VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“JNANA SANGAMA”, BELAGAVI-590018.

2024-2025

Internship Report on

“Hindustan Aeronautics Limited (HAL)”

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING IN
ELECTRONICS AND COMMUNICATION ENGINEERING
Submitted By

AASHISH PRADEEP KUNNUMMAL [1JB21EC002]

UNDER THE GUIDANCE OF

Dr. Chandrappa D N
Professor & Head
Dept. of ECE, SJBIT

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

SJB INSTITUTE OF TECHNOLOGY

B G S HEALTH AND EDUCATION CITY
Kengeri, Bangalore-560060
 || JAI SRI GURUDEV||
Sri Adichunchanagiri Shikshana Trust ®
SJB INSTITUTE OF TECHNOLOGY
BGS Health & Education City, Kengeri, Bangalore-560060.

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

CERTIFICATE
Certified that the Industry internship work entitled “Hindustan Aeronautics Limited (HAL) ”
carried out by Aashish Pradeep Kunnummal [1JB21EC002] is bonafide student of SJB
Institute of Technology in partial fulfillment for the award of “BACHELOR OF
ENGINEERING” in ELECTRONICS AND COMMUNICATION ENGINEERING as
prescribed by VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELAGAVI during
the academic year 2024-2025. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report deposited in the department library. The report has been
approved as it satisfies the academic requirements in respect of Industry Internship work prescribed the
said degree.

Dr. Chandrappa D N Shri. Hareesh Venugopal Dr. K.V. Mahendra Prashanth

Guide, Professor & Head CM (Eqp & FA) Principal
Dept. of ECE, SJBIT HAL SJBIT

EXTERNAL VIVA-VOCE

Name of the Examiners Signature with date

1.

2.
 ACKNOWLEDGEMENT

I would like to express my profound gratitude to His Divine Soul Jagadguru Padma Bhushan Sri Sri
Sri Dr. Balagangadharanatha Mahaswamiji and His Holiness Jagadguru Sri Sri Sri Dr.
Nirmalanandanatha Swamiji for providing me with an opportunity to be a part of this esteemed
institution. We would also like to express my sincere thanks to Revered Sri Sri Dr. Prakashnath
Swamiji, Managing Director of SJB Institute of Technology, for his continuous support in providing the
necessary amenities to carry out this industry internship at this esteemed institution.
I express my heartfelt gratitude to Dr. Puttaraju, Academic Director BGS and SJB Group of Institutions,
Dr. K. V. Mahendra Prashanth, Principal, SJB Institute of Technology, and Dr. Chandrappa D N,
Professor & Head of the Department of Electronics and Communication Engineering for providing me
with outstanding amenities and for their unwavering support, state-of-the-art facilities, and the enriching
academic environment, which were instrumental in the successful completion of my industry internship
work.
I extend my heartfelt gratitude to all the Deans of SJB Institute of Technology for their unwavering
support, cutting-edge facilities, and the inspiring academic environment, all of which played a pivotal role
in the successful completion of my industry internship work.
I express my truthful thanks to Dr. Somashekar K and Mrs. Anushree R, industry internship
coordinators, Dept. of Electronics and Communication, for their valuable support.
I would like to thank Mr. Ashwin S Shankar, HR, LCA Tejas Division, for offering me the prestigious
Internship. Special appreciation goes to my guide, Shri. Hareesh Venugopal CM (Eqp & FA) LCA
Tejas Division, HAL Bangalore, for sparing his valuable time to extend help at every step of my
internship, which paved the way for smooth progress and the fruitful culmination of the internship.
Finally, I take this opportunity to extend my earnest gratitude and respect to my parents, the teaching &
technical staff of the department, the library staff, and all my friends, who have directly or indirectly
supported me during the period of my industry internship.

Regards,

Aashish Pradeep Kunnummal [1JB21EC002]

I
 DECLARATION

I hereby declare that the entire work embodied in this industry internship report has been carried
out under the supervision of Shri. Hareesh Venugopal, CM (Eqp & FA) in partial fulfilment
for the award of “BACHELOR OF ENGINEERING” in ELECTRONICS AND
COMMUNICATION ENGINEERING as prescribed by VISVESVARAYA
TECHNOLOGICAL UNIVERSITY, BELAGAVI during the academic year 2024 - 2025.

Aashish Pradeep Kunnummal [1JB21EC002]

II
 ABSTRACT

Hindustan Aeronautics Limited (HAL) is a premier aerospace company engaged in the design,
development, and production of military and civilian aircraft. The Light Combat Aircraft (LCA)
Tejas, a key project of HAL in collaboration with the Aeronautical Development Agency
(ADA), represents a significant milestone in India’s indigenous defense capabilities. This single-
engine, multirole fighter jet is designed for superior maneuverability, advanced avionics, and
enhanced combat performance.
The LCA Tejas features a delta-wing configuration, a fly-by-wire flight control system, and
extensive use of composite materials to reduce weight while maintaining structural strength.
Powered by the General Electric F404-GE-IN20 turbofan engine, the aircraft integrates
cutting-edge technologies, including an integrated digital flight control system, advanced
electronic warfare suite, multimode radar, and high-performance avionics.
Key subsystems such as hydraulics, power generation, fuel management, environmental
control, and weapons integration enhance operational efficiency and mission adaptability. The
aircraft’s modular construction ensures ease of maintenance and upgrades, making it a
formidable asset for the Indian Air Force and Navy.
HAL continues to contribute to India’s aerospace sector by producing critical components for
space programs and defense applications, reinforcing self-reliance in aviation technology. The
advancements in structural design, propulsion, and avionics demonstrated in the Tejas
program signify a step forward in India’s aeronautical engineering expertise and defense
modernization.

III
 TABLE OF CONTENTS

Sl. No. Particulars Page

No.
1 ACKNOWLEDGEMENT I
2 DECLARATION II
3 ABSTRACT III
4 TABLE OF CONTENTS IV-
V
5 LIST OF FIGURES VI

Sl. No. Particulars Page

No.
About The Company
1 6-11
1.1 Introduction

1.2 History of LCA Tejas

1.3 Introduction of LCA Tejas

1.4 System Equipped in LCA Tejas

About The Department
12-14
2 2.1 Overview of the LCA Tejas division

2.2 Core functions and objectives

2.3 Theoretical Foundations and Engineering

Applications

2.4 Departmental Infratructure and Technologies

2.5 Internship Scope and Technical Exposure

2.6 Significance of the Division in India’s Aerospace

Landscape
Tasks Performed
3 15-18
3.1 Airframe Structure and Components
3.2 Powerplant and Fuel System
3.3 Flight Control System (FCS)
V
 3.4 Hydraulic System
3.5 Environmental Control System (ECS)
3.6 Electrical and Avionics Systems
3.7 Observational Summary

Results And Conclusion

4 19-20
4.1. Technical Outcomes of the Internship
4.2. Academic and Professional Impact
4.3. Broader Significance and National Relevance
4.4. Conclusion

Reflections Notes
5 21-23
5.1. Technical Growth and Systems Understanding
5.2. Exposure to Aerospace Standards and Industrial
Practices
5.3. Personal and Professional Development
5.4. Strategic Realizations and Broader Reflections
5.5. Future Aspirations and Learning Direction

V
 LIST OF FIGURE

Sl. No. Particulars Page No.

Hindustan Aeronautics Limited

1.1. 6

1.2. LCA Tejas Mark I 9

VI
 Hindustan Aeronautics Limited 2024-25

Chapter 1
Introduction
1.1. Introduction

Hindustan Aeronautics Limited (HAL): A primary Aerospace Company in Asia is engaged in

design, development and manufacturing of military and civil aircraft for over 75 years. The
product range covers basic piston engine trainer aircraft to helicopters to sophisticated state of
the art deep penetration strike aircraft. Hindustan Aeronautic Limited is an organization where
integrated airborne weapons platforms are conceived, developed, manufactured and serviced. It
is one of the few corporate giants in Asia whose capabilities span the entire range of activities
from product conception to after sale support. HAL is also involved in the manufacturing and
assembly of structures requires for Indian's space programs.

Fig 1.1 : Hindustan Aeronautics Limited

The company which had its origin as the Hindustan Aircraft Company was incorporated on 23
Dec 1940 at Bengaluru by shri Walchand Hirachand a foresighted visionary in association with
the Government of Mysore with an Authorized Capital of Rs.4crores (paid by capital Rs.40
lakhs) and with the aim of manufacturing aircraft in India. In March 1941, the Government of
India became one of the shareholders in the company holding 1/3 of its paid- up capital and
subsequently took over its management in 1942.

Hindustan Aeronautic Limited (HAL) came into existence on 1" October 1964. The company
was formed by the merged of Hindustan Aircraft Limited with Aeronautic India Limited and
Aircraft Manufacturing Deport, Kanpur. HAL is a fully owned Government of India undertaking
under the administrative control of Ministry of Defense, Department of Defense Production.
HAL is the largest Public Unit (PSU) under the Department of Defense Production and is a
Navaratna Company.
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HAL is currently meeting the requirement of structure for aerospace launch vehicles and
satellites of ISRO through its dedicated Aerospace Division. Infrastructure has also been set up
to undertake completed assembly of the strap-on L-40 stage booster. Structures for GSLV MK 3
have been productionised. HAL has also contributed to Mars mission by supplying riveted
structure assemblies and welded propellant tankages for the Polar Satellite Launch Vehicle
(PSLV-C25).

Today, HAL has 19 production Units and 9 Research and Design Centers in 7 locations in India.
The Company has an impressive product-track record-12 types of aircraft manufactured with in
house R&D and 14 types produced under license. HAL has manufactured 3550 aircraft (which
includes 11 types designed indigenously). 3600 engines and overhauled over 8150 aircraft and
27300 engines.

HAL has been successful in numerous R&D programs developed for both Defense and Civil
Aviation sectors. HAL has made substantial progress in its current projects:

HAL has made substantial progress in its current projects:

 Dhruv-Advanced Light Helicopter - Weapon System Integration (ALH_WSI)

 Tejas-Light Combat Aircraft (LCA)
 Intermediate Jet Trainer (IUT)
 Light Combat Helicopter (LCH) Various Military and Civil upgrades

Hindustan Aeronautics Limited (HAL), located in Bangalore, India, is among the biggest
aerospace firms in Asia. Operated by the Indian Ministry of Defense, this government-owned
firm mainly focuses on the aerospace sector, producing and putting together aircraft, navigation
tools, and associated communication devices, in addition to managing airports.
HAL constructed the initial military airplane in South Asia and is presently involved the
development, production, and construction of airplanes, jet engines, and helicopters, as well as
their parts and replacements. Several states in India, such as Nasik, Korwa, Kanpur, Koraput,
Lucknow, Bangalore, and Hyderabad, host numerous facilities.

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The German engineer Kurt Tank designed the HF-24 Marut fighter-bomber, the first fighter
aircraft made in India. HAL has a long history of collaboration with numerous international and
domestic aerospace agencies such as Airbus, Boeing, Lockheed Martin, Sukhoi Aviation
Corporation, Elbit Systems, Israel Aircraft Industries, RSK MiG, BAE Systems, Rolls-Royce
plc, Dassault Aviation, MBDA, EADS, Dornier Flugzeugwerke, the Indian Aeronautical
Development Agency, and the Indian Space Research Organization.

The divisions in HAL Bangalore include:

 Aircraft Division Bangalore
 Engine Division Bangalore
 Overhaul Division Bangalore
 Foundry & Forge Division Bangalore
 Aerospace Division Bangalore
 IMGT Division Bangalore Airport Services Centre Bangalore
 LCA-Tejas Division Bangalore
 Helicopter Division Bangalore
 RWR & DC, ARDC Division

1.2. HISTORY OF LCA TEJAS

In 1983, IAF realized the need for development of an Indian combat aircraft for two primary
purposes. The principle and most obvious goal were the development of a replacement aircraft
for India's ageing Mig-21 fighters. The Mig-21 has been the mainstay of the Indian air force
since the 1970s. The "long Term Re-Equipment Plan 1981" noted that the Mig-21s would be
approaching the end of their service lives by the mid-1990s, and that by 1995, the IAF would
lack 40% of the aircraft needed to fill its projected force structure requirements. The LCA
program's other main objective was to serve as the vehicle for an across-the-board advancement
of India's domestic aerospace industry. The value of the aerospace "self-reliance" initiative is not
simply the production of an aircraft, but also the building of a local industry capable of creating
state-of-the- art products with commercial spin -offs for a global market, The LCA programme
was intended in part to further expand and advance India's aerospace capabilitics.

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To better accomplish these goals, the government choose to take a different management
approach, and in 1984 established the aeronautical development agency (ADA) to manage the
LCA programme. Although Tejas is most often described as the product of Hindustan
Aeronautics Limited (HAL), responsibility for the development of Tejas actually belongs to
ADA, a national consortium of over 100 defense laboratories, industrial organizations, and
academic institutions with HAL being the principal contractor.

1.3. INTRODUCTION OF LCA TEJAS

The HAL Tejas is a light multirole fighter aircraft with a compound delta wing design, single
engine, and made by collaboration between ADA and ARDC of HAL for Indian Air Force and
Navy. Derived from the LCA program initiated in the 1980s to replace India's outdated MiG- 21
jets, the Tejas was later integrated into a broader fleet modernization initiative. The designation
"Tejas" was officially given to the LCA in 2003.

It is the tiniest and most lightweight supersonic fighter jet in its category. The Tejas is designed
with "relaxed static stability" to improve its maneuverability and agility. It is capable of fulfilling
multiple roles such as interception, air-to-surface, and anti-shipping tasks in one mission due to
its versatile capabilities. Testing in wind tunnels and analysis using computational fluid
dynamics have enhanced the design of Tejas to reduce both transonic and supersonic wave drag,
as well as to achieve a low wing-loading.

Fig 1.2: LCA Tejas Mark I

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The HAL Tejas is the lightest in its class of contemporary supersonic combat aircraft. It is the
second fighter developed by HAL with the intention of supersonic performance, following the
HAL HF-24 Marut. The Tejas achieved initial operational clearance in 2011 and final
operational clearance in 2019. The first Tejas squadron became operational in 2016, with No. 45
Squadron IAF "Flying Daggers" being the first to replace their MIG-21s with the Tejas.

1.3.1 Major features of LCA:

 Unstable configuration
 Vortex dominated Aerodynamics
 Fly-by-wire
 High performance avionics
 Advanced cock pit design

1.3.2 Special features:

 Compound Delta planform

 Relaxed static stability
 Fly by wire flight control
 Composite structure
 Computer based monitor and control of electromechanical system
 Glass cockpit
 Multi-mode radar

1.3.3 Overall dimension of LCA:

 Length: 13.20m (42ft 4in)

 Height: 04.40m
 Wingspan: 8.20m
 Powerplant: 1 x General Electric F404-GE-IN20
 Internal fuel capacity: 3000 Kg tanks
 External fuel capacity: 5 x 800 litre tanks or 3 x 1200 litre tank

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1.3.4 Performance of LCA:

 Maximum speed: Mach 1.8 (2,220 km/h, 1,380 mph, 1,200 kn))
 Range: 850km
 Without refueling range:300 km
 Service ceiling: 15,240 m (50,000 ft)
 Thrust/weight: 1.07

1.4. SYSTEM EQUIPPED IN LCA TEJAS

The LCA Tejas is constructed and developed using a variety of unique components, each
essential to creating a fully functional aircraft. These components are categorized into several
departments, each contributing a crucial role in the aircraft’s overall design and performance.
The main systems involved are:
1. Structures
2. Power Plant System
3. Hydraulics System
4. Flight Control System
5. Electrical and Avionics System
6. Environmental Control System
7. Seat and Safety

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Chapter 2
About The Department

2.1. Overview of the LCA Tejas Division – HAL, Bangalore

The Light Combat Aircraft (LCA) Tejas Division at Hindustan Aeronautics Limited
(HAL), Bangalore, is a specialized unit dedicated to the design, production, final assembly, and
integration of India's first indigenously developed multirole combat aircraft, the Tejas. Operating
under the administrative control of the Ministry of Defence, Government of India, the division is
an integral component of India’s aerospace ecosystem and contributes significantly to national
defense preparedness and technological self-reliance.

The division functions in close coordination with the Aeronautical Development Agency
(ADA) and other research entities, ensuring that the Tejas aircraft meets evolving operational,
structural, and performance requirements defined by the Indian Air Force (IAF) and Indian
Navy.

2.2. Core Functions and Objectives

The division’s responsibilities span multiple domains:

 Manufacturing of major structural assemblies such as the front, center, and rear fuselage sections
 Integration of key systems including avionics, powerplant, hydraulic, and environmental control
systems (ECS)
 Testing and quality control of subsystems prior to aircraft roll-out
 Coordination with R&D partners for implementation of technological upgrades

The division operates under strict quality assurance protocols and follows systems engineering
principles to ensure optimal integration of various subsystems into a single, cohesive aerospace
platform.

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2.3. Theoretical Foundations and Engineering Applications

Several core aerospace engineering principles are actively implemented within the division’s
workflow:

 Aircraft Structures and Materials: The Tejas airframe uses semi-monocoque construction
and advanced materials like carbon-fiber reinforced composites (CFC) and aluminum-
lithium alloys, optimizing strength-to-weight ratio and improving agility.
 Flight Dynamics and Control: The delta-wing configuration and relaxed static stability (RSS)
necessitate the use of a quadruplex digital fly-by-wire (FBW) system. This ensures aircraft
stability and responsiveness despite an inherently unstable aerodynamic design.
 Thermal Management Systems: The Environmental Control System (ECS) draws bleed air
from the engine compressor and regulates cockpit conditions through multistage heat
exchangers, maintaining safe operational parameters for both pilot and avionics.
 Systems Integration: Interdisciplinary integration of subsystems such as electrical power,
hydraulics, and avionics is accomplished through modular design and rigorous simulation/testing
procedures.

2.4. Departmental Infrastructure and Technologies

The LCA Tejas Division is equipped with a wide range of advanced infrastructure to support
precision manufacturing and assembly:

 Computer Numerical Control (CNC) machines for precision machining

 Autoclaves and layup stations for composite panel manufacturing
 Wire harnessing labs for electrical and avionics systems
 Hydraulic and fuel system test rigs for performance validation
 Cockpit integration and simulation bays for avionics setup

These facilities enable the production of structurally optimized and electronically integrated
aircraft that meet both defense specifications and international standards.

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2.5. Internship Scope and Technical Exposure

The internship was conducted under the guidance of Shri. Hareesh Venugopal, Chief Manager
(Equipment & Final Assembly), in the LCA Tejas Division. The scope of exposure included
the observation and study of:

 Fuselage assembly processes including structural alignment and modular jig setups
 Powerplant installation procedures, focusing on the integration of the GE F404-GE-IN20
turbofan engine
 Flight control system components, including elevons, rudders, and the Digital Flight Control
Computer (DFCC)
 Electrical and avionics systems, involving layout, interfacing, and testing protocols
 Hydraulic actuation mechanisms for control surfaces and landing gear
 Environmental control and fuel system configuration, emphasizing safety and operational
reliability

This structured exposure provided insights into the interdisciplinary nature of aerospace systems
and the rigorous processes involved in combat aircraft manufacturing.

2.6. Significance of the Division in India’s Aerospace Landscape

The LCA Tejas Division plays a strategic role in strengthening India's defense capabilities. Its
ability to deliver high-performance aircraft that are both indigenously designed and
technologically advanced reflects a significant achievement in aerospace self-sufficiency. The
division's contributions directly support national defense modernization and open avenues for
future developments such as the Tejas Mk-1A, Mk-2, and Naval Tejas variants.

By fostering innovation in materials engineering, control systems, propulsion integration, and

avionics, the LCA Tejas Division stands as a symbol of India's advancing aerospace and defense
prowess.

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Chapter 3
TASKS PERFORMED

During the course of the internship at the LCA Tejas Division, HAL, Bangalore,
comprehensive exposure was provided to the structural design, system integration, and
operational principles of various critical subsystems involved in the Tejas aircraft. The tasks
undertaken were largely observational and learning-focused, offering technical insight into the
multidisciplinary nature of combat aircraft production.

The following subsystems and associated technologies were explored in depth:

3.1. Airframe Structure and Components

The LCA Tejas employs a semi-monocoque airframe constructed using a combination of

composite materials (45%), aluminum alloys (40%), and high-strength metals such as
titanium and steel. The aircraft's structure is divided into:

 Front Fuselage: Houses cockpit, radar, avionics, and nose landing gear.
 Centre Fuselage: Includes air intake ducts, fuel tanks, and main landing gear bays.
 Rear Fuselage: Contains engine bay, fin and rudder mounts, and air brakes.
 Wings: Composed of carbon fiber composites for weight reduction and increased agility.
Integrates elevons for combined pitch and roll control.

Each section is manufactured and assembled using advanced processes such as CNC machining,
chemical milling, composite layup, and forging, following modular alignment through jigs and
fixtures.

3.2. Powerplant and Fuel System

The aircraft is powered by a GE F404-GE-IN20 afterburning turbofan engine, offering a

maximum thrust of 17,700 lbf with afterburner. Exposure was provided to the modular
configuration of the engine, its lubrication systems, and the Aircraft Mounted Accessory
Gearbox (AMAGB) that drives auxiliary components like the IDGs (Integrated Drive
Generators) and Hydraulic Pumps.

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Key topics covered included:

 Engine architecture (two-spool low bypass turbofan)

 Jet Fuel Starter (JFS) system
 Flow path of internal fuel tanks (wing tanks, center fuselage tank)
 Fuel system components: Booster pumps, refueling valves, drain valves, pressure sensors, and
flow meters
 Refueling methods: Pressure and gravity-based systems

3.3. Flight Control System (FCS)

The Tejas aircraft incorporates a quadruplex digital fly-by-wire (FBW) control system to compensate
for its aerodynamically unstable delta-wing configuration. The Digital Flight Control Computer
(DFCC) developed by BEL interprets pilot commands via side-stick controllers and rudder pedals.

The system includes:

 Primary Control Surfaces: Elevons, Rudder

 Secondary Surfaces: Slats, Airbrakes
 Sensors: Air Data System (for speed, AoA, altitude)
 Control Logic: Auto low-speed recovery, disorientation recovery

Exposure included the control surface actuation, signal flow from pilot interface to flight surface, and
system redundancy measures.

3.4. Hydraulic System

Tejas utilizes two independent hydraulic circuits, each operating at 280 bar. The system powers flight
control surfaces, landing gear, and air brakes. In case of total hydraulic failure, an Engine Motor Driven
Pump (EMDP) ensures aircraft stabilization for emergency ejection or landing.

Key learning areas:

 Pump types: Engine Driven, Motor Driven
 Hydraulic actuators and valves
 Filtering systems (pressure, return, case drain)
 Cooling system: Fuel Cooled Oil Coolers (FCOCs)
 Selector valve logic (normal vs. emergency operation)
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3.5. Environmental Control System (ECS)

The ECS ensures optimal thermal and pressure conditions in the cockpit and critic

al avionics bays. Cooling air is tapped from the 7th stage compressor of the engine and
processed through heat exchangers, condenser units, and a Cold Air Unit (CAU).

Subsystems included:

 Bleed air control and PRSOV logic

 Re-heaters and high-speed water separators
 Pressurization of cockpit and fuel tanks
 Smoke detection and demist systems

A flow sequence was studied from air tapping to cabin distribution, emphasizing temperature-
pressure regulation and subsystem integration.

3.6. Electrical and Avionics Systems

The Tejas aircraft employs a hybrid electrical generation system with AC and DC power
sources, supported by two Ni-Cd emergency batteries.

Power components studied:

 AC Sources: 30/40 KVA IDGs, 5 KVA HMDGs

 DC Sources: 5 KW DC generator, Transformer Rectifier Units (TRUs)
 Distribution: Master Boxes (AC/ DC), Distribution Boxes, Bus Bars
 Emergency Power Logic: Float charge and automatic switchover systems

Avionics exposure included:

 Glass cockpit: Multi-function displays (MFDs), HUD

 Navigation and Communication Systems: INS/GPS, TACAN, VOR/ILS
 Electronic Warfare Suite: RWR, LWR, ECM, Chaff/Flare systems
 Mission Management: Open Architecture Computer (OAC), BHEEM, ECFM-EU

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3.7. Observational Summary

The internship provided hands-on observational exposure to real-world engineering practices in

the aerospace sector. Through guided sessions and departmental interactions, core technical
knowledge in flight systems, integration engineering, avionics, and aircraft safety systems
was significantly enhanced.

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Chapter 4
RESULTS AND CONCLUSION

4.1. Technical Outcomes of the Internship

The internship at the LCA Tejas Division of Hindustan Aeronautics Limited (HAL) offered a
comprehensive and structured overview of the systems engineering approach adopted in modern
fighter aircraft production. Through detailed observation and guided learning, the following
technical outcomes were achieved:

 Understanding of Airframe Design: Gained insights into the structural design of the Tejas
aircraft, including the materials used, the modular assembly of fuselage sections, and the role of
composite materials in weight optimization.
 Familiarity with Powerplant Integration: Acquired knowledge about the working principles of
turbofan engines, specifically the GE F404-GE-IN20, and the integration of auxiliary systems
such as the AMAGB, IDG, and JFS.
 System-Level Comprehension of Flight Control: Understood the principles of digital fly-by-
wire systems, the importance of relaxed static stability in delta-wing aircraft, and the safety
redundancies built into the DFCC architecture.
 Hydraulics and ECS Configuration: Studied the dual hydraulic loop system, component-level
interactions, and the use of Fuel Cooled Oil Coolers (FCOC). Also explored the air supply and
conditioning cycle in the ECS, essential for avionics and pilot safety.
 Electrical and Avionics Integration: Analyzed hybrid AC/DC power generation, battery
backup logic, bus bar distribution, and key avionics systems such as HUD, INS/GPS, MMR,
and OAC. Understood their interdependence in flight management, navigation, and mission
execution.

4.2. Academic and Professional Impact

The internship bridged the gap between theoretical coursework and real-world application in the
aerospace domain. The following competencies were significantly enhanced:

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 Multidisciplinary Systems Thinking: The ability to understand and connect electrical,
mechanical, avionics, and control systems as interlinked components of a high-performance
aircraft platform.

 Attention to Aerospace Standards: Exposure to safety-critical environments, documentation

protocols, and system validation practices essential for defense-grade aviation technology.
 Application of Engineering Fundamentals: Principles from fluid mechanics, thermodynamics,
electronics, control systems, and digital communications were observed in live applications,
enriching domain-specific knowledge.

4.3. Broader Significance and National Relevance

The LCA Tejas program, spearheaded by HAL and ADA, represents a landmark achievement
in India’s defense and aerospace self-reliance. The successful deployment of Tejas into active
Indian Air Force squadrons is a testament to the country's ability to design, develop, and
manufacture frontline combat platforms.

The internship experience highlighted the pivotal role of HAL in national security, technology
leadership, and industrial innovation. Being a part of this environment—even as an intern—
offered a unique glimpse into the complexity, scale, and strategic significance of indigenous
aerospace development.

4.4. Conclusion

In conclusion, the internship served as an invaluable learning opportunity, contributing both to

technical knowledge and professional development. It provided real-world context to classroom
concepts, deepened understanding of aerospace subsystems, and cultivated a deeper appreciation
for the role of engineering in national advancement. The experience has laid a strong foundation
for pursuing future roles in aviation, defense research, or systems engineering.

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Chapter 5
REFLECTION NOTES

The internship at the LCA Tejas Division of Hindustan Aeronautics Limited (HAL) served as
a pivotal opportunity to experience the real-world application of complex engineering theories
and methodologies within the framework of aerospace systems. It allowed for the integration of
classroom learning with practical, industry-grade processes, thereby bridging the gap between
academic theory and engineering practice.

5.1. Technical Growth and Systems Understanding

Exposure to the Tejas aircraft program provided valuable insight into the systems engineering
paradigm, wherein complex aerospace subsystems—such as propulsion, avionics, hydraulics,
control systems, and environmental modules—must function harmoniously to enable safe and
effective flight operations.

Theoretical principles observed in practice include:

 Bernoulli’s Principle and Compressible Flow Theory: Witnessed in the design and operation
of air intake ducts and jet engine airflow dynamics, crucial for maintaining engine efficiency and
thrust regulation.
 Control System Theory: Studied through the implementation of the quadruplex digital fly-by-
wire (FBW) system, which translates pilot inputs into precise actuator commands, ensuring
stability in an inherently unstable delta-wing aircraft configuration.
 Material Science and Stress Analysis: Observed in the application of composite materials
(such as carbon fiber-reinforced polymers) and finite element analysis (FEA) concepts for
optimizing strength-to-weight ratios across airframe structures.
 Thermodynamics and Heat Transfer: Core to the understanding of the Environmental
Control System (ECS), where hot bleed air from the compressor stages is conditioned using
multi-stage heat exchangers for pilot and avionics cooling.

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This theoretical reinforcement enabled a shift from learning “how things work” to “why things
are designed to work that way”—a core transition in the development of an engineering mindset.

5.2. Exposure to Aerospace Standards and Industrial Practices

The internship offered an immersive experience into aerospace-grade manufacturing and

certification protocols that adhere to global standards such as AS9100 for quality management
and DO-178C (for software in airborne systems). Systems had built-in redundancies,
traceability, and real-time monitoring to ensure compliance with fail-operational/fail-safe
principles—key to mission-critical aerospace environments.

Critical observations included:

 Use of MIL-STD-1553B communication protocols in avionics

 Implementation of LRU (Line Replaceable Unit) architecture for maintainability
 Electrical bus bar distribution and load shedding for power optimization
 Modular design for rapid prototyping and upgradability

These practices reflect high-level planning and adherence to lifecycle engineering models,
including V-Model Development Frameworks, commonly used in defense and aerospace
product development.

5.3. Personal and Professional Development

From a professional standpoint, the internship nurtured key engineering soft skills:

 Analytical Thinking: Through dissecting real-time engineering challenges

 Precision and Discipline: Reinforced by rigorous process flows and documentation
 Team Collaboration: Observing interdisciplinary teams working in unison to meet production
goals
 Engineering Ethics: Internalizing the role of accountability in safety-critical domains

These attributes are fundamental not only in defense environments but across all advanced
engineering roles where accuracy and reliability are non-negotiable.

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5.4. Strategic Realizations and Broader Reflections

The internship also underscored the broader value of strategic technological autonomy. The
Tejas program is more than just an aircraft—it is a symbol of India's growing self-reliance and
innovation in aerospace. From observing the use of indigenous subsystems to the implementation
of mission-critical redundancy, the learning experience extended to understanding how
national defense goals are deeply rooted in engineering excellence.

Furthermore, real-time applications of theoretical constructs such as control feedback loops,

fluid power dynamics, signal processing, and embedded systems integration highlighted the
necessity of multi-domain knowledge in modern engineering roles.

5.5. Future Aspirations and Learning Direction

The internship clarified the importance of deeper specialization in areas such as:

 Avionics Systems Engineering

 Embedded Flight Control Software
 Aerospace Structures and Propulsion Dynamics
 Cyber-Physical Systems and Autonomous Flight Algorithms

It also inspired a long-term interest in pursuing research or higher education in aerospace and
defense technology domains, potentially contributing to the next generation of indigenous
aviation systems.

Conclusion

In summary, the internship was a rigorous and enriching experience that merged theory with
high-impact application. It cultivated a mindset of precision, integration, and innovation,
which are essential traits of a competent aerospace engineer. The exposure to India's frontline
defense technologies has reinforced a career trajectory focused on advancing systems that are not
only technically superior but also nationally significant.

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Chapter 6

REFERENCES
1) Aeronautical Development Agency (ADA), LCA-Tejas Brochure and Technical Overview,
Ministry of Defence, Government of India, 2020.
2) Hindustan Aeronautics Limited (HAL), Internship Training Handbook – LCA Tejas Division,
Bangalore, 2024.
3) Rolls-Royce and GE Aviation, “F404-GE-IN20 Turbofan Engine Technical Manual,” General
Electric Aviation, 2023.
4) John D. Anderson Jr., Introduction to Flight, 8th ed., McGraw-Hill Education, 2015.
5) Robert C. Nelson, Flight Stability and Automatic Control, 2nd ed., McGraw-Hill, 1998.
6) Federal Aviation Administration (FAA), Aircraft Powerplant Handbook, U.S. Department of
Transportation, 2000.
7) Bharat Electronics Limited (BEL), “Digital Flight Control Computer (DFCC) Overview,” Internal
Document, 2022.
8) MIL-STD-1553B, Digital Time Division Command/Response Multiplex Data Bus, U.S.
Department of Defense, 1978.
9) ISRO, PSLV-C25 Mission Profile and Launch Report, Indian Space Research Organisation, 2013.
10) Avionics Magazine, “Understanding Modern Avionics Systems,” Avionics International, Vol. 33,
No. 6, pp. 30–35, 2021.

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