000 s-m of built area set in sylvan
surroundings. At present it is turning out over 1100 different types of accessories. The
Division started with manufacturing various Systems and Accessories viz, Hydraulics,
Engine Fuel System, Air-conditioning and Pressurization, Gyro & Barometric
Instruments, Electrical System items, Undercarriages, Electronic items all under one roof
to meet the requirements of the aircraft, helicopters and engines being produced by HAL.
This was followed up with manufacturing the same range of accessories for MIG series
of aircraft, International Jaguar and repair / overhaul of Mirage-2000 & Sea-Harrier
accessories. In addition the Division manufactures systems for Civil Aircraft i.e. Avro,
Dornier and AN-32 & cheetah, chetak & Advanced Light Helicopters.

The Division, right from the beginning, laid a lot of emphasis on developing indigenous
capability for Design and Development of various System and Accessories. This
capability has culminated in indigenous design and development of a variety of systems
and accessories for the Light Combat Aircraft (LCA) and Advanced Light Helicopter (all
versions i.e. Army, Air force, Navy & Civil) - two prestigious aircraft programs in the
country and IJT (Intermediate Jet Trainer). The Division has also developed and has
made successful strides into the area of Microprocessor based control systems for the
LCA Engine as well as other systems.

The Division diversified not only in other defence applications like tanks and armoured
vehicles for Army, it look commercial applications of hydraulic items. Gyroscopic
Equipment, Special Purpose Test Equipment & Group Support Equipment and
successfully supplied in the market. The Division has been in the forefront of accessories
development and supply not only to Indian Force but to Army, Navy and various Defence
Laboratories as well as for Space applications.

The Division today has a prime name in the Aviation market and various international
companies are interested to join hands with it for future projects.
 SERVICES

REPAIRS, MAJOR SERVICING AND SUPPLY OF SPARES

The Division carries out Repair and Overhaul of Accessories, with minimum turn-
around-time. Site Repair facilities are offered by the Division by deputing team of expert
Engineers / Technicians .Services provided for:

Military Aircraft

• MIG Series
• Jaguar
• Mirage-2000
• Sea - Harrier
• AN-32
• Kiran MK- I / MK- II
• HPT - 32
• SU-30 MKI

Civil Aircraft

• Dornier-22B
• AVRO HS-748

Helicopters

• Chetak (Alouette)
• Cheetah (Lama)
 • ALH (IAF / NAVY / COAST GUARD / CIVIL)

Sub-contract Capabilities

• The Division has comprehensive manufacturing capabilities for various Hi-tech

components, Equipment and Systems to customer's specifications and ensures
high quality, reliability and cost effectiveness.

• The Division has over 25 years of experience in producing aeronautical

accessories making it an ideal partner for the International Aero Engineering
Industry.

The Division also manufactures and supplies complete range of components of Cheetah
(Lama) & Chetak (Alouette) Helicopters, Jaguar and MIG series Aircraft to Domestic
and International Customers to support their fleet.

AIRCRAFT & HELICOPTER WITH INDIAN NAME

It is predefined that each and every helicopter or aircraft have a Indian name. That is the
name by which we are familiar. We are given some examples as a list given below-

HTP-32 DEEPAK

MIG-29 BAJJ

MIG-21FL BADAL

MIG21M/MF TRISUL

MIG23BN VIJAY

MIG23MF RAKSHAK

MIG-25 GARUD

MIG-27M BAHADUR

MIG-21BIS VIKRAM

JAGUAR SHAMSHER

HS-748(AVRO) CHITRA

MIRAGE-2000 VAJRA

AN-32 SUTLEJ

IL-76 GAJRAJ

LCA JEJAS

HJT-16 KIRAN

MI-8(H/C) PRATAP

LAMA(H/C) CHEETAH

ALOVETTE(H/C) CHETAK

ALH(H/C) DHRUV

MI-4(H/C) AKBAR

ACCESSORIES OF HAL LUCKNOW AIRCRAFT

 GYROSCOPE

INTRODUCTION

A Gyroscope is an accurately balanced flywheel having a mass and freedom of in one or

more axis which crossed on a point at right angle to each other and having the property of
RIGIDITY & PRESSION.

RIGIDITY

It is the ability of a gyroscope to resist any freedom with tends to change the direction of
spin axis. Rigidity depends upon

• Speed of gyro(in RPM)

• Mass of the gyro(rotor)
• The radius of gyro rotor/motor.

PRESSION

It is the angular change in the direction of plane of the spin of the rotor resulting from the
application of external torque. The ratio of press ion depends upon
• The magnitude of applying torque.
• Rotor speed which is directly proportional to the applied torque and inversely
proportional to the rotor speed.

PURPOSE OF USE

The gyroscope is used to provide the basic and correct reference in unknown & blind
space or place because it is unaffected by other movements so we can say that it is a
artificial base by which it gives correct information in any axis.

TYPES OF GYRO

• FREE GYRO
• TIED GYRO
• EARTH GYRO
• RATE GYRO
• SPACE GYRO etc.

ALTIMETER
Altimeter is the instrument which is use in aircraft for measure the height of the aircraft
from sea level. Because we assume that sea level is same worldwide that’s why we take
sea level as a reference.

PRINCPLE OF ALTIMETER

The pressure is an Aneroid barometer that measures the pressure of the atmosphere at the
level where altimeter is located, and presents an altitude indication in feet. The altimeter
uses static pressure as its source of operation. Air is denser at sea level than other, so as
altitude increase, atmospheric pressure decreases. This difference in pressure at various
levels causes the Altimeter to indicate changes in Altitude.

The presentation of altitude varies considerably between different types of altimeters.

Some have one pointer while others have two or more. Only the multi pointer type will
be discussed in the viands book.

The dial of a typical altimeter is graduated with numerals arranged clockwise from 0to 9.
Movement of the aneroid element is transmitted through gears to the three hands that
indicate altitude .The shortest hand indicates altitude in ten thousands of feet and the
longest hand in hundreds of feet.

This indicated altitude is correct however, only when the sea level barometric pressure is
standard (29.92 inches of mercury), the sea level free air temperature is standard (+15c or
59F), and the pressure and temperature decreases at a standard rate with an increase in
altitude. Adjustments for nonstandard conditions are accomplished by the connected
pressure into a barometric scale located on the face of the altimeter. Only after the
altimeter is set done in indicate the correct altitude.

The rate at which pressure decreases is much greater near the earth’s surface than at
altimeter (Between sea level and 1000 ft the pressure has been reduced from 1013mb to
697mb , Between 2000ft to 3000ft , pressure reduces from 446mb to 301mb).

For aircraft performance calculations international standard atmosphere ISA is used. This
defines the precise values of lapse rate, height of troposphere, and sea level values of
temperature, pressure and density.

FUEL SENSING PROBE (FSP)

DESCRIPTION

Supply Tank (ST) Probes are two of the six fuel sensor probes installed in ALH. These
ST probes are installed from bottom of the tank. ST probes are for gauging fuel content.
These probes also have built-in low level (L/L) warning sensor which is electrically
isolated from fuel content sensing circuit.

FUNCTION DESCRIPTION

Fuel Content Gauging (FCG) Probe, this consists of two concentric precision Aluminum
Alloy tubes (inner tube pt. no. 9E-61-01-0.4, outer tube pt. no. 9E-61-01-003) insulated
from each other to form capacitance plates. When the plates are not immersed in the fuel,
only air is left in between the two tubes. The dielectric constant of air being lowest, the
probe exhibits low capacitance. When the probe is wholly or partially immersed in
aviation fuel, air is accordingly replaced by the fuel. This increase probe capacitance
accordingly to its length immersed in fuel. The dielectric property of aviation fuel being
higher than air by approximate factor of two, the capacitance value also increases
accordingly. The sensing capacitance is converted into frequency by a stable oscillator
circuit. The entire circuit is placed in the flange head. Thus the o/p of this gauging circuit
is frequency, which varies inversely with immersed fuel level (heights) of the probe.

FUEL LOW LEVEL WARNING SENSORS

The fuel content gauging is integrally fitted with a shallow level sensing tubes, mounted
at the specified height. The low level electronic circuit is also placed in the flange head.
Low-level indicator circuit Independent of gauging circuit. It is basically a sample
precision oscillator tuned with the capacitance value between the low level tubes with
fuel level at the midway of the tube length. The arrangement is such that the oscillator
does not oscillate when fuel is above warning level and oscillates when fuel is below this
level. This oscillation operates the power switch capable to drive a warning lamp on.
Through low level indicator is integrated with main gauging system, electrically both the
system operate independent of each other.
 HORIJON GYRO

It is very important instrument which is bond on the Gyro Motor & its property. At the
ground label we have a reference But in the air no reference. So here we use Gyro. So in
horijon gyro we measure two things Pitch &Roll. By use of vacuums at height we rotate
the motor and keep the property of Rigidity & Presion. It is totally mechanically system
when aircraft wave downward then motor axis remain 90 to axis but its pitch axis goes
change. This will be shown on the indicator. Similarly when plane is rolling then its roll
axis changes which is shown on indicator of the Horijon Gyro.

DIRECTION GYRO

When ever we go any place by motor we have to need the direction of our destination.
Similarly in the air also we need the direction that on which direction we go then we
our destination that need is accomplished by direction gryo. By this instrument we set the
angle of destination, match it with zero and until it is at zero position this is like that will
confirmation about that we are gone at right path.

CAPSULE SHOP

It is very important shop in the factory because in this shop the basic barometric
instrument are manufactured for altimeter and other instruments.

There are following items are manufactured in this shop

1. Capsule and barometric instrument

2. Temperature switch
3. Pressure switch
4. Dc master box
5. Air speed indicator

Capsule
It is the heart of the large no of instrument for aircraft .It simply consists of two diafram
of beryllium and copper material for better handling capability.
We first cut the two pieces of circular shape from the sheet and then make them as like
bowl shape and then joint both the diafram by inductance soldering after that we joint
them at the centre by capillary tube by resistance soldering called breezing
There are two types of capsule
1. altitude capsule
2. pressure capsule
In altitude capsule we make vacuums inside the capsule and sealed the other end of the
capillary
But in pressure capsule we made open the other end of the capillary tube
Both type of instrument are used as barometric instrument

yTEMPERATURE SWITCH

Air temperature gauge is a panel mounted instrument and indicate the out side air
temperature .The sensor position of instrument produces o/p on the cockpit and sense the
outside air temperature
Coding particulars
NAME outside air temp gauge
CODE 1629.00.000
WEIGHT 150 Gms
SIZE 56 *155 mm
ACCURACY +-1.5 %
OPERATING TEMP -45to +75 cel

Temp switch is used in ALH to close the electric circuit when the temp in surrounding air
reaches the predetermined value
The unit also senses the oil temp of the transmission system

It works on vapor pressure action and consists of bulb containing ethyl alcohol, due to
sufficient change in temp the organic liquid vaporizes and build up pressure with in the
closed chamber
This high vapor pressure compresses a bellow assembly which in tern operates the snap
action micro switch
Gear box oil temp senses temp with in the range 115+4to 115-4max and 110+4to 110-4
min
 PRESSURE SWITCH
The pressure switch is used in ALH to close the electric connection of the system when
ever the pressure of system falls below the predetermined value

Coding particulars
NAME pressure switch
CODE 1657.00.000
WEIGHT 90 Gms
ELECTRIC SUPPLY 28v dc
CURRENT CONSUMPTION 500mA
OPERATING RANGE 0.00 to 25 bar
FUNCTION
Pressure switch senses the oil pressure of the auxiliary gear box of the transmission
system

OPERATION
The unit uses a bellow assembly .As the pressure sensing element .The upper end of the
bellow assembly is being fixed leak proof to pipe union with the help of sealing washers
and sealing nuts .When the external pressure is applied to the bellow assembly
compressor and its free end moves towards expand it and operates a micro switch the
micro switch opens the electric circuit when the pressure of the system rises above pre
determined value

DC MASTER BOX
The dc meter boxes and junction boxes forming a past of the generator control and
protection system for advance light helicopter. The distribution boxes protect the system
against any fault as specified in the technical specifications which are likely to occur and
ensure efficient distribution of the power for different buses allocated in the system. DC
electric master box is a part of the dc distribution system.

It receives power from the respective stator generator or from the other master box or
external power unit or from battery and transfer to the different bus bars depending upon
the availability to electrical power in the aircraft, the bus bars are selectively supplied.

In addition with above function the dc master box provide relay/contactor control through
the respective control unit for all bus bars located inside, and provide facility for isolating
bus bars and power source.

It consists of short circuit detection card (scdc) and over voltage protection card (ovpc).

Battery junction box is a part of dc distribution system. It receives power from the
respective battery and transfer to dc electric master box .The provision has been made for
disconnecting the battery from the main bus. In case of battery temperature exceeds the
safe limit.

Dc distribution system consists of

1. dc master box-1
2. dc master box-2
3. battery junction boxes

A/C ELECTRIC DISTRIBUTION BOX (ACBX)

A/C distribution box is used in the advance light helicopter (ALH).Excluding 2

alternator, 2 alternator control and protection unit and static inverter primary a/c
distribution consists of the following boxes
1. A/C master box-3
2. A/C master box-4
3. 115v a/c emergency bus relay
4. 26v a/c emergency bus relay
A/c master box -3 consists of 3 phase main bus -1(115v), 1 phase emergency bus-1 and 2
(115v), I phase main bus-1(26v) and 1 phase emergency bus-1(26v)

During normal operation (both alternator running), complete system-1 is powered from
alternator-1 .In case of fault on alternator-1 all the bus of system-1 are connected to
alternator-2 with alternator-1 in failed condition. In the case of a short circuit on a main
bus-1 it goes disconnect from the alternator-2.
In case of both alternator fail to supply the power of A/C main buses, emergency buses of
system-1are powered by static inverter with a/c ground power in and selected in the
cockpit, external power control card validates in coming ground power and automatically
energies the external power connecter to supply ground power to all buses of the system
1and 2 through main bus -1 of the system-1 a/c .Master box-4 is resistor in conduction
and function to a/c master box-3 as following.
This box does not include external power conductor and the external power control card.
However this has non essential bus along with its connector. The non essential bus is
powered from the main bus-2 only when both alternators are running or external power is
on and selected .All power o/p at different buses are protected with thermal circuit
breakers which are provided in each master box.

Operational condition
• Master power switch ON and bus tie in normal position

1. external power selected

2. alternator -1 selected
3. alternator -2 selected
4. both alternator are selected
5. inverter switch ON
• bus tie switch in reset position
Monitoring function for failure monitoring

Protection
• external power protection by control card
1. over voltage protection
2. under voltage protection
3. over frequency trip
4. under frequency trip
• phase sequence protection
• short circuit fault protection

FTU (FILTER TRANSFORMER UNIT)

The filter transformer unit (ftu-01) is for JAGUAR aircraft. It gives single phase 26v,
400hz, low distortion output synchronized with phase AB of the 3- phase 200v, 400hz
aircraft power source.
There are two no. of the ftus used in one aircraft .In case of failure of one unit
(ftu), the entire ac load will automatically be transferred to another healthy unit(ftu).

FUNCTIONAL DESCRIPTION

The filter transformer unit is enclosed in a cubic shape box and having natural cooling.
The heat sink fans made on two side of wall are capable to provide the sufficient heat
conduction generated from 4 power transistors. The basic electronics of the unit utilizes
the conventional sine wave oscillator and push pull power amplification principle. The
unit provides single phase 26v (rms), 400Hz output synchronized with phase AB of ac
power.
This unit is capable to drive 60va output power continuously. It is also having short time
overload capacity. The unit is having built in protection against
1. output over voltage
2. output under voltage
3. over load and
4. phase error between phase AB of power and phase of output of unit

The 3 phase, 200v, 400 Hz power supply available from source is being fed to step
down transformer .The output is 11v 3-phase, 400 Hz ac .The output of transformer is
rectified by 3-phase bridge rectifier. The rectified output is passed from capacitor for
filtering after that a smooth dc is available. This dc voltage is used to biased the
circuit .1It is 11v 400 Hz dc. After filtrations a low distortion output is available at the
 connecter .The 11v dc is converted to 11v single phase ac by oscillator circuit .Then it
is passed through step up transformer to amplify at value 26 v 400hz 1- phase ac .

A 3 phase oscillator of ICs and associated resister and capacitor produces the 3 phase
sine wave 120degree apart each other .The sine wave available in phase with the sine
wave signal received at the control card. The phase AB of the a/c supply is fed to the I/p
of the synchronizing transformer. The o/p of transformer is step down and is fed to the
control card so that the sine wave available in phase with AB of the supply.
The sine wave o/p is followed by pre amplifier. The o/p of pre amplifier is followed
by the driver transistor mounted on the bottom. The transistor drives the class B push pull
amplifier. The o/p available at the o/p transformer is filtered through a filter consisting of
inductor and capacitor after filtration a low distortion 26 v 400 Hz ac o/p is available at
the connector
The o/p transformer has voltage feedback winding. A sine wave voltage proportional to
the main o/p is being rectified and filtered through the capacitor on the control card
When the unit o/p voltage decreases, the amplitude of square wave is increases,
hence the amplitude of the sine wave increases which in turns increases the o/p voltage
and vice versa
So the regulated output voltage is achieved

PROTECTION

1. PHASE ERROR PROTECTION

The output sine wave and input phase AB available at the synchronizing
transformer are converted to square wave and fed to PLL. The output of PLL is a
pulse whose width varies with phase difference between two square waves. The
output of PLL is followed by a low pass filter. A smooth dc is available at the
output of the low pass filter and whose amplitude is directly proportional to the
width of the pulse .The dc voltage available at the output of the low pass filter is
compared with a fixed reference voltage by a comparator. The comparator output is
low as long as the phase error between output of the unit and input phase is less
than a specified value. When the phase error exceeds the specified value the
comparator output becomes high. The high o/p is fed to the latching time delay
circuit and the o/p becomes high after a specified time delay and thus unit o/p falls
to zero and aircraft load get connected to the 2nd ftu.

2. OUTPUT OVERLOAD VOLTAGE

The ac voltage induced across the feedback winding of o/p transformer is rectified by
bridge rectifier to obtain dc voltage. T he dc voltage is fed to comparator, which
compares the dc voltage with the fixed reference voltage. If the o/p voltage exceeds the
threshold value the o/p of the comparator becomes high which in turns makes the o/p
of the latching cum time delay circuit to high after a fixed time delay which in turn trip
off the unit and aircraft load is transferred to another ftu.
 3. OUTPUT UNDER VOLTAGE

The dc voltage proportional to ac o/p voltage is fed to the comparator which

compares the dc voltage to the specified reference value. If the dc value falls below the
threshold value the o/p of the comparator becomes high and this activate the latching
cum timer circuit which turns off the current unit and aircraft load is transferred to the
another unit after the certain time delay .

4. OUTPUT OVERLOAD

The ac voltage proportional to the current is achieved by the current transformer

.The voltage is rectified and filtered to obtain the dc voltage proportional to the o/p
current .The dc voltage is compared by the reference value by the comparator. If the
value of the current become high then the o/p of the comparator becomes high this makes
the o/p of the latching cum timer circuit high after a certain time delay to on the other ftu
unit.

ALTERNATOR CONTROL AND PROTECTION UNIT

(ACPU)

Alternator control and protection unit regulates the alternator o/p voltage with in
specified limit under various rated load and rated condition. This unit is having built in
protection against over / under voltage, over / under frequency, overload feeder fault
condition, the unit disconnects the alternator from ac control system by denergizing the
line contractor and field.

The unit will be interfaced with the alternator having characteristics

• Type 3 phase star connection voltage 115/200 400hz
• o/p power 5 kva
• normal speed 12000 rpm
• max speed for regulation 12600 rpm
• min speed for regulation 11400 rpm
• over speed 15000 rpm
• frequency at 12000rpm 400 Hz
ACPU FUNCTION
 1. REGULATION

The unit is designed to regulate the alternator voltage with in specified limit. The design
objectives is achieved by using pwm technique .Alternator o/p voltage is fed to the step
down transformer followed by rectifier and filter unit. The o/p dc voltage proportional to
the alternator is compared against the stable internal reference voltage .Any deviation
from normal set voltage adjust duty cycle of the o/p of the switching transistor which
applies to the current to the alternator field to maintain the constant alternator o/p voltage

2. OVER VOLTAGE PROTECTION

This circuit provides to insure that the alternator voltage does not increase the specified
limit. A dc voltage proportional to alternator o/p voltage is compared against the pre
determined reference value, compared o/p fires the scr after a time delay inversely
proportional to the alternator voltage, protection relay get energized through the field of
alternator

3. UNDER VOLTAGE PROTECTION

Alternator voltage is compared by reference value , whenever alternator voltage falls

below the under voltage limit ,comparator o/p gets high which activates the timer circuit
and after a fixed time delay the timer o/p fires the scr which ultimately energies the
protection relays hence field get disconnected.

4. OVER CURRENT PROTECTION

I transformer o/p which is proportional to the alternator current is rectified and filtered
and fed to the comparator
Whenever alternator current exceed the over current protection limit comparator o/p
followed by a timer circuit which provide the triggering signal after a fixed time interval
inversely proportional to the level of the alternator current through scr. The protection
relay get energized and hence field gets disconnected

OVER/UNDER FREQUNCY PROTECTION

phase of alternator is fed to the band pass filter and a timer circuit whenever alternator
frequency exceed the over/under frequency limit the o/p of the band pass filter starts
decreasing and it is continuously being after a fixed time delay to provide a timing signal
to scr which ultimately energies the protection relay.

5. FEEDER FAULT PROTECTION

There are two set of current transformer, 1 set mounted on the alternator side and another
mounted at the load end.
The o/p of both sets of the transformer are rectified and filtered and fed to the
comparator. At normal condition the o/p of the both transformer is balanced otherwise
comparator o/p becomes high .The timer circuit gets activated and after a fixed time
delay it provides relay gets energized and hence field gets disconnected.

AIR SPEED INDICATOR

The indicated air speed indicator US-1600K is designed to measure the aircraft indicated
air speed with in the range from 150 to 1600 kmph.

The scale is calibrated from 0 to 1600 km/hr The division value is 10 km/hr and is
numbered every 100 km /hr The reading up to 1000km/hr are taken from scale with a
pointer and above 1000km/hr from counter and scale .The pointer moves along with the
scale for the second time and the blind counter opens and digit-1 appear in the center
which indicate 1000kmph to take reading, take the counter reading and add the scale
value against the pointer

PRINCIPLE

This system operates a differential pressure of pitot and static pressure fed inside and
outside of the capsule in leak tight case

Pitot pressure is taken and supplied to the capsule and static pressure to constituent
casing, under the action of difference between pitot and static pressure, pressure capsule
get deformed .The deformation value is proportional to the dynamic pressure .The
deformation of pressure capsule is converted by crank mechanism into rotatory motion of
pin in where sector and blind are rigidity secured. Sector moves into mesh with tube
pointer is fitted onto the taper pin .The deflection of pointer is proportional to the
deflection of pressure capsule, hence proportional to the aircraft indicated speed at a
steady air density.

TACHO TRANSMETER

This is used in Chetak and Cheetah helicopters. Tachometer generator is designed to

operate in conjunction with a Tachometer Indicator, the role of which is used to measure
the RPM, speed of engine in which the tachometer generator is installed.
The two instruments are synchronized and are connected together by a three
conductor cable.
 TACHOMETER INDICATOR

This is used in Chetak and Cheetah helicopters to include simultaneously, the speed of
the rotor and turbine. Each indicator is used in conjunction with two generators. One
mounted on turbine and other on the rotor shaft.

FUNCTION

The speeds are indicated by means of two co-auxiliary mounted points as enclosed within
one case, and with one dial which is comprised of two grounded scales.

CHARACTERISTICS

Weight =1010 gms. + 3 %

Range of Turbine = 1500 – 4000 RPM
Range of Rotor = 20 - 450 RPM

FLIGHT DATA RECORDING SYSTEM

INTRODUCTION

Flight data recording system is most important instrument in any flying system.
Generally it is also called as BLACK BOX which is familiar word for journal person. It
is used to find the information about all that activities or events which are done during
flying time. It starts working just as engine goes start and continuously working until it
comes to the earth again.

Basically inside a box there is a reel which continually records all the data which are
needed by technicians and pilot for knowing about the fault if any occur and by this they
can solve the problem.

The speed of movement of reel is .7 to 1.3mm/sec.that means in one hour it can move
upto7.8centimeter.

Length of reel in box is 12m in Russian system and 8m in British system. We are follow
Russian system.

FDRC has notice many thing which are classify in the categories-
• Pilot Technique
• Technical Parameter
 • Mode of Accident

The different parameters are noticed by the FDRC which are given below-

1. CONTINOUS PARAMETER

It covers following parameters-

• AIR SPEED
• HEIGHT
• ALTITUDE
• STABLIGER OR ANGULAR DEFLECTION
• ENGINE SPEED
• GRAVITATIONAL ACCELARATION

2. TIME MAKER & BASE LINE

Time maker give a fix duration cut in reel by this it is easier to gain
information in some duration about plane.

Base line is fix line which remain constant and below which no line exist.

3. EVENT COMMAND OR ON-OFF COMMAND

These are those events which are done by either pilot or due to some other
fault.

4. SUPER IMPOSED

These types are event are imposed on the continuous parameter. Some are
given below-

• ENGINE PIPE TEMPERATURE

• JPT
• EXAUST GAS TEMPERATURE

CAPACITY OF BLACK BOX

Black box is put on that position on the aircraft which are safe after accident. So it is put
at the Rudder of the aircraft. Black box can bear a temp 2000c up to 15min. and it water
proofing capacity is that it can remain in water up to 2month.
 AWARDS FOR ACHIEVEMENTS
HAL has won several International & National Awards for achievements in R&D,
Technology, Managerial Performance, Exports, Energy Conservation, Quality and
Fulfillment of Social Responsibilities.

• HAL was awarded the “INTERNATIONAL GOLD MEDAL AWARD” for

Corporate Achievement in Quality and Efficiency at the International Summit
(Global Rating Leaders 2003), London, UK by M/s Global Rating and UK in
conjunction with the International Information and Marketing Centre (IIMC).

• HAL was presented the International - “ARCH OF EUROPE” Award in Gold

Category in recognition for its commitment to Quality, Leadership, Technology
and Innovation.

• At the National level, HAL won the "GOLD TROPHY" for excellence in Public
Sector Management, instituted by the Standing Conference of Public Enterprises
(SCOPE).