Dr. G N Dayananda Chief Scientist & Head Centre for Societal Missions & Special Technologies Chairman, Societal Cluster CSIR-National Aerospace Laboratories, Bengaluru-560017 “Polymer Composites for Societal Applications” School on Mechanics of Reinforced Polymer Composites Knowledge Incubation for TEQIP, IIT-K, Jan. 22-25, 2017
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“Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller
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Dr. G N DayanandaChief Scientist & Head
Centre for Societal Missions & Special TechnologiesChairman, Societal Cluster
Contents are the Property of National Aerospace Laboratories, Bangalore
First effort was to “WET” hands in building and flying aircraft LCRA built from plans and raw materials procured from USA First flight : February 1987 First hand experience with foam – fiber glass construction Flown for 259 hours Flying as UAV at ADE
Light Canard Research Aircraft (LCRA)
Contents are the Property of National Aerospace Laboratories, Bangalore
Set up Flight Experiments Division 11 June, 1988 to manage HANSA project Participation of many scientific divisions of NAL First flight of HANSA-2 : 23 November, 1993 LCRA technology was adopted Re-engined with a higher power engine - HANSA-2RE AUW was 868 kg 116 hours of flying Improvements required in fuselage shape & performance – HANSA - 3
Hansa-2
Contents are the Property of National Aerospace Laboratories, Bangalore
First flight of HANSA-3 prototype-1 : 25 November, 1996 Improved fuselage shape Airframe with sandwich construction technology Continental Engine with 125 HP AUW was 800 kg Improvement required in weight reduction - HANSA – 3 PT-2
Hansa-3 PT-1
Contents are the Property of National Aerospace Laboratories, Bangalore
First flight of HANSA-3 prototype-2 : May, 1998AUW achieved 750 kgRotax Engine with 100 HPAircraft was certified by DGCA on 1st Feb’2000Certified under JAR-VLA via FAR23 CategoryDay / Night VFR operations
Hansa-3 PT-2
Contents are the Property of National Aerospace Laboratories, Bangalore
Contents are the Property of National Aerospace Laboratories, Bangalore
Networking with Private Players
AerodynamicDesign
MechanicalDesign
CompositeProcess Electrical &
Electronics
Battery(COTS)
Wind Turbine Rotor
Charge Controllercum Inverter
Outdoor Kiosk
Solar PV Panels
JMJ SwitchGears
ARES
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NAL
Contents are the Property of National Aerospace Laboratories, Bangalore
Summary Solar/Wind energy programs should not be pursued
in isolation or indiscriminately.
A holistic approach to energy needs taking intoaccount all available regional resources is the need ofthe hour.
Integration of renewable energy to grid is a challengeand must be properly addressed.
Storage of energy is an area that needs to bedeveloped.
Promoting indigenous technology and associatedeco-system is the key to growth.
Contents are the Property of National Aerospace Laboratories, Bangalore
Renewable Energy Initiative for EducationalInstitutions
A 1 kW class NALWIN wind turbine system is installed at Jyothi NivasCollege, Kormangala, Bengaluru. Another 1 kW class WiSH system is installed at Vivekanada Institute ofTechnology, Bengaluru. 4 Nos. of WiSH system are under installation at CSIR-IMMT,Bhubaneswar under the CSIR 800 Banner Program.
NALWIN Wind Turbine atJyothi Nivas College
NALCSIRWiSH System at
VKIT
Contents are the Property of National Aerospace Laboratories, Bangalore
South West Monsoon Winds
Contents are the Property of National Aerospace Laboratories, Bangalore
Largest IndigenousWind Turbine
300 kW Wind Turbine(2004)
100 W Savonius WindTurbine, Antarctica (2000)Water Pumper
WP – 2 WindTurbine (1959 – 64)
Sail Wind Mill(1975)
300 W 3- bladedaero-generator (1993)
2 kW 3- bladedSAMIRA Wind
turbine (1987-89)
A legacy ofexperience inR&D of WindTurbines since
1959
500 kW WindTurbine (2008)
History of NAL’s wind turbine activity
Contents are the Property of National Aerospace Laboratories, Bangalore
55
Wind ResourceAssessment
500 kWWTS
600 +400 WWindSolar
HybridSystem
Wind Turbine Development
300 kWWTS
Wind Solar HybridSystem
CSIR-NAL's mission – To translate aerospacetechnologies for societal applications
Contents are the Property of National Aerospace Laboratories, Bangalore
Portable wind batterycharger-Sankalp – remote field
Antarctica- 36 W. 56
CSIR-NAL’s Wind Energy Activities at Antarctica
• Exploitation of wind energy• Power supply to the communication
Contents are the Property of National Aerospace Laboratories, Bangalore
13m Doppler Weather Radome TOTto BEL, Navi Mumbai
• Hands on training to BEL team onprocessing of composite panels atNAL
.• Shipped all tooling, moulds, fixtures.
• Assisted in setting up facility &initial trial runs.
Inauguration of the facilityon 1st Nov. 2013
CherrapunjiNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Material system: E-glass BD fabric and RT cured epoxy matrix
Fabrication Methodology: PU Foam core sandwich construction with RTVacuum bag moulding technology
Total Number of Panels: 11 nos.
Installation location: NARL, Tirupati.
4.2 m dia X-Band RadomeNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Customised Narrow width fabric in Radome panels
4.2 m Diameter X- Band Radome
Housings for WeatherRadars
Radome Panel
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Autoclaves
Contents are the Property of National Aerospace Laboratories, Bangalore
Cooking anAircraft Airframe? NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
CSIR-NAL embarked on the development of autoclaves(when they were in the embargo list) in the earlyeighties to meet the requirements of indigenization ofmilitary and civil aircraft programs.
• First indigenous autoclave commissioned in 1986
• First state of the art computer controlled indigenousautoclave commissioned in 1994
• Largest aerospace autoclave in the countrycommissioned in 2009
Aerospace Autoclave Dev. Initiation at NALNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
CSIR-NAL embarked on the development of autoclaves(when they were in the embargo list) in the earlyeighties to meet the requirements of indigenization ofmilitary and civil aircraft programs.
• First indigenous autoclave commissioned in 1986
• First state of the art computer controlled indigenousautoclave commissioned in 1994
• Largest aerospace autoclave in the countrycommissioned in 2009
Aerospace Autoclave Dev. Initiation at NALNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
• Large and complex shapes that meet thestringent weight and quality requirements
• Obtaining high degree of reliability and consistencyin composite products
Investments in autoclaves are considered to bestrategically important in the aerospace industry
Autoclave Processing/ Manufacture for:
The challenge is to develop robust, ruggedindigenous autoclave technologies (that can safelyand reliably process prepreg based expensivepolymeric composites) with wide vendor base andsuit Indian conditions.
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Autoclave Design - Drivers
• High reliability
• Space Optimization
• Fail-Safe operation
• Safety of Charge & Personnel
• Power failure management
• Modularity
• Upgradability
• Ease of Maintenance
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Range of Autoclave Process Parametersat CSIR - NAL
Sl.No.
Parameter Range Can Cater to
1. Temperature 25 - 350°CPrimary load structuresof military and civilaircraft, Hightemperature enginerelated components,Satellite structures,Leading edges of spaceshuttles,rockets etc.,
2. Pressure 1 - 15 bar
3. Length 1- 9 m
4. Diameter 0.6 - 4.5 m
5. Volume 0.2 - 140 m3
On an average over 200 cures/year performed at NAL
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Typical Autoclave cure cycleNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
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a = MOULD b = RELEASE AGENT APPLIED TO MOULDc = LAY UP d = BLEEDER e = BREATHERf = POROUS RELEASE FILM g = PRESSURE PADh = BAG
Typical Autoclave Molding BaggingScheme NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Industrial Grade, High Temperature and HighPressure Indigenous Autoclaves
Mark IMark II
Mark IV
Mark III Mark 0
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
N2 Gen.plant
Eco-system development- Autoclaves
PressurisedBlower motor,Asian – B’lore
ReservoirsPioneer,Meerut
CoolingPaharpur
Vacuum- Indfos
Indcon andVayutech, Delhi
Autoclave shell, H.E.- UCE,Mumbai
Heaters- Escorts,Faridabad
Control valves – L&TChennai
Electrical Control & Inst. SystemDATASOL, Bangalore
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
85
Three tier layout ofSubsystems NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Innovative Features
HeaterDistribution
•Fool Proof door safety device•Quick Lock Rotating Door•Optimized Door Handling Scheme•Variable Area Heat Exchanger•Evolved Forced Circulation System•Pressurized Blower Motor•Auto, Semi-Auto & Manual mode• Accurate temp. cont. ± 1°C• Temp. uniformity ± 2°C• Open Control Architecture• Fail Safe & Fault Tolerant
Fool proof door locksafety device
Four bar steering mech.-Optimized Door Movement
Variable AreaHeat Exchangerat rear end
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Using Visual studio that supports high levelprogramming such as OPC (Object linking and enablingfor Process Control), MODBUS driver, multi threading,socket programming & low level programminginstructions. Interface with number of process instruments (7nos)
through ‘virtual com’ ports in the computer Main and Hot standby computer architecture PLC software to cater for a novel Heater Power Steering