THDC INSTITUTE OF HYDROPOWER

ENGINEERING & TECHNOLOGY

SUMMER TRAINING

SUBMITTED TO:
S.P.SINGH,
SENIOR MANAGER,
TRAINING AND DEVELOPMENT CENTRE,
HAL, LKO.

SUBMITTED BY:
Sachin Yadav
Bsc..physics

(1st

Lucknow University

00

YEAR)

Acknowledgement :
First I would like to thank Mr. S.P.SINGH, senior
manager of HAL Training Centre, for giving me
the opportunity to do an summer training within
the organization. For me it was a unique
experience to be in and to study an interesting
practical aspects.
I also would like all the people that worked in the
office of HAL. With their patience and openness
they created an enjoyable working environment.
Furthermore I want to thank all the engineers and
students, with whom I did the fieldwork. We
experienced great things together .

Conclusion:
>Aircraft hydraulic systems are designed for high
levels of safety using multiple levels of
redundancy
>Fly-by-wire systems require higher levels of
redundancy than manual systems to maintain
same levels of safety
>System complexity increases with aircraft
weight
On the whole, this
training was a useful experience. I have gained
new knowledge, skills and met many new
people .I got insight into professional practice.
There is still a lot to discover and to improve.
fully to projects .

HINDUSTAN AERONAUTIC S
LIMITED:
It based in Bangalore, India, is one of Asia's
largest aerospace companies. Under the
management of the Indian Ministry of Defence,
this state-owned company is mainly involved in
aerospace industry, which includes
manufacturing and assembling airHAL built the
first military aircraft in South Asia and is currently
involved in the design, fabrication and assembly
of aircraft, jet engines, and helicopters, as well as
their components and spares. It has several
facilities spread across several states in India
including Nasik, Korwa, Kanpur, Koraput,
Lucknow, Bangalore and Hyderabad. The German
engineer Kurt Tank designed the HF-24 Marut
fighter-bomber, the first fighter aircraft made in
India.
Hindustan Aeronautics has a long history of collaboration with several other
international and domestic aerospace agencies such as Airbus, Boeing, Lockheed
Martin, Sukhoi Aviation Corporation, Elbit Systems, Israel Aircraft Industries, RSK
MiG, BAE Systems, Rolls-Royce plc, Dassault Aviation, MBDA, EADS, Tupolev,
Ilyushin Design Bureau, Dornier Flugzeugwerke, the Indian Aeronautical
Development Agency and the Indian Space Research Organisation.craft,
navigation and related communication equipment, as well as operating airports.

History :
HAL was established as Hindustan Aircraft in Bangalore in
1940 by Seth Walchand Hirachand to produce military aircraft
for the Royal Indian Air Force. The initiative was actively
encouraged by the Kingdom of Mysore, especially by the
Diwan, Sir Mirza Ismail and it also had financial help from the
Indian Government. Mysore was favoured because of the
availability of cheap electricity.[1] The organisation and
equipment for the factory at Bangalore was set up by William D.
Pawley of the Intercontinental Aircraft Corporation of New York,
an exporter of American aircraft to the region. Pawley managed
to obtain a large number of machine-tools and equipment from
the United States.
The Indian Government bought a one-third stake in the
company and by April 1941 as it believed this to be a strategic
imperative. The decision by the government was primarily
motivated to boost British military hardware supplies in Asia to
counter the increasing threat posed by Imperial
Japan during Second World War. The Kingdom of Mysore
supplied two directors, Air Marshal John Higgins was resident
director. The first aircraft built was a Harlow PC-5[2] On 2 April
1942, the government announced that the company had been
nationalised when it had bought out the stakes of Seth
Walchand Hirachand and other promoters so that it could act
freely. The Mysore Kingdom refused to sell its stake in the
company but yielded the management control over to the
Indian Government.
In 1943 the Bangalore factory was handed over to the United
States Army Air Forces but still using Hindustan Aircraft
management. The factory expanded rapidly and became the
centre for major overhaul and repair of American aircraft and
was known as the 84th Air Depot. The first aircraft to be
overhauled was a Consolidated PBY Catalina followed by every

type of aircraft operated in India and Burma. When returned to

Indian control two years later the factory had become one of
the largest overhaul and repair organisations in the East. .
After India gained independence in 1947, the management of
the company was passed over to the Government of India.
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
(at the time manufacturing HS.748 under licence) and the
group recently set up to manufacture Mig-21 under licence
(with its new factories planned in Koraput, Nasik and
Hyderabad).[3] 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. HAL has
also obtained several multi-million dollar contracts from leading
international aerospace firms such
as Airbus,Boeing and Honeywell to manufacture aircraft spare
parts and engines.
By 2012, HAL was reportedly been bogged down in the details
of production and on its schedules.

HINDUSTAN AERONAUTICS
LIMITED
(ACCESSORIES DIVISION
,LKO)

Welcome to the Accessories Division of Hindustan Aeronautics

Limited.
Accessories Division of HAL was established in 1970 with the
primary objective of manufacturing systems and accessories for
various aircraft and engines and attain self sufficiency in this
area. Its facilities are spread over 116,000 sqm of built area set
in sylvan surroundings. At present it is turning out over 1300
different types of accessories. The Division started with
manufacturing various Systems and Accessories viz,
Hydraulics, Engine Fuel System, Air-conditioning and
Pressurization, Flight Control, Wheel and Brake, Gyro &
Barometric Instruments, Electrical and Power Generation &
Control System, Undercarriages, Oxygen System and
Electronic System all under one roof to meet the requirements
of the aircraft, helicopters and engines being produced by HAL
like MiG series of aircrafts, Dornier, Jaguar, Advanced Light
Helicopters(ALH), PTA, Cheetal & Su-30 and repair / Overhaul
of Avro, AN-32, HPT-32, Mirage2000 & Sea-Harrier aircrafts,
Cheetah and Chetak helicopters.
The Division undertakes
manufacturing and serviceing of
accessories under Transfer of
Technology (ToT) from more than
40 licensor from different
countries. In addition, a lot of
emphasis has been given on developing indigenous capability
for Design and Development of various systems and
accessories. This capability has culminated in indigenous
design and development of over 350 types of accessories for
the Light Combat Aircraft (LCA) (Air force and Navy version),
Advanced Light Helicopter (all versions i.e. Army, Air force,
Navy & Civil), SARAS 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 has been in the forefront of accessories
development and supply not only to Indian Force but to Army,
Navy, Coast Guard and various Defence Laboratories as well
as for Space applications.
The Division is networked with all
sister Divisions and R& D Centers
by LAN/WAN. Lean manufacturing
and ERP have been implemented
to create an efficient manufacturing
system.
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.
The Division has also made steady progress in the area of
Export.

CONTENTS:
>Introduction
>About HAL
> HAL, LKO
> Uses for and sources of hydraulic power
> Review of Aircraft Motion Control
> Key hydraulic system design drivers
> Hydraulic design philosophies for
conventional, more
electric and all
electric architectures
> Hydraulic System Interfaces
> Sample aircraft hydraulic system block
diagrams
> Conclusions

Controlling Aircraft Motion

Secondary Flight Controls :

High Lift Devices:

Flaps (Trailing Edge), slats (LE Flaps)
increase area and camber of wing
permit low speed flight
Flight Spoilers / Speed Brakes: permit
steeper descent and augment ailerons at
low speed when deployed on only one wing
Ground Spoilers: Enhance deceleration
on ground (not deployed in flight)
Trim Controls: Stabilizer (pitch), roll and
rudder (yaw) trim to balance controls for
desired flight condition

TYPICAL USES OF HYDRAULIC

POWER:

Landing gear
o Extension, retraction, locking, steering,
braking
Primary flight controls
o Rudder, elevator, aileron, active (multifunction) spoiler
Secondary flight controls
o high lift (flap / slat), horizontal stabilizer,
spoiler, thrust reverser
Utility systems
o Cargo handling, doors, ramps, emergency
electrical power generation.

HYDR. MOTOR
GEARBOX

TORQUE TUBE

FLAP DRIVE
LANDING GEAR

>SOURCES OF HYDRAULIC POWER:

Electrical
Pump attached to electric motors, either AC
or DC
Generally used as backup or as auxiliary
power
Electric driven powerpack used for powering
actuation zones
Used for ground check-out or actuating doors
when
engines are not running
Mechanical
Engine Driven Pump (EDP) - primary
hydraulic power source, mounted directly to
engines on special gearbox pads
Power Transfer Unit mechanically transfers
hydraulic
power between systems

Pneumatic
Bleed Air turbine driven pump used for
backup power
Ram Air Turbine driven pump deployed when
all engines

are inoperative and uses ram air to drive the

pump
Accumulator provides high transient power
by releasing stored energy, also used for
emergency and parking brake

AC ELECTRIC MOTORPUMP

POWER TRANSFER UNIT

Key Hydraulic System Design

Drivers :
High Level certification requirement
per aviation regulations:
o Maintain control of the aircraft
under all normal and anticipated
failure conditions
o Many system architectures* and
design approaches exist to meet
this high level requirement
aircraft designer has to certify to
airworthiness regulators by
analysis and test that his solution
meets requirements
o Hydraulic System Architecture:
Arrangement and interconnection
of hydraulic power sources and
consumers in a manner that meets
requirements for controllability of
aircraft

Electrical System
Electric
motors,
Solenoid
Electrical
s
power
variations
under
normal
and all
emergenc
y
conditions
(MIL-STD704)

Power on
Demand

Avionics
Signals from
pressure,
temperature,
fluid quantity
sensors
Signal to
solenoids,
electric motors

Landing
Gear
Flow under
normal and all
emergency
conditions
retract /
extend / steer

Design Philosophy
More Electric Architecture

 Two independent centralized power systems

+ Zonal & Dedicated Actuators
Each engine drives dedicated pump(s),
augmented by independently powered
pumps electric, pneumatic
No fluid transfer between systems to
maintain integrity
System segregation
Route lines and locate components far
apart to prevent single rotor or tire burst
to impact multiple systems
Third System replaced by one or more local
and dedicated electric systems
Tail zonal system for pitch, yaw
Aileron actuators for roll
Electric driven hydraulic powerpack for
emergency landing gear and brake
Examples: Airbus A380, Boeing 787

Mid-Size Jet

Aircrafts Maximum Take-Off

Weight (MTOW) drives
aerodynamic forces that drive
control surface size and
loading

A380 1.25 million lb

MTOW extensive use of
hydraulics
isCessna
2500 of
lb my four
This report
a short 172
description
MTOW
noout
hydraulics
all
weeks training
carried
as compulsory
manual
component of
the aircraft. The training was
carried out within the organization HAL ,LKO.
At the beginning of the training I formulated
several learning goals, which I wanted to
achieve:
>to understand the functioning and working
conditions of a centre governmental
organization;
>to see what is like to work in a professional
environment;
>to see if this kind of work is a possibility for my
future career;
>to use my gained skills and knowledge;
>to see what skills and knowledge I still need to
work in a professional environment;
>to learn about the organizing of a research
project (planning, preparation, permissions etc.)

INTERNSHIP CERTIFICATE

This is to certify that SACHIN YADAV , pursuing

his Bsc., 1st year has successfully completed
summer internship at HAL (ACCESSORIES
DIVISION) at LKO during JULY.
We found him sincere, hardworking,
technically sound and result oriented. He worked
well as part of a team during his tenure. We take
this opportunity to thank him and wish him all
the best for his future.
Name: S.P.SINGH
Place: HAL ,LKO
Date: 4/7/2014
SIGNATURE: