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Student Internship
Programme Report

















Name Amizzuddin Bin MD Amin
Class AE4 (01)
Matrix Number 1200243B
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Diploma in AEL / AEG
Diploma in ELN / MTN



Declaration of Originality


By submitting this work, I / we declare that:
I am / we are the originator(s) of this work.
I / we have appropriately acknowledged all other original sources used in this
work.
I / We understand that Plagiarism is the act of taking and using the whole or
any part of another persons work and presenting it as my/ our own without
proper acknowledgement.
I / We understand that Plagiarism is an academic offence and if I
am/we are found to have committed or abetted the offence of plagiarism in
relation to this submitted work, disciplinary action will be enforced.




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I. Table of Contents

1. Introduction .................................................................................................................................... 4
2. Project Description .............................................................................................................................. 5
2.1 Major Projects Overview .............................................................................................................. 5
2.1.1 Stabilized Power Supply (SPS) Project ................................................................................... 5
2.1.2 Third Hand Project ................................................................................................................. 6
2.1.3 Infra-Red Transceiver Project ................................................................................................ 6
2.2 Details of Major Projects / Selected Practical Exercise ................................................................. 7
2.2.1 Stabilized Power Supply (SPS) Project ................................................................................... 7
2.2.2 Third Hand Project ................................................................................................................. 9
2.2.3 Infra-Red Transceiver Project .............................................................................................. 10
2.3 Rationale and Objectives of major project ................................................................................. 11
2.3.1 Stabilized Power Supply (SPS) Project ................................................................................. 11
2.3.2 Third Hand Project ............................................................................................................... 11
2.3.3 Infra-Red Receiver and Transmitter Project ........................................................................ 11
2.4 Working Principle ........................................................................................................................ 12
2.4.1 Stabilized Power Supply (SPS) Project ................................................................................. 12
2.4.2 Third Hand Project ............................................................................................................... 12
2.4.3 Infra-Red Receiver and Transmitter Project ........................................................................ 13
2.5 Analysis of the SIP Experience .................................................................................................... 15
3. Conclusion ......................................................................................................................................... 15
4. Recommendations ............................................................................................................................ 15


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1. Introduction


The purpose of the Student Internship Programme (SIP) which is part of Aerospace Electronics (AEL)
diploma course is to provide the necessary hand skill training accordance to the aviation
maintenance standards. This explains why the programme is conducted at Lufthansa Technical
Training Centre (LTT) since LTT is one of the approved maintenance organisations by Civil Aviation
Authority Singapore (CAAS) under the Singapore Airworthiness Requirement 147 (SAR 147). At the
same time, LTT has established a reputation for the highest level training as well as Maintenance,
Repair and Overhaul (MRO) services worldwide.

The initial expectation of the SIP as briefed by the lecturers before the start of the programme was
that the programme is supposed to equip the student the necessary hand skills which incorporates
with the standard maintenance practice based on aviation standards. This includes understanding
the proper maintenance procedures and safety.

At the beginning of the programme, the students were brief on the expectation by the diploma unit
on the attendance, safety awareness in the workshop (based on the 5s Sort, Set in Order, Shine,
Standardize and Sustain) and attitude. These expectations were emphasize from time to time during
the theory lessons as well as practical workshop.

One example will be that the 5s signs were put up in the workshop as a reminder to the students the
proper conduct and attitude in the workshop. At the same time the students were constantly
reminded to put on the safety goggles during drilling and punching. Instructors also station on
hazard prone workstation to ensure students correctly use the equipment. Morning briefings are
conduct to inform the students the challenges they might face during fabricating parts as well as the
correct use of equipment.

This programme also provides the student some field trip to understand the nature of work in the
aviation industry. Students of AE 3 and 4 were sent to Panasonic Singapore for a field trip, which
provide inflight entertainment system for Singapore Airlines. Since the students are from the B2
batch which more provision on the avionics system and the electronics, the field trip was indeed
fruitful trip. The manager who gave the student the tour around company was helpful to answer the
student enquiry on the latest job market as well as the job prospect joining the Maintenance Repair
and Overhaul (MRO) companies.




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2. Project Description
2.1 Major Projects Overview
2.1.1 Stabilized Power Supply (SPS) Project


Figure 2.2.3 1 the Final Assembly of the SPS project
The SPS project consists of mechanical as well as electronics sections. In the Mechanical section of
the project, Students are required to fabricate the housing of the SPS based on the interpretation of
the engineering drawing. As for the electronics section of the project, students are required to
construct the circuit as per given PCB and wiring layout. Due to the complication of the project,
students are required to understand the priority of which part of the project required to work on
and apply the necessary skills taught in the theory lessons.

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2.1.2 Third Hand Project


Figure 2.2.3 2 the final assembly of the Third hand project

The Third Hand project is made up of mechanical parts only. The assembly of the project are made
up of 3 parts which requires the student to understand the assembly as well as the interpretation of
the engineering drawing. This project has exposed the students the understanding of handling
different types of materials as the project consist of steel and aluminium.




2.1.3 Infra-Red Transceiver Project

The Infra-Red receiver and transmitter project consists of electronic parts only. The construction of
these 2 circuits differs as the receiver is built from a printed circuit board (PCB) and the transmitter
circuit has to be built from scratch from Vero board. These differences have exposed the students in
different types of skills such as planning, troubleshooting and soft soldering.

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2.2 Details of Major Projects / Selected Practical Exercise
2.2.1 Stabilized Power Supply (SPS) Project
a) 2.2.1 Mechanical Section


Figure 2.2.1 a-1 the materials needed to fabricate SPS housing.

Figure 2.2.1 a-2 the completion of SPS housing

Figure 2.2.1 a-3 the fabrication of the back panel of SPS housing.

The mechanical section of the SPS
project enhance the following
modules of the training:-

M6.5 - Material Hardware
(Fastener and Bolts).
M7.2 - Workshop Practices
M7.3 - Tools.
M7.5 - Engineering
Drawings.
M7.14.1 - Sheet metal
bending.

The SPS housing is made of 4 parts.
They are:-

1 Aluminium Top cover.
2 Aluminium Back Panel.
3 Aluminium Front Panel.
4 Composite Plastic Base Plate.

The attached photos are the
processes for which how the
fabrication of the SPS housing is
done.

The challenges faced during the
fabrication of the SPS housing is that
the connection of the parts requires
alignment before process of making
screw threads. Without the
alignment, it will cause fitting
problems for other parts of the
housing.

At the same time, certain
fabrication requires to match with
the component given rather than
the dimension provided in the
engineering drawing since the
physical component comes in
slightly different size.
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b) 2.2.1(b) Electronics Section


Figure 2.2.1 b-1 Initial stages of SPS circuit
construction.

Figure 2.2.1 b-2 SPS components mount on housing.

Figure 2.2.1 b-3 SPS complete circuitry.

The electronics section of the SPS project
enhance the following modules of the
training:-

M7.4 - Avionics General Test
Equipment.
M7.7 - Electrical Wiring
Interconnection System (EWIS).
M7.15 Soft Soldering.

The SPS electronics consist of 3 parts. They
are:-

1 Component soldering on PCB.
2 Wiring.
3 Final assembly of the circuit.

The attached photos are the progress made
during the assembly of the circuit.

There were no problems in construction of the
electronics parts. However, the challenge only
occurs when there is a functionality problem
came up.

Some of the reasons were the polarity issues
during the soldering of component to the PCB.
Other reasons were the wrong wiring
connection and bad crimping technique which
cause negative connection.
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2.2.2 Third Hand Project


Figure 2.2.2 b-1 the materials needed for Third Hand
project

Figure 2.2.2 b-2 the mark outs for the top plate.

Figure 2.2.2 b-3 filling of top plate
The third hand project is compromising
the following modules of the training:-

M6.5 - Material Hardware
(Fastener and Bolts).
M7.2 - Workshop Practices
M7.3 - Tools.
M7.5 - Engineering Drawings.
M7.14.1 - Sheet metal bending.

The third hand project is made of 3 parts.
They are:-

1 Aluminium Base Plate
2 Aluminium Centre Plate
3 Steel rods

The attached photos are the progress
made during the fabrication of the third
hand project.

The challenge faced during the fabrication
of the third hand is that applying the
correct hand skill technique when filling
and sawing the aluminium plates. It is
difficult to achieve the tolerance based on
the engineering drawing.

This is because the project is mostly done
by hand tools, the importance of the hand
technique very crucial. At the same time,
mistakes were done on this project due
too many markings were done which
cause confusion when drilling through
holes on the base plate.

In this project, it is important to do a
double checking before any execution of
any drilling, filling or sawing action.

However, this project was carried out
without any instruction by the instructors.
This is a very good learning experience as
the student learnt how to work
independently.
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2.2.3 Infra-Red Transceiver Project





Transmitter Circuit Receiver Circuit










The above picture is the circuitry layout for
the transmitting circuit based on the type of
Vero board issued.

The layout helps to identify the placing of the
components as well as wires routing. It also
serve the purpose for trouble shooting since it
shows the copper track of the Vero board.

The above PCB diagram is used for trouble
shooting since the view of the top PCB is
inverted to the bottom of the PCB.

Therefore the diagram provides useful
information on which location of components as
well as points for troubleshooting.
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2.3 Rationale and Objectives of major project
2.3.1 Stabilized Power Supply (SPS) Project
The purpose of the SPS is to convert AC to DC to supply power to project such as FCU and FOP. In a
way, the SPS is the simplification of the aircraft electrical system where the AC generated by the
power plant is converter to DC to supply power to avionics systems.
Modern aircraft uses fly-by-wire systems where correct practice of wiring is important. There a
few accidents where wrong practice of wiring causes catastrophic affect. At the same time, the
repairs of the line replaceable unit (LRU) require proper soldering skills.
Therefore the SPS project is relevant to the MRO industry as the project consist of proper wiring
practice and soldering technique.

2.3.2 Third Hand Project
In the MRO industry, it is common that mechanical based skill is required to fabricate the parts of an
airplane which needed repairs such as the airplane fairings and since the industry is fast paced
where time management and safety is important.
Therefore, the third hand project is relevant as to fabricate a part of an airplane requires knowledge
to interpret engineering drawing, understanding the type of material used for fabrication and proper
hand skills to fabricate the part without affecting the materials strength. Without these skills, it is
almost impossible to repair a part of an airplane on time and obtaining the required material
strength to install on aircraft.

2.3.3 Infra-Red Receiver and Transmitter Project

The Infra-Red RX and TX project is broken into 2 parts which is the receiver and the transmitter. Both
of these circuits are constructed differently with a purpose to expose the student to the different
types of trouble shooting on Vero board and printed circuit board (PCB). Even though the method of
troubleshooting are similar for both boards, but the types of challenges faced to carry out the
troubleshooting differs for both boards.
One good example will be that the trouble shooting done on PCB is easy since the copper is almost
close to schematics drawing. However the troubleshooting done on Vero board is physically
confusing since the copper tracks are too much that troubleshooting has to be done slowly as to
avoid errors.
In addition, proper soldering technique is required to ensure positive connection. Continuity test are
carried out to ensure positive connection.
Therefore, the project is relevant and most important for B2 student since they are specialized in
electronics. Furthermore, this project exposed the student to understand how to read schematics
drawings.
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Stabilized Power Supply
2.4 Working Principle
2.4.1 Stabilized Power Supply (SPS) Project
The function of the SPS is to convert AC to DC variable voltage regulator supplying power to almost
electronics project structured by LTT. The figure below shows the function and operation of the SPS.

















2.4.2 Third Hand Project

The Third Hand project is made up of mechanical parts such as bolts and nut. Its primary function is
to provide an additional hand to allow easy soldering on difficult component of the circuit. Its
secondary function is to provide heat transfer especially soft soldering project where soldering is
done on a copper wire. The heat from solder gun may melt the other soldered parts of the copper
wire.
This project enhances the student understanding on lessons taught in module 7.2, 7.3 and 7.5.
Students were not guide rather instead observe by instructors as to allow student to build
confidence in working on project without any assistance.
Transformer
(Step Down
with centre
tap)
Rectifier
(Full wave)
AC to DC
wave
Filter
(RC filter)
DC wave to
regulated DC
Output

Selection
from :-
1)0-15VDC
2)0-30VDC
Supply power to:-
Flap Control Unit
(FCU)
Flap Operating
Mechanism (FOP)
Other LTT electronics
project
2.4.1 0-1 SPS function and working principal
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2.4.3 Infra-Red Receiver and Transmitter Project
The working principal of the project is broken into 2 parts as shown below.

Figure 2.4.3 1 Schematic diagram of transmitter











The push button activates the 2 timers. The frequency of the 2 timers differs as per tabulated result
as per attached PDF file in the block diagram. The outputs of both timers are combined and as a
result, a new output which also tabulated as per attached PDF file.


Transmitter Circuit

Timer 1

LED Transmitter
Adobe Acrobat
Document

Timer 2

Timer 1 + Timer 2
output
Adobe Acrobat
Document


Figure 2.4.3 2 Block diagram on working operation of Transmitter.
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Figure 2.4.3 3 Schematic diagram of receiver














The receiver circuit consist of a receiver infra-red LED which received signal from the TX which in
turn provide pulse to the JK flip flop. The output the JK flip flop will turn the LED on or off. As long as
no signal received, the output of the JK flip flop will remain the same. Thus acting like a remote
control.

Receiver Circuit

LED Receiver

Voltage Regulator
(Provide regulated voltage)

Schmitt Trigger Delay

JK Flip Flop

Output

Figure 2.4.3 4 Block diagram on working operation of receiver.
Control
Circuit
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2.5 Analysis of the SIP Experience

The programme has indeed beneficial to the students as the theory lessons conducted were further
enforced by the practical workshop. In order words, the lessons that LTT has structured the
programme that all types of students with different capability of learning to understand the modules
thought by the instructors. Different platform of learning were introduce such as watching videos
related to the modules the students were thought.
The instructors are very helpful in assisting the students whenever the students have doubts.
3. Conclusion

In Conclusion, the attachment objectives of the programme were met. The reason is that the
structure of the module were schedule in such a way that student will first learn the theory of
proper maintenance practice before doing the actual workshop. Even though there wasnt any
training done on the airplane system, the workshop structured in the programme is totally relevant
to the maintenance practice.
Overall, the programme which structured by LTT is indeed useful not just for future career as an
Licensed Aircraft Engineer (LAE) but it also further enforce the theory knowledge which the student
learnt during the diploma course conducted by Temasek Polytechnic.
4. Recommendations

LTT has structured wide range training from mechanical to electronics skill based training. However,
the training can be further improved by making amendments to certain project such as the FOP.
Since the FOP is newly introduced into the programme, and the project consist of both mechanical
and electronics. The number of days given to complete the project which is 8 days may not be
sufficient. This is because unlike other projects, the FOP electronics section has a complicated wiring
such that the wires route outward to inward of the FOP. However, the FOP is indeed a very excellent
project introduced by LTT.