PREFACE

The report on the following pages is the outcome of six weeks training at the
industry.
The report is the outcome of the practical knowledge that we acquire during our
training. This report presents the brief summary of our industrial training.
I had the privilege of receiving such training at HINDUSTAN AERONAUTICS
LIMITED ,LUCKNOW.
There could not be a better place to learn…
ACKNOWLEDGEMENT

I would like to express my sincere gratitude to the management of

HINDUSTAN AERONAUTICS LIMETED for having given this opportunity

to carry out my training.

I am grateful to my esteemed guide Mr.Dy. General manger of instrument

department for his whole hearted cooperation and support.

I also acknowledge my gratefulness to Mr. Nirmaljeet Singh, training and

placement officer, H.E.C. Jagadhri, for giving me the opportunity to undergo

this training

And last but not the least, I would like pay my sincere gratitude to all the

employees of the HAL , LUCKNOW, for there valuable help and technical

support at various times.

COMPNY PROFILE
HINDUSTAN AERONAUTICS LIMITED
LUCKNOW

The history of the Indian Aircraft Industry can be traced to the founding of Hindustan
Aircraft Limited at Bangalore in December 1940 in association with the erstwhile princely State
of Mysore and late Shri Seth Walchand Hirachand, an Industrialist of extra -ordinary vision.
Govt. of India became one of its shareholders in March 1941 and took over the management in
1942. Hindustan Aircraft Limited was merged with Aeronautics India Limited and Aircraft
Manufacturing Depot, Kanpur to form Hindustan Aeronautics Limited (HAL) on 01st October
1964.

Today HAL has got 16 production units and 9 research and design centers spread out in
seven different locations in India. Its product track record consists of 12 types of aircraft from in
house R &D and 13 types by license production.

HAL has so far produced over 3300 aircraft, 3400 Aeroengines and
overhauled over 7700 aircraft and 26000 engines.

HAL has engaged & succeeded in number of R & D programs for both the military and
civil aviation sectors. Substantial progress has been made in the current projects like Dhruv
-Advanced Light Helicopter (ALH), Tejas-Light Combat Aircraft (LCA), Intermediate Jet
Trainer (IJT) and various military and civil upgrades. The deliveries of Dhruv were effected to
Indian Army, Navy, Air Force and Coast Guard in March 2002, in its first year of production
which is a unique achievement.

HAL has played a significant role for India's space programs in the manufacturing of
satellite launch vehicles like PSLV (Polar Satellite Launch Vehicle), GSLV (Geo Stationary
Launch Vehicle), IRS (Indian Remote Satellite) & INSAT (Indian National Satellite).

HAL has also two joint venture companies, BAeHAL Software Limited and Indo-
Russian Aviation Limited (IRAL). Apart from the two, 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 Guard and Border
Security Force. 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.

INSTRUMENTATION SHOP OF SUKHOI

INSTRUMENTATION SHOP OF SUKHOI

TEMPERATURE INDICATOR :

This instrument sense temperature of aircraft’s air conditioning system in case temperature rises above
required level, it transmits following warning signals to pilot :

1. Above 25 deg C : failure of temperature control system

2. Above 35 deg C : switch off air conditioning

3. Above 45 deg C : close air intakes to special cooling system

SEMICONDUCTOR RELAY CONTROL UNIT :

It is a part of automatic control portion of str-51 system. This instrument works as an amplifier and a
switching device for the signals required for opening & closing of value of variation tanks of aircrafts.

DIGITAL LIGHT INDICATOR :

This instrument is a cockpit display device. It continuously displays fuel quantity of service tank. The gets
fuel quantity from fuel quantity unit process it and display accordingly both the cabin.

ELECTRONIC TRANSDUCER UNIT :

This unit is the main process part of automatic control portion of STR-51 system. It manages fuel flow
based on signals from sensor, magnetic operated level switched fitted in various tanks. It also senses
total residual fuel quantity of 600 kg & transmits this warning signals to pilot.

FUEL FLOW TRANSMITTER :

These are imparellel type of sensor which produces electrical signal proportional to the rate of flow of fuel
through it fuel consumed by aircraft is computed based on the signals provided by the sensor. It is a part
of fuel flow metering system of str-51 system.

CONTACT SIGNALING TRANSMITTERS :

These are the sensors for sensing the fuel level in various tanks of the aircraft. Magnetic output level
switch off these probes generated level signal at one particular level of fuel in tanks. Different type of
probes, senses different type of fuel signal generated by these sensor, act as input for automatic control
portion.

A.C. MASTER BOXES

INTRODUCTION :

It mainly including the two alternator, protection unit, static inverter, primary AC distributer system _

· AC Master Box-3 & 4

· 115 V AC supply bus relay

· 26 V AC emergency bus

It also consist of 3-phase main Bus & 1-phase emergency bus (AC & DC)
OPERATION :

During normal condition both the alternator are used together to provide the supply for aircraft. They
both work together as they share the supply for machine. They are back up for each other if any
suddenly stop working or fails to operator, then only one remain alternator work for supply and command
all supply in its hand provide current and voltage to necessary parts of engine.

If both the alternator fails to work then inverter is used to make the condition in hands and it provide 15
min to engine to land the machine in any safe place.

AC MBX-4

It do not include external power contractor & control card.

This bus is powered by main bus.

AC MBX-3

It is used in conjunction with two alternator, two ACPU & static inverters.

PARAMETERS :

NAME ACMBX

Code 22530000

Weight 5.5 kg max

Length 266 ± 5 mm

Width 240 ± 5 mm

Height 120 ± 5 mm

Input DC 28V

Input AC power supply 115 V

Power 5KVA

D.C. MASTER BOXES

· The supply of generator goes through it

· There are two generators for supply.

· There are two battery boxes are also available.

· It works at 28 volts.

· ECPU is in 57 no. card which works as a protection unit in it.

· The life time of battery is 15 min.

· Battery work at 24 volts.

· Indicator indicates when both 57 & 58 cards fails.

· Contactor works as relay unit in it.

· The over load condition is avoided by short ckt card or ECPU.

Most of the function of this box is same as AC master box. Here generator & battery takes place of
alternator & inverter.

FUEL CONTENT GAUGE

INTRODUCTION-

This Fuel gauging system, Type FCG-11 indicates to the pilot the availability of usable fuel in the aircraft
fuel tank, & also gives a visual warning when the fuel contents fall below a predetermined quantity. The
system makes use of the principle of variation of capacitance with the change of dielectric medium. There
is integral static low level warning device & the system uses all solid state circuitry. The system replaces
existing float type gauging & low level warning system.

The complete system designated as F.C.G-11 is designed to be used in Allotted 111 & SA315 Helicopters
with quadriplegic tanks & existing mounting facility.

The system comprises of –

1) Cable assembly

2) Transistorized sensing amplifier box (Sensing box)

3) A moving coil indicator to indicate the fuel content in liters.

4) A gauging probe with integer fitted low level sensor attachment.

The gauging probe assembly mounted in the fuel tank is connected to the sensing box by means of cable
assemblies depending upon the fuel level in the tank .The capacitance formed by the two tube of the
probe assembly varies, Which is sensed in the amplifier box, gets converted into current & is displayed by
means of indicating meter fitted in the cockpit. The probe assembly also h
 
ouses low level sensor module. A small semicircular plate mounted at a predetermined height, senses the
low level by means of capacitance formed b/w this plate & the main gauging outer tube.

An oscillator circuit in the form of a molded module fitted inside the probe flange converts this
capacitance variation into an electrical signal. The D.C voltage supply is fed from amplifier box to tube
assembly for low level operation. This feeds back low level output signal & the variable capacitance signal
for main gauging to the amplifier box through B.N.C connectors mounted on to the tube flange. The
amplifier box contains a transistorized D.C to D.C converter & an oscillator circuit which converts the
variable capacitance to an electrical milli-ampere signal. The low level signal after being amplified in the
box & along with the milli-ampere signal. The low level signal after being amplified in the box & along
with the milliamps signal, is fed to the fuel indication & low level warning Fuel indicating meter with is a
D.C Milli-ampere meter with the fuel level calibrated in terms of liters & also houses a drive lamp for low
level indication. Normally the lamp for remains ‘OFF’ & turns ‘ON’ in the case of fuel level being reached .

The various cable assemblies inter-connect the amplifier box, D.C bus bar, indicating meter & the probe
assembly.

AMPLIFIER SENSING BOX –

This consist of a chassis on which 3MS-3 pin connections one each for supply, low level input / output &
meter output connection , one B.N.C connector for variable capacitance input from the probe two
potentiometer with locknut for empty and fuel setting of the indicator meter are fitted . Two 12 pin edge
connector are mounted inside the box. Two PCBs (Power supply card and oscillator card are plugged into
edge connectors by sliding though the guides inverted to the chassis.

1. Indicating meter –

This meter is used 2^3 /8” Square SAE case & is moving coil type of milliammeter graduated in term of
liters *100 . This houses an indicating lamp assembly positioned b/w dial & meter movement assembly .
These three items are held together with screws and the lamp is held at the top of the dial . This light is
normally ‘OFF’ & become ‘ON’ for fuel low level . The incoming signal is provided by means of a 3 pin M.S
connector mounted at the rear of meter casing by means of screw . The front glass is held in position
b/w the case is taken up by a sealing gasket . The case and bezel & the gap in b/w glass and case is
taken up by a sealing gasket . The case & glass are held together by means of 4 locknuts & studs . Meter
movement assembly is held to the rear of the case by spacer and screws.

SENSING BOX CIRCUIT –

Transistor T1 with Z1 forms a constant current source feeding into T3 collector &T2 base D.C voltage at
the emitter of T4 through the series regulator T2 to T4 is supplied to the mini inverter formed by T5 & T6
,Feedback through the secondary of inverter after rectification is applied at the base of T3 which is
maintained constant due to Z2. The stabilized D.C supply of 8.5V is available between the edge terminal
of supply card 02.

Oscillator sensor card 03-

T1 to T4 from a square wave free running multi-vibrator for which the 01V & OFF time of 50 microsecond
can be adjusted by four resistances R1 , R2, R8 & R9. The square wave converted into pulses & fed to
the comparator circuit .The unknown capacitor formed by tube immersed in fuel is charged &discharged.
The mark space controlled output pulses at collector are applied to the edge connector through full fuel
setting potentiometer .This current is supplied to the indicating meter.

Power switch card-

Transistor T1 along with Z1 & Z3 forms the constant current stabilised supply of 10V . The low level
signal from module is fed & after switching supplies current to the warning lamp in meter via T3 & pin.

G.C.P.U.

The generator control & protection unit is a solid state device which can be directly filled across the DC
generator to give a regulated DC output for all loading & speed condition. The GCPU regulator OIC is
used in Helicopter.

FUCTION :

GCPU having two circuits one for regulation (gen. control) & other for protection.

Generator voltage is applied through R.I. suppression filter which suppress the radio frequency noise. The
output from the filter goes through the protection relay, to power transistor, regulation & protection PCBs
& to the starting relay. The starting relay contacts are normally closed units. The generator voltage build
up to a predetermined voltage of 18 ± 1 V, above this voltage the relay get energized & the regulator
takes over to control the generator. The main power transistor is connected across +G of the generator &
the field. The transistor is switched ON & OFF alternatively at a fixed frequency of 500 ± 100 Hz which is
independent of generator characteristic. Since the field circuit is highly inductive in nature, a re-
circulating diode is connected parallel to the field.

This is done in such a way that when the power transistor is ON and pumping current from the field i.e.
the re-circulating diode remains OFF & when the transistor switch OFF the diode takes over remain slowly
decaying field current due to the back EMF of highly inductive field, the av. of transistor ON time over
each switching cycle determine the field current.

A sensing circuit senses generator voltage & compress with its internal refers voltage & accordingly
control the power transistor in such a way that if the generator voltage falls below a present voltage, the
on time increases. This turn increases the field current to increase the generator voltage & via-versa.

Protection voltage senses gen. voltage which if excess limit, will disconnect the regulator from the
generator.

A reset facility has been powered to set the generator having tripped OFF due to over voltage period, the
earlier faults have dis-appeared before that.

CHARECTRISTICS :

Functional specification_

These are divided into two sections, i.e. Regulation & Protection
Regulation Specification_

It can give maximum 10A to a field for 3 minutes maximum. The steady state field current is up to 7A for
2 V maximum, voltage regulation is 28 ± 0.5 V at normal & 28 ± 1 V at environmental condition. Ripple
content is 420 µV RMS & its frequency shall be 500 ± 100 Hz.

Protection Specification_

The unit automatically disconnected the generator from aircraft DC bas-bar and it is a case of over
voltage.

If the sensed load current exceed some pre-determined time value over a pre-determined GCPU will
indicate input fault in cockpit. Under voltage failure will be indicated at the also cockpit. The set under
voltage point is 25 ± 1 V.

EQUIPMENT REQUIED :

1. GCPU Test Rig (REG-T-01)

2. Duel Track CRO

ACKNOWLEDGEMENT

Words fail to express my gratitude towards the respective General Manager (Personal & Administration)
for providing me an opportunity to undergo summer training in H.A.L Lucknow Division, which helped me
to prepare this project report. While doing this project the whole staff took keen interest in giving me
information on the various topics.

I am greatly indebted to the whole staffs of the Personal & Administration Department, who have given
their precious time thoughtful discussion expert suggestion & perpetual encouragement to me.

I am also thankful to the friends who helped me in this project and provide me a healthy environment to
make this convenient. PRODUCTS IN CURRENT TIME_

Ø Instrument, Sensor, gyros

Ø Electrical Power Generation & Control

Ø Land Navigation System

Ø Microprocessor Controller

Ø Undercarriage, Wheels and Breaks

Ø Hydraulic System & Power Control

Ø Environmental Control System

Ø Ejection System

Ø Engine Fuel Control System

Ø Ground Support Equipments & Test Rigs

REPAIR, MAJOR SERVICING AND SUPPLY OF SPARES_

MILITARY AIRCRAFT:

Ø Mig Series

Ø Jaguar

Ø Mirage 2000

Ø Sea-Harrier

Ø AN-32

Ø Kiran

Ø HPT-32

Ø SU-30 MKI

CIVIL AIRCRAFT:

Ø Dorniner-22B

Ø AVRO-HS-748

HELICOPTERS:

Ø Chetak

Ø Cheetah

ALH

ACKNOWLEDGEMENT

Words fail to express my gratitude towards the respective General Manager (Personal & Administration)
for providing me an opportunity to undergo summer training in H.A.L Lucknow Division, which helped me
to prepare this project report. While doing this project the whole staff took keen interest in giving me
information on the various topics.

I am greatly indebted to the whole staffs of the Personal & Administration Department, who have given
their precious time thoughtful discussion expert suggestion & perpetual encouragement to me.

I am also thankful to the friends who helped me in this project and provide me a healthy environment to
make this convenient.