ltt project report

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Student Internship

Programme Report

Name Amizzuddin Bin MD Amin

Class AE4 (01)

Matrix Number 1200243B

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Diploma in AEL / AEG Diploma in ELN / MTN

Declaration of Originality

By submitting this work, I / we declare that:

I am / we are the originator(s) of this work.

I / we have appropriately acknowledged all other original sources used in this work.

I / We understand that Plagiarism is the act of taking and using the whole or any part of another person’s work and presenting it as my/ our own without proper acknowledgement.

I / We understand that Plagiarism is an academic offence and if I

am/we are found to have committed or abetted the offence of plagiarism in

relation to this submitted work, disciplinary action will be enforced.

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I. Table of Contents

1. Introduction .................................................................................................................................... 4

2. Project Description .............................................................................................................................. 5

2.1 Major Projects Overview .............................................................................................................. 5

2.1.1 Stabilized Power Supply (SPS) Project ................................................................................... 5

2.1.2 Third Hand Project ................................................................................................................. 6

2.1.3 Infra-Red Transceiver Project ................................................................................................ 6

2.2 Details of Major Projects / Selected Practical Exercise ................................................................. 7

2.2.1 Stabilized Power Supply (SPS) Project ................................................................................... 7

2.2.2 Third Hand Project ................................................................................................................. 9

2.2.3 Infra-Red Transceiver Project .............................................................................................. 10

2.3 Rationale and Objectives of major project ................................................................................. 11

2.3.1 Stabilized Power Supply (SPS) Project ................................................................................. 11

2.3.2 Third Hand Project ............................................................................................................... 11

2.3.3 Infra-Red Receiver and Transmitter Project ........................................................................ 11

2.4 Working Principle ........................................................................................................................ 12

2.4.1 Stabilized Power Supply (SPS) Project ................................................................................. 12

2.4.2 Third Hand Project ............................................................................................................... 12

2.4.3 Infra-Red Receiver and Transmitter Project ........................................................................ 13

2.5 Analysis of the SIP Experience .................................................................................................... 15

3. Conclusion ......................................................................................................................................... 15

4. Recommendations ............................................................................................................................ 15

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1. Introduction The purpose of the Student Internship Programme (SIP) which is part of Aerospace Electronics (AEL) diploma course is to provide the necessary hand skill training accordance to the aviation maintenance standards. This explains why the programme is conducted at Lufthansa Technical Training Centre (LTT) since LTT is one of the approved maintenance organisations by Civil Aviation Authority Singapore (CAAS) under the Singapore Airworthiness Requirement 147 (SAR 147). At the same time, LTT has established a reputation for the highest level training as well as Maintenance, Repair and Overhaul (MRO) services worldwide. The initial expectation of the SIP as briefed by the lecturers before the start of the programme was that the programme is supposed to equip the student the necessary hand skills which incorporates with the standard maintenance practice based on aviation standards. This includes understanding the proper maintenance procedures and safety. At the beginning of the programme, the students were brief on the expectation by the diploma unit on the attendance, safety awareness in the workshop (based on the 5s – Sort, Set in Order, Shine, Standardize and Sustain) and attitude. These expectations were emphasize from time to time during the theory lessons as well as practical workshop. One example will be that the 5s signs were put up in the workshop as a reminder to the students the proper conduct and attitude in the workshop. At the same time the students were constantly reminded to put on the safety goggles during drilling and punching. Instructors also station on hazard prone workstation to ensure students correctly use the equipment. Morning briefings are conduct to inform the students the challenges they might face during fabricating parts as well as the correct use of equipment. This programme also provides the student some field trip to understand the nature of work in the aviation industry. Students of AE 3 and 4 were sent to Panasonic Singapore for a field trip, which provide inflight entertainment system for Singapore Airlines. Since the students are from the B2 batch which more provision on the avionics system and the electronics, the field trip was indeed fruitful trip. The manager who gave the student the tour around company was helpful to answer the student enquiry on the latest job market as well as the job prospect joining the Maintenance Repair and Overhaul (MRO) companies.

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2. Project Description

2.1 Major Projects Overview

2.1.1 Stabilized Power Supply (SPS) Project

Figure 2.2.3 1 the Final Assembly of the SPS project

The SPS project consists of mechanical as well as electronics sections. In the Mechanical section of

the project, Students are required to fabricate the housing of the SPS based on the interpretation of

the engineering drawing. As for the electronics section of the project, students are required to

construct the circuit as per given PCB and wiring layout. Due to the complication of the project,

students are required to understand the priority of which part of the project required to work on

and apply the necessary skills taught in the theory lessons.

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2.1.2 Third Hand Project

Figure 2.2.3 2 the final assembly of the Third hand project

The Third Hand project is made up of mechanical parts only. The assembly of the project are made

up of 3 parts which requires the student to understand the assembly as well as the interpretation of

the engineering drawing. This project has exposed the students the understanding of handling

different types of materials as the project consist of steel and aluminium.

2.1.3 Infra-Red Transceiver Project

The Infra-Red receiver and transmitter project consists of electronic parts only. The construction of

these 2 circuits differs as the receiver is built from a printed circuit board (PCB) and the transmitter

circuit has to be built from scratch from Vero board. These differences have exposed the students in

different types of skills such as planning, troubleshooting and soft soldering.

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2.2 Details of Major Projects / Selected Practical Exercise


a) 2.2.1 Mechanical Section

Figure 2.2.1 a-1 the materials needed to fabricate SPS housing.

Figure 2.2.1 a-2 the completion of SPS housing

Figure 2.2.1 a-3 the fabrication of the back panel of SPS housing.

The mechanical section of the SPS project enhance the following modules of the training:-

M6.5 - Material Hardware (Fastener and Bolts).

M7.2 - Workshop Practices

M7.3 - Tools.

M7.5 - Engineering Drawings.

M7.14.1 - Sheet metal bending.

The SPS housing is made of 4 parts. They are:- 1 Aluminium Top cover. 2 Aluminium Back Panel. 3 Aluminium Front Panel. 4 Composite Plastic Base Plate. The attached photos are the processes for which how the fabrication of the SPS housing is done. The challenges faced during the fabrication of the SPS housing is that the connection of the parts requires alignment before process of making screw threads. Without the alignment, it will cause fitting problems for other parts of the housing. At the same time, certain fabrication requires to match with the component given rather than the dimension provided in the engineering drawing since the physical component comes in slightly different size.

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b) 2.2.1(b) Electronics Section

Figure 2.2.1 b-1 Initial stages of SPS circuit construction.

Figure 2.2.1 b-2 SPS components mount on housing.

Figure 2.2.1 b-3 SPS complete circuitry.

The electronics section of the SPS project enhance the following modules of the training:-

M7.4 - Avionics General Test Equipment.

M7.7 - Electrical Wiring Interconnection System (EWIS).

M7.15 – Soft Soldering. The SPS electronics consist of 3 parts. They are:- 1 Component soldering on PCB. 2 Wiring. 3 Final assembly of the circuit. The attached photos are the progress made during the assembly of the circuit. There were no problems in construction of the electronics parts. However, the challenge only occurs when there is a functionality problem came up. Some of the reasons were the polarity issues during the soldering of component to the PCB. Other reasons were the wrong wiring connection and bad crimping technique which cause negative connection.

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Figure 2.2.2 b-1 the materials needed for Third Hand project

Figure 2.2.2 b-2 the mark outs for the top plate.

Figure 2.2.2 b-3 filling of top plate

The third hand project is compromising the following modules of the training:-

M6.5 - Material Hardware (Fastener and Bolts).

M7.2 - Workshop Practices

M7.3 - Tools.

M7.5 - Engineering Drawings.

M7.14.1 - Sheet metal bending.

The third hand project is made of 3 parts. They are:- 1 Aluminium Base Plate 2 Aluminium Centre Plate 3 Steel rods The attached photos are the progress made during the fabrication of the third hand project. The challenge faced during the fabrication of the third hand is that applying the correct hand skill technique when filling and sawing the aluminium plates. It is difficult to achieve the tolerance based on the engineering drawing. This is because the project is mostly done by hand tools, the importance of the hand technique very crucial. At the same time, mistakes were done on this project due too many markings were done which cause confusion when drilling through holes on the base plate. In this project, it is important to do a double checking before any execution of any drilling, filling or sawing action. However, this project was carried out without any instruction by the instructors. This is a very good learning experience as the student learnt how to work independently.

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2.2.3 Infra-Red Transceiver Project

Transmitter Circuit Receiver Circuit

The above picture is the circuitry layout for the transmitting circuit based on the type of Vero board issued. The layout helps to identify the placing of the components as well as wires routing. It also serve the purpose for trouble shooting since it shows the copper track of the Vero board.

The above PCB diagram is used for trouble shooting since the view of the top PCB is inverted to the bottom of the PCB. Therefore the diagram provides useful information on which location of components as well as points for troubleshooting.

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2.3 Rationale and Objectives of major project


The purpose of the SPS is to convert AC to DC to supply power to project such as FCU and FOP. In a

way, the SPS is the simplification of the aircraft electrical system where the AC generated by the

power plant is converter to DC to supply power to avionics systems.

Modern aircraft uses “fly-by-wire” systems where correct practice of wiring is important. There a

few accidents where wrong practice of wiring causes catastrophic affect. At the same time, the

repairs of the line replaceable unit (LRU) require proper soldering skills.

Therefore the SPS project is relevant to the MRO industry as the project consist of proper wiring

practice and soldering technique.


In the MRO industry, it is common that mechanical based skill is required to fabricate the parts of an

airplane which needed repairs such as the airplane fairings and since the industry is fast paced

where time management and safety is important.

Therefore, the third hand project is relevant as to fabricate a part of an airplane requires knowledge

to interpret engineering drawing, understanding the type of material used for fabrication and proper

hand skills to fabricate the part without affecting the material’s strength. Without these skills, it is

almost impossible to repair a part of an airplane on time and obtaining the required material

strength to install on aircraft.

2.3.3 Infra-Red Receiver and Transmitter Project

The Infra-Red RX and TX project is broken into 2 parts which is the receiver and the transmitter. Both

of these circuits are constructed differently with a purpose to expose the student to the different

types of trouble shooting on Vero board and printed circuit board (PCB). Even though the method of

troubleshooting are similar for both boards, but the types of challenges faced to carry out the

troubleshooting differs for both boards.

One good example will be that the trouble shooting done on PCB is easy since the copper is almost

close to schematics drawing. However the troubleshooting done on Vero board is physically

confusing since the copper tracks are too much that troubleshooting has to be done slowly as to

avoid errors.

In addition, proper soldering technique is required to ensure positive connection. Continuity test are

carried out to ensure positive connection.

Therefore, the project is relevant and most important for B2 student since they are specialized in

electronics. Furthermore, this project exposed the student to understand how to read schematics

drawings.

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Stabilized Power Supply

2.4 Working Principle


The function of the SPS is to convert AC to DC variable voltage regulator supplying power to almost

electronics project structured by LTT. The figure below shows the function and operation of the SPS.


The Third Hand project is made up of mechanical parts such as bolts and nut. Its primary function is

to provide an additional “hand” to allow easy soldering on difficult component of the circuit. Its

secondary function is to provide heat transfer especially soft soldering project where soldering is

done on a copper wire. The heat from solder gun may melt the other soldered parts of the copper

wire.

This project enhances the student understanding on lessons taught in module 7.2, 7.3 and 7.5.

Students were not guide rather instead observe by instructors as to allow student to build

confidence in working on project without any assistance.

Transformer

(Step Down

with centre

tap)

Rectifier

(Full wave)

AC to DC

wave

Filter

(RC filter)

DC wave to

regulated DC

Output

Selection

from :-

1)0-15VDC

2)0-30VDC

Supply power to:-

Flap Control Unit

(FCU)

Flap Operating

Mechanism (FOP)

Other LTT electronics

project

2.4.1 0-1 SPS function and working principal

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2.4.3 Infra-Red Receiver and Transmitter Project

The working principal of the project is broken into 2 parts as shown below.

Figure 2.4.3 1 Schematic diagram of transmitter

The push button activates the 2 timers. The frequency of the 2 timers differs as per tabulated result

as per attached PDF file in the block diagram. The outputs of both timers are combined and as a

result, a new output which also tabulated as per attached PDF file.

Transmitter Circuit

Timer 1

LED Transmitter

Adobe Acrobat Document

Timer 2

Timer 1 + Timer 2

output

Adobe Acrobat Document

Figure 2.4.3 2 Block diagram on working operation of Transmitter.

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Figure 2.4.3 3 Schematic diagram of receiver

The receiver circuit consist of a receiver infra-red LED which received signal from the TX which in

turn provide pulse to the JK flip flop. The output the JK flip flop will turn the LED on or off. As long as

no signal received, the output of the JK flip flop will remain the same. Thus acting like a remote

control.

Receiver Circuit

LED Receiver

Voltage Regulator

(Provide regulated voltage)

Schmitt Trigger Delay

JK Flip Flop

Output

Figure 2.4.3 4 Block diagram on working operation of receiver.

Control

Circuit

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2.5 Analysis of the SIP Experience

The programme has indeed beneficial to the students as the theory lessons conducted were further

enforced by the practical workshop. In order words, the lessons that LTT has structured the

programme that all types of students with different capability of learning to understand the modules

thought by the instructors. Different platform of learning were introduce such as watching videos

related to the modules the students were thought.

The instructors are very helpful in assisting the students whenever the students have doubts.

3. Conclusion

In Conclusion, the attachment objectives of the programme were met. The reason is that the

structure of the module were schedule in such a way that student will first learn the theory of

proper maintenance practice before doing the actual workshop. Even though there wasn’t any

training done on the airplane system, the workshop structured in the programme is totally relevant

to the maintenance practice.

Overall, the programme which structured by LTT is indeed useful not just for future career as an

Licensed Aircraft Engineer (LAE) but it also further enforce the theory knowledge which the student

learnt during the diploma course conducted by Temasek Polytechnic.

4. Recommendations

LTT has structured wide range training from mechanical to electronics skill based training. However,

the training can be further improved by making amendments to certain project such as the FOP.

Since the FOP is newly introduced into the programme, and the project consist of both mechanical

and electronics. The number of days given to complete the project which is 8 days may not be

sufficient. This is because unlike other projects, the FOP electronics section has a complicated wiring

such that the wires route outward to inward of the FOP. However, the FOP is indeed a very excellent

project introduced by LTT.

ltt project report

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