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Nimrod Simulator
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Academic period: 2013-2014
Development of Nimrod Flight Simulator to Teaching Aide Standard.
Student Name: Pavan Kumar Tirumala
Academic period: 2013-2014
Student I.D: 10011066
Date of Submission: 12/05/2014
Abstract:
Student I.d:10011066 Page 2
The main theme of the report is the development of the Nimrod flight
simulator to teaching aide standards. The simulator needed to be modified into
an A320 model replica simulator, and also provides the hurdles faced to achieve
the final goal. It also includes the information about the lessons that is learnt by
the author during the project.
Contents1. Introduction:......................................................................................................................6
Student I.d:10011066 Page 3
2. Aim and Objectives:........................................................................................................9
3. Research and practical activities:..............................................................................10
3.1. PRINCE 2:.................................................................................................................10
3.1.1. Advantages of PRINCE 2:.............................................................................11
3.2. Design and construction of the frame:.............................................................11
3.2.1. Design Frame:.................................................................................................12
3.2.2. Modifying the simulator:...............................................................................14
3.2.3. Purchase Equipment:....................................................................................15
3.2.4. Build the frame:...............................................................................................15
3.2.5. Assembling frame to Simulator:.................................................................16
3.3. Primary Flight Controls:.......................................................................................16
3.4. Autopilot Systems:.................................................................................................18
4. Procedures followed during the Practical Activities:............................................20
4.1. Metal Cutting:..........................................................................................................20
4.1.1. Metal cutting band saw:................................................................................20
4.1.2. Hydraulic Guillotine Sheet Metal Machine:..............................................21
4.1.3. Hacksaw cutting:............................................................................................21
4.2. Welding:....................................................................................................................22
4.3. Grinding:...................................................................................................................23
4.4. Metal Bending:........................................................................................................24
4.5. Drilling:......................................................................................................................25
4.6. Soldering:.................................................................................................................26
5. Analysis:...........................................................................................................................28
6. Conclusion:......................................................................................................................32
7. Recommendations:........................................................................................................34
8. Acknowledgements:......................................................................................................35
9. Bibliography..................................................................................................................36
10. Diagram not included in the text:...............................................................................37
List of abbreviation and symbols:
Student I.d:10011066 Page 4
Abbreviation:
CDU - Control Display Unit.
FCU - Flight Control Unit.
LED - light-Emitting Diode.
CPU - Central Processing Unit.
Symbols:
AND gate
OR gate
1. Introduction:
Student I.d:10011066 Page 5
Technology is the key part in the development of all the human race. By
using and developing the technology we are creating new equipment that are
widely used in the human race. Introducing Flight Simulators a great way of
practicing aviation skill and gain flying experience on the ground, which is the
best way of attaining virtual reality. Simulators are the replicas of the real
instruments that are representing the operation of the real system over time. The
act of simulation first of all requires to develop a model which has all the
characteristics and the functional behaviour of the real system. By simulating the
model we can test, train and can also used for the educational purposes. Now a
day's these simulators are widely developed in all fields, especially in the
aviation industry because everyone can get access and get easily trained or get
educated without any risk or damage of the property, this is the very main
reason for adopting these simulators.
Student I.d:10011066 Page 6
1
Figure 1- Typical Flight Simulator.
The background of this project is to develop the existing Nimrod flight
simulator that in the college to the teaching aide standards of the Airbus A320.
To acquire these standers the author has to gain some knowledge on the
simulator hardware and software and has to identify where the simulator need
some developments and the parts that are needed to be replaced, for the in-
class teaching aide standard the author has to get the simulator breakdown the
complete simulator into two half's and on the wheels so that the simulator can
be easily moved to other classes for presentations. And connecting all
hardware components to the software is also required to function all the other
instruments working simultaneously.
1http://img.tomshardware.com/us/2008/03/06/aircraft_simulators_get_multi_gpu_graphics_horsepower/425pixcae5000.jpg
Student I.d:10011066 Page 7
The following report will provide a clear idea of how the author tried to
achieve the objectives, and what are the problems faces or involved in the
objectives and his management to overcome those problems. And it also
represents the initial planning to reach the objectives by preparing the Gantt
charts and risk registers so to attain a pre-knowledge of the risk involved in this
particular project. It also illustrates the topics that are learned by achieving these
objectives, and the reason behind why this project is chosen and how the
students are going to attain benefited by doing this project. This report also
provides information on all the research and the practical activities carried out to
achieve his objectives, significant factors identified and studied.
2. Aim and Objectives:
Student I.d:10011066 Page 8
The main Aim of the project is the development of the Nimrod flight
simulator to teaching aid standard. It can achieve that by classifying the main
objective into three sub objectives, they are
Even though there are some sub objectives involved in each and every
objective the report will clearly discuss about those sub objectives and what the
research had done and practical activities he has gone through to achieve these
objectives.
3. Research and practical activities:
Student I.d:10011066 Page 9
Autopilot system
Primary flight controls
Design and construction of the frame
On the day of the project chosen the investigation and planned for each
and every objective were done. This completed project is designed depending
on the PRINCE 2 model.
3.1. PRINCE 2:
PRINCE 2 stands for "Project In Controlled Environment", Its a
project management framework which helps to plan, manage and control
the project. Generally projects will deliver products the organization
needs changes or outcomes, for example more efficient working
practices, that can be measured in the form of the benefits. It is a cycle as
shown in the figure 2 with the Starting and initiating, Planing and
directing, Stage control, stage management and ends with the closing of
the project.
2
Figure 2- PRINCE 2 Model.
3.1.1. Advantages of PRINCE 2:
2 http://siliconbeach-media.s3.amazonaws.com/legacy/blog/uploads/2012/11/Prince-2-phases.jpg
Student I.d:10011066 Page 10
Suitable for any type of project or industry.
Based upon best Practices.
Can be tailored to suit your project.
The author has divided the entire project into three major objectives, they
are
1. Design and construction of the frame.
2. Primary flight controls
3. Autopilot system
3.2. Design and construction of the frame:
All the investigation has been done for the modification of the
simulator. For each and every objective the research is done and consult
the project coordinators and other professors to seek some advices from
them, and attain the best high quality standard outcomes. The research
for required materials is also done like the properties of those materials,
and has to purchase them looking at the budget that how much money he
is willing to spend on them. He had divided this objective into five sub-
objectives, so to get the step by step results in each and every stage. As
shown in the figure 3 he has divided the objective as
Design Frame
Modifying the simulator
Purchase Equipment
Build the frame and
Assemble the simulator to the Frame.
Student I.d:10011066 Page 11
Figure 3- Classifing the design and construction of frame objective.
Along with these objectives, the external screens which have already
fitted to the frame need to be cut down a bit to get the screens in position.
Which helps to move the simulator to other classes if necessary. The
report is provided with all the investigation and practical work that is done
on the each and every Sub-Objectives.
3.2.1.Design Frame:
Multiple designs were referred while designing the frame and came
out with a final design which is high reliable and had high strength to
carry the simulator. All the final designs for the simulator are shown in the
below diagrams, Figure 4 was designed to carry the base part of the
Nimrod simulator, Figure 5 was designed to hold the Glare shield part of
the Nimrod simulator, and the Figure 6 was designed as a throttle holder
to carry the A320 model throttles.
Student I.d:10011066 Page 12
Design and Construction of frame
Design Frame
Modifying the simulator
Purchase equipment
Build the Frame
Assemble frame to simulator
Figure 4- Dimensions of the base frame of simulator.
Figure 5- Dimensions of the glare shield frame of simulator.
Student I.d:10011066 Page 13
Figure 6- Dimesions of the throttle Holder.
3.2.2.Modifying the simulator:
The Simulator had stripped down the complete and stored all the existing
control panels into the safest place to avoid the damage. The simulator is also
dismantled into two parts with the help of the project coordinators so that the
frame can be easily carried from the class to workshop. The control column
holder had removed to modify the simulators Side Stick into into A320 model
Side Stick.
3.2.3.Purchase Equipment:
Student I.d:10011066 Page 14
A investigated is done for the selection of equipment which are
required to build the frame, and chosen mild steel to build the frame. By
consulting the workshop professionals the purchase of materials needed
for the project is done. The project coordinator had ordered all the
equipment needed.
3.2.4.Build the frame:
Several manufacturing procedures were referred for the construction of
the frame because, to attain a better and efficient outcome for the objectives.
Even though the availability of the workshop is less the task need to be finished
within the time. This can be achieved by making the proper management of the
time. Safety precautions for the workshop like wearing overalls and boots are to
be considered while constructing the frame. In the workshop there are different
procedures which are required to build the frame they are
Metal cutting
Welding
Grinding
Metal Bending
Drilling
The discussion about these procedures and work done for the
construction of the frame by using these methods were described in the
section 5 of this report.
3.2.5.Assembling frame to Simulator:
Student I.d:10011066 Page 15
The frame is constructed according to the pre-planned designs and
assembled it to the simulator. Holes are also drilled into the frame for the
bolts to assemble the frame to the simulator. A hand drilling machine is
used for the drilling while fixing the base of the simulator to the frame
drilled the simulator using the. Coming to fix the glare shield of the
simulator the a problem occurred that initially planned for welding the
catches to the frame and then realized that the catches are not made of
steel and it can't get welded to the frame. A solution comes out to solve
this problem that by making some plates to the catches that can get fitted
with bolt and nuts so that the plates can be welded to the frame. After
finishing all the assembly another problem appeared that the wheels are
getting stuck to the bolts fitted to the frame, that eventually decreases the
rotation of the casters. To avoid this the excess part of the bolt is
removed so that the casters can easily rotate through 3600. And also
removed the excess part of the bolt of the throttles holder by grinding
because to give some space to the CDU holder.
3.3. Primary Flight Controls:
Primary flight controls are necessary for the manoeuvrability of the
aircraft. They are Ailerons, elevators, rudder, Landing gear and Throttles.
The ailerons and the elevator are controlled by the Side stick and the
rudder by the rudder pedals. So the report focus on the four objectives
that are shown in the diagram below. More concentrated on the primary
flight controls is done because, it is the primary priority of the Simulator to
Student I.d:10011066 Page 16
give access to the primary flight controls to the customers. According to
the objective modifying the existing flight control systems to an A320
model side stick and the throttles. A Side stick is purchased that looks
similar to the A320 model side stick and also bought the replica of the
A320 model throttles. The rudder pedals are available along with the
simulator under working conditions. All these controls are the plug and
play models so all the work needed to do is to connect the controls to the
software. An additional frame is need to be build for the side stick to fit on
it, So by using the wooden frame which available in the collage with the
required dimensions for the side stick and assembled a metal sheet on
that wooden frame to fit the side stick on the top of the plate.
Figure 7- Primary flight controls
Student I.d:10011066 Page 17
Flight controls
Side stick
Throttles
Rudder pedals
Landing Gear
The simulator is needed to be fitted with flaps and slats levers to
the so it is necessary to purchase all the landing gear and the flaps and
slats levers. But all the money is spent on rest of part and crossed the
budget limit, so the Project supervisor suggests not to buy these levers to
cross the budget. Instead of buying these levers there are another two
options which are by modifying the existing bomb door leaver into a
landing gear lever or by installing a switch for the landing gear and linked
to the software to lower or raise the landing gear using the mouse.
3.4. Autopilot Systems:
The existing FCU was fully damaged that the only LED lights are working,
most of the dials and the rotary switches went missing from the autopilot
system. So it is initially planned to change the complete FCU module, but
the price of the FCU is very higher than the given budget, so by
contacting his supervisor and discuss the problem and got some
suggestions from him. The Supervisor suggested that rather than
purchasing a new module make the existing module to work and make
the functional. So the author had examined the full autopilot system
module and realized that some of the cables were broken and the
switches that are remaining were not working, so soldering is done to
those switches which are not working and fixed them. And also marked
all the wires which are coming out of those switches. Investigated to
purchase the dials and a rotary switch that went missing and later
Student I.d:10011066 Page 18
realized that, the switches which are required need to fit to the FCU are
not available in the market so build some looks similar to those switches.
Figure 8- Classification of autopilot system objective.
As shown in the figure above, there is a necessity to work
on both the Hardware and the software of the FCU. A program is needed
to be written using the SIOC software. The program needed to write is to
get the output to the displays and has taken command from all the dials
and switches.
Student I.d:10011066 Page 19
Autopilot system
Hardware
Make all switches functional
Buy switches that are missing
Software Modify software after assembling.
4. Procedures followed during the Practical Activities:
As explained in the above section 4.2.4 The report had gone through six
different procedures that are involved in reaching the final outcomes. All the
procedures used are listed below.
Metal cutting
Welding
Grinding
Metal Bending
Drilling &
Soldering.
4.1. Metal Cutting:
There are three different types of metal cutting that are available in
the market today, these are the three procedures which are required to
finish these objectives, they are.
Metal cutting band saw
Hydraulic Guillotine Sheet Metal Machine
Hacksaw cutting
4.1.1.Metal cutting band saw:
Clarke's superb metal cutting band saw is engineered specifically
for daily use in many engineering plants, fabrication workshops &
garages. It boasts a powerful motor & adjustable cutting blade speeds to
Student I.d:10011066 Page 20
effortlessly cut through ferrous & non-ferrous metal & alloy tubes, bars &
profiles. It also benefits from adjustable, bearing mounted blade guides
for accuracy. The coolant has been continuously flowed to decrease the
temperature developed during cutting the metal bars.
4.1.2.Hydraulic Guillotine Sheet Metal Machine:
The machine may be foot powered or mechanically or hydraulically
powered. It works by clamping the material with a ram first. A moving
blade, then comes down across a fixed blade to shear the material. For
larger shears the moving blade may be set on an angle or "rocked" in
order to shear the material progressively from one side to the other; this
angle is referred to as the shear angle.
4.1.3.Hacksaw cutting:
A hacksaw is a fine-tooth hand saw with a blade held
under tension in a frame, used for cutting materials such
as metal or plastics. Handheld hacksaws consist of a metal arch with a
handle, usually a pistol grip, with pins for attaching a narrow disposable
blade. A screw or other mechanism is used to put the thin blade under
tension. The blade can be mounted with the teeth facing toward or away
from the handle, resulting in cutting action on either the push or pull
stroke. On the push stroke, the arch will flex slightly, decreasing the
tension on the blade, often resulting in an increased tendency of the
blade to buckle and crack.
Student I.d:10011066 Page 21
The person who is working on these machines must wear the
safety glasses and the gloves for the health and safety. And the
individuals have to make sure they have to turn off the power switch off
after finishing the usage of the machine.
The metal pieces were marked with the dimensions which is
required and as designed before. The mild steel metal bars that have
used in this report is about 30 mills so that metal cutting band saw is
used. By using this saw the metal bars were cut down with their
dimensions by following all the safety requirements. And used the hand
saw to cut the ribs of the simulator to fix the throttle holder in the position.
The Hydraulic Guillotine Sheet metal cutting machine is also used to
make the throttle holder because the metal sheet used in the holder is
about 2 mills and it is easy to cut the metal using this machine accurately.
This is done by making design and mark the sheet as per "Diagram 3". All
these processes were very risky, so all the safety procedures as
mentioned above were followed.
4.2. Welding:
The process of joining together two pieces of metal so that
bonding accompanied by appreciable inter-atomic penetration takes
place at their original boundary surfaces. The boundaries more or less
disappear at the weld, and integrating crystals develop across them.
Student I.d:10011066 Page 22
Welding is carried out by the use of heat or pressure or both and with or
without added metal.
The machine works at the very high temperatures so there is a
need to wear the Industrial grade auto darkening helmet, heavy duty
gloves, apron and the safety boots.
All the metal bar has to be joined together to build the frame, so
this process is chosen for it. All the joints were attached and the corners
with the help of welding. All the casters were assembled to the frame by
using this process. There is a problem while fixing the catches to the
frame and it is resolved by making a metal plate that supports the catches
while welding. Welding is a difficult process and the author is not allowed
directly to work on this process due to health and safety, so with the help
of workshop professors welding the required parts is done.
4.3. Grinding:
When the surface of the metal has to be smooth and of a very high
quality a grinding machine may be used. A grinding machine consists of
an abrasive wheel which turns while in contact with the metal, thus
wearing the surface down. It is also used to decrease remove the excess
part of the metal using the grinding machine with the doing the
hammering action.
Student I.d:10011066 Page 23
The author has to wear the safety glasses and gloves when work
is carried out using both these machines. He has to make sure the power
is turned off after the work and he has to very careful with the grinding
wheel while working on it.
The author faces a problem that the simulator is not standing on
the frame, because it got some glitzes below the simulator. To overcome
this he has to grind those glitzes below the simulator. He also has to grind
the excess part of the bolt which are used to assemble the frame to the
simulator, Because the excess part of the bolt is obstructing the casters
to move freely.
4.4. Metal Bending:
In folding, clamping beams hold the longer side of the sheet. The
beam rises and folds the sheet around a bend profile. The bend beam
can move the sheet up or down, permitting the fabricating of parts with
positive and negative bend angles. The resulting bend angle is influenced
by the folding angle of the beam, tool geometry, and material properties.
Large sheets can be handled in this process, making the operation easily
automated. There is little risk of surface damage to the sheet using this
process.
Student I.d:10011066 Page 24
With the help of Standard sheet metal hand brake machine, the
metal sheets were bent and are used in the design to hold the throttles.
The sheet has been marked and drilled as designed and it has to be
bend the two ends of the frame to fit the holder between the ribs of the
Nimrod simulator. The procedure which is followed to finish this tasks
were mentioned in the above part of the report.
4.5. Drilling:
Drilling, on the one hand, consist of a drill bit which is applied to the
metal using a combination of force and rotation, and which therefore cuts
through it. Thus, a hole of the required size will be cut right through the
metal in question. There are two different types of the drilling machines
1. Hand drilling
2. Machine drilling
The hand drilling works as similar to the machine-drilling, but the we
can easily carry it to the other places and can work on the materials where
we get less access to the specimen, but the person who is working on it must
apply some physical load to drill hole into the specimen. Coming to the
machine-drilling there is no need to apply any load, all the person has to do
is change the gear depending on the thickness and the material that going to
be getting drilled, and he has to hold the specimen to get drilled in position.
Student I.d:10011066 Page 25
The safety glasses and gloves were necessary when work is carried
out using both these machines. The drill bits must be removed and has to
turn the power off after finishing the work.
They are two different drilling machines to finish the task, those are
machine-drilling and the hand drilling. The firstly used machine is machine
driller to make holes in the frames and the plates that are used to fix the
catches. The author has also used this machine to drill holes on the metal
sheet for the throttle holder. The secondly used the hand Drilling machine to
drill holes on the simulator because he can't get the simulator in the position
of the machine, drilling and the other problem very little access to drill in
some holes inside the simulator to fix the frame. And also used the hand
driller to drill in some holes through the base and the glare shield parts of the
Nimrod simulator to lock both these parts when the simulator is assembled
together. Maintained a standard of 6.1 mills holes on all the simulator. And
used 3 mills drill the fit the screws through the metal sheet and the wooden
frame used to fit the A320 model Side side.
4.6. Soldering:
Soldering is a process in which two or more metal items are joined
together by melting and flowing a filler metal (solder) into the joint, the
filler metal having a lower melting point than the adjoining metal.
Soldering differs from welding in that soldering does not involve
melting the workpieces. In brazing, the filler metal melts at a higher
Student I.d:10011066 Page 26
temperature, but the workpiece metal does not melt. In the past,
nearly all solders contained lead, but environmental concerns
increasingly dictated the use of lead-free alloys for electronics and
plumbing purposes.
The method is used to fix the autopilot switches. Most of the
switches, wires were broken and remaining got shorted, so it requires
to attach some new "single core aluminium" wires to the switches and
had removed the excess soldering the rest of the switches were the
switches are shorted. And has also named all the wired coming out
from each and every switch, and fixed all the earthing wire into one
single wire.
Student I.d:10011066 Page 27
5. Analysis:
The main need is to get the Nimrod flight simulator and the screens to move
from one class to another for the demonstrations and the control column of the
simulator has to be modified with the control columns to an A320 model
simulator by modifying the control column with the side stick and A320 replica
model throttles. The author has learned time management, Quality management
activities and how to manage the risks that are involved in the project. The
author has divided the complete project into some sub objectives and also show
that what the issues he faced with those objectives and how he overcome those
issues and finished them are shown in the table below.
Objective Review
Investigation All the investigation has been done for the modification of the
simulator. For each and every objective the Author had done the
research and consult the project coordinators and other professors to
seek some advices from them, to get the best high quality standard
outcomes.
Design and
Construction of the
Frame
The work had gone through multiple designs while designing the frame
and came out with one final design which is high reliability and also
have high strength to carry the simulator with the help of the project
supervisor. And also consulted workshop professors to select the best
metal to work on and all the other parts required to build the frame.
Even though he faced some difficulties with the availability of the
workshop, All the frame has been built and locking mechanism has
Student I.d:10011066 Page 28
been assembled between the two simulator frames. The author has
managed time to get to the workshop and get hands on the job.
Modifying the
simulator
The Simulator had been stripped down completely and stored all the
existing control panels in the safest place to avoid the damage. And
also dismantled the simulator with the help of the project coordinators
so that the frame can be easily carried from the class to workshop and
removed the control column holder because to modify the simulator
into A320 model Side Stick. All the work is done to build the frame for
the simulator and to build the frame for the side stick and a throttles
holder.
Assembling frame
to the simulator
All the frame for the simulator and the side stick had been built and the
frame has been assembled to the Nimrod simulator and wheels has
been assembled to carry the simulator easily for the demonstrations.
Even the length of the screens has been decreased a bit to move
easily from one class to another. They are two different problems
While assembling frame to the simulator arises.
The simulator is not standing on the frame, because it got
some glitzes below the simulator. In order to overcome
this problem grinding process is appropriate and used to
eliminate those glitzes below the simulator.
Another problem is also solved by grinding the excess
part of the bolt which are used to assemble the frame to
the simulator, because the excess part of the bolt is
obstructing the casters to move freely.
Student I.d:10011066 Page 29
Refurbishing the
autopilot system
The Autopilot system has been several damaged elements and most
of the switches and dials were missing and remaining switches are not
functioning properly. So the available switches were repaired and
bring them back to working condition and left the remaining dials
because they are not available in the market, and didn't get enough
time to build them. Even though there is another option to buy a new
FCU, it is much expensive and increasing the budget, and it's wise to
buy a new module rather than making use of the available autopilot
unit.
Constructing frame
for joystick and
holder for throttles
The frame had to be built separately for the simulator, the main
purpose of this frame is to hold the throttles right is positioned, it is
simple and light in weight to carry to other classes. The holder for the
throttles also been designed and fitted in the simulator so that the it is
helpful in fixing the throttles right in position. Specific dimensions of the
throttles were taken so to make sure that the trim wheels can rotate.
And also drilled the throttle holder and fixed to the frame using bolts
and screwed the metal plate to the wooden frame.
Connecting control
columns to the
Software
So far all the control surfaces were assembled to the simulator and
also all the screens were fitted, but there is a technical problem with
the second CPU (central processing unit) so the control columns were
not connected to the software so far. Once if the CPU is back in
function, it is easy to connect all the control columns to the software.
The author had also provided the risk management strategy and the Gantt chart
in the initial report and he had changed the initial plan because of some
Student I.d:10011066 Page 30
personal issues and had the conversation with one of the project supervisors
and had changed the plan in the mid check point report. Coming to the "Quality
management systems" a good reporting culture is maintained with the project
supervisors and kept a "Logbook" which contain the record of all the work done
and also carried from the beginning to the end of the entire project. And also
consulted his project supervisor every week to report and update the work status
of the project and also to inform the issues which are interrupting the objectives.
The budget had been planned and it is of about 500 Pounds. It is planned
to invest some of the money on the frame, tolls and also needed to finish the
frame. A new side stick, and A320 model throttles were bought to replicate the
Simulator into Airbus model. And some part money is spent on the LED lights to
make the simulator more illuminate and make sure that all the control surfaces
are visible. Even though there is a thought of purchasing the Landing gear, flaps
and slats levers which are expensive but it has already crossed budget and the
supervisor told not to spend any more money on it and suggested that to modify
the bomb door available on the simulator into a landing gear lever. There is no
time left behind to do the further modifications like the lever to landing gear. And
there is some other work left behind which is to connect all the control columns
to the software because of the malfunction in the CPU, and when the problem is
solved the task can be completed easily. By maintaining a good desired
procedures and safety the output will reach to the customer quality expectations.
Student I.d:10011066 Page 31
6. Conclusion:
The main theme of the project is to develop the Nimrod Flight simulator to
Teaching Aide Standard. Initially the author planned to modify the simulator into
A380 model simulator, but due to the lack of resources he changed the aim to
modify the simulator into the A320 model. Even though the aim and objectives
are so clear the author has to plan the complete project in the format of the
PRINCE 2. The project had been classified into three sub objectives. Initially the
complete simulator is stripped down and had to store all the control panels and
the control columns into the safe to avoid the damage to the simulator. Later on
he has dismantled the simulator into two parts so that he can easily carry the
simulator from one place to another. The primary goal is to design and build the
frames fixed with casters for the simulator, so that it will be easy to carry the
simulator from one place to another.
To build the frame there is a need to go through several processes, so he
learned all this process which is required to build the framework. Even though
he has finished the frame there are some problems like glitches taken place
while assembling the frame to the simulator, so he has Grinded the glitches that
are causing problem while assembling. After the assembling of the frame there
is an another issue arose that the bolts are obstructing the caster rotation, so he
also Grinded the excess bolt to solve this problem. By doing all this process the
author has learned to manage the time and he maintains a good reporting
culture to maintain Quality management activities. He also maintained a log
book so that he can record all the work he had done in a book. One of the
Student I.d:10011066 Page 32
objectives is to modify the existing control column to A320 model simulator, so
to do that the author has built a frame for the side stick and also a holder for the
throttles. He bought an A320 model side stick and the throttles, both of them are
plug and play models so that they can easily programmable to the Simulator
software. The LED strip light was bought to replace all the lights that are not
functioning in the glare shield part of the simulator. Even though he still have to
buy the landing gear and the flaps and slats levers the author haven't bought
them due to the increase in the budget in the project.
The author had missed the initial planning of the project due to some
personal issues and to decrease those he had arranged a meeting with the
group coordinator and modified the plan to decrease the delay impact on the
project, and have made a new Gantt chart at the time of the checkpoint report.
Even though he changed the plan he didn't achieve the complete project due to
the lack of time and the budget issues where he had faced a problem with it.
Due to the delays caused to build the frame because of the very less availability
of the workshop he is simultaneously doing work on the rest of his objectives.
He bought the best side stick and throttles within his budget and done some
work on the FCU. Even though the author had planned for the purchase of a
new autopilot system, The new FCU is expensive and he wants to work on the
existing FCU and done soldering to the malfunctioned switches and made them
fully functional and marked them. Even though he finishes the work he need to
wait until the completion of the construction and assembling the frame. Until
then he cannot assemble the control columns and the control panels to the
Student I.d:10011066 Page 33
simulator. Even though after finishing of the framework and assembled all the
panels to the simulator he got a problem that one of the CPU is not functioning,
so he cannot connect the control columns & the panels to the software until he
resolves the problem with the CPU. Which is being reported to the necessary
project supervisor and requested to resolve this problem. If it is resolved the
thing like attachment of the control columns and panels of the software will be
simplified.
7. Recommendations:
To increase the quality of the project the author would like to give a couple of
recommendations to get the better outcomes than what he had expected
It’s a big project and the college has to increase the budget for these
kind of projects.
Still need to buy landing gear, slats and flap levers that are needed to
get increase the simulation experience.
Autopilot system has to be refurbished and has to make it fully
functional.
The college has to provide better functional CPU to increase the
functionality of the simulation.
Allocating a room for the flight simulator will helps to store and can
get more access to work on it will decrease the time pressure on the
author.
Student I.d:10011066 Page 34
8. Acknowledgements:
First and foremost I offer my sincerest gratitude to my supervisors,
who had supported me throughout my project with his patience and
knowledge whilst allowing me the room to work in my own way.
In the workshops I have been aided for an academic year in running
the equipment by Mr Kevin and Mr Alster. In my daily work I have been
blessed with a friendly and cheerful group of fellow students. The Aircraft
Engineering Department has provided all the support and equipment I
have needed to produce and complete my project.
Finally, I would like to thank my parents for supporting me throughout
all my studies at University, and college library acting as a home in which
to complete my writing up.
Student I.d:10011066 Page 35
9. Bibliography:(n.d.). Retrieved dec 4, 2014, from www.clarketooling.co.uk:
http://www.clarketooling.co.uk/tools/Metal_Cutters__Shears__Folders___Formers.html
(n.d.). Retrieved feb 24, 2014, from thelibraryofmanufacturing.com: http://thelibraryofmanufacturing.com/sheetmetal_bending.html
(n.d.). Retrieved March 20, 2014, from www.lekseecon.nl: http://www.lekseecon.nl/sioc.html
(2014, may 12). Retrieved March 3, 2014, from www.listoftools.com: http://www.listoftools.com/soldering/soldering_procedure.html
ASTM, D. m. (2002). Retrieved feb 20, 2013, from metals.about.com: http://metals.about.com/library/bldef-Welding.htm
Bland, D. J. (2003, march 15). Retrieved March 12, 2014, from www.cmp.liv.ac.uk: http://www.cmp.liv.ac.uk/frink/thesis/thesis/node2.html
Metals, C. (2012 , July 24). Retrieved Jan 12, 2014, from www.castlemetalsuk.com: http://www.castlemetalsuk.com/blog/different-forms-processes-metal-cutting/
Ryan, V. (2009). Retrieved feb 12, 2013, from www.technologystudent.com: http://www.technologystudent.com/equip_flsh/hacksw2.html
Student I.d:10011066 Page 36
10.Diagram not included in the text:
3
Figure 9: A320 model side stick.
4
Figure 10- A320 model throttles.
3 http://i.ebayimg.com/t/Logic-3-PC-Pro-Flight-2-JS282-Vibrating-joystick-force-feedback-USB-/00/s/MTE5NVgxNjAw/z/N5cAAOxy0bRTGKLm/$_35.JPG4 http://www.fsthrottles.com/images/A320trim1thumb.jpg
Student I.d:10011066 Page 37
Figure 11- Stages to do the Final Assembly.
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