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It's a report on industrial training at HAL
Typology: Summaries
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Hindustan Aeronautics Limited Helicopter Division, Bangalore- 560017 Submitted to UNIVERSITY VISVESVARYA COLLEGE OF ENGINEERING K.R CIRCLR BANGALORE- BY:- AANTU MATHEW SHAJI ENROLLMENT NO:-! 7GAEM AMBRESH ENROLLMENT NO- 17GAEM
I would like to offer my sincerest thanks and deepest appreciation to all those who helped me to complete my training with a bunch of useful knowledge. I also offer a very special thanks to “HAL, HELICOPTER DIVISION” for giving me such a golden opportunity of grateful stay in its industry as a trainee. I also thank my department HOD “Mr. SHIVARUDRIAH” for his time to time suggestions about the fields we can opt for in our future interest as an Aerospace Engineer. I also pay my sincere thanks to our ALH department head MR-SENTHIL KUMAR for being my soul inspiration towards my training in helicopter division as he continuously monitored me with all the available suggestions about how good and exciting once career can be in the field of rotary wing mechanism and that helped me a lot in setting my approach towards this professional training. I will also greet my special thanks to all colleague trainees and staff members, who treated me as their junior and helped me on every aspect. .I would like to thank HR manager “ MR KHAN “ for the necessary guidance.I would also like to thank my fellow trainees for making this visit a joyful experience
Hindustan Aeronautics Limited (HAL) established as Hindustan Aircraft in 1940, based in Bangalore, India, is one of Asia's largest aerospace companies. The primary engineering divisions that this industry possess are manufacturing, assembling & Diagnosis. HAL built the first military aircraft in South Asia. The primary engineering divisions that HAL currently possess are designing, fabrication and assembly of aircraft, jet engines, and helicopters, as well as their components and spares. Hindustan Aeronautics Limited (HAL) was formed on 1 October 1964 when Hindustan Aircraft Limited joined the consortium formed in June by the IAF Aircraft Manufacturing Depot, Kanpur and the group recently set up to manufacture Mig-21 under license. Though HAL was not used actively for developing newer models of fighter jets, the company has played a crucial role in modernization of the Indian Air Force. In 1957 company started manufacturing Bristol Siddeley Orpheus jet engines under license at new factory located in Bangalore. During the 1980s, HAL's operations saw a rapid increase which resulted in the development of new indigenous aircraft such as the HAL Tejas and HAL Dhruv. HAL also developed an advanced version of the MiG-21, known as MiG-21 Bison, which increased its life-span by more than 20 years.
Trimming of Trim Tabs Twist check Static Balancing Weighing Dynamic Balancing Deliver for assembly helicopter section of 16 jan Transmission assembly of Chetak Cheetah helicopters Transmission Assembly 17 jan (^) Electrical connections and electric installations of gauges CHETAK & CHEETAH HELICOPTER in final assembly hanger Chetak assembl y Cheetah final 17 jan Transmission Assembly of ALH (IDS) ALH transmission 18 jan Bringing together of subassembly of ALH like Transmission equipment deck Tail boom structure Bottom structure Etc…. ALH structural assembly 18 jan Fitting together of subassembly on jig ALH Final Assembly 20 jan Equipping of helicopter Rain water test & Flight test ALH Final Assembly
Brief Training Exposure: ALH Final Assembly ALH Final Assembly looks after the assembling & equipping of ALH (Advanced Light Helicopter). In particular I was trained to the ALH hanger which is engaged in development & manufacture of ALH named 'DHRUV' DHRUV is a light 5.5 tonne class, multi-role, multi-mission helicopter, fitted with two Turbomeca TM333 2B2 engines. The advanced technologies incorporated in the ALH design includes: Automatic Flight Control System (AFCS) Anti-Resonance Vibration Isolation System (ARIS) Active Vibration Control System (AVCS) Full Authority Digital Engine Control (FADEC) Hinge Less Main Rotor & Bearing Less Tail Rotor Integrated Dynamic System (IDS) Automatic Flight Control System(AFCS) An AFC system is a system which augments the stability, improves handling and provides automatic flying thus relieving the pilot’s workload and also freeing him for other mission related activity by providing auto pilot functions such as velocity hold, altitude hold, heading hold etc. Control system comprises of:
Active Vibration Control System (AVCS) Dhruv (ALH) helicopter incorporates a highly advanced hinge less main rotor. This rotor configuration induces high dynamic loads on the airframe, particularly at the blade passing frequency 4/rev (21 Hz), which is equal to the number of blades 4 multiplied by the rotor speed of 314 rpm. The 4/rev main rotor vibration is a cause of discomfort for passengers and crew, reduces fatigue life, cause damage to on-board sensitive equipment and increase maintenance cost. The Active Vibration Control System (Frahm Damper system) developed by M/s Lord Corporation , USA have been employed on the helicopter to augment the existing ARIS system for further reduction in vibration level over the flight envelope for different helicopter configurations. The AVCS along with ARIS will enhance the crew and passenger comfort and attenuate the 4/rev main rotor vibration to acceptable levels. Full Authority Digital Engine Control (FADEC) The TM333-2B2 engine is controlled by the Full Authority Digital Engine Control (FADEC). The heart of this system is a computer, which is provided in avionics bay / hinged panel. The FADEC receives the input signal from the sensors mounted on engine and pilot orders and control switches. FADEC functions and operations are explained latter.
Hinge Less Main Rotor & Bearing Less Tail Rotor The technological advancement in material science especially composites, has lead to the elimination of physical hinges in the rotor system. The main rotor blades of Dhruv (ALH -Advanced Light Helicopter), uses the flexibility of fiber reinforced composites in order to eliminate the need for hinges. The flap and lead-lag articulations are provided by the flexing of the soft neck area of the rotor blades. This type rotor without mechanical hinges is called Hinge less Rotor. The pitch change bearings have been replaced by elastomeric bearings which do not need any lubrication. In tail rotor of Dhruv, all the three articulations (flap, lead-lag and pitch) are obtained through flexing and twisting of flex beam. Such rotors are called Bearingless Rotors. Specifications of main rotor:- Rotor type :- Hingeless, Fiber- elastomeric Number of blades :- 4 (composite material) Rotor speed :-314 rpm. Direction of rotation :- Clockwise (as seen from top) Rotor diameter :- 13.2 m (43.3 feet) Blade plan form :- Rectangular with Parabolic tip. Blade chord :- 0.5 m up to 0.9242R, 0.167 m at the tip Airfoil :- DMH 4 up to 0.8R (STA 5280) DMH3 from 0.9242R (STA 6100) to 1R (STA 6600)
Fig :- IDS of DHRUV TURBOMECA 333-2B2 ENGINE SPECIFICATION: Model : TM–333 M/s TurboMeca (France) Version : 2B Power Output : 801 kW (1073 Shp) at SL ISA Length : 1045 mm Breadth : 450 mm Width : 745 mm Weight : 166.5 Kg. Output shaft speed : 6000 rpm (CW view from rear) Gas Generator Speed : 45000rpm (100%) (CCW view from rear) Power Turbine Speed : 37562 rpm (100%) (CW view from rear) Operating altitude : -500 m to 7000m Operating temperature : -50 °C to + °C Fuel used : ATF K- Oil Used : MIL–L–23699(JET OIL II)
Assembling & Equipping of ALH ALH final assembly assembles the DHRUV helicopter in four specific stages carried out at 4 different work stations under the same hanger consisting of 37 equipping stages. After the helicopter is assembled, the various functional tests are carried out for each system under differing atmospheric conditions, it includes:- o Functional testing of Hydraulic system o Functional testing of PP & FUEL system o Functional testing of electrical AFCS & Avionic system o Rain water testing o Break out force Measurement testing Then in next stage “Optional equipment” is installed to the helicopter. Once helicopter is ready with all the required equipment as per customer demand, it is taken for final inspection followed by FOD check & CRI. After these all, the helicopter is ready for ground run.
Mr. Kishor Sami Reddy (D.M., ALH Final Assembly) Mr. Gaurav Kumar (D.M., ALH Final Assembly) Mr. Vara Prasad (D.M., ALH Transmission) OBJECTIVES OF TRAINING This full training was oriented towards a big positive on the exposure to the works carried out in an aviation industry and hence learnt a good deal from them. It was a major step towards the practical things going outside our syllabus, which was like a really different world and the environment we usually get in our college under the umbrella of our university syllabus. The base aim of the training was to know about how and in how many stages a helicopter blade is manufactured. It was also towards the learning of how complicated a helicopter’s working mechanism can be and what are the ways our engineers have found to bring it of simplest mechanism, better safety and more efficiency. The advancement in helicopter since it was first built in any Indian industry to presently an armed ALH has been a great example of advancement and of premier example set upon for me and all the upcoming engineers in future. METHODOLOGY My training consisted of three sessions; In first session I did attained an industrial environment where I observed the process and procedure going on in the industry about how machines are used and
how to use the instruments with a comprehensive explanation. In this I observed the working of all the staff and how they operated the machines with great care, taking all the possible precautions. In second session we were given a manual about the instruments which included all the details about the parts to be manufactured and how to use all these instruments under the guidance of my seniors in industry. And then my guide explained all the machine parts with a great sincerity. Later in the last session I observed all the product produced on day and observed the final assembly obtained from that whole day. It also included observing and comparing the product with the master sample product available and checking for if any deviation had occurred from master piece data and how that was compensated, followed by a doubt clearance and questionnaire session on the topics we covered on that day. BENEFIT OF THE TRAINING As the training was fully concentrated towards our approach in any industry, it was a dare time to face our future in present scenario as a student. This training will work up as a boost for me in future, when I step up in the shoes of an engineer
