“polymer composites for societal applications” · design wind speed ~ 2 x annual average wind...
TRANSCRIPT
Dr. G N DayanandaChief Scientist & Head
Centre for Societal Missions & Special TechnologiesChairman, Societal Cluster
CSIR-National Aerospace Laboratories, Bengaluru-560017
“Polymer Composites for SocietalApplications”
School on Mechanics of Reinforced Polymer CompositesKnowledge Incubation for TEQIP, IIT-K, Jan. 22-25, 2017
Outline
• Societal Missions @ NAL
• HANSA
• Renewables - focus on wind
• Radomes
• Autoclaves
• Micro Air Vehicles
Contents are the Property of National Aerospace Laboratories, Bangalore
HANSASARAS
C-NM5LCA Tejas
Participation of CSIR-NAL inAircraft Programmes NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
CSIR NAL’s Aircrafts
Slybird
Hansa CNM – 5
Black KiteLCAContents are the Property of National Aerospace Laboratories, Bangalore
Societal Missions @ NAL
Contents are the Property of National Aerospace Laboratories, Bangalore
Centre for Societal Missions & SpecialTechnologies – Primarily Composites Research
Airborne Radomes Wind Turbine Ground Based Radomes
Autoclaves UAVs / MAVsImpregnation Machine
Contents are the Property of National Aerospace Laboratories, Bangalore
0°
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+45°
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90°
0°
±45°
0°/90°
±45°
0°/90°
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±45°
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0°/90°
Symmetric & Balanced Composite laminates
Quasi-isotropic Laminateusing Uni-directionalLaminae
Quasi-isotropic Laminate usingBi-directional woven Laminae
Contents are the Property of National Aerospace Laboratories, Bangalore
Continuous Fibre Reinforced laminated Composites
Contents are the Property of National Aerospace Laboratories, Bangalore
Sandwich Composite Constructions
Foam Core Sandwich Honeycomb Core Sandwich
Face Sheet / Skin
CoreAdhesive Bond
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Short Fibre
Discontinuous Reinforcements in Composites
Particulate
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Hansa-3 Aircraft Program
Contents are the Property of National Aerospace Laboratories, Bangalore
Materials :• Epoxy Resin Systems• PVC Foam Cores• Glass Fabrics• Carbon Tapes
Processes :• RT Vacuum Bag Moulding• Carbon Tape Impregnation• Post Curing• Thermoforming• Adhesive Bonding
Material Characterisation :• Mechanical• Thermal• Hygrothermal• Design Data Generation
• NDT• Static Testing• Analysis• Flight Testing
QUALIFICATION/ CERTIFICATION
(JAR-VLA , AUW < 750Kgs.)
All Composite Aircraft - HANSA
Contents are the Property of National Aerospace Laboratories, Bangalore
LCRA (Feb. ‘87) HANSA-2 (Nov. ‘93)
HANSA-3 Proto-I (Nov. ‘96) HANSA-3 Proto-II (May ‘98)
LCRA to HANSA-3
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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)
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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
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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
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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
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Fibre glass composite structureRotax 914 F3 turbo-charged engine
100 BHP continuous115 BHP max.
Constant speed propeller
Certified under JAR-VLA forday / night VFR operationsLightning protected
PerformanceStall speed with flaps : 48 KIASMax. cruise speed : 115 KTASMax R/C : 650 ft / min.Endurance : 4 hTake-off distance : 450 mLanding distance : 600 m
Specifications of Hansa-3
Contents are the Property of National Aerospace Laboratories, Bangalore
Side by side seating, neat cockpit,very good visibility
Conventional instruments &modern Nav-Com units
Dual flight controls with excellentcontrol harmony
Turbo-charged engine withconstant speed propeller
COCKPIT
Rotax 914 F3 engine
Features of Hansa-3
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Extensively tested and documented (for its class)
Fuselage test rig
Engine mount test rig
Wing test rig
Features of Hansa-3 Continued..
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Innovative vacuum bag moldingtechnique process for fabricationof airframe
Maintenance and repair of glassfiber composite structure
Design of composite aircraftstructures & integration of smallaircraft
Lightning protection scheme
Structural testing of components
Type certification for civil use
Technologies Developed
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Hansa-3 Fabrication in a Nut ShellNALCSIR
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Renewables - focus on wind
Contents are the Property of National Aerospace Laboratories, Bangalore
Present
Antarctica Past
Recent Past
300 kWWTS
500 kWWTS
Kethanur,TNKethanur
Kanyakumari, TN
WindResource
Assessment
A Legacy in Renewable Energy
Kethanur, TN
Contents are the Property of National Aerospace Laboratories, Bangalore
The Trade Winds:
Steady northeast/southwest
winds between equator and
horse latitudes.
EQUATOR
30°N
60°N
30°S
60°S
Some weather(wind) characteristics of atmosphere
Wind Patterns differfrom one continentto the other.
Vast differences :American/European toIndian sub-continent.
WITHOUTCORIOLIS EFFECT
WITHCORIOLIS EFFECT
Easterlies
Westerlies
NortheastTrades
SoutheastTrades
Doldrums
Westerlies
Easterlies
Contents are the Property of National Aerospace Laboratories, Bangalore
Major Surface weather characteristicsP Cell
F Cell
H Cell
L L L L L
H H H H
H H H H
H
H
EquatorITC
Trade Winds
Subtropical HighPressure Belt
Prevailing WesterliesPolar Front
Polar Westerlies
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Small Wind Solar Hybrids at
Center for Societal Missions & SpecialTechnologies- CSMST
National Aerospace Lab, Bengaluru
Wind-Solar Hybrid (WiSH) System PT1
Targeted for low wind regimes in tropics
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NALCSIR
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29
NALCSIR
Wind-Solar Hybrid (WiSH) System PT2
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Composites
RenewableEnergy
Controls
Aerodynamics
Indigenous Wind Turbine Rotor
Contents are the Property of National Aerospace Laboratories, Bangalore
500 kW2
3
1
421 VC
PD
overallP
50 kW
5 kW
Roto
r Dia
met
er, m
NAL’s Small Wind turbine Rotor Systems
NAL’s Effort
0.5 kW
North America& Europe
Design Wind Speed ~ 2 X Annual Average Wind Speeds(Source : Large Wind Turbines, Eric Hau)
10000
1000
100
10
1
0.1 0 2 4 6 8 10 12 14 16Design Wind Speed, m/s
Contents are the Property of National Aerospace Laboratories, Bangalore
Fundamental Equation of Wind PowerWind Power depends on air:• Volume• Velocity• Density
Kinetic Energy definition:• KE = ½ * m * v2
Power is KE per unit time:• P = ½ * m. * v2
Mass flow rate• dm/dt = A * v
• Power ~ cube of velocity• Power ~ air density• Power ~ rotor swept area A = r2
• P = ½ * A * v3
m = dm/dt mass flux
V
A
Contents are the Property of National Aerospace Laboratories, Bangalore
Design Methodology for NALWIN
Aerodynamic analysisby GH-Bladed
Wind TurbineConfiguration, Airfoil
selection, AerodynamicDesign for operating
conditions
Load Matchingusing different
methods
TowTesting
FieldTesting
Systemperformance
studies
Fabrication and off-line structural testing
Quantification ofMass & stiffness
properties of blades
Structuralanalysis using
NASTRAN for thestress & stiffness
based design
Aeroelastic analysisusing GH – Bladed
NALWIN
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Aerodynamic Design & Analysis
Twist Distribution
Analysis by GH-Bladed CAD Model of the blade
Chord Distribution
Twist
Chor
d
Radius RadiusContents are the Property of National Aerospace Laboratories, Bangalore
Structural Design and Analysis
CFRP Structural Design and Analysis of the blade using Hypermesh –NASTRAN
Moulds
FE Model
Blade c/s and composite layupscheme
Blade Fabrication Scheme
Stress Distribution
Contents are the Property of National Aerospace Laboratories, Bangalore
Composite Blade ManufacturingTechnology
Tooling Development• NC machined Master
• Carbon composite (CFRP) Blade fabrication• Novel light weight coreless carbon composite blade
•Room temp. vacuum bag moulding process• Weight of the blade ~950 gms
• Split composite mould
Contents are the Property of National Aerospace Laboratories, Bangalore
Static Deflection Testing of Blade& Dynamic Balancing of Rotor
Dynamic Balancing of RotorStatic Deflection Testing of BladeContents are the Property of National Aerospace Laboratories, Bangalore
Tow Testing at HAL Airport, Bengaluru
Simulate
Wind speeds
up to 20 m/s
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Tow-Testing of Wind Turbine
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Unique features of NALWIN
Indigenously developed rotor blade system
Furling for overspeed protection.
Eco-friendlier composite CFRP rotor blade system
Suitable for Indian low wind speed regimes.
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Development of 1 kW Wind SolarHybrid (WiSH) system
Contents are the Property of National Aerospace Laboratories, Bangalore
System Configuration
InverterBatteriesDump Load
AC Load
Solarcharge
controller
WindTurbine
controller
NALWIN Solar PVPanels
CSIR-NAL
CSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
WiSH System Specification
Type : Horizontal AxisNo. of blades : 3 Nos. / 4 Nos.Blade material : CFRPRated Power : ~ 1000W @ 12 m/sOperating wind speed : 3 – 18 m/sRotor diameter : 2.05 mDirectional control : Tail vaneOverspeed protection : Furling & Dump loadGenerator : Multi-pole Permanent
MagnetDrive train : Direct driveTower : Guyed tilt down typeTower height : > 20m (site specific)
Integrated with 500 W Solar PV Panels
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As a Roof Top Application
Wind Turbine
Solar PV Panel
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Field trials of Wind Solar Hybrid systems atRenewable Energy Park , NAL
Wind Turbine
Solar Panel
Wind Turbine
Solar Panel
Smart Structures BuildingCSIR-NAL
Field trials at NAL Campus, Kodihalli,Bengaluru
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Press Release on WiSH System
The New Indian Express,May 16, 2014
The Hindu, May 24, 2014
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NALCSIR
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NAL-Win @Jyoti Nivas CollegeKoramangala Bengaluru
Wind Turbine :- 900 WDate of Installation :- 26-05-2016
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NAL-Win @ Vivekananda Institute of TechnologyKumbalagudu- Bengaluru
Wind Turbine :- 900 WSolar :- 500 WDate of Installation :- 17-09-2016
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
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South West Monsoon Winds
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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
repeater station & for remote fieldexperiments
NAL’s Savonious Wind battery charger atVittaiah peak, Maitri, Antarctica – 75 W
Contents are the Property of National Aerospace Laboratories, Bangalore
Radomes
Contents are the Property of National Aerospace Laboratories, Bangalore
Airborne Radomes
Jaguar Nose Radomes (11 Nos.) for HAL/Indian Air Force (IAF)
Material system: E-glass BD fabric & elevated temp. epoxy matrix
Manufacturing Technology: Contoured fabric preforms & closedmould
pressure assisted Resin InjectionTechnology
(RTM)
Current Status: Transfer of Technology (ToT) to HAL completed formanufacture of 60-70 Nos. of radomes
JAGUAR Nose RadomeNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Material : Composite(E-GlassFabric & HighTemp. EpoxyResin)
Shape : StreamlinedType : MonolithicLength : 965.50 mmBase dia.(OD): 522.61 mmWeight : 13.5 kgs.
Jaguar Radome SpecificationsNALCSIR
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Conical Preforms for Air-Borne Radomes(Contour varying in 3-Dimensions)
Fighter AircraftJacquard wovenconical seamless
preform(Varying contourfrom base to tip)
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Static Load Test Vibration Test
Lightning Test
Testing of Jaguar Radome
EM Test
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Material system: E-glass BD fabric & RT epoxy matrixManufacturing Technology: Honeycomb core sandwichconstruction with RT vacuum bag moulding technologyWeight : 3.5 Kgs.End use: CSIR-NAL’s SARAS prototype
Nose Radome for CSIR-NAL built 14 seater civilian aircraft
SARAS Nose RadomeNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
• Composite components made from prepregs and Autoclave moulding• Over 30% composite in Air Frame• Use of UD carbon Prepregs
Reinforcements in SARAS AircraftNALCSIR
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Total Direction Finder Radome for TU-142M Aircraft
Total Direction Finder Radome - TU142Aircraft
Material system: Quartz BD fabric & high temp. epoxy matrixManufacturing Technology: Contoured fabric preforms and closedmould pressure assisted resin injection technology (RTM)Weight : 95 gms.Supplied : 16 nos.End use: DRDO/ IAF
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Ground based RadomesPrinciple of construction is based on Platonic Solids
TruncatedIcosahedron
Dodecahedron
Soccer Ball
DWR
X-Band
(GoldbergPolyhedron)
12 Pentagons+ 20 Hexagons
12 Pentagons
NALCSIREuler char. formula for Polyhedra = V(60) - E (90) + F(32) = 2
Euler char. formula for Polyhedra = V(20) - E (30) + F(12) = 2
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Trial Assembly At BEL,Bangalore
66 Panels, 3700 fasteners
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Mark-I (146 panels)
Material system: E-glass BD fabric and RT cured epoxy matrix
Manufacturing Technology: PU Foam core sandwich construction with RTVBM
End use: Indian Meteorological Department (IMD) /ISRO
Current Status: ToT to BEL completed for manufacture of 30 Nos. of radomes
Installed at Bhuj, Gujarat
Mark-II (66 panels)NALCSIR
13 m Dia DWR Mark-II Radome
Installed at Satish Dhawan SpaceCentre, SHAR – ISRO, Sriharikota
Contents are the Property of National Aerospace Laboratories, Bangalore
Mark-I (146 panels)
Material system: E-glass BD fabric and RT cured epoxy matrix
Manufacturing Technology: PU Foam core sandwich construction with RTVBM
End use: Indian Meteorological Department (IMD) /ISRO
Current Status: ToT to BEL completed for manufacture of 30 Nos. of radomes
Installed at Bhuj, Gujarat
Mark-II (66 panels)NALCSIR
13 m Dia DWR Mark-II Radome
Installed at Satish Dhawan SpaceCentre, SHAR – ISRO, Sriharikota
Contents are the Property of National Aerospace Laboratories, Bangalore
1. BEL, Bangalore 2. Bhuj, Gujarat 3. Cherrapunji, Meghalaya, NE
4. SHAR, Sriharikota 5. Odisha 6. Port Blair
6
13 m Dia DWR Mark-II RadomeNALCSIR
SPECIFICATIONS
1. Dia. : ~13 m
2. Surface Area : 514 m2
3. Operating frequency : 2.7 - 2.9 GHz
4. Design wind speed :250 – 300 kmph5. Construction : Sandwich Composite
Panel1
5
Installed
2
To be Installed
4
6
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
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Customised Narrow width fabric in Radome panels
4.2 m Diameter X- Band Radome
Housings for WeatherRadars
Radome Panel
NALCSIR
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Autoclaves
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Cooking anAircraft Airframe? NALCSIR
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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
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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
• High-performance, advanced prepreg polymericcomposite aircraft structural components
• 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
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Typical Autoclave cure cycleNALCSIR
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82
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
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Industrial Grade, High Temperature and HighPressure Indigenous Autoclaves
Mark IMark II
Mark IV
Mark III Mark 0
NALCSIR
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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
Logic, pressure sensitive variable speed blower, safetyrequirements, sequential and automatic starting andshutdown control, interlocks etc
In-house Software for Autoclave Cure ControlNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
6Orders completed5 Orders under execution
Enquiries from Strategic sectorEnquiries from Societal sector
MIT
VSSC
HAL,ADE,ISAC
ASL
DMRL
IITK
DMSRDEMKU
Godrej
OF
Autoclave OrdersExecuted, ongoing
&Bids submitted
IITKharagpur.
6 orders won againstInternational
Bidding
Revenue generatedby PPP
about 31 croresof rupees
RPP
IIT B
IIT Guwahati
Contents are the Property of National Aerospace Laboratories, Bangalore
3D- Model of Lab scaleAutoclave
3D- Model of Lab scaleAutoclave
900mm dia& 1000mmworking length, 210DegC,7 Barg
Contents are the Property of National Aerospace Laboratories, Bangalore
Lab Scale Autoclave for IIT Kanpur
Successfully commissioned and handed overon 25.03.14
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Lab scale autoclave for MIT, Manipal, Mangalore
Successfully commissioned andhanded over on 26.08.14
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Longest Autoclave – 3D Model4m dia., 15m length, 10 bar
Mandrel -15 Tons
Crab
Unique Mandrel rotating mechanism
Trolley
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Autoclave Shell Fabrication in progressat UCE, Mumbai
4m Dia x15 m LengthLongest Autoclave in Indian Aerospace Sector
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Longest Autoclave designed and Developed byNAL
• Optimised flange design using FEA•Unique Mandrel rotating mechanism,•Hydrotest @ 20 barg with strain monitoring
Contents are the Property of National Aerospace Laboratories, Bangalore
Upgradation of Vertical Autoclave forVSSC, Comp. Mfr. Divn., Vattiyoorkavu
Top half of autoclave shell
CONTROLPANEL
Supply and warrantycompleted on 27.04.2014
Specifications:Working Dia. : 4mWorking Height :1.5mMax. Pressure : 7 bargMax. Temp : 200º C
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Autoclave User’s Meet, 3rd Sept. 2013NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Press Coverage: On Lab scale autoclaveVijay Karnataka
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
NAL’s Microwave Hybridized Autoclave
• Working Dimensions:Ø0.8m X 1.5m lengthTemp: 425 Deg CPres : 15 Barg
• Autoclave shell designedwith multiple Microwaveports and rotating platform.
• Fabrication is in progress.
Study of EM field & temperaturedistribution for Autoclave
ambients.
Microwave ports
Rotating platform
Significant EnergySavings Likely
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Desk top Autoclave forcomposites processing
• Compact, affordableautoclave for
educational& Research Institutions
• Fits in a space of 1.5cubic metre
• Working temperature :200 Deg C
• Working pressure : 7barg
• Works on single phase ,32 A power source
Contents are the Property of National Aerospace Laboratories, Bangalore
Micro Air Vehicles
Contents are the Property of National Aerospace Laboratories, Bangalore
Lightweight MAV Airframes; How ‘light’ can itbe?
MaterialDensity(kg/m3) Weight
(grams)
Air 1.2 10Solimide® 6.3 46Rohacell® 32 245PU foam 42 322
Skin StiffenerConst. - 1600
Approx. VolumeOf 1.6 m wing spanSlybird : 0.00768m3
Building an MAVusing only airmolecules !!!
Air Molecules
Contents are the Property of National Aerospace Laboratories, Bangalore
Micro Air Vehicles @ NAL
Sl.No. MAV Wing span
class (mm)Weight(gms.)
AirframeWeight
Endurance(min.)
A. Microbeacon 150 120 15 15B. Black Kite 300 292 50 35C. Pushpak 450 730 280 45D. Suchan 1600 3600 1800 55-75
A B C D
1600
mm
From the NAL MAV Stables
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Structural Concepts for Airframes…Contd
Black Kite Pushpak
Suchan
Contents are the Property of National Aerospace Laboratories, Bangalore
Suchan 1.6 m MAV
Wing span : 1.6mLength : 1.3mWeight : 3.6 kgs (str. wt: 1.8 kgs.)Endurance : 45-60 minutes
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Features Modular construction Light weight Materials design
Crashworthy features Snapping longerons in
fuselage By design
Mounting for electronicsCOTS items
Stiff CFRP Wing-Fuselage Interface
Fuselage Trolley
‘Suchan’ 1.6 m MAVNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Modular wing of MAV-Exploded view
CSIR-NALCSIR
• Completed more than 100 landingsContents are the Property of National Aerospace Laboratories, Bangalore
MAV - Pushpak
Wing span : 450 mmLength : 550 mmWeight : 730gms. (str. wt: 300 gms.)Endurance : 40 min
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
MAV - Micro Beacon
Wing span : 150 mmLength : 160 mmWeight : 145 gms (str. wt: 25 gms.)Endurance : ~30 min
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
Before droop After droop
Lateraldroop line
Inclineddroop lineLE droop (morphing) of black kite MAV
Morphing 300mm Black Kite MAVNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
110
Acknowledgements
1. Sri J J Jadhav, Director, CSIR – NAL
2. Director General, CSIR
3. Team CSMST @ CSIR – NAL
4. Team C-CADD
5. Team ACD
6. Dr. U N Sinha.
7. Flosolver Team, NAL
Thank You