India's "Diamond"
Sergei Mikhailov / Moscow
At the end of 1970. India's
thinking about replacing
the MiG-21, then be a basis of
fighter aircraft of national air
forces. In the
long term, re-emerging just in 1981. noted that
"MiGs" worn out by mid-1990's and the Air Force would lose about
40% of its fighter fleet.
The project, known as LCA (Light
Combat Aircraft - light combat aircraft), should have been,
first and foremost, to serve as air defense fighters. The
task of supporting
ground troops then considered only as a secondary. The
machine was supposed to be highly manoeuvrable and have the
most modern avionics
and weaponry. In
addition, the plane was supposed to be affordablefor
military budget of the country, as until 2000
the Air Force planned to replace the 230 MiG-21
on the LCA. The
first flight of the prototype was scheduled at the turn of
1990-1991. No
less important was
the desire to give impetus to the development of the
national aircraft industry. After
gaining political India has sought to obtain and economic
independence, at least in strategically important areas, to
which be seen as members and aviation. Therefore,
during the formation of the concept of LCA there was a
government program "confidence". In
order to achieve what was planned to solve the most complex
in India's problems, namely
create your own: a system-wire aircraft control,
multifunction radar and modern turbofan engine.From the
beginning, participation in the program of foreign partners
was limited. Nevertheless,
in the early stages, only as a temporary measure, permits
the use of imported components, which gave the domestic
industry time to create your own samples. Today,
India is already well aware of how naive and optimistic
forecasts were thirty years ago ...
But to move forward is needed basis. India
intended to create their own fourth-generation fighter,
which is impossible without a national engineering school. And
now boast was nothing special. In
1955, based on experience gained in developing the first
national TCB HT-2, and on licensed production of British
fighter jets de Havilland Vampire FB.52 and T.55 corporation
Hindustan Aeronautics Limited (HAL) has begun to develop
their own multi-purpose jet fighter plane Marut.Its chief
designer was a German aircraft designer Kurt Tank - the
creator of the famous fighter FW 190. In
August 1956, when it started designing "Maruta" in HAL there
were only three Indian design engineer, and all personnel
bureau consisted of 54 employees. In
1962, the Indians have mastered the licensed production of
British light fighter Folland Gnat F.1, on the basis of
which they themselves have developed Gnat Mk.ll Ajeet. At
the same time period, based on a British jet TCB Jet Provosl
appeared his Indian analogue HJT-16 Kiran. From
1969 to 1975, HAL has made an attempt to create an
independent fighter, but to cope with the task failed. Small
power engineering corporation engaged in fine-tuning
aircraft Ajeet and Kiran. By
the beginning of the first studies on LCA talking about some
kind of continuity between generations of developers have
been impossible. Those
who designed the Marut (primarily German specialists), long
retired, but the real future designers of LCA in those years
were still boys.
In these circumstances, in 1983, a research organization in
India Defense - Office of Defense Research and Development
DRDO (Defence Research and Development Organisation) - got
permission to start a program to create a light combat
aircraft.
In 1984, the Government of India organized an aviation
development agency - ADA (Aeronautical Development Agency),
to which, and given the task of managing the program LCA.
LCA is often referred to as the brainchild of HAL, but the
corporation is only responsible for production of the
aircraft, and its developer - ADA. In
essence, this consortium, bringing together over one hundred
laboratories, industry and academic institutions. Formally,
the agency is part of the DRDO. Its
headquarters is located in Bangalore, just a mile from the
office building HAL. The
management structure ADA consists of three levels: Technical
Committee (Technical Committee) (Chairman - General Director
of ADA, Co-Chair - President HAL), JMA (Governing Body)
chaired by the Scientific Adviser to the Minister of Defence
and the General Authority (General Body) chaired by the
Minister of Defence . In
addition to program management LCA, ADA responsible for
avionics and software development.
ADA's main partner is the corporation HAL, in particular its
branches in Bangalore, Hyderabad, Lucknow, Nasik, and Corvo. Participated
in the program, and several independent organizations, such
as, for example, the company BEL (Bharat
Electronics Ltd.) And CSIO (Central Scientific and
Industrial Organisation). DRDO
laboratories have developed a number of units of the
aircraft: the main onboard computer, control elements, a box
of the motor drive, carbon brake wheels and other chassis
management ADE (Aeronautical Development Establishment) was
responsible for flight control system and
information-control field cabin. National
Aeronautics Laboratory NAL (National Aeronautics Laboratory,
(today - National Aerospace Laboratories) to create designs
of composite materials (CM) and to ensure that experiments
in wind tunnels. Office of electronics and radar ERDE
(Electronics and Radar Development Establishment) in
conjunction with HAL been developing a multi-function radar
and management of gas turbine engines GTRE (Gas Turbine
Research Establishment) was responsible for creating India's
first turbofan. From the research organizations participated
in the program department Indian Institute of Technology
(Indian Institute of Technologies) in Bombay, Kanpur,
Kharagpur, Madras and New Delhi and Indian Institute of
Science (Indian Institute of Science) in Bangalore.
The total number of employed over hundreds of major business
centers and another 300 smaller organizations. A
very active part in the program took the Indian Air Force -
Military acceptance has become an integral part of the
program.
No exaggeration to say that the plane was built the whole
country. For
flight testing, design of composite wing and flight control
laws were even created a special "national team", which
combine
best minds in India. To
address some of the key tasks in the program initially
involved, and some foreign companies: the Italian Alenia
(composite wing skin panel), the U.S. Martin Marietta
(control system), the Swedish Ericson (radar), the British
BAE (consultation under the laws of the flight control) .
"Critical Technologies"
Originally it was planned already in 1995 to begin
deliveries of the new fighter. But
the Indian Air Force formulated the final demands to him
only in October 1985, which enabled the ADA «gather strength
and to determine which technologies can be created in India,
and which will initially be imported.
At the beginning of the program ADA has identified five
"critical technologies". Two
of them were eventually successfully mastered the industry:
production of structural composite materials and "glass"
cockpit. However,
these achievements have remained almost unnoticed in the
background of the problems encountered in the development of
the remaining three. Nevertheless,
today the LCA by about 70% have an Indian product. Of
the 35 major components of the avionics, only three are
imported. This
multi-function displays (IFIs), supplied by Sextant (France)
and Elbit (Israel), helmet-mounted sight Elbit production
and container with a laser targeting system of the Israeli
company Rafael. But
by the time production begins IFIs will have to supply the
Indian manufacturers.
On the plane were used, and some other imported parts, such
as ejection seat of the American company Martin-Baker, but
then the embargo the United States to India in 1988 after
its nuclear test, prompting the country to accelerate the
creation of analogues.
When forming the shape of the new plane of his experience
was not enough, and India was forced to seek foreign
assistance. By
Research Connect the four European companies: the British
BAE Systems, the French Dassault Aviation, the German
Dornier and MBB. It
is curious that neither the U.S. nor the Russian developers
at work on the image of the LCA did not participate.
The process has started
At the end of 1983 with VAM signed a contract for consulting
work, but to develop
the aircraft in 1985 attracted Dassault
Aviation, a specialist team which
arrived in Bangalore. Director
of theProject appointed Dr. Kota Harinarayana (Kota
Harinarayana). Preliminary
design LCA went from October 1987 to September
1988 and ended in the workplace in
1990 Sophisticated avionics and design of KM
caused concern to the leadership of the
Air Force, doubted the possibility of
industry . Therefore,
in May 1989 A
committee was formed, soon
came to the conclusion that the Indian industry in most
areas "ripe" to implement this project. However,
took the prudent decision
to implement the program in two stages. On
the first - have decided to buildtwo aircraft-demonstrator
TD-1 and TD-2 and airframe
for static tests. Then the
Indian government had given permission
to build two prototypes PV-1 and PV-2 (PV - PrototypeVehicle). At
the second stage of the intended construction
of three prototypes. One of
them was to become the first production single-seat fighters
(PV-3), second
(PV-4) - the
first-deck version of the aircraft, the third (PV-5) -
two-seat trainer version.
In mid-1991 HAL began construction of airplanes
of the demonstrators. However,
the outbreak while the financial crisis has slowed down. Only
in April 1993,
almost 10 years after the "launch"Project LCA, the
government formally authorized
the program and the allocation to the
first phase of its implementation of 630 million USD, but
the real work could begin only
in June. TD-1
rolled out initially planned
for February 1995 and the beginning of its
flight tests - on June 1996 TD-2
were going to build in September 1997
both "technology demonstrator" had
to bump to 200 hours. However,
the TD-1 ( board KH 2001) in the presence of Indian
Prime Minister PVNarashima Pao
(PVNarasimha Rao) rolled out from the assembly shop only on
Nov. 17, 1995 weighing showed that the machine
peretyazhelena, but it has already decided to improve on the
TD-2, facilitating the latter to 100 kg. In
June and July 1996 on specially constructed stands passed
ground tests systems. The
first flight of LCA was planned for
mid 1997, however, a few years and
the TD-1 TD-2 standing on the ground because of problems
with the design and nedovedennosti management system.
Made in India
LCA was created by aerodynamic configuration "tailless" with
delta wing and a low degree of longitudinal static
stability. The
shape of the wing, its aerodynamic and geometric twist,
pairing with the fuselage to optimize both numerically and
blowdowns models in wind tunnels.Mechanization was deflected
out of socks across the front edge for improved performance
at high angles of attack, as well as the elevons. In
the research also examined the aerodynamic scheme of "duck",
but, according to Dr. Harinarayana, such a scheme "only
increases the weight of the aircraft and the EPR. Likely
to impact and influence the firm Dassault, «no one ate the
dog" in the scheme "tailless".
The main construction materials glider LCA - aluminum and
titanium alloys, as well as carbon fiber. Proportion
of KM in construction - up to 45% by weight of airframe. Of
those executed covering the fuselage and wing spars and ribs
of the wing, elevons, keel with the rudder and landing gear
doors niches. Empty
weight thanks to the CM was reduced by 21%. Their
use has significantly reduced complexity and manufacturing
fighter aircraft, reducing the total number of
sub-assemblies for about 40% compared with traditional metal
structure, reducing the number of fasteners by nearly half
and reduce the number of holes about 2000. For
example, the keel of the aircraft, made of sandwich panels
of the Cabinet, has the complexity of manufacturing at the
80% lower compared with the assembly of traditional aluminum
construction. In
designing the airframe and its systems were widely used
computer technology. Subsequently,
the exhibition Aero India 2001, ADA was shown at the booth
of "virtual model of the aircraft."
Since the climate in the country mostly rain, given the
bitter experience of the pilots in the cockpits potevshih
import MiG-21 and Jaguar, ADA and HAL have paid special
attention to air-conditioning system (ACS). Aggregate
separation (Accessories Division) corporation HAL in Lucknow
has designed a special refrigerator that provides the FCC in
limiting the temperature and humidity conditions. The
temperature in the cabin should not rise above 22-29 ° C
(humidity not exceeding 50%) when operating in hot and humid
day. In addition,
the FCC provides cooling of avionics, including radar.
Another group of ADA has worked to develop and debug
software for the host computer - MC (Mission Computer). Four-wire
control system and software it has developed ADE. It
also created a dynamic and integrated avionics bench, which
was tested a complete set of avionics LCA and simulate
possible flight profiles. Three
modules of the stand came into effect in early 1995 Avionics
aircraft on the principle of open architecture, functionally
integrated through the use of bus data exchange standard
MIL-STD-1553B. The
total volume of verification tests, the computer and its
integration with the avionics of the aircraft was more than
2000 hours. Man-machine
interface is being followed on the mock cockpit.
Weapons weighing up to 4000 kg is placed on the seven sites
outside of the suspension: one under the fuselage and three
under each wing. There's
also the eighth node suspension under the left air intake,
which can accommodate container with equipment targeting or
intelligence.
Internal fuel capacity is 3000 kg, which is enough for about
40 minutes of flight. Right
in front of the lantern can be placed a fixed rail system in-flight
refueling. In
addition, under the fuselage and wing possible suspension of
three drop tanks with a capacity of 1200 liters, or five to 800
liters.
Passive defense Mayavi (in Sanskrit "The Illusionist")
developed by the DARE (Defence
Avionics Research Establishment) (until
July 2001 it was called ASIEO - Advanced
Systems Integration and Evaluation Organisation). It
includes a notification system for radar and laser irradiation,
a system of early warning of missile attack, the ejection
device traps and
jamming. Reported
that the experimental
aircraft was the Israeli system
of self-defense company Elisra.
Particular attention in the development of ADA paid
to the radar visibility. It
helped reduce thesmall size of the aircraft, as well as the shape
of air intake duct, and special coatings.
Reduced margin of static stability has become one of the
most difficult points
of tactical and technical requirements for the aircraft
and the development of by-wire control system (FBWCS) LCA has
been one of the aforementioned "critical technologies". In
1988, Dassault offered to install on their aircraft FBWCS,
but the Indian
government considered this issue so
important that the import of finished product
could not be considered. As
a result, in 1992, NAL, specifically its division CLAW (LCA
National Control Law), began to establish its similar
system. Scientists
rather quickly mastered the design of control laws, but
check them out in practice was not possible. Had
in 1993 to seek assistance from companies BAE and Lockheed
Martin. Around
the same time for the mathematical interpretation of these
laws took longer than expected.Initially, control laws
tested at the booth of BAE, and then a similar stand (Ironbird
or "Iron Bird") appeared in the HAL and ADA (Minibird -
«Mini-Bird). The
second phase of mining Mathematics FBWCS passed in the U.S.
in July 1996, at the flying laboratory F-16 VISTA (Variable
In-flight Stability Test Aircraft).
However, the program of mining was done only 33 flight: in
May 1998 with the introduction of an embargo Lockheed Martin
stopped all these activities. Nevertheless,
the system has managed to bring its own and hold its
successful 50-hour ground test on TD-1. Only
after this plane declared ready to perform the first flight. Before
this "unity" was a lot of ground checks, including the study
of electromagnetic compatibility of systems with the engine
running. Test
with the engine began in 1999 in 2000 followed by taxiing up
to speeds of 200 km / h, and only after 50 runs had been
received "good" on the first flight.
Starting in the sky
The first flight of TD-1 in the National Flight Test Center
NFTC (National Flight Test Centre) in Bangalore, January 4,
2001 Later, the local newspaper wrote that "on January 4 for
the Indian aviation industry will become a significant date
as July 4 for U.S. residents . this
day made the first flight of the first world-class combat
aircraft, developed in India. " However,
the car was still far from the present level of combat
aircraft.
The first flight lasted only 18 minutes. Piloted
the TD-1 test pilot Kothiyal Rajiv (Rajiv Kothiyal) ". On
the cloudless day at the airport were: LCA Programme
Director Dr. K. Harinarayana, Indian Defence Minister George
Fernandes (George Fernandes), president of the corporation
HAL Krishnadas Nair (Krishnadas Nair) and many other
officials. Commander Indian Air Force Marshal Anil Tipnis
(Anil Tipnis) personally accompanied TD-1 in the air, while
in the cockpit of one of two Mirage 2000 fighter jets. After
landing test was met, as a national hero - he left the cabin
to the sounds of the national anthem .
The prototype was literally bustles with equipment,
recording nearly 2000 flight parameters. The
only "extraneous" items in the first flight were models of
R-60 on the pylons under the wing.Speed was limited to 450
km / h, and height - 3000 m. Therefore, the chassis is not
removed.Maneuvers were performed very smoothly. Run
and run, despite a small take-off weight, have been very
long that the press associated with the "minimum use of the
runway of mechanization and braking wheels in the first
flight."
After leaving the cabin, Rajiv Kothiyal said that despite
"some uncertainty at first," he "really enjoyed the flight." "India
has become the eighth country in the world, capable of
creating supersonic fighters," - noted then the defense
minister. Air
Force Commander a more realistic assessment of the situation
and said that the first flight confirmed the calculations of
designers, but it will still be a long time before LCA will
become full-fledged fighter.
Flight test program was to verify the correctness of
embedded designers solutions. True,
some concerns remained associated with the American embargo
on India's high-tech products for military equipment. And
it is directly concerned the LCA, because the "demonstrator"
was established American engine F404-F2J3. In
the late 80's, India has received from the United States, 11
such engines.
The second flight of TD-1 took place in late January. February
9, during the air show Aero India 2001, he completed his
fourth flight. In
the static display was shown full-scale model of LCA, which
is slightly different from the TD-1. By
the beginning of the February 2001 three prototypes were
built: two "a demonstrator and a prototype PV-1.
August 1, 2003 Mr. TD-1 made its first supersonic flight. Test
TD-2 (aircraft KH 2002) planned to start in September 2001. but
he fell just 6 June 2002 debuted this aircraft at Aero India
2003.If the salon in 2001, TD-1 only once passed over the
airfield, then in 2003, this machine, previously carefully
hidden from the public showed in the air, and on the ground
surrounded by a whole arsenal of weapons, including a guided
aerial bombs KAB-500Kr, space-detonating ammunition
Odaba-500, guided and unguided missiles, stressing the
ability of an aircraft to "work" and ground targets.
The heart of the aircraft
Equipped with the first prototype of an American fighter jet
engine GE F404-F2J3 General Electric Company has decided in
1986 at the same time launched a program to create your own
turbofans. Developing
a new engine management led GTRE, which already had some
experience in building jet engines. India's
first jet engine with afterburner GTX37-14U has been created
it in 1977, new turbofans was designated GTX-35VS own name
and Kaveri. Full-scale
development began in April 1989 was designed for 93 months,
and for its implementation have identified about 82 million
USD. It was
assumed that the serial LCA will be exactly this engine.
Kaveri - twin-shaft turbofan engine with a low-pass ratio
and characteristics close to the American F404 and the
Russian RD-33. When
designing the engine and more attention was paid to pick the
parameters and the altitude-speed characteristics than the
economy. Certain
effect on the structure imposed, and tropical environments. Low-pressure
compressor - a three-tiered, high-pressure - six. Turbine
- single-stage.
Originally planned to build 17 advanced engines. Initially
experienced a gas generator, which was named Kabini. His
first launch took place in March 1995, a full engine test
started in 1996 By 1998, ground tests have been already five
experimental motors. Flight
tests scheduled to begin in 1999 and a year later to install
the engine on the LCA. However,
these plans have prevented the political and technical
problems.
By 2001, five were Kaveri bench tests, three planned to make
in the coming months. One
of them was supposed to take place in October 2001, the
altitude-speed tests in Russia, flying laboratory Tu-16. Thus
the term installation at the Kaveri LCA moved in 2005 the
technical problems the engine was not reported, it is
regularly shown at exhibitions Aero India, but we know that
the developer had problems with vanes and a digital control
system.
The press articles began to appear that the LCA in the near
future will not be able to rise into the air. However,
the decision to replace the engine to take no time, in
September 2001, the U.S. lifted the embargo, and in February
2002, the government of the United States agreed to sell
India an additional 40 engines F404-F2J3.
In 2003, the ADA has decided to establish eight
pre-production aircraft and the prototypes of deck options
LCA modernized engine F404-GE-IN20. In
February 2004, the ADA has signed a contract worth 105
million dollars with General Electric for the modernization
and construction of 17 such engines, the supply of which
should begin in 2006
The possibility of use on aircraft engines SNECMA M88-2,
Eurojet EJ200 and RD-33. In
April 2004, Russian media reported that the JSC "Ufa Engine
Industrial Association (UMPO) won the tender and contracted
to sell to the Government of India 180 AL-31F engines for
aircraft Tejas more than $ 200 million USD with the start of
deliveries in in 2005, but this fact has not yet been
confirmed.
And in mid-2004, Kaveri «disgraced" in the tests on the
Tu-16LL, then all hope to install it on the first production
car finally died away.
This has forced the Defense Ministry of India in 2005 to
order another 40 turbofan F404-GE-IN20 for equipping the
first production aircraft, and "open door" to foreign
participation in the program Kaveri. In
February 2006, the ADA has contracted with the French
company SNECMA for technical assistance, and in the same
year another Kaveri sent to Russia. He
is undergoing flight tests at the flying laboratory IL-76
from June to September 2006
Today, attempts to bring engine continues, there is hope
that he will still be ready to fly in 2009, however, the
cost of his program has risen to 640 million USD. Obviously,
the first two squadrons of aircraft LCA still be equipped
with American engines. In
February 2007, the corporation HAL has ordered an additional
24 F404-GE-IN20 is to equip the production aircraft.
In addition, in September 2008 it became known that the ADA
is planning to develop a more powerful engine with a thrust
of 9500-10000 kg. As
the candidates addressed the European turbofan Eurojet EJ200
and the American General Electric F414. And
at the show Aero India 2009 Zaporozhian Ivchenko-Progress,
"stated the possibility of a turbofan AI-9500F with a
takeoff thrust of 9,500 kgf.
Creating radar
One of the "critical" technology was the creation of
multi-function radar MMR (Multi-Mode Radar). Originally
I planned to use the LCA imported radar PS-05 / A company
Microwave Systems, designed for the fighter Saab JAS-39
Gripen. However,
after analyzing their foreign counterparts, conducted in
early 1990, DRDO has been insisting on developing their own
sample.Implementation of the project decided to implement
the division by HAL in Hyderabad and management of LRDE. Work
on the MMR began in 1997, and flight testing center tasked
CABS (Centre for Airborne Studies). In
1997, there for testing avionics and radar LCA re-equipped
aircraft in the flying laboratory HAL/HS-748M ASP (Airborne
Surveillance Post).
By mid-2002 work on the locator stalled, including because
of rising project costs, and by early 2005 had been worked
out only two modes: air-air and earth observation. In
May 2006, it was reported that on other modes MMR «not live
up to expectations." According
to some sources, the apparent incompatibility of the station
module and SPM (signal processor module), which developed
the LRDE. After
that began address the issue of a temporary installation on
the aircraft radar Israeli Elta EL/M-2052 with an active
phased array. In
the future instead of MMR is planned to develop a new
station, possibly on the basis of EL/M-2052. It
can occur on planes of the second series (Mark II) in about
2012-2013.
Cut Diamonds
May 4, 2003, Prime Minister Atal Bihari Vajpayee (Atal
Bihari Vajpayee) has assigned the aircraft's own name-Tejas,
which in Sanskrit means
"Diamond".