DAYANANDA SAGAR COLLEGE OF ENGINEERING Batch

SHAVIGE MALLESHWARA HILLS, KUMARASWAMY LAYOUT, BANGALORE-560078 Number

(AN AUTONOMOUS INSTITUTE AFFILIATED TO VTU, APPROVED BY AICTE &ISO 9001: 2008 CERTIFIED) 29
ACCREDITED BY NATIONAL ASSESSMENT & ACCREDITATION COUNCIL (NAAC) WITH ‘A’ GRADE
DEPARTMENT OF MECHANICAL ENGINEERING

Internship Presentation
Title: HAL – LCA TEJAS ( LIGHT COMBACT AIRCRAFT)

Guide Name MADHAVA MOORTHY

Designation ASSISTANT PROFESSOR

Student Name SUDEEP S

USN 1DS21ME480
Contents
1. Company Description
2. Task Performed
o Powerplant and Fuel system
o Electrical and Avionics system
o Seat and Safety & Armament system
o Flight Control system
o Hydraulics system
o Environment Control system

3. Conclusion
4. Certificate
1. COMPANY DESCRIPTION
Hindustan Aeronautics Limited (HAL) is an Indian public sector aerospace and defence company, headquartered in Bangalore.
Established on 23 December 1940, HAL is one of the oldest and largest aerospace and defence manufacturers in the world. HAL
began aircraft manufacturing as early as 1942 with licensed production of Harlow PC-5, Curtiss P-36 Hawk and Vultee A-31 Vengeance
for the Indian Air Force.

Hindustan Aeronautics Ltd (HAL) is an aerospace and defense company, owned by the government of India. The company develops,
designs, manufactures, and supplies aircraft, helicopters, avionics, and communications equipment for military and civil markets. It
also provides repair, maintenance, and support services for aircraft.

HAL offers aircraft accessories, helicopters, aero engine, aerospace equipment, advanced communication, and navigation equipment.

It serves the Indian Air Force, Indian Army, Indian Navy, Defence Research & Development Organization, Indian Coast Guard, Indian
Space Research Organization, Mauritius Police Force, Boeing, and AirbusIndustries.
2. Task Performed
1) Power plant and Fuel system
There are two types of powerplant systems:
o Main power plant system - Engine (GE - F404 - IN20 )
o Secondary power system – AMAGB ENGINE

F404GE- IN20 is divided into 6 modules and an accessory gearbox:

• Fan module- The fan module compresses incoming ram air, dividing it into primary and secondary airflows. While the primary
airflow powers the engine's core, the secondary airflow, passing through the bypass section, contributes to thrust.
• Compressor module- The compressor module, located after the fan module, weighs approximately 600 lbs when dry. Its primary
function is to further increase air pressure after the fan stage, preparing it for combustion.
• Combustor module- The combustion chamber, weighing about 21 kg dry, sits at the rear casing bolt flange of the compressor stator.
It features an annular shape housing fuel and air mixtures, managed by 18 spray nozzles and dual igniter plugs.
• HP turbine module- The HP Turbine Module, weighing approximately 98 kg, converts thermal energy from the combustor into
mechanical energy, powering the HP compressor and other engine accessories.
• LP turbine module- The LP Turbine Module, weighing around 133 kg dry, extracts kinetic energy from gases exiting the HP turbine to
drive the LP compressor.
• Afterburner module- The Afterburner Module, weighing 352 lbs (160 kg) dry, is located at the rear section of the engine. It
enhances thrust by burning fuel downstream of the turbine, augmenting aircraft performance during takeoff, climb, and combat
situations.
AMAGB
The Aircraft Mounted Accessory Gear Box (AMAGB) is a crucial Line Replacement Unit (LRU) within the Secondary Power System (SPS) of LCA Tejas,
boasting lightweight, compact, high-speed, single input, multi-output gearbox, and self-contained lubrication system, with indigenous versions demonstrating
reliability through over 6000 flying hours. AMAGB consists of 4 components
1. Left bottom – JFS (Jet Fuel Starter)
2.Right bottom – IDG (Integrated Driven Generator)
3.Left top – Hydraulic pump.
4.Right top – Hydraulic pump

FUEL SYSTEM
The LCA Tejas fighter has a total fuel capacity of 2400 kg internal fuel capacity. The trainer version has a capacity of 2100 kg internal fuel. The fuel system
has a total four internal fuel tanks:
• FIA- FIA-The F1A is located in between the stations from 18th to the 20th station. It has a total capacity of 436 kg of fuel. It sits below the avionics rack.
•F1/F2- F1-It is located between the 22nd to the 24th station. F2- It is located between the 24th to the 30th station. They are known as the main feeder tank.
It is L. shaped.
•Wing- Wing tanks on each side of the aircraft store 580 kgs of fuel internally, while additional external drop tanks, including inboard and mid-board variants,
provide extra fuel capacity with 1200L and 800L capacities respectively.
2) ELECTRICAL AND AVIONICS
The LCA Tejas aircraft features a sophisticated electrical system powering components such as the Fly-by-Wire system, converting
mechanical input into electrical signals. Additionally, it employs a hybrid power generation system alongside two emergency
batteries, with power distributed as AC from the Integrated Driven Generator (IDG) and DC, distinguished by frequency
presence in AC power.

MAIN POWER SOURCE:

•30/40 KVA, 115/200V, 3 phase AC IDGC (Alternator 1)

•Two 250 amps TRU's giving 28V DC output.

•0.3550 KVA HMDG system, 28V output (Rectifier Converter Unit)

STANDBY POWER SOURCES:

•5KVA, 115/200V, 400Hz, 3 phase HMDG (Alternator 2)

•5KW, 28V DC Generator

EMERGENCY SOURCES:

•44Ah, 24V Nickel Cadmium Battery 1 21 |

•44Ah, 24V Nickel Cadmium Battery 2

AC GENERATION SYSTEM:
Basic Power Generator, 30/40 KVA (Main Source) with standby sources of KVA Hydraulically Driven Generator and 5 KW DC generator
mounted on the engine gear box.
FEATURES OF THE AC GENERATION SYSTEM:
•The Generator Control Unit (GCU) is provided for control, regulation and protection of the respective generator.
•The GCU controls generator line contactors which in turn control all the generators to respective bus bars.
•Power transfer and load shedding are carried by connecting/disconnecting bus tie contactors.
•Emergency AC Power is provided by a static inverted of 250 KVA

The Tejas Aircraft relies on the F404 GE IN 20 Engine as its primary power source, with mechanical power transferred via the PTO
shaft to drive the AMAGB. One of the drivers on the AMAGB powers the 30/40 KVA IDG, providing the main power generation
capacity, requiring 71 HP for a continuous output of 40 KVA.
3) SEAT AND SAFETY & ARMAMENT SYSTEM
In times of crisis, the aircraft's escape system, incorporating the MK IN 16G ejection seat, guarantees pilot safety by swiftly ejecting

them and ensuring their comfort post-separation. It combines the canopy severance system and the ejection seat, serving as the

foremost method for pilots to evacuate during emergencies, equipped with both Inflight Egress System (IES) and Ground Egress

System (GES) functionalities.

The escape system consists of the following systems:

• Ejection seat- Installed within the aircraft, the Martin Baker IN 16G ejection seat is equipped with full automation and rocket

assistance, guaranteeing safe ejection from zero altitude to 15 km and speeds of up to 600 knots. Activation is initiated by pulling

the ejection handle, triggering gas pressure and rocket propulsion mechanisms to propel the pilot securely. Following ejection, a

drogue parachute is deployed for initial stabilization, succeeded by the main parachute for a controlled descent to the ground.

• Canopy Severance System (CSS)- The CSS has a dual inflight egress system and ground egress system. Th canopy bubbles are

embedded with dual MDC. MDC of IES fractures the Canopy bubbles at U-looped MDC line and MDC of GES fractures the canopy

bubbles around its periphery.

Brake Parachute System: Installed at the tail end, the aircraft incorporates a brake parachute system crucial for decelerating during
landing roll and aborted take-offs. Its activation significantly increases drag, providing supplementary braking alongside wheel brakes
for optimal deceleration. Simplifying the deployment process, the 'CHUTE' switch located on the LH main instrument panel ensures
efficient operations for both deploying and jettisoning the brake parachute.

The system comprises of the following main components:

•Brake Parachute

•Container

•End caps

•Release mechanism

•Shear pin (Fuel safe automatic jettison device)

ARMAMENT SYSTEM: Tejas boasts a variety of hardpoints, including options beneath the port-side air-intake, under the fuselage
(centerline station), and three on each wing, with three designed for carrying drop tanks. The port-side air intake hardpoint is
dedicated to sensor pods like FLIR, IRST, or laser rangefinder/designator, which can also be mounted on the centerline pylon and
inboard pairs of wing stations. Its armament comprises I-Derby ER, Astra, R-73, Python-5, and ASRAAM missiles, supplemented by an
internal 23mm Gryazev-Shipunov GSh-23 twin-barreled autocannon positioned under the starboard side air-intake. Additionally, the
Tejas anticipates integration with the BrahMos-NG supersonic cruise missile.
4) FLIGHT CONTROL SYSTEM
Flight control system (FCS) is a system which controls airborne flight activity. LCA Tejas has an integrated flight control system, i.e., the
basic FSC includes hydraulics as well as electrical and avionics system in it.

Integrated flight control system can be classified into three systems, namely:

a) Flight control surfaces

b) Air data systems

c) Feedback/Monitoring systems

There are two types of flight control surfaces on this aircraft, or any aircraft for that matter, namely:

o primary flight control surfaces: The aircraft features two primary flight control surfaces elevons and rudder, which are operated by
electrically operated hydro servo actuators. Together, these primary flight control surfaces are responsible for executing pitching,
rolling, and yawing maneuvers during flight.

o secondary flight control surfaces: The aircraft is equipped with two secondary flight control surfaces: leading edge slats and air
brakes. Leading edge slats augment lift by increasing camber, thereby generating additional lift when needed. Conversely, air
brakes are employed to generate extra drag, facilitating speed reduction as necessary.
Elevons:

The LCA, being tailless, integrates elevators and ailerons into elevons for pitch and roll control. Four elevons, two on each wing, are
individually operated by hydraulic actuators, allowing differential or combined movement for rolling and pitching motions with a
maximum deflection of ±25°.

Rudder:

The rudder is present on the fin (vertical stabilizer) of the aircraft and is moved by using a hydraulic actuator. The rudder controls the
yawing motion of the aircraft. The maximum deflection is ±30°.

Slats:

The aircraft's slats, located on the leading edge of each wing, serve to enhance lift. Controlled by the FCS, they deploy during close-
to-stalling speeds, crucial for low-speed landings and maneuvers. Inboard slats have a maximum deflection of 17.5°, mid-board slats
reach 27.5°, and outboard slats can achieve a maximum deflection of 30°.

AIR DATA SYSTEMS:

After appropriate data collection, Voting based on collected data produces air data parameters, crucial for the FCS to process ambient
pressures, temperatures, and flow angles. The ADS delivers critical air data metrics like angle of attack, altitude, Mach number, etc.,
utilized by Air Data Computers to compute outputs for DFCC parameters, ensuring longitudinal and lateral stability.
Nose Air Data Probe (NADP): The nose air data probe is commonly known as the pitot. static tube.

It consists of:

• Pt- Total Pressure: It measures the critical Indicated air speed, Ps- Static Pressure: It measures the altitude of the aircraft,

• α1- it measures the pitch up angle of the aircraft.

• α2- It measures the pitch down angle of the aircraft.

• β1- It measures the right-side banking of aircraft.

• β2- It measures the left-side banking of aircraft

5) HYDRAULICS SYSTEMS
The TEJAS aircraft incorporates a dependable hydraulic power system that sustains essential functions such as the Flight Control
System, Landing Gear, Wheel Brake System, and Utility Systems.

It features two independent systems, System 1 (RH) and System 2 (LH), supplemented by an emergency backup, guaranteeing
operational persistence in the face of dual system failure.

This redundancy allows for a minimum of 10 minutes of flight at cruise speed while ensuring primary flight controls remain
functional.

The hydraulic fluid pipelines are carefully routed to enhance operational reliability and ensure smooth functioning of the
hydraulic system.

The hydraulic power system consists of Main Hydraulic Pump (RH & LH), Engine Driven Pump (EDP), Electric Motor Driven Pump
(EMDP), Boot Strap Reservoir (RH & LH), Accumulators (RH & LH), Accumulator (Wheel Brake), Hydraulic Motor Driven Generators
(HMDG 1, HMDG 2, & HMDG 3) and Hydraulic Motor Driven Fuel Pump (HMDFP)
Engine Driven Pump: It is a standby pump which is present on the L.H.S. of the engine and provides hydraulic pressure if the primary
pump fail.

Electric Motor Driven Pump: The EMDP provides emergency power when both hydraulic systems 1 & 2 fail.

Hydraulic Motor Driven Fuel Pump: It is the primary fuel pump to transfer fuel from the wing tanks to the central tank then to the
engine. It supplies fuel to the engine feed line during failure of the main booster pump.
HYDRAULICS – There are 4 hydraulics system which are

• Landing air extension and retraction

• Wheel braking

• Nose wheel stearing

• Elevons rudder and slat

Hydraulics pipeline materials based on temperature and pressure:

 High temp= titanium

 Low pressure= aluminum
 High pressure= stainless steel
6) ENVIRONMENTAL CONTROL SYSTEM
The Environmental Control System (ECS) in TEJAS ensures automatic temperature control, cabin pressurization, and avionics
temperature regulation efficiently. Altitude-induced changes in temperature and cabin gas composition are managed by the ECS
through the Electronic Control and Fuel Management Unit (ECFMU). Air is sourced from the 7th stage of the compressor, with
temperatures ranging from 400-600℃ and pressures of 18-20 bar. This air is then routed through a heat exchanger and utilized for
various purposes within the aircraft.

• Pressurization & Air condition

• Fuel Tank Pressurization

• De-Misting System

• Cabin Sealing System

• Radar pressurization System

• Avionics Cooling System

• Radar Cooling System

• Bleed Air Control System (BACS)

• Hot Air Leak Detection System (HLDS)

• Air Distribution System (ADS)

• Fuel Tank Pressurization System (FTPS)

• Cabin Ventilation System (CVS)

• Cabin Pressure Control System (CPCS)

• Wind Screen Demisting System (WSDS)

• Cold Air Generating System (CAGS)

• Cabin Sealing System (CSS)

• Radar Pressurization System (RPS)

PRSOV (Pressure relief shut off valve) - The 15-20 bar pressure which is coming from the engine is restricted to 6 bar.

Condenser - It is used to condense the water which is formed in the Re Heater. High Speed Water Separator (HSWS) - The condensed
water is collected in this stage to ensure that dry air will be supplied to all the ECS systems
3. CONCLUSION
(LCA) programme was started by the Government of India in 1984 when they established the Aeronautical Development Agency
(ADA) to manage the LCA programme.

• LCA Tejas was designed and developed by India's HAL (Hindustan Aeronautics Limited).

• It replaced the ageing Mig 21 fighter planes.

• It was in 2003 that the Light Combat Aircraft programme was named ‘Tejas' (meaning radiance in Sanskrit) by the then PM Atal
Bihari Vajpayee.

• It is the second supersonic fighter jet that was developed by HAL (the first one being IHAL HF-24 Marut).

• LCA Tejas is a single-engine multirole light combat aircraft. It is the lightest and smallest multi-role supersonic fighter aircraft in its
class.

• It is designed to carry a range of air-to-air, air-to-surface, precision- guided, and standoff weaponry.
4. CERTIFICATE