HINDUSTAN AERONAUTICS LIMITED (HAL)

AIRCRAFT DIVISION, BANGALORE

MISSION AND COMBAT SYSTEM RESEARCH AND DEVELOPMENT CENTRE (MCSRDC)

REPORT ON IN-PLANT TRAINING

BMS COLLEGE OF ENGINEERING (An Autonomous Institute Affiliated to VTU)

BASAVANGUDI, BANGALORE

Submitted To: Submitted By:

Dr. T.Balagurunathan Srirama.N

HOD (SYS), MCSRDC Podapati Shivani Rao

HAL, Bangalore

ACKNOWLEDGEMENT

The internship opportunity we had with HAL was a great chance for learning and

professional development. Therefore, we consider ourselves as very lucky individuals as

we were provided with an opportunity to be a part of it. We are also grateful for having a

chance to meet many wonderful people and professionals who led us through this

internship period.

We take this opportunity to express our profound gratitude and deep regards to Dr.

T. Balagurunathan, HOD(Systems) Of MCSRDC, HAL who in spite of being extremely busy

with his duties, took time to teach, hear, guide and keep us on a learning curve during this

training. The blessing, help and guidance given by him time shall carry us a long way in the

journey of life.

We express our deepest thanks to Mr. H V Babu, CM (D), MCSRDC ; Mr. K D Shelley,

Head, HMA; Mr. Murali, AGM, MCSRDC.

INTRODUCTION

Hindustan Aeronautics Limited (HAL) based in Bangalore, India, is one of Asia's

largest aerospace companies. Under the management of the Indian Ministry of Defense, this

state-owned company is mainly involved in aerospace industry, which includes

manufacturing and assembling aircraft, navigation and related communication equipment,

as well as operating airports.

Today, HAL has 19 Production Units and 10 Research & Design Centers in 8

locations in India. The Company has an impressive product track record - 15 types of

Aircraft/Helicopters manufactured with in-house R & D and 14 types produced under

license. HAL has manufactured over 3658 Aircraft/Helicopters, 4178 Engines, Upgraded

272 Aircraft and overhauled over 9643 Aircraft and 29775 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:

Advanced Light Helicopter – Weapon System Integration (ALH-WSI)

Tejas - Light Combat Aircraft (LCA)

Intermediate Jet Trainer (IJT)

Light Combat Helicopter (LCH)

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.

MCSRDC

Mission and Combat System R&D Centre (MCSRDC) is the latest R&D Center of HAL,

established in November 2008 to design and develop Integrated Avionics Systems for Fixed

and Rotary wing aircraft.MCSRDC's strength is in design and development of avionics

systems from conceptual designto final product and certification for aircraft and

Helicopters applications. Following are the core competencies of the R&D Centre

Design & Development of Integrated Avionics Systems for fixed & rotary wing

upgrade and new aircraft.

Integration of Avionics and Weapon Systems on aircraft.

Aircraft System software development.

Algorithm development for Navigation, Weapon Guidance & Displays.

Design of Integration Test Rigs.

Electrical & Structural Installation design, analysis and Certification.

Some of the Projects Executed:

DARIN II (Display Attack Ranging and Inertial Navigation) upgrade of Jaguar aircraft

significantly enhancing mission and operational capabilities with advanced

navigation, EW and attack features and precision weapon deliveries through

contemporary avionics systems.

Avionics Upgrade of Sea Harrier (LUSH Upgrade) significantly enhancing mission

effectiveness through integration of the state of the art Fire Control Radar, Data link,

Navigation systems, Beyond Visual Range Missile and Network-based engagement

features.

Integration of various avionics systems (Electronic Warfare suite, Autopilot, FLIR &

Laser Pod, VOR/ILS/TACAN, GPS, Reconnaissance system, Air Combat Maneuvering

training system, Helmet Mounted Display System, etc.) on different combat &

transport aircraft enhancing their Mission capability and performance.

Current Programs that MCSRDC has been involved with:

DARIN-III avionics upgrade (with Fire Control Radar and near Glass Cockpit with

two Smart Multi-Function Displays and Engine & Flight Instrumentation System,

integrated around an advanced Mission Computer ) on DARIN Jaguar aircraft for

improved operational capabilities.

Development of Automatic Flight Control System for Light Combat Helicopter and

Light Utility Helicopter.

Development of Integrated Avionics and Display System for Light Combat Helicopter

and Light Utility Helicopter.

FLIGHT PRINCIPLES& AIRCRAFT STRUCTURE

Forces acting on an airplane: There are four forces acting on the airplane all the time during airplane is flying. The four forces are

(1) Lift,

(2) Gravity force or Weight,

(3) Thrust, and

(4) Drag.

Lift: Lift is produced by a lower pressure created on the upper surface of an airplane's

wings compared to the pressure on the wing's lower surfaces, causing the wing to be

LIFTED upward. The special shape of the airplane wing (airfoil) is designed so that air

flowing over it will have to travel a greater distance and faster resulting in a lower

pressure area thus lifting the wing upward. Lift is that force which opposes the force of

gravity (or weight).

Lift depends upon (1) shape of the airfoil (2) the angle of attack (3) the area

of the surface exposed to the airstream (4) the square of the air speed (5) the

air density.

Weight: The weight acts vertically downward from the center of gravity (CG)

of the airplane.

Thrust: is defined as the forward direction pushing or pulling force

developed by aircraft engine. This includes reciprocating engines, turbojet

engines, and turboprop engines.

Drag: is the force which opposes the forward motion of airplane. Specifically, drag is

retarding force acting upon a body in motion through a fluid, parallel to the direction of

motion of a body. It is the friction of the air as it meets and passes over an airplane and

its components. Drag is created by air impact force, skin friction, and displacement of

the air.

Aircraft Flight Control

An airplane is equipped with certain fixed and movable surfaces or airfoils which

provide for stability and control during flight.

Each of the named of the airfoil is designed to perform a specific function in the flight of

the airplane. The fixed airfoils are the wings, the vertical stabilizer, and the horizontal

stabilizer. The movable airfoils called control surfaces, are the ailerons, elevators,

rudders and flaps. The ailerons, elevators, and rudders are used to "steer" the airplane

in flight to make it go where the pilot wishes it to go. The flaps are normally used only

during landings and extends some during takeoff.

Aileron: may be defined as a movable control surface attached to the trailing edge of a

wing to control an airplane in the roll, that is , rotation about the longitudinal axis.

Elevator: is defined as a horizontal control surface, usually attached to the trailing edge

of horizontal stabilizer of an airplane, designed to apply a pitching movement to the

airplane. A pitching movement is a force tending to rotate the airplane about the lateral

axis,that is nose up or nose down.

Rudder: is a vertical control surface usually hinged to the tail post aft of the vertical

stabilizer and designed to apply yawing movement to the airplane, that is to make it

turn to the right or left about the vertical axis.

Wing Flaps: are hinged or sliding surfaces mounted at the trailing edge of wings and

designed to increase the camber of the wings. The effect is to increase the lift of the

wings.

FLIGHT INSTRUMENTS

Flight instruments are the instruments in the cockpit of an aircraft that provide the

pilot with information about the flight situation of that aircraft, such as altitude, speed and

direction. The flight instruments are of particular use in conditions of poor visibility, such

as in clouds, when such information is not available from visual reference outside the

aircraft.

Altimeter

The altimeter shows the aircraft's altitude above sea-level by measuring the

difference between the pressure in a stack of aneroid capsules inside the altimeter and the

atmospheric pressure obtained through the static system. It is adjustable for local

barometric pressure which must be set correctly to obtain accurate altitude readings. As

the aircraft ascends, the capsules expand and the static pressure drops, causing the

altimeter to indicate a higher altitude. The opposite effect occurs when descending. With

the advancement in aviation and increased altitude ceiling the altimeter dial had to be

altered for use both at higher and lower altitudes. Hence when the needles were indicating

lower altitudes i.e. the first 360 degree operation of the pointers was delineated by the

appearance of a small window with oblique lines warning the pilot that he is nearer to the

ground. This modification was introduced in the early sixties after the recurrence of air

accidents caused by the confusion in the pilot's mind. At higher altitudes the window will

disappear.

Airspeed indicator

The airspeed indicator shows the aircraft's speed (usually in knots ) relative to the

surrounding air. It works by measuring the ram-air pressure in the aircraft's Pitot tube. The

indicated airspeed must be corrected for air density (which varies with altitude,

temperature and humidity) in order to obtain the true airspeed, and for wind conditions in

order to obtain the speed over the ground.

Magnetic compass

The compass shows the aircraft's heading relative to magnetic north. While reliable

in steady level flight it can give confusing indications when turning, climbing, descending,

or accelerating due to the inclination of the Earth's magnetic field. For this reason, the

heading indicator is also used for aircraft operation. For purposes of navigation it may be

necessary to correct the direction indicated (which points to a magnetic pole) in order to

obtain direction of true north or south (which points to the Earth's axis of rotation).

Heading indicator

The heading indicator (also known as the directional gyro, or DG; sometimes also

called the gyrocompass, though usually not in aviation applications) displays the aircraft's

heading with respect to magnetic north. Principle of operation is a spinning gyroscope, and

is therefore subject to drift errors (called precession) which must be periodically corrected

by calibrating the instrument to the magnetic compass. In many advanced aircraft

(including almost all jet aircraft), the heading indicator is replaced by a horizontal situation

indicator (HSI) which provides the same heading information, but also assists with

navigation.

Vertical speed indicator

The VSI (also sometimes called a variometer, or rate of climb indicator) senses

changing air pressure, and displays that information to the pilot as a rate of climb or

descent in feet per minute, meters per second or knots.

Course deviation indicator

The CDI is an avionics instrument used in aircraft navigation to determine an

aircraft's lateral position in relation to a track, which can be provided by a VOR or an

instrument landing system (ILS).This instrument can also be integrated with the heading

indicator in a horizontal situation indicator.

AIR NAVIGATION

The basic principles of air navigation are identical to general navigation, which

includes the process of planning, recording, and controlling the movement of a craft from

one place to another. Successful air navigation involves piloting an aircraft from place to

place without getting lost, breaking the laws applying to aircraft, or endangering the safety

of those on board or on the ground.

Air navigation differs from the navigation of surface craft in several ways: Aircraft

travel at relatively high speeds, leaving less time to calculate their position on route.

Aircraft normally cannot stop in mid-air to ascertain their position at leisure. Aircraft are

safety-limited by the amount of fuel they can carry; a surface vehicle can usually get lost,

run out of fuel, then simply await rescue.

There is no in-flight rescue for most aircraft. Additionally, collisions with

obstructions are usually fatal. Therefore, constant awareness of position is critical for

aircraft pilots. The techniques used for navigation in the air will depend on whether the

aircraft is flying under visual flight rules (VFR) or instrument flight rules (IFR).

In the latter case, the pilot will navigate exclusively using instruments and radio

navigation aids such as beacons, or as directed under radar control by air traffic control. In

the VFR case, a pilot will largely navigate using "ded-reckconing or "dead reckoning"

combined with visual observations (known as pilotage), with reference to appropriate

maps. This may be supplemented using radio navigation aids.

RADAR COMMUNICATION

Radar is an object-detection system that uses radio waves to determine the range,

altitude, direction, or speed of objects. It can be used to detect aircraft, ships, spacecraft,

guided missiles, motor vehicles, weather formations, and terrain. The radar dish or antenna

transmits pulses of radio waves or microwaves that bounce off any object in their path. The

object returns a tiny part of the wave's energy to a dish or antenna that is usually located at

the same site as the transmitter.

Principles

A radar system has a transmitter that emits radio waves called radar signals in

predetermined directions. When these come into contact with an object they are usually

reflected or scattered in many directions. Radar signals are reflected especially well by

materials of considerable electrical conductivity—especially by most metals, by seawater

and by wet ground. Some of these make the use of radar altimeters possible. The radar

signals that are reflected back towards the transmitter are the desirable ones that make

radar work. If the object is moving either toward or away from the transmitter, there is a

slight equivalent change in the frequency of the radio waves, caused by the Doppler effect.

Radar receivers are usually, but not always, in the same location as the transmitter.

Although the reflected radar signals captured by the receiving antenna are usually very

weak, they can be strengthened by electronic amplifiers. More sophisticated methods of

signal processing are also used in order to recover useful radar signals.

The weak absorption of radio waves by the medium through which it passes is what

enables radar sets to detect objects at relatively long ranges—ranges at which other

electromagnetic wavelengths, such as visible light, infrared light, and ultraviolet light, are

too strongly attenuated. Such weather phenomena as fog, clouds, rain, falling snow, and

sleet that block visible light are usually transparent to radio waves. Certain radio

frequencies that are absorbed or scattered by water vapor, raindrops, or atmospheric gases

(especially oxygen) are avoided in designing radars, except when their detection is

intended.

Radar relies on its own transmissions rather than light from the Sun or the Moon, or

from electromagnetic waves emitted by the objects themselves, such as infrared

wavelengths (heat). This process of directing artificial radio waves towards objects is called

illumination, although radio waves are invisible to the human eye or optical cameras.

Radar Data Processing & Display System (RDPDS), Flight Data Processing System

(FDPS) and Simulator System (SIM) -- (The heart of the air traffic control system). The

RDPDS processes the radar data from various primary and secondary radars to present the

aircraft position and its related information, e.g. aircraft call sign, altitude, ground speed,

aircraft category, etc. on the radar display. This information is used by air traffic controllers

to control the approach/departure, terminal and en-route traffic.

Primary Surveillance Radar (PSR)

This type of radar detects and provides both range and bearing information of an

aircraft within its effective coverage by radio wave reflection. Depending on the

application, the coverage will be within 80NM for approach control or within 200NM for

en-route control purpose.

Surface Movement Radar (SMR)

This radar is mounted on top of the Aerodrome Control Tower for surveillance of

the movement of aircraft and vehicles on the runway and taxiways. The accurate

information provided enables the tower controller to maintain a smooth flow of traffic

during low visibility or darkness.

RADIO COMMNICATION

Radio is the radiation (wireless transmission) of electromagnetic signals through

the atmosphere or free space. Information, such as sound, is carried by systematically

changing (modulating) some property of the radiated waves, such as their amplitude,

frequency, phase, or pulse width. When radio waves strike an electrical conductor, the

oscillating fields induce an alternating current in the conductor. The information in the

waves can be extracted and transformed back into its original form.

SAFETY DEVICES

Ejection seat-

In aircraft, an ejection seat (or ejector seat) is a system designed to rescue the pilot

or other crew of an aircraft (usually military) in an emergency. In most designs, the seat is

propelled out of the aircraft by an explosive charge or rocket motor, carrying the pilot with

it. The concept of an eject able escape crew capsule has also been tried. Once clear of the

aircraft, the ejection seat deploys a parachute. Ejection seats are common on certain types

of military aircraft.

The purpose of an ejection seat is pilot survival. The pilot typically experiences an

acceleration of about 12–14 g (117–137 m/s2). Western seats usually impose lighter loads

on the pilots; 1960s-70s era Soviet technology often goes up to 20–22 g (with SM-1 and

KM-1 gun barrel-type ejection seats). Compression fractures of vertebrae are a recurrent

side effect of ejection.

Pilots have successfully ejected from underwater in a handful of instances, after

being forced to ditch in water. Documented evidence exists that pilots of the US and Indian

Navies have performed this feat.

As of 20 June 2011 – when two Spanish Air Force pilots ejected over San Javier airport – the

number of lives saved by Martin-Baker products was 7,402 from 93 air forces.[15] The

company runs a club called the 'Ejection Tie Club' and gives survivors a unique tie and lapel

pin.[16] The total figure for all types of ejection seats is unknown, but may be considerably

higher.

Black box-

A black box is a device, system or object which can be viewed in terms of its input,

output and transfer characteristics without any knowledge of its internal workings. Its

implementation is "opaque" (black). Almost anything might be referred to as a black box: a

transistor, an algorithm, or the human brain.

The opposite of a black box is a system where the inner components or logic are

available for inspection, which is sometimes known as a clear box, a glass box, or a white

box.

A flight recorder is an electronic recording device placed in an aircraft for the

purpose of facilitating the investigation of aviation accidents and incidents. Commonly

referred to as a black box. There are two common types of flight recorder, the flight data

recorder (FDR) and the cockpit voice recorder (CVR). In some cases, the two recorders may

be combined in a single unit.

Flight recorders are required to be capable of surviving the conditions likely to be

encountered in a severe aircraft accident. For this reason, they are typically specified to

withstand an impact of 3400 g and temperatures of over 1,000 °C (1,830 °F) as required by

EUROCAE ED-112.

Lightning diverters-

Lightning Attaches to entry and exit points almost simultaneously, and most

commonly strikes the nose, wingtips, engine cowlings, and tip of the vertical tail. Lightning

diverters, thin metallic strips incorporated onto the surface of the radome, act as little

lightning rods to prevent lightning from puncturing the radome and damaging its

electronics. Conductive metals are used to bond lights to the wingtips, and the bonding

protects the lights by grounding them to the rest of the airplane.

Auto Pilot-

An autopilot is a system used to control the trajectory of a vehicle without constant

'hands-on' control by a human operator being required. Autopilots do not replace a human

operator, but assist them in controlling the vehicle, allowing them to focus on broader

aspects of operation, such as monitoring the trajectory, weather and systems. Autopilots

are used in aircraft, boats (known as self-steering gear), spacecraft, missiles, and others.

Autopilots have evolved significantly over time, from early autopilots that merely held an

attitude to modern autopilots capable of performing automated landings under the

supervision of a pilot.

Modern autopilots use computer software to control the aircraft. The software reads

the aircraft's current position, and then controls a Flight Control System to guide the

aircraft. In such a system, besides classic flight controls, many autopilots incorporate thrust

control capabilities that can control throttles to optimize the airspeed, and move fuel to

different tanks to balance the aircraft in an optimal attitude in the air. Although autopilots

handle new or dangerous situations inflexibly, they generally fly an aircraft with lower fuel

consumption than a human pilot.

The autopilot in a modern large aircraft typically reads its position and the aircraft's

attitude from an inertial guidance system. Inertial guidance systems accumulate errors

over time. They will incorporate error reduction systems such as the carousel system that

rotates once a minute so that any errors are dissipated in different directions and have an

overall nulling effect. Error in gyroscopes is known as drift. This is due to physical

properties within the system, be it mechanical or laser guided, that corrupt positional data.

The disagreements between the two are resolved with digital signal processing, most often

a six-dimensional Kalman filter. The six dimensions are usually roll, pitch, yaw, altitude,

latitude, and longitude.

CONCLUSION

The internship program at HAL aimed at enhancing the trainee’s technical

knowledge and skills, providing exposure to the real world situations/ problems,

familiarizing the trainee with the aeronautical industry and giving an insight into the

altitude necessary for a potential trainee to work in an industry.

REFERENCES

Aircraft electricity and electronics by EISMIN

Pilots handbook of Aeronautical knowledge- FAA

Aircraft Radio System by JAMES POWELL

Aircraft Communication and Navigation System by MIKE TOLEY

Aircraft Basic Science by KROES AND RARDON