A presentation on HAL helicopter division which i did in the July of 2017

1. Presentation on
Summer Training at
By-
Mayank Gupta
15/788
B.tech. Final Year
Aeronautical Engg.
UCE, RTU Kota.
Bengaluru, Helicopter Division

2. Table of Contents
• Introduction to HAL
• Helicopter Complex
• HAL - Helicopter division
• Machine shop
• Blade Shop
• Structural assembly
• Transmission assembly
• ALH “Dhruv”
• Cheetah
• Cheetal
• LCH
• ALH Final Assembly
• Bibliography

3. What is HAL?
Type PSU (Navratna)
Industry Aerospace and defence
Founded 1940; 77 years ago (As Hindustan Aircraft)
1964; 53 years ago (Renamed Hindustan Aeronautics)
Headquarters Bangalore, Karnataka, India
Key people Shri T. Suvarna Raju (Chairman and Managing director)
Products Transport aircraft, Fighter aircraft, Helicopters
Table no. 1- “HAL details”

4. More about HAL
Revenue ₹177.532614 billion(US$2.8 billion) (2014)
Net income ₹26.925169 billion(US$420 million) (2014)
Total assets ₹638.984194 billion(US$10 billion) (2014)
Total equity ₹150.146363 billion(US$2.3 billion) (2014)
No. of employees 32108 (March, 2014)
Website www.hal-india.com
Table no. 2- “HAL financial details”

5. The Mission
“To become a global player in the aerospace industry”
• Hindustan Aeronautics Limited is the largest PSU under the
department of defence Production and is a Navaratana Company.
• HAL is one of the largest aerospace companies in Asia with its annual
turnover to be running above US$ 2 billion.
• It has several facilities throughout India including Nasik, Korwa,
Kanpur, Koraput, Lucknow, Bangalore and Hyderabad.

6. Collaborations of HAL
• Airbus
• Boeing
• Sukhoi Aviation Corporation
• Israel Aircraft Industries
• Bharat Dynamics Limited (BDL)
• BAE Systems
• Rolls-Royce
• Dassault Aviation
• Dornier
• Indian Aeronautical Development Agency (ADE)
• Indian Space Research Organisation (ISRO)

7. Fig. no. 1- “HAL locations”

8. Sl. R & D Centre Activity
1 Aircraft R&D Centre, Bangalore Design and Development of Fixed Wing aircraft (LCA,
IJT, MTA, FGFA, UAV)
2 Rotary Wing Aircraft R&D Centre, Bangalore Design and Development of Rotary Wing aircraft
(ALH, LCH, LUH, MLH, NRUAV)
3 Mission & Combat Systems R&D Centre,
Bangalore
Mission systems, Aircraft upgrades and technology
development
4 Aero Engine R&D Centre, Bangalore Small, Medium Engines & Test Bed design
5 Strategic Electronics R&D Centre, Hyderabad Avionics Items.
6 Transport Aircraft R&D Centre, Kanpur Development & Modification/ upgrades of Transport
Aircraft
7 Aircraft Upgrades R&D Centre, Nasik Aircraft/ System Upgrade Work on Russian Aircraft
8 Aerospace Systems & Equipment R&D
Centre, Lucknow
Development of Mechanical, Hydraulic and Electrical
accessories.
9 Gas Turbine R&D Centre, Koraput Design Improvement of Russian Engines
10 Central Materials & Processes Laboratory &
NDT Centre, Bangalore
Development of Materials, Castings, Forgings & New
Processes
Table no. 3- “HAL R&D centres”

9. HELICOPTER COMPLEX (Bangalore)
• HAL helicopter complex consists of three divisions
• Helicopter division
• Rotary Wing Research &Design Centre (RWRDC)
• Helicopter MRO Division

10. Helicopter Division
1. HR department
2. Machine shop
3. Ch/Ck transmission assembly
4. Structural assembly
5. Final assembly hanger Ch/Ck
6. Final assembly hanger ALH
7. Civil helicopter Hanger
8. Flight test runway
9. LUH hanger
10. ALH transmission assembly
11. RWRDC
2
1
6
54
3
7
8
9
11
10
Fig.no.2-“Divisionlayout”

11. Customers
NATIONAL
• IAF
• Navy
• Army
• Coast guards
• Border security force
• Govt. of Jharkhand
• ONGC
• GSI
INTERNATIONAL
• Mauritius
• Nepal
• Afghanistan
• Maldives
• Namibia
• Suriname
• Ecuador

12. Products of Helicopter Division
• Dhruv — Advanced Light Helicopter (ALH)
• Rudra - Attack helicopter
• Light Combat Helicopter (LCH) (just launched)
• Cheetah
• Cheetal
• Light Utility Helicopter (LUH) (under development)
• Indian Multi-role Helicopter (IMH) (under development)

13. Main Facilities
• Machining of precision components and gears
• Welding of light alloys and Steels
• Heat Treatment & Protective treatments
• Transmission Assembly
• Structural Assembly
• Final Assembly and field servicing

14. Machine Shop
• Place where machining work is done.
• Machining – the removal of material from a workpeice
• Types of machining processes carried out in HAL
• Cutting
• Turning
• Milling
• Finishing
• Grinding
• CNC work

15. Other Processes
• Other types of processes carried out for manufacturing –
• Heat treatment
• Methods and Tooling
• Welding and sheet metal

16. Machine Shop
Machining Hanger Structure Support Cell
Fig. no. 3- “Machine Shop”

17. CNC Milling Machines
DMG 5 Axis CNC Machining Center 4 Axis CNC Machining Center
Fig.no.4-“CNCmillingmachines”

18. Gear Machining Centers
Cooper CNC Gear shaper Gleason Conventional Gear Generator
Fig.no.5-“GearMachiningcentres”

19. Blade Shop
• Blade shop consist of the following-
• Manufacturing of MRB and TRB
• Repairing of MRB and TRB
• Static balancing tests for MRB and TRB
Fig. no. 6- “Cross Sec. of a helicopter blade”

20. Structural assembly
• Basically 2 types of construction is done
• Truss type - Tubular construction eg- Cheetah,Cheetal
• Semi-monocoque/monocoque type- Stressed construction eg- LCH,ALH

21. Types of fuselage construction
Tubular construction Stressed construction
Fig. no. 7- “Tabular type fuselage construction” Fig. no. 8- “Stressed type fuselage construction”

22. Transmission Assembly
• Transmission is been developed in 2 different parts-
• Main Rotor Transmission
• Tail Rotor Transmission
Fig. no. 9- “Transmission of a Helicopter”

23. Fig.no.10-“TransmissionofALH”

24. Main Rotor Transmission
Fig.no.11-“MainRotorTransmissionofALH”

25. Main Rotor Transmission
Fig. no. 12- “Main Rotor Transmission”

26. Tail Rotor Transmission
Fig.no.13-“TailRotorTransmissionofALH”

27. Transmission Assembly
Fig. no. 14- “Transmission Unit of ALH”

28. ALH
Advanced Light Helicopter (ALH-DHRUV)
• Twin engine
• Multi-role, multi-mission
• 5.5 ton weight class
• Both Skid version and Wheeled version.
• Dhruv is “type –Certified” for Military operations by the Centre for
Military Airworthiness Certification (CEMILAC) and civil operations
by the Directorate General of Civil Aviation (DGCA)
• Dhruv has 4 variants Mk I, MK II, MK III & Mk IV

29. Technical Parameters
Technical Parameters
Length 15.9 m
Width 13.2 m
Height 4.98 m
MTOW 5500 kg
Speed 295 Km/h
Range 640 km
Endurance 3.7 hr
PAX 12 + 2
Table no. 3- “ALH Technical Parameters”

30. Variant Power Plant / Major Systems Roles
ALH Mk. I - TM-333-2B2 engine
- Conventional cockpit instruments
Utility
ALH Mk. II - TM-333-2B2 engine
- Integrated Architecture Display
system (Glass cockpit)
Utility
ALH Mk.III - Shakti engine
- IADS with Digital Moving Map
- Electronic Warfare Suite
- Electro Optical pod
- Counter Measure Dispensing
system
- Infra Red Suppressor
- Health & Usage Monitoring
system
Utility roles of defence Services
suited for high altitude operations
ALH Mk. IV ALH Mk.III with weapons &
additional systems like..
- Turret Gun
- Rocket
- Air-to-Air Missile
- Air-to-Ground Missile
- Helmet Pointing System
- Data Link
- Infra Red Jammer
- Obstacle Avoidance System
Armed variant for Attack, Close Air
Support and High altitude operations.
Tableno.4-“ALHVariants”

31. Roles of Dhruv
• Passenger / Commuter Role
• VIP Travel
• Causality Evacuation
• Under Slung Load
• Rapid Deployment of Forces
• Logistic Air Support
• Search and Rescue
• Training

32. Features of Dhruv
• Composite Hinge less Interchangeable Main Rotor Blades
• Composite Bearing less Tail Rotor Blades
• Composite Air Frame
• Glass Cockpit & AFCS
• Flare Dispenser
• Digital Video Recording System
• EO Pod with FLIR, LRF & LP
• IR Suppressor

33. Fig. no. 15- “ALH- DHRUV”

34. CHEETAH
• Cheetah (identical to LAMA SA 315B of Eurocopter, France)
• High performance
• Designed for operation over a very wide range of weight, centre of gravity
and altitude conditions.
• 5 seated
• High maneuverable and rugged in construction.
• It holds the world record in high altitude flying among all categories of
Helicopters.
• The helicopter is powered by Artouste - III B turbo shaft engine.
• The helicopter is suitable for commuting, observation, surveillance,
logistics support, rescue operations and high altitude missions.

35. Technical Parameters
Technical Parameters
Length 12.91 m
Width 2.38 m
Height 3.09 m
MTOW 1950 kg
Cruise Speed 192 Km/h
Range 560 km
Endurance 3.10 hr
No. of Passengers 3 + 2
Table no. 5- “Cheetah Technical Parameters”

36. Fig. no. 16- “Cheetah”

37. CHEETAL
• Cheetal is the re-engined version of the Cheetah helicopter.
• Artouste-III B engine of Cheetah was replaced with the modern fuel efficient
TM333–2M2 for better performance.
• Quicker start-up and easier re-light procedure.
• Improved reliability and easier handling of engine.
• Higher thermal margins resulting in better climb performance at high altitudes.
• Lower noise levels.
• Low specific fuel consumption provides Higher payload, Better range and
Increased Endurance
• Light weight electrically driven Artificial Horizon, Directional Gyro, Flight
Monitoring System (FMS), Cockpit Voice Recorder (CVR), Modular Warning
Lights, Master Flasher Warning and modern electrical system.

38. Technical Parameters
Technical Parameters
Length 12.92 m
Width 2.38 m
Height 3.09 m
MTOW 1950 kg
Cruise Speed 192 Km/h
Range 640 km
Endurance 3.50 hr
No. of Passengers 3 + 2
Table no. 6- “Cheetal Technical Parameters”

39. Fig. no. 17- “Cheetal”

40. LCH
LCH- “Light Combat Helicopter”
• Dual engine - SHAKTI engine (895 kW)
• Only for combat operations.
• Armour protection, Night attack capability and crash worthy landing gear for
better survivability
• Glass Cockpit
• Fixed tricycle type with tail wheel landing gear
• Hinge less Main Rotor / Bearing less Tail Rotor
• Anti Resonance isolation system
• Integrated Avionics and Display System (IADS)
• IR Suppressor
• 20mm Gun, Rocket & Missiles

41. Armament
• Guns: 1 × 20 mm M621 cannon on Nexter THL-20 turret
• Hard points: 4 (two under each wing) and provisions to carry
combinations of:
• Rockets: 4 × 70/80 mm rocket-pods
• Missiles: 4 × two-round MBDA Mistral air-to-air missiles, anti-
radiation, and 2 × four-round Helina, LAHAT anti-tank missiles
• Bombs: 4 × 250 kg (550 lb) bombs including Gravity bombs,
cluster bombs and grenade launchers

42. Technical Parameters
Technical Parameters
Length 15.8 m
Rotor diameter 13.3 m
Height 4.7 m
MTOW 5500 kg
Cruise Speed 265 Km/h
Range 550km
Service ceiling 6,500 m
Rate of climb 12.7 m/s
No. of Passengers 2
Table no. 7- “LCH Technical Parameters”

43. LCH performing aerobatics during Aero India 2017
having a paint pattern similar to Sukhoi/HAL FGFA
Fig. no. 18- “LCH- Light Combat Helicopter”

44. ALH Final Assembly
Structural Assy Equipping & Final Assy
Fig. no. 19- “Final Assembly Hanger”

45. BIBLIOGRAPHY
• www.hal-india.com/Product_Details.aspx?Mkey=54&lKey=&CKey=24
• https://en.wikipedia.org/wiki/HAL_Dhruv
• http://www.hal-india.com/Helicopter%20Complex/M__124
• http://www.hal-india.com/Rotary%20Wing/M__147
• ‘‘Trade trainong notes on Airframe systems vol-1’’ [ALH(Mk-IV)
Structures and transmission system]