“Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced...
-
Upload
nguyenhanh -
Category
Documents
-
view
219 -
download
0
Transcript of “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced...
![Page 1: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/1.jpg)
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
![Page 2: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/2.jpg)
Outline
• Societal Missions @ NAL
• HANSA
• Renewables - focus on wind
• Radomes
• Autoclaves
• Micro Air Vehicles
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 3: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/3.jpg)
HANSASARAS
C-NM5LCA Tejas
Participation of CSIR-NAL inAircraft Programmes NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 4: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/4.jpg)
CSIR NAL’s Aircrafts
Slybird
Hansa CNM – 5
Black KiteLCAContents are the Property of National Aerospace Laboratories, Bangalore
![Page 5: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/5.jpg)
Societal Missions @ NAL
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 6: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/6.jpg)
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
![Page 7: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/7.jpg)
0°
90°
+45°
-45°
+45°
-45°
90°
0°
±45°
0°/90°
±45°
0°/90°
0°/90°
±45°
±45°
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
![Page 8: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/8.jpg)
Continuous Fibre Reinforced laminated Composites
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 9: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/9.jpg)
Sandwich Composite Constructions
Foam Core Sandwich Honeycomb Core Sandwich
Face Sheet / Skin
CoreAdhesive Bond
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 10: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/10.jpg)
Short Fibre
Discontinuous Reinforcements in Composites
Particulate
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 11: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/11.jpg)
Hansa-3 Aircraft Program
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 12: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/12.jpg)
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
![Page 13: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/13.jpg)
LCRA (Feb. ‘87) HANSA-2 (Nov. ‘93)
HANSA-3 Proto-I (Nov. ‘96) HANSA-3 Proto-II (May ‘98)
LCRA to HANSA-3
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 14: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/14.jpg)
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
![Page 15: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/15.jpg)
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
![Page 16: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/16.jpg)
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
![Page 17: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/17.jpg)
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
![Page 18: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/18.jpg)
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
![Page 19: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/19.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 20: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/20.jpg)
Extensively tested and documented (for its class)
Fuselage test rig
Engine mount test rig
Wing test rig
Features of Hansa-3 Continued..
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 21: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/21.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 22: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/22.jpg)
Hansa-3 Fabrication in a Nut ShellNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 23: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/23.jpg)
Renewables - focus on wind
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 24: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/24.jpg)
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
![Page 25: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/25.jpg)
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
![Page 26: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/26.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 27: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/27.jpg)
Small Wind Solar Hybrids at
Center for Societal Missions & SpecialTechnologies- CSMST
National Aerospace Lab, Bengaluru
![Page 28: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/28.jpg)
Wind-Solar Hybrid (WiSH) System PT1
Targeted for low wind regimes in tropics
28
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 29: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/29.jpg)
29
NALCSIR
Wind-Solar Hybrid (WiSH) System PT2
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 30: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/30.jpg)
Composites
RenewableEnergy
Controls
Aerodynamics
Indigenous Wind Turbine Rotor
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 31: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/31.jpg)
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
![Page 32: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/32.jpg)
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
![Page 33: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/33.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 34: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/34.jpg)
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
![Page 35: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/35.jpg)
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
![Page 36: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/36.jpg)
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
![Page 37: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/37.jpg)
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
![Page 38: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/38.jpg)
Tow Testing at HAL Airport, Bengaluru
Simulate
Wind speeds
up to 20 m/s
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 39: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/39.jpg)
Tow-Testing of Wind Turbine
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 40: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/40.jpg)
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.
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 41: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/41.jpg)
Development of 1 kW Wind SolarHybrid (WiSH) system
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 42: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/42.jpg)
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
![Page 43: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/43.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 44: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/44.jpg)
As a Roof Top Application
Wind Turbine
Solar PV Panel
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 45: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/45.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 46: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/46.jpg)
Press Release on WiSH System
The New Indian Express,May 16, 2014
The Hindu, May 24, 2014
46
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 47: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/47.jpg)
NAL-Win @Jyoti Nivas CollegeKoramangala Bengaluru
Wind Turbine :- 900 WDate of Installation :- 26-05-2016
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 48: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/48.jpg)
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
![Page 49: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/49.jpg)
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
49
NAL
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 50: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/50.jpg)
![Page 51: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/51.jpg)
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
![Page 52: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/52.jpg)
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
![Page 53: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/53.jpg)
South West Monsoon Winds
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 54: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/54.jpg)
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
![Page 55: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/55.jpg)
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
![Page 56: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/56.jpg)
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
![Page 57: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/57.jpg)
Radomes
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 58: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/58.jpg)
Airborne Radomes
![Page 59: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/59.jpg)
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
![Page 60: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/60.jpg)
Material : Composite(E-GlassFabric & HighTemp. EpoxyResin)
Shape : StreamlinedType : MonolithicLength : 965.50 mmBase dia.(OD): 522.61 mmWeight : 13.5 kgs.
Jaguar Radome SpecificationsNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 61: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/61.jpg)
Conical Preforms for Air-Borne Radomes(Contour varying in 3-Dimensions)
Fighter AircraftJacquard wovenconical seamless
preform(Varying contourfrom base to tip)
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 62: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/62.jpg)
Static Load Test Vibration Test
Lightning Test
Testing of Jaguar Radome
EM Test
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 63: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/63.jpg)
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
![Page 64: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/64.jpg)
• Composite components made from prepregs and Autoclave moulding• Over 30% composite in Air Frame• Use of UD carbon Prepregs
Reinforcements in SARAS AircraftNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 65: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/65.jpg)
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
![Page 66: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/66.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 67: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/67.jpg)
Trial Assembly At BEL,Bangalore
66 Panels, 3700 fasteners
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 68: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/68.jpg)
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
![Page 69: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/69.jpg)
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
![Page 70: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/70.jpg)
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
![Page 71: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/71.jpg)
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
![Page 72: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/72.jpg)
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
![Page 73: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/73.jpg)
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
![Page 74: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/74.jpg)
Autoclaves
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 75: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/75.jpg)
Cooking anAircraft Airframe? NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 76: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/76.jpg)
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
![Page 77: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/77.jpg)
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
![Page 78: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/78.jpg)
• 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
![Page 79: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/79.jpg)
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
![Page 80: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/80.jpg)
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
![Page 81: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/81.jpg)
Typical Autoclave cure cycleNALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 82: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/82.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 83: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/83.jpg)
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
![Page 84: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/84.jpg)
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
![Page 85: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/85.jpg)
85
Three tier layout ofSubsystems NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 86: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/86.jpg)
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
![Page 87: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/87.jpg)
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
![Page 88: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/88.jpg)
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
![Page 89: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/89.jpg)
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
![Page 90: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/90.jpg)
Lab Scale Autoclave for IIT Kanpur
Successfully commissioned and handed overon 25.03.14
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 91: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/91.jpg)
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
![Page 92: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/92.jpg)
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
![Page 93: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/93.jpg)
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
![Page 94: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/94.jpg)
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
![Page 95: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/95.jpg)
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
![Page 96: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/96.jpg)
Autoclave User’s Meet, 3rd Sept. 2013NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 97: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/97.jpg)
Press Coverage: On Lab scale autoclaveVijay Karnataka
NALCSIR
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 98: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/98.jpg)
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
![Page 99: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/99.jpg)
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
![Page 100: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/100.jpg)
Micro Air Vehicles
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 101: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/101.jpg)
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
![Page 102: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/102.jpg)
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
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 103: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/103.jpg)
Structural Concepts for Airframes…Contd
Black Kite Pushpak
Suchan
Contents are the Property of National Aerospace Laboratories, Bangalore
![Page 104: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/104.jpg)
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
![Page 105: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/105.jpg)
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
![Page 106: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/106.jpg)
Modular wing of MAV-Exploded view
CSIR-NALCSIR
• Completed more than 100 landingsContents are the Property of National Aerospace Laboratories, Bangalore
![Page 107: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/107.jpg)
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
![Page 108: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/108.jpg)
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
![Page 109: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/109.jpg)
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
![Page 110: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/110.jpg)
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
![Page 111: “Polymer Composites for Societal Applications” on mechanics... · Symmetric & Balanced Composite laminates Quasi-isotropic Laminate using Uni-directional ... Constant speed propeller](https://reader030.fdocuments.in/reader030/viewer/2022011803/5b8c4b1209d3f245638cafa5/html5/thumbnails/111.jpg)
Thank You