Pavan Project Report

Academic period: 2013-2014

Development of Nimrod Flight Simulator to Teaching Aide Standard.

Student Name: Pavan Kumar Tirumala

Academic period: 2013-2014

Student I.D: 10011066

Date of Submission: 12/05/2014

Abstract:

Student I.d:10011066

The main theme of the report is the development of the Nimrod flight

simulator to teaching aide standards. The simulator needed to be modified into

an A320 model replica simulator, and also provides the hurdles faced to achieve

the final goal. It also includes the information about the lessons that is learnt by

the author during the project.

Contents1. Introduction:......................................................................................................................6


2. Aim and Objectives:........................................................................................................9

3. Research and practical activities:..............................................................................10

3.1. PRINCE 2:.................................................................................................................10

3.1.1. Advantages of PRINCE 2:.............................................................................11

3.2. Design and construction of the frame:.............................................................11

3.2.1. Design Frame:.................................................................................................12

3.2.2. Modifying the simulator:...............................................................................14

3.2.3. Purchase Equipment:....................................................................................15

3.2.4. Build the frame:...............................................................................................15

3.2.5. Assembling frame to Simulator:.................................................................16

3.3. Primary Flight Controls:.......................................................................................16

3.4. Autopilot Systems:.................................................................................................18

4. Procedures followed during the Practical Activities:............................................20

4.1. Metal Cutting:..........................................................................................................20

4.1.1. Metal cutting band saw:................................................................................20

4.1.2. Hydraulic Guillotine Sheet Metal Machine:..............................................21

4.1.3. Hacksaw cutting:............................................................................................21

4.2. Welding:....................................................................................................................22

4.3. Grinding:...................................................................................................................23

4.4. Metal Bending:........................................................................................................24

4.5. Drilling:......................................................................................................................25

4.6. Soldering:.................................................................................................................26

5. Analysis:...........................................................................................................................28

6. Conclusion:......................................................................................................................32

7. Recommendations:........................................................................................................34

8. Acknowledgements:......................................................................................................35

9. Bibliography..................................................................................................................36

10. Diagram not included in the text:...............................................................................37

List of abbreviation and symbols:


Abbreviation:

CDU - Control Display Unit.

FCU - Flight Control Unit.

LED - light-Emitting Diode.

CPU - Central Processing Unit.

Symbols:

AND gate

OR gate

1. Introduction:


Technology is the key part in the development of all the human race. By

using and developing the technology we are creating new equipment that are

widely used in the human race. Introducing Flight Simulators a great way of

practicing aviation skill and gain flying experience on the ground, which is the

best way of attaining virtual reality. Simulators are the replicas of the real

instruments that are representing the operation of the real system over time. The

act of simulation first of all requires to develop a model which has all the

characteristics and the functional behaviour of the real system. By simulating the

model we can test, train and can also used for the educational purposes. Now a

day's these simulators are widely developed in all fields, especially in the

aviation industry because everyone can get access and get easily trained or get

educated without any risk or damage of the property, this is the very main

reason for adopting these simulators.


1

Figure 1- Typical Flight Simulator.

The background of this project is to develop the existing Nimrod flight

simulator that in the college to the teaching aide standards of the Airbus A320.

To acquire these standers the author has to gain some knowledge on the

simulator hardware and software and has to identify where the simulator need

some developments and the parts that are needed to be replaced, for the in-

class teaching aide standard the author has to get the simulator breakdown the

complete simulator into two half's and on the wheels so that the simulator can

be easily moved to other classes for presentations. And connecting all

hardware components to the software is also required to function all the other

instruments working simultaneously.

1http://img.tomshardware.com/us/2008/03/06/aircraft_simulators_get_multi_gpu_graphics_horsepower/425pixcae5000.jpg


The following report will provide a clear idea of how the author tried to

achieve the objectives, and what are the problems faces or involved in the

objectives and his management to overcome those problems. And it also

represents the initial planning to reach the objectives by preparing the Gantt

charts and risk registers so to attain a pre-knowledge of the risk involved in this

particular project. It also illustrates the topics that are learned by achieving these

objectives, and the reason behind why this project is chosen and how the

students are going to attain benefited by doing this project. This report also

provides information on all the research and the practical activities carried out to

achieve his objectives, significant factors identified and studied.

2. Aim and Objectives:


The main Aim of the project is the development of the Nimrod flight

simulator to teaching aid standard. It can achieve that by classifying the main

objective into three sub objectives, they are

Even though there are some sub objectives involved in each and every

objective the report will clearly discuss about those sub objectives and what the

research had done and practical activities he has gone through to achieve these

objectives.

3. Research and practical activities:


Autopilot system

Primary flight controls

Design and construction of the frame

On the day of the project chosen the investigation and planned for each

and every objective were done. This completed project is designed depending

on the PRINCE 2 model.

3.1. PRINCE 2:

PRINCE 2 stands for "Project In Controlled Environment", Its a

project management framework which helps to plan, manage and control

the project. Generally projects will deliver products the organization

needs changes or outcomes, for example more efficient working

practices, that can be measured in the form of the benefits. It is a cycle as

shown in the figure 2 with the Starting and initiating, Planing and

directing, Stage control, stage management and ends with the closing of

the project.

2

Figure 2- PRINCE 2 Model.

3.1.1. Advantages of PRINCE 2:

2 http://siliconbeach-media.s3.amazonaws.com/legacy/blog/uploads/2012/11/Prince-2-phases.jpg


Suitable for any type of project or industry.

Based upon best Practices.

Can be tailored to suit your project.

The author has divided the entire project into three major objectives, they

are

1. Design and construction of the frame.

2. Primary flight controls

3. Autopilot system

3.2. Design and construction of the frame:

All the investigation has been done for the modification of the

simulator. For each and every objective the research is done and consult

the project coordinators and other professors to seek some advices from

them, and attain the best high quality standard outcomes. The research

for required materials is also done like the properties of those materials,

and has to purchase them looking at the budget that how much money he

is willing to spend on them. He had divided this objective into five sub-

objectives, so to get the step by step results in each and every stage. As

shown in the figure 3 he has divided the objective as

Design Frame

Modifying the simulator

Purchase Equipment

Build the frame and

Assemble the simulator to the Frame.


Figure 3- Classifing the design and construction of frame objective.

Along with these objectives, the external screens which have already

fitted to the frame need to be cut down a bit to get the screens in position.

Which helps to move the simulator to other classes if necessary. The

report is provided with all the investigation and practical work that is done

on the each and every Sub-Objectives.

3.2.1.Design Frame:

Multiple designs were referred while designing the frame and came

out with a final design which is high reliable and had high strength to

carry the simulator. All the final designs for the simulator are shown in the

below diagrams, Figure 4 was designed to carry the base part of the

Nimrod simulator, Figure 5 was designed to hold the Glare shield part of

the Nimrod simulator, and the Figure 6 was designed as a throttle holder

to carry the A320 model throttles.


Design and Construction of frame

Design Frame

Modifying the simulator

Purchase equipment

Build the Frame

Assemble frame to simulator

Figure 4- Dimensions of the base frame of simulator.

Figure 5- Dimensions of the glare shield frame of simulator.


Figure 6- Dimesions of the throttle Holder.

3.2.2.Modifying the simulator:

The Simulator had stripped down the complete and stored all the existing

control panels into the safest place to avoid the damage. The simulator is also

dismantled into two parts with the help of the project coordinators so that the

frame can be easily carried from the class to workshop. The control column

holder had removed to modify the simulators Side Stick into into A320 model

Side Stick.

3.2.3.Purchase Equipment:


A investigated is done for the selection of equipment which are

required to build the frame, and chosen mild steel to build the frame. By

consulting the workshop professionals the purchase of materials needed

for the project is done. The project coordinator had ordered all the

equipment needed.

3.2.4.Build the frame:

Several manufacturing procedures were referred for the construction of

the frame because, to attain a better and efficient outcome for the objectives.

Even though the availability of the workshop is less the task need to be finished

within the time. This can be achieved by making the proper management of the

time. Safety precautions for the workshop like wearing overalls and boots are to

be considered while constructing the frame. In the workshop there are different

procedures which are required to build the frame they are

Metal cutting

Welding

Grinding

Metal Bending

Drilling

The discussion about these procedures and work done for the

construction of the frame by using these methods were described in the

section 5 of this report.

3.2.5.Assembling frame to Simulator:


The frame is constructed according to the pre-planned designs and

assembled it to the simulator. Holes are also drilled into the frame for the

bolts to assemble the frame to the simulator. A hand drilling machine is

used for the drilling while fixing the base of the simulator to the frame

drilled the simulator using the. Coming to fix the glare shield of the

simulator the a problem occurred that initially planned for welding the

catches to the frame and then realized that the catches are not made of

steel and it can't get welded to the frame. A solution comes out to solve

this problem that by making some plates to the catches that can get fitted

with bolt and nuts so that the plates can be welded to the frame. After

finishing all the assembly another problem appeared that the wheels are

getting stuck to the bolts fitted to the frame, that eventually decreases the

rotation of the casters. To avoid this the excess part of the bolt is

removed so that the casters can easily rotate through 3600. And also

removed the excess part of the bolt of the throttles holder by grinding

because to give some space to the CDU holder.

3.3. Primary Flight Controls:

Primary flight controls are necessary for the manoeuvrability of the

aircraft. They are Ailerons, elevators, rudder, Landing gear and Throttles.

The ailerons and the elevator are controlled by the Side stick and the

rudder by the rudder pedals. So the report focus on the four objectives

that are shown in the diagram below. More concentrated on the primary

flight controls is done because, it is the primary priority of the Simulator to


give access to the primary flight controls to the customers. According to

the objective modifying the existing flight control systems to an A320

model side stick and the throttles. A Side stick is purchased that looks

similar to the A320 model side stick and also bought the replica of the

A320 model throttles. The rudder pedals are available along with the

simulator under working conditions. All these controls are the plug and

play models so all the work needed to do is to connect the controls to the

software. An additional frame is need to be build for the side stick to fit on

it, So by using the wooden frame which available in the collage with the

required dimensions for the side stick and assembled a metal sheet on

that wooden frame to fit the side stick on the top of the plate.

Figure 7- Primary flight controls


Flight controls

Side stick

Throttles

Rudder pedals

Landing Gear

The simulator is needed to be fitted with flaps and slats levers to

the so it is necessary to purchase all the landing gear and the flaps and

slats levers. But all the money is spent on rest of part and crossed the

budget limit, so the Project supervisor suggests not to buy these levers to

cross the budget. Instead of buying these levers there are another two

options which are by modifying the existing bomb door leaver into a

landing gear lever or by installing a switch for the landing gear and linked

to the software to lower or raise the landing gear using the mouse.

3.4. Autopilot Systems:

The existing FCU was fully damaged that the only LED lights are working,

most of the dials and the rotary switches went missing from the autopilot

system. So it is initially planned to change the complete FCU module, but

the price of the FCU is very higher than the given budget, so by

contacting his supervisor and discuss the problem and got some

suggestions from him. The Supervisor suggested that rather than

purchasing a new module make the existing module to work and make

the functional. So the author had examined the full autopilot system

module and realized that some of the cables were broken and the

switches that are remaining were not working, so soldering is done to

those switches which are not working and fixed them. And also marked

all the wires which are coming out of those switches. Investigated to

purchase the dials and a rotary switch that went missing and later


realized that, the switches which are required need to fit to the FCU are

not available in the market so build some looks similar to those switches.

Figure 8- Classification of autopilot system objective.

As shown in the figure above, there is a necessity to work

on both the Hardware and the software of the FCU. A program is needed

to be written using the SIOC software. The program needed to write is to

get the output to the displays and has taken command from all the dials

and switches.


Autopilot system

Hardware

Make all switches functional

Buy switches that are missing

Software Modify software after assembling.

4. Procedures followed during the Practical Activities:

As explained in the above section 4.2.4 The report had gone through six

different procedures that are involved in reaching the final outcomes. All the

procedures used are listed below.

Metal cutting

Welding

Grinding

Metal Bending

Drilling &

Soldering.

4.1. Metal Cutting:

There are three different types of metal cutting that are available in

the market today, these are the three procedures which are required to

finish these objectives, they are.

Metal cutting band saw

Hydraulic Guillotine Sheet Metal Machine

Hacksaw cutting

4.1.1.Metal cutting band saw:

Clarke's superb metal cutting band saw is engineered specifically

for daily use in many engineering plants, fabrication workshops &

garages. It boasts a powerful motor & adjustable cutting blade speeds to


effortlessly cut through ferrous & non-ferrous metal & alloy tubes, bars &

profiles. It also benefits from adjustable, bearing mounted blade guides

for accuracy. The coolant has been continuously flowed to decrease the

temperature developed during cutting the metal bars.

4.1.2.Hydraulic Guillotine Sheet Metal Machine:

The machine may be foot powered or mechanically or hydraulically

powered. It works by clamping the material with a ram first. A moving

blade, then comes down across a fixed blade to shear the material. For

larger shears the moving blade may be set on an angle or "rocked" in

order to shear the material progressively from one side to the other; this

angle is referred to as the shear angle.

4.1.3.Hacksaw cutting:

A hacksaw is a fine-tooth hand saw with a blade held

under tension in a frame, used for cutting materials such

as metal or plastics. Handheld hacksaws consist of a metal arch with a

handle, usually a pistol grip, with pins for attaching a narrow disposable

blade. A screw or other mechanism is used to put the thin blade under

tension. The blade can be mounted with the teeth facing toward or away

from the handle, resulting in cutting action on either the push or pull

stroke. On the push stroke, the arch will flex slightly, decreasing the

tension on the blade, often resulting in an increased tendency of the

blade to buckle and crack.


http://en.wikipedia.org/wiki/Pistol_grip

http://en.wikipedia.org/wiki/Plastic

http://en.wikipedia.org/wiki/Metal

http://en.wikipedia.org/wiki/Cutting

http://en.wikipedia.org/wiki/Tension_(physics)

http://en.wikipedia.org/wiki/Blade

The person who is working on these machines must wear the

safety glasses and the gloves for the health and safety. And the

individuals have to make sure they have to turn off the power switch off

after finishing the usage of the machine.

The metal pieces were marked with the dimensions which is

required and as designed before. The mild steel metal bars that have

used in this report is about 30 mills so that metal cutting band saw is

used. By using this saw the metal bars were cut down with their

dimensions by following all the safety requirements. And used the hand

saw to cut the ribs of the simulator to fix the throttle holder in the position.

The Hydraulic Guillotine Sheet metal cutting machine is also used to

make the throttle holder because the metal sheet used in the holder is

about 2 mills and it is easy to cut the metal using this machine accurately.

This is done by making design and mark the sheet as per "Diagram 3". All

these processes were very risky, so all the safety procedures as

mentioned above were followed.

4.2. Welding:

The process of joining together two pieces of metal so that

bonding accompanied by appreciable inter-atomic penetration takes

place at their original boundary surfaces. The boundaries more or less

disappear at the weld, and integrating crystals develop across them.


Welding is carried out by the use of heat or pressure or both and with or

without added metal.

The machine works at the very high temperatures so there is a

need to wear the Industrial grade auto darkening helmet, heavy duty

gloves, apron and the safety boots.

All the metal bar has to be joined together to build the frame, so

this process is chosen for it. All the joints were attached and the corners

with the help of welding. All the casters were assembled to the frame by

using this process. There is a problem while fixing the catches to the

frame and it is resolved by making a metal plate that supports the catches

while welding. Welding is a difficult process and the author is not allowed

directly to work on this process due to health and safety, so with the help

of workshop professors welding the required parts is done.

4.3. Grinding:

When the surface of the metal has to be smooth and of a very high

quality a grinding machine may be used. A grinding machine consists of

an abrasive wheel which turns while in contact with the metal, thus

wearing the surface down. It is also used to decrease remove the excess

part of the metal using the grinding machine with the doing the

hammering action.


The author has to wear the safety glasses and gloves when work

is carried out using both these machines. He has to make sure the power

is turned off after the work and he has to very careful with the grinding

wheel while working on it.

The author faces a problem that the simulator is not standing on

the frame, because it got some glitzes below the simulator. To overcome

this he has to grind those glitzes below the simulator. He also has to grind

the excess part of the bolt which are used to assemble the frame to the

simulator, Because the excess part of the bolt is obstructing the casters

to move freely.

4.4. Metal Bending:

In folding, clamping beams hold the longer side of the sheet. The

beam rises and folds the sheet around a bend profile. The bend beam

can move the sheet up or down, permitting the fabricating of parts with

positive and negative bend angles. The resulting bend angle is influenced

by the folding angle of the beam, tool geometry, and material properties.

Large sheets can be handled in this process, making the operation easily

automated. There is little risk of surface damage to the sheet using this

process.


With the help of Standard sheet metal hand brake machine, the

metal sheets were bent and are used in the design to hold the throttles.

The sheet has been marked and drilled as designed and it has to be

bend the two ends of the frame to fit the holder between the ribs of the

Nimrod simulator. The procedure which is followed to finish this tasks

were mentioned in the above part of the report.

4.5. Drilling:

Drilling, on the one hand, consist of a drill bit which is applied to the

metal using a combination of force and rotation, and which therefore cuts

through it. Thus, a hole of the required size will be cut right through the

metal in question. There are two different types of the drilling machines

1. Hand drilling

2. Machine drilling

The hand drilling works as similar to the machine-drilling, but the we

can easily carry it to the other places and can work on the materials where

we get less access to the specimen, but the person who is working on it must

apply some physical load to drill hole into the specimen. Coming to the

machine-drilling there is no need to apply any load, all the person has to do

is change the gear depending on the thickness and the material that going to

be getting drilled, and he has to hold the specimen to get drilled in position.


The safety glasses and gloves were necessary when work is carried

out using both these machines. The drill bits must be removed and has to

turn the power off after finishing the work.

They are two different drilling machines to finish the task, those are

machine-drilling and the hand drilling. The firstly used machine is machine

driller to make holes in the frames and the plates that are used to fix the

catches. The author has also used this machine to drill holes on the metal

sheet for the throttle holder. The secondly used the hand Drilling machine to

drill holes on the simulator because he can't get the simulator in the position

of the machine, drilling and the other problem very little access to drill in

some holes inside the simulator to fix the frame. And also used the hand

driller to drill in some holes through the base and the glare shield parts of the

Nimrod simulator to lock both these parts when the simulator is assembled

together. Maintained a standard of 6.1 mills holes on all the simulator. And

used 3 mills drill the fit the screws through the metal sheet and the wooden

frame used to fit the A320 model Side side.

4.6. Soldering:

Soldering is a process in which two or more metal items are joined

together by melting and flowing a filler metal (solder) into the joint, the

filler metal having a lower melting point than the adjoining metal.

Soldering differs from welding in that soldering does not involve

melting the workpieces. In brazing, the filler metal melts at a higher


http://en.wikipedia.org/wiki/Brazing

http://en.wikipedia.org/wiki/Welding

http://en.wikipedia.org/wiki/Melting_point

http://en.wikipedia.org/wiki/Solder

http://en.wikipedia.org/wiki/Filler_metal

http://en.wikipedia.org/wiki/Metal

temperature, but the workpiece metal does not melt. In the past,

nearly all solders contained lead, but environmental concerns

increasingly dictated the use of lead-free alloys for electronics and

plumbing purposes.

The method is used to fix the autopilot switches. Most of the

switches, wires were broken and remaining got shorted, so it requires

to attach some new "single core aluminium" wires to the switches and

had removed the excess soldering the rest of the switches were the

switches are shorted. And has also named all the wired coming out

from each and every switch, and fixed all the earthing wire into one

single wire.


5. Analysis:

The main need is to get the Nimrod flight simulator and the screens to move

from one class to another for the demonstrations and the control column of the

simulator has to be modified with the control columns to an A320 model

simulator by modifying the control column with the side stick and A320 replica

model throttles. The author has learned time management, Quality management

activities and how to manage the risks that are involved in the project. The

author has divided the complete project into some sub objectives and also show

that what the issues he faced with those objectives and how he overcome those

issues and finished them are shown in the table below.

Objective Review

Investigation All the investigation has been done for the modification of the

simulator. For each and every objective the Author had done the

research and consult the project coordinators and other professors to

seek some advices from them, to get the best high quality standard

outcomes.

Design and

Construction of the

Frame

The work had gone through multiple designs while designing the frame

and came out with one final design which is high reliability and also

have high strength to carry the simulator with the help of the project

supervisor. And also consulted workshop professors to select the best

metal to work on and all the other parts required to build the frame.

Even though he faced some difficulties with the availability of the

workshop, All the frame has been built and locking mechanism has


been assembled between the two simulator frames. The author has

managed time to get to the workshop and get hands on the job.

Modifying the

simulator

The Simulator had been stripped down completely and stored all the

existing control panels in the safest place to avoid the damage. And

also dismantled the simulator with the help of the project coordinators

so that the frame can be easily carried from the class to workshop and

removed the control column holder because to modify the simulator

into A320 model Side Stick. All the work is done to build the frame for

the simulator and to build the frame for the side stick and a throttles

holder.

Assembling frame

to the simulator

All the frame for the simulator and the side stick had been built and the

frame has been assembled to the Nimrod simulator and wheels has

been assembled to carry the simulator easily for the demonstrations.

Even the length of the screens has been decreased a bit to move

easily from one class to another. They are two different problems

While assembling frame to the simulator arises.

The simulator is not standing on the frame, because it got

some glitzes below the simulator. In order to overcome

this problem grinding process is appropriate and used to

eliminate those glitzes below the simulator.

Another problem is also solved by grinding the excess

part of the bolt which are used to assemble the frame to

the simulator, because the excess part of the bolt is

obstructing the casters to move freely.


Refurbishing the

autopilot system

The Autopilot system has been several damaged elements and most

of the switches and dials were missing and remaining switches are not

functioning properly. So the available switches were repaired and

bring them back to working condition and left the remaining dials

because they are not available in the market, and didn't get enough

time to build them. Even though there is another option to buy a new

FCU, it is much expensive and increasing the budget, and it's wise to

buy a new module rather than making use of the available autopilot

unit.

Constructing frame

for joystick and

holder for throttles

The frame had to be built separately for the simulator, the main

purpose of this frame is to hold the throttles right is positioned, it is

simple and light in weight to carry to other classes. The holder for the

throttles also been designed and fitted in the simulator so that the it is

helpful in fixing the throttles right in position. Specific dimensions of the

throttles were taken so to make sure that the trim wheels can rotate.

And also drilled the throttle holder and fixed to the frame using bolts

and screwed the metal plate to the wooden frame.

Connecting control

columns to the

Software

So far all the control surfaces were assembled to the simulator and

also all the screens were fitted, but there is a technical problem with

the second CPU (central processing unit) so the control columns were

not connected to the software so far. Once if the CPU is back in

function, it is easy to connect all the control columns to the software.

The author had also provided the risk management strategy and the Gantt chart

in the initial report and he had changed the initial plan because of some


personal issues and had the conversation with one of the project supervisors

and had changed the plan in the mid check point report. Coming to the "Quality

management systems" a good reporting culture is maintained with the project

supervisors and kept a "Logbook" which contain the record of all the work done

and also carried from the beginning to the end of the entire project. And also

consulted his project supervisor every week to report and update the work status

of the project and also to inform the issues which are interrupting the objectives.

The budget had been planned and it is of about 500 Pounds. It is planned

to invest some of the money on the frame, tolls and also needed to finish the

frame. A new side stick, and A320 model throttles were bought to replicate the

Simulator into Airbus model. And some part money is spent on the LED lights to

make the simulator more illuminate and make sure that all the control surfaces

are visible. Even though there is a thought of purchasing the Landing gear, flaps

and slats levers which are expensive but it has already crossed budget and the

supervisor told not to spend any more money on it and suggested that to modify

the bomb door available on the simulator into a landing gear lever. There is no

time left behind to do the further modifications like the lever to landing gear. And

there is some other work left behind which is to connect all the control columns

to the software because of the malfunction in the CPU, and when the problem is

solved the task can be completed easily. By maintaining a good desired

procedures and safety the output will reach to the customer quality expectations.


6. Conclusion:

The main theme of the project is to develop the Nimrod Flight simulator to

Teaching Aide Standard. Initially the author planned to modify the simulator into

A380 model simulator, but due to the lack of resources he changed the aim to

modify the simulator into the A320 model. Even though the aim and objectives

are so clear the author has to plan the complete project in the format of the

PRINCE 2. The project had been classified into three sub objectives. Initially the

complete simulator is stripped down and had to store all the control panels and

the control columns into the safe to avoid the damage to the simulator. Later on

he has dismantled the simulator into two parts so that he can easily carry the

simulator from one place to another. The primary goal is to design and build the

frames fixed with casters for the simulator, so that it will be easy to carry the

simulator from one place to another.

To build the frame there is a need to go through several processes, so he

learned all this process which is required to build the framework. Even though

he has finished the frame there are some problems like glitches taken place

while assembling the frame to the simulator, so he has Grinded the glitches that

are causing problem while assembling. After the assembling of the frame there

is an another issue arose that the bolts are obstructing the caster rotation, so he

also Grinded the excess bolt to solve this problem. By doing all this process the

author has learned to manage the time and he maintains a good reporting

culture to maintain Quality management activities. He also maintained a log

book so that he can record all the work he had done in a book. One of the


objectives is to modify the existing control column to A320 model simulator, so

to do that the author has built a frame for the side stick and also a holder for the

throttles. He bought an A320 model side stick and the throttles, both of them are

plug and play models so that they can easily programmable to the Simulator

software. The LED strip light was bought to replace all the lights that are not

functioning in the glare shield part of the simulator. Even though he still have to

buy the landing gear and the flaps and slats levers the author haven't bought

them due to the increase in the budget in the project.

The author had missed the initial planning of the project due to some

personal issues and to decrease those he had arranged a meeting with the

group coordinator and modified the plan to decrease the delay impact on the

project, and have made a new Gantt chart at the time of the checkpoint report.

Even though he changed the plan he didn't achieve the complete project due to

the lack of time and the budget issues where he had faced a problem with it.

Due to the delays caused to build the frame because of the very less availability

of the workshop he is simultaneously doing work on the rest of his objectives.

He bought the best side stick and throttles within his budget and done some

work on the FCU. Even though the author had planned for the purchase of a

new autopilot system, The new FCU is expensive and he wants to work on the

existing FCU and done soldering to the malfunctioned switches and made them

fully functional and marked them. Even though he finishes the work he need to

wait until the completion of the construction and assembling the frame. Until

then he cannot assemble the control columns and the control panels to the


simulator. Even though after finishing of the framework and assembled all the

panels to the simulator he got a problem that one of the CPU is not functioning,

so he cannot connect the control columns & the panels to the software until he

resolves the problem with the CPU. Which is being reported to the necessary

project supervisor and requested to resolve this problem. If it is resolved the

thing like attachment of the control columns and panels of the software will be

simplified.

7. Recommendations:

To increase the quality of the project the author would like to give a couple of

recommendations to get the better outcomes than what he had expected

It’s a big project and the college has to increase the budget for these

kind of projects.

Still need to buy landing gear, slats and flap levers that are needed to

get increase the simulation experience.

Autopilot system has to be refurbished and has to make it fully

functional.

The college has to provide better functional CPU to increase the

functionality of the simulation.

Allocating a room for the flight simulator will helps to store and can

get more access to work on it will decrease the time pressure on the

author.


8. Acknowledgements:

First and foremost I offer my sincerest gratitude to my supervisors,

who had supported me throughout my project with his patience and

knowledge whilst allowing me the room to work in my own way.

In the workshops I have been aided for an academic year in running

the equipment by Mr Kevin and Mr Alster. In my daily work I have been

blessed with a friendly and cheerful group of fellow students. The Aircraft

Engineering Department has provided all the support and equipment I

have needed to produce and complete my project.

Finally, I would like to thank my parents for supporting me throughout

all my studies at University, and college library acting as a home in which

to complete my writing up.


9. Bibliography:(n.d.). Retrieved dec 4, 2014, from www.clarketooling.co.uk:

http://www.clarketooling.co.uk/tools/Metal_Cutters__Shears__Folders___Formers.html

(n.d.). Retrieved feb 24, 2014, from thelibraryofmanufacturing.com: http://thelibraryofmanufacturing.com/sheetmetal_bending.html

(n.d.). Retrieved March 20, 2014, from www.lekseecon.nl: http://www.lekseecon.nl/sioc.html

(2014, may 12). Retrieved March 3, 2014, from www.listoftools.com: http://www.listoftools.com/soldering/soldering_procedure.html

ASTM, D. m. (2002). Retrieved feb 20, 2013, from metals.about.com: http://metals.about.com/library/bldef-Welding.htm

Bland, D. J. (2003, march 15). Retrieved March 12, 2014, from www.cmp.liv.ac.uk: http://www.cmp.liv.ac.uk/frink/thesis/thesis/node2.html

Metals, C. (2012 , July 24). Retrieved Jan 12, 2014, from www.castlemetalsuk.com: http://www.castlemetalsuk.com/blog/different-forms-processes-metal-cutting/

Ryan, V. (2009). Retrieved feb 12, 2013, from www.technologystudent.com: http://www.technologystudent.com/equip_flsh/hacksw2.html


10.Diagram not included in the text:

3

Figure 9: A320 model side stick.

4

Figure 10- A320 model throttles.

3 http://i.ebayimg.com/t/Logic-3-PC-Pro-Flight-2-JS282-Vibrating-joystick-force-feedback-USB-/00/s/MTE5NVgxNjAw/z/N5cAAOxy0bRTGKLm/$_35.JPG4 http://www.fsthrottles.com/images/A320trim1thumb.jpg


Figure 11- Stages to do the Final Assembly.


Pavan Project Report

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