nal-technical-brochures.pdf - National Aerospace Laboratories

C-NM5 Multi-Mission General Aviation Aircraft : C-NM5Joint Development by

CSIR - National Aerospace Laboratories and Mahindra Aerospace Pvt. Ltd.

First Flight on 1 September 2011 in Australia Prototype Manufactured by Mahindra Gipps Aero.

Features

Multi-Mission : Air Taxi, Training, Tourism, Cargo, Executive Transport

Certification basis : FAR Part 23, Normal Category, Day / Night VFR / IFR

Equipping options : StandardConventional instruments, Stand alone avionics, Limited cabin environment control, Basic audio for pilot and passengers

DeluxeGlass cockpit with Electronic Flight Instruments System (EFIS), Autopilot integrated with GPS-enabled Nav / Com, Air-conditioning, Improved sound-proofing, Improved cabin audio system

Airframe

All metal construction with composite cowling and fairings

Dimensions

Overall length : 8.8 m (28 ft 9 in)Overall height : 3.0 m (9 ft 10 in)Wing span : 10.9 m (35 ft 8 in)Wing area : 16.0 m2 (172 ft2 )

Avionics system

AMS, NAV / COM / GPS, CDI, Transponder, and ELT

Electrical system

24 V DC electrical system28 V, 70 A external generator24 V, 19 Ah maintenance free battery

Performance (ISA)

Take off distance : 500 m (1640 ft) Landing distance : 450 m (1476 ft)Max. Level speed : 296 km/hr (160 KIAS) Max. Rate of climb : 335 m/min (1100 fpm) Flaps-up stall speed : 120 km/hr (65 KIAS) Flaps-down stall speed : 102 km/hr (55 KIAS) Range : 1300 km (700 nm)(with 320 kg payload) Cruise altitude : 3050 m (10000 ft)

Optional systems Air-conditioning and 2-Axis Autopilot

Avionics System AMS, NAV / COM / GPS, CDI, Transponder, and ELT

Weights

Max. take-off weight : 1500 kg (3306 lb)Empty weight : 1000 kg (2204 lb)Useful load : 500 kg (1102 lb)

Power plant

Continental CD-300 engine, 272 bhp @ 2300 rpm, FADEC, 3-bladed constant-speed propeller

For more information contact :- Director, CSIR-National Aerospace LaboratoriesPB 1779, HAL Airport Road, Bangalore 560 017, India.Tel: 91-080-25086000. 25270584; e-mail: [email protected]; www.nal.res.in

Mahindra Aero Structures Pvt. Ltd.Plot # 251 to 265, Narasapura Industrial Aera, Kolar TalukKarnataka 563 133, India Tel :- 91-8152 280510

HANSA HANSA – 3Hansa - 3 is India’s first all-composite light aircraft designed and developed by CSIR-NAL ideally suited for ab-initio flying training, sport and hobby flying. Certified by DGCA under the FAR-23, amendment 23-42 using the requirements of JAR-VLA dated 26th April 1990, including amendment VLA/92/1 in February 2000.

Aircraft is lightning protected, is cleared for VFR and Night Flight Operations and has excellent flying qualities.

Twelve production standard aircraft have been supplied to flying clubs for pilot training. Hansa-3 is also used by IIT-Kanpur for extensive R&D work and student familiarization. Hansa-3 fleet has accumulated a total of more than 4000 flying hours.

HANSA NGNew generation Hansa aircraft called Hansa-NG is being developed by incorporating state of the art technologies and design improvements in the present type certified Hansa-3 aircraft based on operator’s feedback.

CSIR-NAL and M/s Mesco Aerospace Ltd have collaborated for the joint development of Hansa-NG aircraft.

Features

• IFR Certification • New MIP with Glass Cockpit • Advanced Fuel Efficient Engine• Increased Range & Endurance• Improved Engine Cowling shape• Option of using MoGas or Avgas fuel• Landing Gear Wheel Fairings• Steerable Nose Wheel• Electrically Operated Flap • Heated Pitot unit & LED type Lights • Improved Manufacturing Process• Improved Ingress/Egress • Better Cockpit Aesthetics & Ergonomics• Provision for Baggage

HANSA NG Specifications

Weight

Empty weight 540 kg (1190 lb) All-up-weight 750 kg (1653 lb)Useful load 210 kg (463 lb) Usable fuel capacity 95 ltr

Performance (ISA)

Take-off distance 467 m (1532 ft)Landing distance 600 m (1968 ft)Max rate of climb 213 m/min (700 ft/min)Max cruise speed 200 km/hr (108 KTAS)Stall speed (flaps 20) 80 km/hr (43 KCAS)Range 594 nm (1100 km) (with 45 min reserves) Endurance 5.9 hr

Electrical System12V, 24Ah maintenance-free battery14V, 40 A external generator

PropellerTwo-blade constant speed MT propeller of 175 cm (69 Inch) diameter

Power plantRotax 912iSc Sport (naturally aspirated engine with Take-off power of 100 bhp @ 5800 rpm and max continuous power of 98bhp @ 5500 rpm)

Geometry

Overall lenghth 7.6 m (25 ft) Overall height 2.61 m (8.5 ft) Wing span 10.47 m (34.35 ft) Wing area 12.47 sq m (136 sq ft) Cabin width 1.07 m (3.5 ft)


Cheif Opertating Officer, Mesco Aerospace Ltd.Mesco Towers, H-1, Zamrudpur Community Centre, Kailash Colony, New Delhi 110048, India. Tel: 011-25675334, email: [email protected]

Industry Partner

SARAS

Features

¡ Multi-Role Light Transport Aircraft with air taxi and services as its primary roles

¡ Ideal for Executive Transport, Light Package Carrier, Remote Sensing, Aerial Search / Survey, Coast Guard, Border Patrol, Air Ambulance, Other Community Services

Status

PT1 upgraded to PT1N incorporating design improvements FIRST FLIGHT : 24th January 2018SARAS 14/19 : Two LSPs and one STS Planned for certification

Avionics system

SARAS has a state of the art Arinc-429 compatible integrated digital avionics system

Performance (ISA)

Take-off distance : 670 m (2200 ft)

Landing distance : 900 m (2950 ft)

Max. rate of climb : 610 m/min (2000 ft/min)

Max. range* (14 pax) : 590 km (318 nm)

Max. range* (8 pax) : 1275 km (688 nm)

Ferry range* : 1627 km (878 nm)

Max. cruise speed : 520 km/hr (280 Kts)

Endurance : 4 hr 45 min

* With 45 min reserve

Special features

¡ Low cabin noise (<80 db)

¡ Operable from semi - prepared runways

¡ Operable from hot and high altitude airfields

¡ Designed to meet FAR-23 requirements

Main dimensions

Overall length : 15.02 m (49.3 ft)Overall height : 5.25 m (17.2 ft)Wing span : 14.70 m (48.2 ft)

Weights

Max. take-off : 7100 kg (15653 lb)Max. fuel weight : 1568 kg (3457 lb)Max. pay load : 1232 kg (2716 lb)

Power plant

SARAS is powered by two Pratt and Whitney Canada PT6A-67A turbo-prop engines (flat rated at 1200shp) driving 2.65 m diameter 5 bladed constant speed propellers at 1700 rpm in a pusher configuration.

For more information contact :Director, CSIR-National Aerospace LaboratoriesPB 1779, HAL Airport Road, Bangalore 560 017, India.Tel: 91-080-25086000. 25270584; e-mail: [email protected]; www.nal.res.in

SARAS MK 2


Features

¡ 19 Seat Multi- Role Light Transport Aircraft with air taxi and services as its primary roles

¡ Ideal for Commuter connectivity under UDAAN Scheme for variety of applications like Air Taxi, Executive Transport, Light Package Carrier, Remote Sensing, Aerial Search / Survey, Coast Guard, Border Patrol, Air Ambulance, Other Community Services

¡ Low cabin noise (<80 db) ¡ Operable from semi-prepared runways ¡ Operable from hot and high altitude airfields ¡ Designed to meet FAR-23 requirements

Avionics system

¡ Full glass cockpit: EFIS-Four PFD/ ND/ MFDs ¡ Comm/Nav suite: VHF-VOR and radio, ADF, DME, ILS ¡ TAWS- Terrain Avoidance Warning System ¡ FMS: Flight Management System ¡ TCAS: Traffic Collision Avoidance System ¡ Auto pilot and Weather Radar

Performance (ISA)

Take-off distance : 800 m (2625 ft) Landing distance : 880 m (2887 ft)Max. rate of climb : 10.6 m/s (2080 ft/min)Max. range* (19 pax) : 800 km (432 nm)Max. range* (10 pax) : 2050 km (1107 nm)Ferry range* : 2170 km (1172 nm)Max. cruise speed : 540 km/hr (292 Kts)Endurance : 5 hours * With 45 min reserve

Power plant

SARAS is powered by two Pratt and Whitney Canada PT6A-67A turbo-prop engines (flat rated to 1100 shp) driving 2.6 m diameter 5 bladed constant speed propellers at 1700 rpm in a pusher configuration.

Main dimensions

Span : 16 m (52.5 ft)Length : 15 m (49.2 ft)Height : 5.1 m (16.7 ft)

Weights

Max. take-off : 7400 kg (16314 lb)Operating empty wt. : 4900 kg (10803 lb)Max. fuel weight : 1568 kg (3457 lb)Max. pay load : 1710 kg (3770 lb)

DHVANILOCATIONOF BULLET ONTARGET SYSTEM

Using

Joint collaboration CSIR- NAL and SDD, INDIAN ARMY

Precise and Perfect

Low cost and Ruggedized

Why DHVANI ?

Automated system to detect bullet using supersonic acoustic detection and localization of hits on target by acoustic time delay estimation methods.

Real time and precise system, catering for individual to tactical level of exercise settings.

Indigenous

Tailor made for Indian Armed Forces with high degree of ruggedisation to meet Mil Grade Standards. Configured out of COTS item to ensure low post sale maintenance cost.

DHVANI

Unique Features

¡ Automated Range Control with database management ¡ Variable firing positions without any re-calibration ¡ Exercises as per SAO 12/S/85 and facility for user defined exercise setting ¡ Seamless wireless network with Ethernet enabled network ¡ Roaming Firing Point Officer (RFI) and Firer End Display Interface (FEDS) ¡ Interactive and User Friendly GUI ¡ Power on self diagnostic and real time diagnostic during the exercise ¡ Pop Up Target System with Self Healing Targets and simulation units ¡ for illumination, smoke and flash ¡ Unit Level Package for firer management and performance evaluation outside the range ¡ All weather-proof carbon fiber composite sensor bar

System Capabilities

¡ Accuracy better than globally available systems ¡ Detection zone of 9 ft radius from centre of target ¡ Wide Azimuth and elevation angles ¡ Hit localization by position of X & Y and velocity of projectile ¡ Varied categorization of shot as per performance

i.e. Hit, Miss, Improper, Ricochet and Cross Shot ¡ Real time Performance evaluation ¡ Real time HAT analysis ¡ Interactive Grouping and Zeroing ¡ Simplified alignment procedure


Director (Marketing) Bharat Electronics Limited,Outer Ring Road, Nagava, Bangalore 560 045, India. Tel: 91-80-25039300; www.bel-india.in

Industry Partner

ABHIAS is an automated system to detect bullets using acoustic detection and localization of hits on target by acoustic time delay estimation methods. Real time and precise system, catering for individual to tactical level of exercise settings. System caters to almost all weapons including rifles and CQC weapons.

Indigenous design tailor made for Indian Armed Forces and Paramilitary Forces with high degree of ruggedisation to meet Mil Grade Standards. Configured out of COTS item to ensure low post sale maintenance cost.

DHVANI

Unique Features

¡ Automated Range Control with database management

¡ Variable firing positions without any recalibration

¡ Exercises as per SAO 12/S/85 and facility for user

defined exercise setting

¡ Seamless wireless network with Ethernet enabled

network

¡ Roaming Firing Point Officer (RFI) and Firer End Display

Interface (FEDS)

¡ Interactive & User Friendly GUI

¡ Power on self diagnostic and real time diagnostic

during the exercise

¡ Unit Level Package for firer management and

performance evaluation outside the range

¡ All weather-proof carbon fibre composite sensor bar

System Capabilities

¡ Accuracy better than globally available systems

¡ Detection zone of 600mm diameter from centre

of target

¡ Wide Azimuth and elevation angles

¡ Hit localization by position of X & Y

¡ Varied categorisation of shot as per performance

i.e. Hit, Miss, Improper and Cross Shot

¡ Self Healing Targets capable of withstanding

atleast 8000 shots

¡ Real time Performance evaluation

¡ Real time HAT analysis

¡ Interactive Grouping and Zeroing

ABHIAS


Director (Marketing) Bharat Electronics Limited,Outer Ring Road, Nagava, Bangalore 560 045, India. Tel: 91-80-25039300; www.bel-india.in

Industry Partner

The indigenous Wankel engine development program was originated from DRDO through Vehicles Research & Development Establishment (VRDE), Ahmednagar, and was jointly designed, developed and successfully flight tested by CSIR-NAL, VRDE, and ADE. Under this program the 55 hp Wankel engine was developed for ADE’s NISHANT UAV. NAL designed and developed the core engine; VRDE and ADE were in-charge of peripheral systems and flight testing respectively.

The Wankel engine is the first of its kind to be totally designed and developed in the country. Very few countries in the world have the capability to develop and master this technology. CEMILAC accorded the Certificate for ‘Limited Series Production’ on 7th February 2013. Twenty Wankel engine are being manufactured by VRDE, DRDO.

Features

Type : Single rotor Wankel engine Cycle : Otto cycle Power : 55 hp (41 kW) @ 8000 rpm at ISA-sea level Thrust : 90 kgf with 1 m diameter propeller Compression ratio : 9.2 Housing Cooling : Water-Glycol mixture Rotor cooling : Air Lubrication : Total loss forced lubrication system Ignition : CDI system Carburettor : Diaphragm type Specific fuel consumption : 335 to 365 g/ kWh (0.55 to 0.60 lb/ hp/ h)

Engine weight (dry) : 25 kg

Other Applications

This type of engines are used for powering smaller air vehicles and also in automotive (Mazda, and Racing Cars), hybrid vehicles as range extenders, out-board motor for boats and other industrial applications in particular for compact power generators.

Cost Economics

Presently this technology is direct substitute for an imported 51 hp engine for DRDO’s NISHANT UAV. The cost of the indigenous engine is around 40 percent less than the imported one during the limited series production stage. The cost will further come down during the mass production.

55 Hp Wankel engine UAV-Nishant maiden successful flight with Wankel engine

Wankel Engine Indigenous Wankel Engine for a UAV A CSIR & DRDO Partnership


CARBON FIBRE

Carbon fibre, is a new breed of high-strength materials, mainly used as reinforcement in advanced composite materials. It is a long, thin strand of material about 5-7 micron of diameter and composed of more than 94% of carbon. Due to their unique characteristics such as light weight, high strength, high stiffness, improved fatigue resistance & vibration damping, corrosion resistance, low thermal expansion, and thermal & electrical conductivity, carbon-fibre composites are an attractive substitute for various metals and special alloys.

CSIR-NAL has established the facility for carbon fibres research and development and pioneered the technology of carbon fibre. The standard modulus grade carbon fibre developed and produced at CSIR-NAL has been certified by Centre for Military Airworthiness and Certification (CEMILAC).

CSIR-NAL offers complete process ‘Know-How’ for standard modulus grade carbon fibres, which includes ¡ Synthesis of Polyacrylonitrile copolymer ¡ Wet spinning of Special Acrylic Fibre (SAF) ¡ Heat treatment of special acrylic fibre to ‘Carbon Fibre’.

Carbon Fibre plant at CSIR-NAL

Products developed at CSIR-NAL

Components developed from indigenous Carbon Fibre

Indigenous Technology - Self Reliance


Airborne Nose Radome- For Fire Control Radar of Jaguar Maritime Fighter Aircraft Fleet (IAF)

CSIR-NAL has designed and developed a composite nose radome for the Fire Control Radar of Jaguar Maritime Aircraft for

HAL, Bangalore, end user being IAF. Manufacturing technology for production of the Airborne Nose Radome for the Indian

Air Force Jaguar Maritime Fighter Aircraft fleet has been transferred to HAL,Bengaluru. The ToT of Airbone Radomes to

HAL was completed in 2013. Features

The monolithic Nose Radome was fabricated using high performance GFRP. It is a variable thickness, nose thick and base

thin design radome. An in-house developed closed mould resin injection technology has been used in fabrication of the

radome. The composite radome is protected with anti-static / anti rain erosion paint subjected to qualification tests, viz.,

EM, lightning protection, static loading, vibration and rain erosion tests in presence of CRI. The radome has successfully

met the stringent airworthiness qualification standards.

Ground based Radomes – for protection of DWR Radars of Indian Metrological Department

The huge out-door radomes protect the steerable antenna from the harsh, all-weather conditions, while permitting the

electromagnetic waves to pass through without any interference or significant loss. Radomes were designed and developed

by CSIR NAL for the India Meteorological Department and Indian Space Research Organisation.

CSIR-NAL has successfully designed and installed 12.88m diameter composite spherical Doppler Weather Radome

(DWR) protecting the weather radar belonging to BEL/ISRO at IMD campus Cherrapunji within a record time. CSIR-NAL

has successfully completed the installation of DWR Mark II Radome at Gopalpur - Odhisa, Kochi - Kerala, cherrapunji -

Meghalaya, Bhuj - Gujarat and Shar - Sriharikota (2018). With the successful completion of the installations, the DWR Mark

II Radome indigenization program, that has a significant role in weather monitoring activities of IMD, has successfully met

the objectives and culminated with dissemination of the technology to industry.

Jaguar Nose RadomeJaguar

RADOMES Indigenous Radomes for Airborne and Weather Applications

Features

The Ground Based Weather Radome is a spherical radome of diameter 12.88m. It has 66 polygonal panels fabricated using PolyUrethane (PU) Foam core glass epoxy sandwich composite. A cost-effective wet layup and Room Temp. vacuum bag moulding process has been adopted. The Radome is designed to withstand 250 km/h wind speed with gusts upto 300 km/h.

Industry Partnership

ToT of weather Radomes to BEL, Navi Mumbai completed in 2014. Saving of foreign exchange of minimum of 30% vis-à-vis imported US radomes and also allows deployment in strategic locations.

Electromagentic Design & Analysis for Radomes

The Computational Electromagnetics Laboratory (CEM Lab.) was founded in 1993 at the CSIR-National Aerospace Laboratories (CSIR-NAL) to initiate the activities in the area of computational electromagnetics for aerospace applications.

¡ Integrated antenna-radome analysis capability ¡ FSS-based radome designs ¡ Monolithic/ sandwich

(including honeycomb) designs ¡ Variable thickness radome (VTR) design ¡ Hybrid-VTR design for missile radomes ¡ Multi-sector optimization radome design ¡ Ground-based and airborne radomes

(for aircraft, missiles, etc.) ¡ High-temperature, high performance radomes ¡ Stealth radomes ¡ Radome EM performance enhancement ¡ Broadbanding techniques ¡ In-house EM material characterization of candidate radome materials

DWR Radome at Gopalpur, Odisha.

The 12.88m dia. DWR Radome installed at Cherrapunji, Meghalaya.

DWR Radome at Kochi, Kerala.

RADOMES

Director (Marketing) Bharat Electronics Limited,Outer Ring Road, Nagava, Bengaluru 560 045, India. Tel: 91-80-25039300; www.bel-india.inDirector (Marketing)

Hindustan Aeronautics Limited15/1 Cubbon Road, Bengaluru 560001, India. Tel: 91-80-2232 0701 www.hal-india.co.in


Industry Partners

Salient Features

¡ Auto, semi-auto and manual modes of operation ¡ PC, PLC, Front-end controllers and Recorder based

C&l architecture ¡ User friendly Mimic & Touch screen based data

acquisition ¡ Fail-safe and simple to operate ¡ Quick-lock door without lock-ring ¡ Compact and skid mounted ¡ High efficiency pressurized fan motor with health

monitoring ¡ Peripheral duct for efficient air circulation ¡ Creep and oxidation resistant high temperature

heating elements ¡ SS tubular Heat exchanger with fins for better heat

transfer ¡ Exhaust silencer for noise reduction ¡ Closed loop water cooling system to minimize

consumption ¡ Water softener for long life of heat exchanger and fan

motor ¡ Pressurization with built-in compressor and storage

tank ¡ Automatic vacuum level control with bag burst

protection ¡ Advanced part temperature control

Specifications

Working space 900 mm dia and 1000 mm lengthMaximum Temperature 200°CMaximum Pressure 7 bar(g)Heating Rate 0 to 3°C per min Cooling Rate 3°C / min (Avg) Temperature Control Accuracy ±1°C (Air Temperature)

Temperature Uniformity ±2°C (under steady state conditions) Pressure Control Accuracy ±0.1 bar Vacuum Control Accuracy ±5% of FSRMaximum Vacuum at source 3 mbarTotal Power Rating 23 kW

Safeties

¡ Door lock safety device to prevent opening under pressure

¡ Emergency pressure dump ¡ Pressure & Temperature overshoot prevention ¡ Auto-hold to prevent higher temperature gradient ¡ Manual override (if the computer, PLC and control

system fails) ¡ Earth leakage trip for the electrical system ¡ High current and overload protection for all the

motors

AUTOCLAVE


Aerospace Autoclave with state of the art features at an affordable cost Developed to cater the needs of R&D and Educational Institutions An ideal equipment for Research Labs with interest in Polymer Composites

Industry Partners

Labscale Autoclave

The Managing Director, KRR Engineering Pvt. Ltd.L-17,18 - Ambattur Industrial Estate, Chennai-600058, Tel: +91-44-26880-210/738/684 www.krr.co.in

The Chief Executive Officer, Unique Chemoplant Equipment Level 3, Sejj Plaza, 3rd Floor, Near Nutan High School,Malad (W), Mumbai - 400 604, Maharashtra. Tel.: +91-22-40736736 www.uniquechemoplant.com

AUTOCLAVE


Industry Partners

Compact, affordable Aerospace Autoclave with state of the art features Ideal for Academic and Research institutions for composites processing

Specifications

Working space 450mm dia. and 500mm lengthMaximum Temperature 200°CMaximum Pressure 7 bar(g)Heating Rate 0 to 3°C /min on airCooling Rate 1°C per min (Avg) up to 70°C on airTemperature Control Accuracy ±1°C (Air Temperature)

Temperature Uniformity ±2°C (under steady state conditions) Pressure Control Accuracy ±0.1 bar Vacuum Control Accuracy ±0.5% of FSR (digital)Maximum Vacuum at source 3 m barTotal Power Rating 7 kW single phase

Safeties

¡ Burst Disc ¡ Double Safety Relief Valve ¡ Wedge Lock Type Door Safety ¡ High Pressure switch ¡ Thermostat ¡ Emergency Dump Valve ¡ Earth fault protection at Incomer ¡ Protection for blower and Vacuum pump ¡ Emergency stop Push button ¡ Key switch for cure start

¡ Fail-safe and easy to operate ¡ Quick lock hinged door with integrated lock ring ¡ Compact table mounted ¡ Works on 32A, 230V Single phase power supply ¡ Forced air circulation with compact pressurized fan

¡ Fits in a space of 1.5m cube ¡ Optional closed water circulation system ¡ Optional compressed air system ¡ Automatic vacuum bag failure protection ¡ Air less, solenoid operated control valves

Salient Features

Desktop Autoclave

The Managing Director, Milvus Aero Solutions Pvt. Ltd.#68, Bhuvaneshwari Nagar, C.V. Raman Nagar, Bangalore 560093, Tel : 080 43712200; e-mail: [email protected]

The Managing Director, DATASOL (B) Pvt. Ltd. # No793, Vyalikaval HBCS Layout,17th cross,Veeranna Palya, Nagawara, Bangalore 560 045Tel: 080-2544 0642; www.datasolindia.com

The Managing Director, Lakshmi Engineering Works111/96, 5th Street, 3rd Lane, North Phase, Sidco Industrial Estate, Ambathur,Chennai 600 098. Tel: +91-44-2635-6043 www.lewind.com

AUTOCLAVE Industrial Grade Autoclave Technology

National Aerospace Laboratories (NAL), Bangalore, India has an acknowledged capability in building large, computer

controlled, state-of-the-art autoclaves along with the associated subsystems.

NAL’s expertise in designing and building autoclaves is evident from the number of autoclaves that are operational in NAL

itself, namely Mark I, Mark II, Mark III and Mark IV, catering to various requirements. While Mark III is a high temperature

(350°C) and high pressure (15 barg) autoclave, Mark IV is built to be an industrial workhorse with operating space as much

as 4.4m in diameter and 9m in length.

Earlier, NAL has supplied an autoclave with a working space of 4m dia x 8m length, to Hindustan Aeronautics Ltd., Bangalore,

India, which has been functioning satisfactorily over the years. NAL has also revamped a few autoclaves for Vikram Sarabhai

Space Centre, Trivandrum, India.

M/s. KRR Heavy Engineering, Chennai and M/s. Unique Chemoplant Equipments (UCE), Mumbai, India, have taken License

from NAL for marketing and manufacturing of Industrial and lab scale grade Autoclaves

World-class Autoclave Technology Indigenously Developed by CSIR-NAL

Industrial Duty, High temperature (425°C) and High Pressure (15 barg) Autoclaves for Demanding Applications

Industry Partners

Managing Director, KRR Engineering Pvt. Ltd.L-17,18 - Ambattur Industrial Estate, Chennai-600058, Tel: +91-44-26880-210/738/684 www.krr.co.in

Chief Executive Officer, Unique Chemoplant Equipment Level 3, Sejj Plaza, 3rd Floor, Near Nutan High School,Malad (W)Mumbai - 400 604, Maharashtra. Tel.: +91-22-40736736, www.uniquechemoplant.com

AUTOCLAVE


Industrial Grade Autoclave Technology

CONDUCTIVE COMPOSITE ENCLOSURE


Salient Features of the Product

¡ Lighter in weight (50% as compared to Metal) ¡ Lower in Cost (50% as compared to Metal) and Low

production time ¡ Enhanced fuel economy and Saving on

maintenance, operation cost of Aircraft ¡ Under CEMILAC certification

Industry tie-ups

¡ HAL, ADA and Datasol (B Pvt. Ltd.)

End users ¡ ADA,HAL,ISRO and Automobiles

EMI/ EMC,

Inner Intricacies of the Chassis Data Acquisition and Retrieval

Thermal Cycling and Vibration

Specifications of the Composite Enclosure

Dimensions : 171.7mm x 80.2mm x 62.4mm (LxWxH)

Weight : <650 gms (including electronics)

Chassis configuration : Conductive CFRP Nanocomposite/Foam sandwich structure

Coating : Polyurethane/CNT Nano Coating

Manufacturing method : Matched die Compression moulding

EMI/EMC compliance : MIL-STD-461

Performance Compliance : MIL-STD-810F

Operating Frequency : 10KHz to 18GHz

Light Weight Conductive Polymer Composite based Enclosure for Avionics

8 Channel RS 422 DRU with Composite Chassis

COMPOSITE REPAIR


Multi Zone Hot BonderFor Airframe and Composite Repair

Salient Features

¡ High performance and cost effective repair kit ¡ Advanced features for complex and multiple repair ¡ 7” Colour touch screen (PLC-HMI) controller ¡ 2 simultaneous repairs with independent ¡ 12-zone temperature control ¡ Menu driven program to create, run, view

Cure Cycles (CC) ¡ Online and offline reporting / printing ¡ Hold, modify and continue or extend CC

Specifications

Number of temperature zones : 12 independently controlled zonesMaximum temperature : 230°C (for silicon heater blankets)Number of Controlled vacuum levels : TwoMaximum heater area : 0.9sq. meter (1380sq.inch) per zoneMaximum heater power : 6900W (30A/230V) per heater / per zoneTotal heater power rating : 13.8KW (60A/230V) for 2 zonesNumber of Temperature sensors : 24 Numbers (J type)Temperature control accuracy : ± 1°C of set valueTemperature uniformity : ± 2°C among the 12 zone controlled valueHeater – sensor mapping : Any heater to any one or more sensorsTemperature control basis : Online selection as the leading, lagging or average of any set of sensorsWeight and Size : 20 Kg (MiL standard package): 660 x 430 x 330 mm (LxWxH)

Applications

¡ To perform in situ repair / hot bonding of aircraft/ automobile structures

¡ Thermo-forming of foams for aircraft structures

Touch Screen Controller

Safeties

¡ Detection of heater–sensor mismatch ¡ Sensor failure management ¡ Protection against sensor faults such as

Open, Short or improper contact Auto-hold if Temp. Gradient exceeds limit

¡ Over temperature cut-off ¡ Alarm on vacuum failure and other faults ¡ Power interruption management

Industry PartnersThe Managing Director, Ajay Sensors & Instruments# 45/17, 12th “A” Cross, Gubbanna Indl. Garden, VI Block, Rajajinagar, Bangalore 560010Tel: 080 2330 4997, www.ajaysensors.in

The Managing Director, San Process Automation48/3,11th Main ,3rd Cross , Channappa Building, A.K.Colony, M.S.Ramaiah Industrial EstateMathikere, Bangalore - 560054Tel: 08040926026 www.sanprocessautomation.com

COMPOSITE REPAIR

CSIR-NAL over he years has developed expertise in aerospace structural design, analysis, testing, qualification, certification and Research and Technology development in aerospace structures and contributed to all aeronautics and space programs of India. The laboratory has immensely contributed to the technical life extension, carriage & handling studies, static & fatigue testing, vibration qualification tests and design analysis studies for active military aircraft of Indian Air force thereby supporting the supporting the national defence.

High-end services to Life Extension Studies & Up-gradation Programmes of IAF’s Aircraft

Full Scale & Component Level Fatigue Testing of Aircraft

CSIR-NAL has been a pioneer in full scale fatigue testing of aircraft and has developed the techniques of simulation and application of loads experienced by the aircraft in operation. First, Full Scale Fatigue Testing Facility (FSFT) at NAL was built in 1973 and subsequently an upgraded one was built in 1991. Under the 11th Five Year Plan (2007-12) the 18-channel/actuator in-house controller (mostly top loaded) has been upgraded to 96-channel/actuator standard controller (mostly bottom loaded).

This enhanced facility is capable of testing all the fighter aircrafts which the Indian Air Force has in service. This facility has immensely contributed to the total technical life extension (TTLE) of HAL/IAF’s Gnat-Ajeet, MiG -21 Bis (late 1990’s) and MiG-29 (mid 2000) thus adding enormous value to the defence forces.

Total Technical Life Extension of Ageing Aircraft (MiG-21) :

¡ Over 200 aircrafts in the feet of MiG-21 ¡ Life extended from 2400 to 3200 flight hours through laboratory testing and

analysis

Studies for MiG-29 :

¡ Life of landing gears extended from 2700 to 3000 landings

¡ Ground work for TTLE

¡ Material database generation

¡ Derivation of operational load spectrum

¡ CFD analysis for pressure distribution

¡ In-flight Vibration & Thermal Mapping

¡ Development of indigenous vibration qualification spectrum based on flight data

¡ Vibration characteristics through GVT

¡ Development of software tools for qualification spectrum generation

Studies for MiG-27

¡ Low band transmitting antenna

¡ EW Shell

¡ EWSFA Radomes

STRUCTURES Structural Design, Analysis, Testing, Qualification & Certification

High End Technical Services to the Strategic Aerospace Sector

MiG-21 in FSFT

MiG-29 landing gears

MiG-29 qualification

spectrum

Carriage & Handling Studies for Jaguar: Integration of Next Generation Missiles

¡ Ground vibration testing (GVT) ¡ Modal parameter estimation ¡ GVT based flutter estimation ¡ Flight flutter testing

Carriage & Handling: Mirage 2000 Upgrade

¡ System identification using GVT ¡ Modal parameter estimation ¡ GVT based flutter estimation ¡ GVT on aircraft with FOC stores ¡ Flutter scenario of FOC aircraft ¡ Flight flutter testing with FOC stores

TU 142: Ground Resonance Test & Flight Test

¡ Ground vibration testing (GVT) ¡ Modal parameter estimation ¡ Flight test instrumentation ¡ In-flight vibration measurement

Active Antenna Array Unit: Modal analysis Tests

¡ Tests on both Version 4 & 5 ¡ Fixed & Free-free boundary conditions ¡ Modal parameter estimation ¡ Establishment of rigid body and elastic bending modes

ALH : Ground Vibration Testing

¡ Free-free condition ¡ Modal testing ¡ Mode identification ¡ Response analysis ¡ Blade frequencies

Helicopter

¡ Life extension for tail rotor blades of MI-8 helicopter from 1500 to 2000 flight hours.

¡ (over 150 helicopters in the fleet) ¡ Significant FE savings to exchequer

STRUCTURES


MAGNETIC SENSOR BASED ON

GIANT MAGNETO RESISTANCE

(GMR) EFFECT

Developed by,

CSIR – National Aerospace Laboratories

(CSIR – NAL), Bangalore, INDIA.

Magnetic sensor in brief Magnetoresistive sensing element (MRE) based on Giant Magneto-Resistance (GMR) properties are primarily developed to decode the information from linear or angular encoders made of ferrous materials. Low hysteresis and high sensitivity, smaller in size and cheaper cost make magnetic sensors suitable for wide range of applications. Moreover, these sensors, made of passive elements in Wheatstone’s bridge configuration removes the limitation to use even in high frequencies (0 < f < 1MHz). The fabricated sensor (NAL MRA 1426) is in the form of 8 TDFN plastic package (3 mm x 3 mm) with each active element area of 250 x 300 µm2. The sensor can produce large output voltages (in range of few hundred mV) and can be operated up-to an air gap as large as 10 mm.

Notes

The sensor is fabricated with a typical bridge resistance of 6.3 KΩ. It produces a pure ratiometric output for input voltages between 0.1V to 30V. The non-linearity and hysteresis were measured for unipolar operation. Thermal effects are compensated in the Wheatstone’s bridge configuration.

Specifications of NAL MRA 1426

Features

Larger air-gap High sensitivity Low hysteresis Good temperature stability Can handle large magnetic fields Small size and low cost

Bridge characteristics

Variation of output voltage with air gap

PCB with sensor and signal conditioning circuit

8-pin DFN package

Vin = 12V

Thermal stability at 225°C

Applications

Linear and angular speed sensing

Linear and angular position sensing Current sensing Pressure sensing Eddy current probe measurement

Schematic for speed sensing using sensor

Implantable medical devices

Power electronics modules

Vibration detection Micro-Air Vehicle (MAV)

Automotive

Consumer

Industrial

Aero

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Defence

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Director CSIR – National Aerospace Laboratories HAL Airport Road Post Bag No – 1779 Bangalore, 560017 INDIA Tel : +91 – 80 – 2508 6000 Fax : +91 – 80 – 2526 0862 Email : [email protected]

Applications

NAL818 Aerospace Electronics and Systems Division


ARINC 818 IP core for High Speed Avionics Solution

High Speed Solution for Tomorrow

¡ NAL818 is ARINC 818 compliant FPGA IP Core

with support for video and data for high speed

application.

¡ Easy to use interfaces for native connectivity.

¡ Device Support: Xilinx Spartan-6, Zync-7 Series,

¡ Tools Support : ISE and Vivado Design suite

¡ DO 254 Complaint : By Q2 2016

Current Status:

¡ Functionally tested as per ARINC 818 for both

transmitter and receiver

Native Interface:

¡ Raw 24 Bit RGB with Vsync, Hsync, DE and CLK

¡ DVI and HDMI interfaces (Optional)

Key Features:

¡ High Performance optimized for video data

¡ 3 .178 Gbps data rate tested

¡ Functionally tested for 1400 X 1050 pixel of video

data at 60 Hz refresh rate

¡ Configurable to custom resolution

¡ Resource Optimized design for Transmitter and

Receiver

Certification:

¡ DO 254 Process is in progress and expected to

comply by Q2 2017.

Aerospace Electronics and Systems Division

Main Instrument Panel for Regional Transport Aircraft

RTA COCKPIT


Features

¡ FAR 25 Complaint Avionics Architecture

¡ Advanced Full Glass Cockpit

¡ Fully Digital Multi-layered digital communication bus protocols - ARINC 818 and ARINC 664

¡ Integrated Modular Avionics (IMA) based architecture with ARINC 653 complaint Time and

Memory partitioning platform

¡ Dual Redundant architecture from sense to actuation

¡ Five 15” Wide Screen advanced displays – 2 PFD and 3 MFD

¡ Integrated Touch Controlled Device

¡ Dual Redundant data and Video Bus for the complete cockpit

¡ Integrated CNS suite

¡ Dual Flight Management System with Autopilot

¡ Defined set of optional systems having seamless integration with avionics suite.

RTA Main Instrument Panel RTA Cockpit Environment for design studies


Centre for Electromagnetics (CEM)

Multilayer RAM Design Software using Particle Swarm Optimization

¡ Design of Broadband Radar Absorbers using Particle Swarm Optimization ¡ Optimized thickness from user updateable material database ¡ Maximum absorption with minimum thickness profile ¡ Validated through measurement

Features

¡ User friendly Graphical User Interface (GUI) ¡ Capable of modifying the material database ¡ Visualization of absorption performance w.r.t .

frequency ¡ Displays the convergence of result through

optimization ¡ Computationally efficient software (less computation

time)

Applications

¡ Stealth platforms : Aerospace, Navy, IAF, HAL ¡ Mobile industry (EMI shielding) ¡ Health care industry (radiation hazard mitigation)

Inputs

¡ Measured permittivity and permeability, (EM characterization facilities available for measurement)

¡ Operating frequency band ¡ Number of layers ¡ Desired reflection value ¡ Optimization / Accuracy parameters

Output

¡ Best material combinations ¡ Optimized thickness of each layer ¡ Absorption characteristics ¡ Reflection loss over broadband ¡ Optimization convergence plot ¡ Computation time ¡ RCS reduction using material can be provided

through indigenously developed SPARCS software

CEM

RCS reduction with RAM Cylindrical duct RCS validation

Ray tracing inside air-intake duct

¡ Fast RCS estimation of analytical models¡¡ ¡Parallelized numerical ray tracing based hybrid high

frequency methods for RCS estimation of Complex Surfaces such as aircraft, UAV, missiles, ships

SPARCS can be used in area of aerospace, automotive, defense and naval domains

to estimate the radar cross section of 3D complex surfaces

SPARCS

SPARCS: RCS Prediction Software with/without RAS

Stealth Platform Asymptotic Radar Cross section Software (SPARCS)

¡ Indigenous Radar Cross Section estimation software using hybrid asymptotic high frequency methods

¡ Optimization of radar absorber thickness profile towards payload reduction over broadband¡¡ ¡RCS estimation with/without radar absorber coating/

structures (RAM/RAS)

GUI of the RCS estimation software

RCS of typical fighter aircraft model

Centre for Electromagnetics (CEM)

RCS reduction with RAM Cylindrical duct RCS validation

SPARCS


Features

¡ Software support for parallel computing, including GPU processing.¡¡ ¡Indigenous algorithms with enhanced precision and better run-times¡¡ ¡User friendly Graphical User Interface (GUI).¡¡ ¡Supports STL (stereolithography) CAD format¡¡ ¡RCS data vs. frequency and aspect angle (Cartesian and Polar)¡¡ ¡Ray tracing/ray path visualization and access to ray path data¡¡ ¡Ray data to facilitate the perceptions of the scattering mechanism towards low RCS design¡¡ ¡Software Validation Test Cases

(with Accurate Solvers/Measurement Results)


SUCHAN - MiNi UAV

Suchan is an all composite, light weight, modular mini UAV designed and developed by CSIR-NAL. Its designed to meet high altitude operation requirements and has a ceiling altitudes of 5000 m ASL. This Indigenously designed and developed mini-UAV is a far more cost efficient solution than other UAVs.

Key Features

¡ Rugged system for harsh environments ¡ Easy and quick assembly ¡ Fully autonomous operation(Take-off to Landing) ¡ GPS aided waypoint navigation and loiter ¡ User friendly GCS with real time video and recording ¡ RPV and Safety Pilot ¡ Return to home at loss of link and/or low battery ¡ Two man portable (Backpack or Trolley)

Advance features

¡ Software Image Stabilization and Mosaicking ¡ GEO Tagging ¡ Target Tracking

¡ ISTAR Missions ¡ Border and Coastal Patrol ¡ Battle damage assessment ¡ Situational Awareness ¡ Observing the enemy lines

In-House Sub-systems Development

¡ Inhouse UAV Design ¡ Inhouse Airframe Manufacturing ¡ NALAutopilot Hardware ¡ NAL Control Algorithm ¡ NAL Ground Control Software ¡ Inhouse Gimbal- Interchangable Camera ¡ NAL Vision Algorithms

Specifications

Payload : Interchangeable nose assembly (Pan-tilt Gimbal) - Option 1 : EO camera (1080p) - Option 2 : Infra-red camera (640x480 pix)Range : 10 km (Communication Link)Endurance : 90 minSpeed : 10- 25 ms-1

Wing span : 1.85 mLength : 1.40 mWeight : 5.0 kg (Max. take-off wt.)Launch : Hand LaunchRecovery : Belly LandingPropulsion : Pusher type BLDC MotorOperating Altitude : 100 - 300 m AGL, with 5000 m max Altitude

RTA COCKPITUAV

¡ Search and rescue mission ¡ Traffic monitoring ¡ Forest fire detection ¡ Commercial aerial surveillance ¡ Mapping Applications

Orthomosaic of the Coal Mines at West Bengal

Digital evaluation model of a coal mining area at West Bengal

In flight video tracking &Night Surveillance

Mission Applications

DRISHTI & AWMS


DRISHTI and Aviation Weather Monitoring System (AWMS)

KIA, Bangalore

IGI Airport, New Delhi

¡ Indigenous and Cost Effective

¡ Base line : 30 meters

¡ Measurement Range of Visibility :

10-10000 meters

¡ Meets International Civil Aviation

Organisation (ICAO) and World

Meteorological Organsation

(WMO) requirements

AWMS

DRISHTI gives Runway Visibility to Pilots

AWMS gives

¡ Wind speed ¡ Wind direction ¡ Pressure ¡ Temperature ¡ Dew Point ¡ Humidity

At Kannur International Airport

Mandatory systems for safe landing and

take off operations at Airports

DRISHTI and AWMS together gives all the weather parameters

required for

SAFE Airport operations

Drishti has hit Century

47 Drishtis

in 21 International

Airports

54 Drishtis in 18 IAF Air bases

101 DRISHTI SYSTEMS IN THE COUNTRY

Drishti Transmissometer, a visibility measuring system is an innovative, indigenous product first of its kind,designed and developed by CSIR-NAL.

DRISHTI uses novel signal processing techniques with high accuracy and resolution. The data acquisition at fieldsite is in FPGA embedded platform with computation of Visibility using “Drishti RVR software” in industry standard Lab View environment. Web enabled health monitoring, remote control of the system from any location in the country for accessing the data and for maintenance are the other important features of this state of the art system.

The system is extremely robust with high mean time between failures. DRISHTI has been issued International Class-I Certification. Servicing is made user-friendly and cost-effective by modular electronics and virtual instrumentation concepts in the design.

nal-technical-brochures.pdf - National Aerospace Laboratories

Documents

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