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INTERNSHIP REPORT

Pakistan Aeronautical Complex Kamra Final Report

Prepared by

Awais Ahmed Siddiqui Registaration # uw-07-EE-021

Wah Engineering College University of Wah Wah Cantt. Dated: 27th September 2010

Pakistan Aeronautical Complex, Kamra

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Acknowledgements: I would like to thank my Parents, Teachers and especially Principal Wah Engineering College Mr. Akbar Saeed Awan for giving us me this opportunity to have internship in Pakistan Aeronautical Complex Kamra where it would impossible to get it if I were studying somewhere else except Wah Engineering College. I also like to thank Director Student's Affairs Dr. Shahid whose support remained with us throughout the internship. I pay thank each and every member of staff in Technical Board PAC for his guidance and supervision this summer during my internship experience with Pakistan Aeronautical Complex Kamra. I also want to thank the entire staff in the ARC for taking the time to share their expertise and knowledge of the field. The staff was most responsive to my requests helped me in given project. My heartedly thanks goes to HRD department as well as Integration Department where experience was more than I could have expected.


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DAY 01 First day was introduction day Introduction to PAC The Pakistan Aeronautical Complex Kamra comprises of four factories which are spread over an area of 10 square kilometers. i.e. • F-6 Rebuild Factory • Mirage Rebuild Factory • Aircraft Manufacturing Factory • Kamra Avionics & Radar Factory PAC has more than 30 years of experience in Avionics, Maintenance, Repair and Overhaul (MRO) of fighter aircraft’s components and engines. Brief History In the year In the year 1972, PAC started with the MRO of aircraft of Chinese origin and subsequently progressed towards MRO of Mirage III & V aircraft and ATAR 09C engines, F100-220E engines modules of F-16 aircraft, J-69 engines of T-37 aircraft, T-56 engines of C-130 aircraft and avionics upgrades of fighters aircrafts of Pakistan Air Force. Organization Of PAC Pakistan Aeronautical Complex works under Ministry of Defense Production. However approximately 90% of its staff works under Ministry of Defense i.e. Pakistan Air Force.


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Day 02

KARF

KAMRA AVIONICS & RADAR FACTORY

It is the only avionics setup among the four factories which make the Pakistan Aeronautical Complex (PAC). It is located on the Grand Trunk road and is also linked through railway. The factory was initially established as the Radar Maintenance Center (RMC) in 1983 for overhaul / rebuild of ground radar systems but in 1989 it was transformed into a full fledged avionics factory with ability to handle airborne avionics as well. Today the factory stands with state of the art facilities and infrastructure to undertake production of any avionics equipment. KARF has proven capabilities for rebuilding of radars, control and reporting centers (CRC), generators and manufacture and repair of avionics systems. Currently it is producing ESM equipment and airborne radar systems. Being ISO-9002 qualified, it enjoys an excellent reputation for quality, reliability and customer satisfaction. The electronics


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Internship Report complex is also equipped with anti-static facilities including air shower, wrist bands, ionized air blowers, static dissipative mats and grounding terminals. All the work is properly scheduled, supervised and quality checked. Term Avionics Avionics is a blend of the words "aviation" and "electronics". It comprises electronic systems for use on aircraft, artificial satellites and spacecraft, comprising communications, navigation and guidance, display systems, flight management systems, sensors and indicators, weather radars, electrical systems and various other computers onboard modern aircraft and spacecraft MPRD (Mobile Plus Doppler Radar) There is a ground based radar service centre which is responsible of servicing all components of MPRD. A master Radar is mounted in the building of the electronics block. Ground based radars are relatively of low frequency and high range i.e. 1.2GHz~1.4GHz. Crystal oscillator is usually used to generate these frequencies.

K

Day 03 Radars are one of the most costly components of aircraft. For example, in JF17 fighter, the total avionics cost is 3million $. Among which the cost of radar is 1.4 million $. There are several ways to build radar. The cheapest way is to assemble radar is through complete knockdown kits. GRIFO RADAR: Over the past 20 years airborne fire control radar have become smarter as the advent of micro processing has improved the speed and capacity of the system to search for, track, and identify targets. At the same time, the physical size of the hardware has shrunk. Thus, it is possible for in-service fighter aircraft to be given a state of the art radar system which, in turn, allows the use of new generations of air to air missiles. Development of the Grifo pulse- doppler, multi-mode radar began in late 1980s, and following a comprehensive series of flight testing on a company owned T-39 Saberliner test bed, is considered complete. The four versions share a common architecture and much common hardware and according to the company, offer feature Pakistan Aeronautical Complex, Kamra

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Internship Report normally associated highly expensive and complex aircraft. FIAR entered the market in 1991 with the Grifo,. it is testament to FIAR's expertise that it won the competition in the face of stiff competition from British, Israeli, and American companies. Grifo is a pulse Doppler multi mode, multi roll radar operating in the X band (I/J band), featuring a planer antenna. with a performance claimed to be better than the APG-66 radar fitted to the F-16AB. it has five air to air search modes, with the capability of tracking up to eight targets, four air combat modes and nine air to surface modes.

ARC Avionics Radar Centre. Mirrage

Project ROSE (Retrofit Of Strike Element) was a programme initiated by the Pakistan in 1992 to modernize a number of its Dassault Mirage IIIand Mirage 5 fighter aircraft with new avionics, some of which were supplied by European companies including SAGEM of France and FIAR (now SELEX Galileo) of Italy. Most of the aircraft were retrofitted at the Pakistan Aeronautical Complex (PAC) in Kamra, Pakistan, others being upgraded in France. Further upgrades were under consideration but Project ROSE was cancelled due to a combination of high costs and ageing Mirage III/5 airframes. 33 Mirage III fighters, designated ROSE I, were upgraded to perform multiple mission types including air superiority and strike missions. 34 Mirage 5 fighters Pakistan Aeronautical Complex, Kamra

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Internship Report were configured to specialise in the night time surface attack role, the first 20 designatedROSE II and the last 14 aircraft ROSE III. All ROSE-modified aircraft are expected to remain in service with the Pakistan Air Force beyond 2010, being replaced by theJF-17 multi-role fighter by 2015. The repair facility available in ARC is for all three types of ROSE i.e. 

ROSE I

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ROSE II

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ROSE III

ROSE I In June 1998 the cockpit upgrades for the 33 Mirage III fighters was completed, including installation of multi-function displays (MFD), head-up display (HUD),HOTAS controls, radar altimeter and a Sagem nav/attack system. The integration of a new Italian fire-control radar, the FIAR (now SELEX Galileo) Grifo M3, gave Mirage III ROSE I fighters the ability to fire advanced beyond visual range (BVR) radar guided air-to-air missiles. ROSE II Cockpit upgrades consisted of multi-function displays, wide-angle stroke/raster HUD, HOTAS controls, SAGEM Circe 2001 mission planning system and on-board oxygen generating system (OBOGS). The cockpit was made compatible with night-vision goggles. A ventral fairing under the cockpit section of the fuselage was also fitted, containing a forward-looking infra-red (FLIR) thermal imaging sensor and laser range-finder. An integrated electronic warfare suite and single-point pressure refueling system were also installed. ROSE III In the late 1990s, 33 Dassault Mirage 5F fighters were bought from France, 14 of them upgraded to ROSE III standard with a FLIR and other systems/modifications circa 2004.[A follow-up to ROSE II, this upgrade gives an improved night-time precision strike capability to the Mirage with the addition of a new SAGEM navigation/attack avionics suite. ROSE system is subdivided into three main parts. 

Display


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Internship Report 

Navigation

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Interface system

Display segment consists of following parts: 

Pilot display Unit.

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Mult-function Display

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Hard electronis Unit.

Nevigation segment consist of following parts: 

Centre Display Unit

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FLUR

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GPS (global positioning system)

Interface Group: This segment consists of following part: 

1553 Bus

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Stick

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Failure Pannel

Weak 4 Integration Block Avionics Aircraft avionics

The software written for the JF-17's avionics totals more than one million lines of instructions, incorporating the concept of open architecture. Rather than using the Ada programming language, which is optimised for military applications, the software is written using the popular civilian C++ programming language to better utilise the large number of civilian software programmers available. Avionics equipping the JF-17 prototypes used the Motorola 88000 microprocessor, which can be changed to othermicroprocessors of the same class. The redesigned PT-04 prototype JF-17 had more advanced avionics than its predecessors, which are included on the production version of the aircraft.


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Internship Report The aircraft's glass cockpit incorporates an Electronic Flight Instrument System (EFIS) and a wide-angle holographic Head-Up Display (HUD), which has a minimum total field of view of 25 degrees. The EFIS is made up of three colour multi-function displays (MFD) providing basic flight information, tactical information and information on the engine, fuel, electrical, hydraulics, flight control and environment control systems. The HUD and MFD are "smart", meaning they can be configured by the pilot to show any of the available information. Each MFD is 20.3 cm (8 in) wide and 30.5 cm (12 in) tall, arranged side-by-side in a portrait orientation (height greater than width). The central MFD is placed lower down to accommodate an up-front control panel (UFCP) between it and the HUD. But in JF17 thunder the HUD is in its modified form and called SHUD (smart Head-up Display) The People's Liberation Army Air Force (PLAAF) experienced problems with the HUDs of its Russian designed combat aircraft, these tended to fog up due to deployment in humid sub-tropical and tropical zones. The Chinese HUD fitted to the JF-17 was developed to ensure this problem would not occur when deployed in any environment. Western HUDs can be incorporated directly onto the aircraft, if desired by the user, with little effort due to the modular avionics design and the adoption of the MIL-STD-1553B databus architecture. Information from the onboard radar can be displayed on the head-down multi-function displays or projected onto the HUD, the latter feature believed to have been inspired by the HUDs of Russian aircraft. This enables the pilot to keep his eyes focused at infinity so that he can simultaneously view radar images and monitor the airspace around him, without having to re-focus his eyes. Monochrome images from electro-optical navigation/targeting pods carried by JF-17 can also be projected onto the HUD. The aircraft has a composite flight control system (FCS), comprising conventional controls with stability augmentation in the yaw and roll axis and a digital fly-bywire (FBW) system in the pitch axis.


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VISIT DSI (Dynamic System Integration Lab) In DSI lab there is a complete model of avionics of JF17 thunder fighter. Basic purpose of this model is to provide an environment to the developers to validate their modified applications in plane. There is a simulated cockpit same as the original cockpit of jf17 thunder. It is used for pilot’s training as well as system engineers to test there software and hardware programs. LRUs (Line Replaceable Units) are mounted in series and interfaced with mission computer through 1553 bus. Line Replaceable Units  Radar Warning Receiver: Its is the system that warns the pilot that his plane is being monitored by enemies radar. Its also sends a continues warning in case the plane is locked.


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 Tactical Air Navigation: This system is used during the Air Shows when planes makes a formation.  Radio voice communication With the help of this system, pilot can communicate with other planes and to the ground verbally.  Identification of Friend and Foe: This enables a pilot to differentiate between friend and foe.  Inertial Navigation system With the help of inertial navigation system, the positon of plane with respect to a static point is determined.  Instrument Landing System An ILS is a ground-based instrument approach system that provides precision guidance to an aircraft approaching and landing on a runway, using a combination of radio signals and, in many cases, high-intensity lighting arrays to enable a safe landing during instrument meteorological conditions (IMC), such as low ceilings or reduced visibility due to fog, rain, or blowing snow.  Optoelectronic Self Protection this is a defense system in which plane emits flairs and metallic strips to deceive guided missiles and radars.


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PROBLEMS Although this was a marvelous experience to work in laboratories with state of the art equipment and having top professionals of country but the problem was that our internship program was out of their regular internship schedules and vacation of Eid were also included in that four weeks span. We submitted an application to extend this duration for one more week to compensate this gap but this request was rejected.


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