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The Aeronautical Development Agency (ADA) is advancing the Tejas combat aircraft program by incorporating technology from the forthcoming Tejas Mk2 into an existing Tejas Mk1 simulator.
This initiative focuses on fitting and testing the advanced Right Hand (RH) Console, a key component of the next-generation Tejas Mk2, within the simulator cockpit to assess its design and usability before full-scale production.
The Tejas program, a cornerstone of India's indigenous aerospace and defence capabilities, has seen the development of the Light Combat Aircraft (LCA) Tejas Mk1 and its improved version, the Mk1A.
The Tejas Mk2 is planned as a more advanced, medium-weight combat aircraft with enhanced capabilities. This current project, detailed in a recent Statement of Work, aims to refine the Tejas Mk2's cockpit by evaluating new components in a simulated environment.
The cockpit of the Tejas Mk2 is being designed to maximize pilot efficiency and comfort. It will provide sufficient space for the pilot's ejection seat while integrating the necessary controls and displays for managing the aircraft's primary and secondary systems.
The RH Console is particularly important as it will house the side-stick controller (used for flying the aircraft) and various switches and panels, primarily used during operations on the ground.
To effectively test this new console, ADA will manufacture and install it into an existing Tejas Mk1 cockpit located at the Real-Time Simulator (RTS) Facility at the Aeronautical Development Establishment (ADE) in Bengaluru. ADE plays a crucial role in the research and development of aeronautical systems for the Indian armed forces.
Simulators like the RTS are vital tools in modern aircraft development, allowing for rigorous testing and pilot familiarisation without the risks and costs associated with actual flight testing of developmental systems.
The work will involve the fabrication of the RH Console itself, a bottom mounting bracket, and a side plate. These new parts will then be integrated into the Tejas Mk1 simulator.
This process will require on-the-spot modifications to the existing cockpit structure to ensure a proper fit and maintain structural soundness. This step is considered crucial for smoothly transitioning cockpit technologies to the more advanced Tejas Mk2.
Key Modifications for Integration
Several specific changes are planned for the Tejas Mk1 simulator cockpit to accommodate the new RH Console:- Cockpit Floor and Mounting Points: Adjustments will be made directly to the simulator's cockpit floor and existing mounting holes to match the RH Console's design.
- Structural Adjustments: Modifications to internal structures like the #9 bulkhead (an upright partition) and the RH longeron (a longitudinal structural member) are required. These changes will create necessary clearance for the side-stick controller's grip and reinforce the area.
- RH Console Construction: The RH Console will be built from HE30 grade Aluminium Alloy, a 10 mm thick material known for its strength and workability. It will feature precise cutouts for various panels and switches and will house the side-stick assembly. ADA will provide detailed 3D models and 2D drawings for its construction following a purchase order.
- Bottom Mounting Bracket: A special bracket for the side-stick, also made from HE30 Aluminium Alloy and featuring M8 threaded inserts in four locations, will be produced to ensure the stick is securely mounted.
- Finishing Touches: After assembly, the console will be painted according to ADA's specified colour code to ensure it meets aesthetic standards and provides a realistic environment for pilot evaluation.
ADA, acting as the project's purchaser, will supply all necessary design specifications, including 3D models and 2D drawings, to guide the manufacturing process.
The selected supplier will be responsible for the complete fabrication of the RH Console, its mounting bracket, and side plate. They will also perform the on-site modifications to the cockpit floor, mounting points, #9 bulkhead, and RH longeron.
Furthermore, the supplier will integrate the RH Console with the side-stick unit and other switches and panels as per ADA's designs.
Upon completion, the supplier must submit a dimensional acceptance report, which ADA and ADE will review. All manufactured components are to be delivered within 20 days from the project's official start, accompanied by technical documentation and the acceptance report.
The supplier will also provide a one-year warranty covering manufacturing defects, faulty design, or poor workmanship, committing to resolve any identified issues within 15 days of notification.
The project deliverables include one RH Console with panel cutouts, one bottom mounting bracket with a side plate, and all associated documentation. Payment will be made to the supplier after the complete delivery and approval of the dimensional report by the Tejas Mk2 development team.
This strategic integration of the Tejas Mk2's RH Console into a Tejas Mk1 simulator represents a cost-effective and efficient method for validating critical new cockpit designs.
By using an existing platform for these tests, ADA aims to identify and resolve potential issues early, ensuring a smoother transition to the advanced cockpit systems planned for the Tejas Mk2 aircraft, ultimately bolstering India's indigenous defence aviation capabilities.
