Internship on
HINDUSTAN AERONAUTICS LIMITED
HELICOPTER DIVISION
BANGALORE
BY : CHARAN K N
1CR20EC404
Under the Guidance of :
Prof.Venkateswaran K
Dept of ECE
ELECTRONICS AND COMMUNICATION
DEPARTMENT
2
Completion Certificate
19/04/2024
3
ABOUT THE COMPANY
The history and growth of Hindustan Aeronautics Limited is
synonymous with the growth of Aeronautical industry in India for
more than 79 years. The Company which had its origin as
Hindustan Aircraft Limited was incorporated on 23 Dec 1940 at
Bangalore by Shri Shet Walchand Hirachand, a farsighted
visionary, in association with the then Government of Mysore, with
the aim of manufacturing aircraft in India .
In March 1941, the Government of India became one of the
shareholders in the Company.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
4
INTRODUCTION
► Hindustan Aeronautics Limited (HAL) is an Indian state-owned
aerospace and defence company, headquartered in Bangalore, India.
Established on 23 December 1940, HAL is one of the oldest and
largest aerospace and defence manufacturers in the world. It is
governed under the management of the Indian Ministry of Defence.
► HAL is currently involved in designing and manufacturing of fighter
jets, helicopters, jet engine and marine gas turbine engine, avionics,
software development, spare supply, overhauling and upgrading of
Indian military aircraft.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
5
INTRODUCTION
⮚ HELICOPTER COMPLEX (Bangalore)
HAL helicopter complex consists of three divisions:
⮚ • Helicopter division
⮚ • Rotary Wing Research & Design Centre (RWRDC)
⮚ • Helicopter MRO Division
Testing and Ground Test Center:
The division has capability of testing various transmission rotables of helicopter programs that includes
Seaking, ALH and Kamov. The Test rigs available in the division are capable of being adapted to cater to
the needs of various other systems and rotables.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
6
Helicopter Overview
Types of Helicopter
⮚ Wheel version
i. Fixed Wheel
ii. Retractable
⮚ Skid version
In this type skids, simple bolt on frames with built in shock absorption system which acts as landing
gear is used.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
7
Helicopter Overview
Helicopters Manufactured At HAL
Cheetah
Chetak
Cheetal
LCH (Light Combat Helicopter)
ALH (Advanced Light Helicopter)
o MARK 1 ALH MK-I (DHRUV)
o MARK 2 ALH MK-II (DHRUV)
o MARK 3 ALH MK-III (DHRUV)
o MARK 4 ALH MK-IV (RUDRA)
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
8
Component level testing:
Component Inspection: Before testing, each component is thoroughly inspected for any
visible damage, wear, or other issues.
Functional Testing: Components are tested to ensure they perform their intended functions.
For example, engine components, such as the turbine or fuel system, would be tested for
power output, fuel efficiency, and response to various operating conditions.
Environmental Testing: Helicopter components must withstand a range of environmental
conditions. Environmental testing can include subjecting components to extreme
temperatures, humidity, vibration, and altitude conditions to ensure they can operate
effectively in various situations.
19/04/2024
ELECTRONICS AND COMMUNICATION DEPARTMENT
9
Component level testing:
Vibration and Shock Testing: Helicopters are subjected to significant vibrations and shocks
during their operation. Components, especially sensitive electronic ones, need to be tested to
ensure they can withstand these forces without failure.
Noise Testing: Helicopter components should meet noise regulations and should not generate
excessive noise. Noise testing assesses the noise levels produced by various components,
including the engine and rotor system.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
10
GEARBOX OF HELICOPTER
Main Gearbox (MGB) Of A Helicopter
In helicopters, power transfer function from the engine to Main Rotor,
Tail Rotor and other necessary accessories is performed by the Main
Gearbox, typically known as Transmission as well.
The main purpose of a helicopter main gearbox or transmission is to
reduce output rpm of the engine to most suitable level for driving the
main rotors and tail rotors of a helicopter.
For example, a helicopter having an engine output rpm of 6000 but
operates a rotor at 300 rpm. This reduction function would be provided
by specially designed Main Gearbox of the helicopter.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
11
GEARBOX OF HELICOPTER
19/04/2024
12
GEARBOX OF HELICOPTER
Tail Rotor Gearbox: The tail rotor gearbox is responsible for transmitting power to the tail rotor,
which is essential for controlling the helicopter's yaw (rotational) movement.
Intermediate Gearbox: Some helicopter designs, including those produced by HAL, may
incorporate an intermediate gearbox to adjust the transmission ratio between the engines and the
main gearbox. This is important for optimizing rotor speed and engine performance.
Lubrication and Cooling: Adequate lubrication and cooling systems are essential to ensure that
gears and bearings within the transmission system remain properly lubricated and within their
temperature limits, preventing overheating and wear.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
13
GEARBOX Functions
Main purposes which a Transmission serves in a helicopter are given as under :
1. Provides angle change to the drive and speed reduction by a train of spiral bevel gears and
one/ two-stage planetary gears in order to drive the rotor mast.
2. A freewheel clutch in the input drive quill coupling disengages the transmission from engine
to allow the main rotor and gear train to turn freely when the engine is stopped.
3. A secondary gear train drives the tail rotor through a shaft supported by hanger bearings or
support bearings.
4. Power is transmitted through one or two gearboxes to the tail rotor. Normally, a 42-degree
gearbox change angle of the drive only and provides a gear ratio of 1:1.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
14
Sensors:
Load Cells: Load cells measure forces, such as tension, compression, and torsion, and are used
in various parts of the helicopter, including the rotor systems and landing gear. They provide
data on structural loads and component stress.
Strain Gauges: Strain gauges are used to measure deformation and strain in helicopter
components. They help assess the structural integrity and fatigue of critical parts.
Accelerometers: Accelerometers measure the acceleration of the helicopter in different
directions. They are crucial for assessing vibrations, monitoring vibrations in the rotor system,
and ensuring passenger comfort.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
15
DIFFERENT SENSORS STUDIED
Starain guage sensor Accelorometer sensor
19/04/2024
16
Sensors:
Pressure Sensors: Pressure sensors are employed to measure various parameters, including
airspeed, altitude, and hydraulic pressure. They are essential for flight control and monitoring
of fluid systems.
Temperature Sensors: Temperature sensors, such as thermocouples and resistance temperature
detectors (RTDs), monitor temperature levels in the engine, avionics, and other critical
components. Accurate temperature data is crucial for safe operation.
Position Sensors: Position sensors, like potentiometers and rotary encoders, measure the
position of control surfaces and other moving components. These sensors are integral to the
helicopter's flight control system.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
17
DIFFERENT SENSORS STUDIED
19/04/2024
18
DIFFERENT SENSORS STUDIED
Torque sensor Temperature sensor 19/04/2024
19
CONCLUSION
RWRDC is one of the main divisions of HAL which carries out all the major services and repairs
of Helicopters Gearbox and Rotar.
►We got our internship in final assembly RWRDC division. This was a great opportunity for us
to learn about gearbox and its variants, major parts maintenance and repairs. We also learnt
about the industry and its working.
►From this internship we got experience and a better understanding of our subjects by applying
theoretical concepts into our practice.
ELECTRONICS AND COMMUNICATION DEPARTMENT 19/04/2024
20
TH
AN
KY
OU
.. !!
19/04/2024
