Mechanical Intern at ASELSAN
METU
Department of Mechanical Engineering
ME 400
Summer Practice Report
August 11, 20
I hereby declare that all information
in this document has been obtained and presented in accordance with academic
rules and ethical conduct. I also declare that, as require by these rules and
conduct, I have fully cited and referenced all material and results that are
not original to this work.
Name, Last Name : Emir Fatih Demir
Signature :
TABLE OF CONTENTS
Contents
2. Organizational Structure of the Company
5. Typical
Projects of the Company
6. Detailed
Analysis of a Project Completed by the Firm
7. Explanation
of Your Contribution to one of the Projects
1.
Introduction
The
primary aim of the summer internship, ME 400, was to strengthen and develop the
theoretical and practical knowledge obtained in prior mechanical engineering
semesters. This program aim to provide students with knowledge of the management connections that
bridge the gap between technical departments and non-engineering sectors. During
my ME 400 Summer Practice, I had the honor of interning at Aselsan Inc.,
located in Gölbası. My specific work involved contributing to the design and
structural analysis departments of the Mechanical Design Unit. The
thorough education I got in CAD and Manufacturing Technologies. Armed with this
information, I embarked on my internship experience, ready to put theory into
practice and bridge the gap between academia and industry. During the
internship, I went on a journey of learning and growth that allowed me to
combine theoretical principles with actual implementations. My tasks included observing
CAD designs for various market sample products. These designs were crucial in
assisting engineers in determining the viability of manufacturing these
devices. Furthermore, I was tasked with carefully detailing the production
methods for an existing part using CAD software, which provided great insights
into the complexities of real-world engineering processes. Aside from the
technical parts of my internship, I got the rare chance to immerse myself in
Aselsan Inc.'s varied operations. The company's organizational structure
revealed a tapestry of complications that played an important part in its
operations, with its five unique campuses acting as independent entities.
Seeing how engineers used the same academic principles and relationships from
our courses while utilizing cutting-edge computer tools for fast
problem-solving fostered a deep appreciation for the integration of technology
and innovation in modern engineering methods. Furthermore, my exploration of
other facilities, particularly in the domain of electronics, increased my
awareness of other systems and processes. The exposure to diverse aspects of
engineering cemented my interest for the discipline and deepened my
understanding of the vital role that multiple departments play in synergy.
Throughout this report, I will go into detail about Aselsan Inc., including its
illustrious industry reputation, the various locations and divisions that
contribute to its success, and insights into the production and analysis techniques
and management information systems that power the organization's efficiency. Summer
internship at Aselsan Inc. has been a transformative phase that has enriched my
academic journey.
2.
Description of the company
In
this chapter of the summer practice report, the company is introduced. This
chapter shouldn’t be more than 3 pages.
1.
Company Name and Location
Aselsan Military Electronics Industries, Inc.
Macunkoy Facilities ( Mehmet Akif Ersoy Mahallesi 296.
Cadde No: 16, 06370 Yenimahalle / Ankara, Turkey), Akyurt Facilities (Cankiri
Yolu 7. Km, 06287 Akyurt / Ankara, Turkey), Golbasi Facilities (Konya Yolu 8.
Km Ogulbey Mahallesi 3051 Sokak No: 3, 06830 Golbasi / Ankara, Turke), ODTU
Teknokent (Universiteler Mahallesi Ihsan Dogramaci Bulvari No: 23 / A, 06800
Teknokent ODTU Cankaya / Ankara, Turkey), Istanbul Icmeler (Mevkii Aydintepe Mahallesi Sahilyolu Caddesi
No: 25 Denizcilik Merkezi 57 / B–C–D Tuzla / Istanbul, Turkey),
2.
Organizational Structure of the
Company
Aselsan Inc.'s
organizational structure was created to ensure efficient coordination and
seamless operation of the company's operations. The corporation's Board of
Directors is organized into two distinct sections: Internal Audit and the Board
Office.
Chief Executive Officer (CEO), Vice
Presidents, Directors, Managers, Chiefs, General Executive and Vice President
(VP) in Each Division, Project Directorates and Functional Directorates, ,Specializations,
Departmental Focus, For
a visual representation of the organizational structure, please refer to the
appendix. Appendix: Organizational Structure of Aselsan Inc.
3.
Engineers and Their Duties
Aselsan Inc. has a talented staff of over
9000 employees, all of whom contribute their skills to the company's success.
An astonishing 61% of these individuals are dedicated engineers, representing
the critical backbone of the organization's operations.
Engineers in Electrical and Electronics:
The bulk of Aselsan engineers are electrical and electronics engineers,
accounting for a sizable share of the workforce. These highly skilled
specialists are largely responsible for the R&D department and calibration
laboratories. Their inventiveness propels the development of cutting-edge,
high-technology items, propelling Aselsan to the forefront of innovation.
Mechanical Engineers: Mechanical engineers
are the second-largest category of engineers. They play an important role in a
variety of areas, particularly in R&D, manufacturing, and production
planning and controlling (PP&C). Mechanical engineers use their skills to
develop product structures and mechanisms, as well as to execute modern and
practical production procedures to bring these concepts to reality.
Additional Engineering Disciplines: Aselsan
is home to a diverse range of engineering specialists in addition to
electrical, electronics, and mechanical engineers. Metallurgical engineers give
their knowledge to certain groups within the organization, ensuring that
materials are selected and used optimally. Furthermore, computer engineers and
industrial engineers contribute vital insights to other divisions, broadening
the company's diversified skill set.
Aselsan's varied engineering pool
represents the company's commitment to multidisciplinary excellence, producing
an environment in which creativity thrives and technological achievements are
the norm. Aselsan continues to push the boundaries of possibility, delivering
high-quality and innovative products to suit the demands of the modern world,
with each engineering discipline adding its own characteristics.
4.
Standard Office Practices
Database,
data processing practices and/or filing systems, correspondence systems, forms
used, etc.
The
Aselsan Golbasi Division is made up of five major directorates, each of which
plays a vital part in the company's operations:
-Production
Direction:
•
Responsibilities include creating production plans for all product lines as
well as preparing manufacturing and delivery schedules. Establishes new product
objects to oversee product sustainability.
•
Sub-Directorates:
•
Production Control: Creates, builds, and maintains precise production schedules
in collaboration with other departments. Monitors manufacturing processes to
discover areas for improvement.
•
Production Management: Oversees production operations, including the
requirements for tools, fixtures, and equipment. Produces layouts for
production.
•
Repair and Maintenance: Responsible for the upkeep of manufacturing equipment
such as jigs and fixtures. Coordinates the calibration of measuring and testing
equipment between departments and laboratories.
•
Production Planning and Coordination: Creates and updates production plans on a
regular basis. Analyzes production data and creates analysis reports.
-Engineering
Directorate:
• Responsibilities: Develops and designs new
equipment and systems based on customer requirements and available technology.
Engineers test designs in collaboration with the Turkish Armed Forces to reduce
after-sales issues.
•
Configuration and Data Management: Creates cumulative manufacturing plans and
starts approval processes with other departments.
-Directorate
of Quality Assurance:
•
Responsibilities: Ensures that product quality meets the company's standards.
Due to the military role of Aselsan, it adheres to Turkish and NATO Military
Standards.
- Finance Directorate: • Responsibilities: Coordinates
and facilitates all financial data control and reporting activities. Manages
asset management, charging, collection, and payment of legal duties, as well as
creating budget and financial reports for weekly and monthly review. Long-term
financial planning for operations, strategic planning, and new business
prospects are all responsibilities of this position.
-Directorate of Human Resources and Administrative
Services:
• Responsibilities include developing, coordinating,
and implementing organizational policies and objectives. Oversees communication
functions and ensures compliance with government laws and regulations.
• Employee Engagement and Retention: Maintains good
employee morale and retention through incentives, competitive pay plans,
performance planning, benefit programs, and chances for employee development.
• Health and Safety: Creates and implements a
comprehensive health and safety program.
• Security and Emergency Planning: Responsible for the
administration of security, emergency, and fire protection plans.
The diverse directorates of Aselsan Golbasi Division
collectively contribute to the company's success by assuring efficient
production, engineering innovation, adherence to quality standards, sound
financial management, and the well-being of its precious staff. As a result of
their dedication and skill, Aselsan maintains its position as a leading force
in the defense and electronics industries in Turkey and worldwide.
5.
Main Area of Business
Aselsan Inc. is an important contributor to
Turkey's defense industry, particularly in the electronics sector. With a
diverse set of skills, the company excels at developing complex electronic
goods and systems. Its expertise is in high-quality military communication,
which ensures secure and efficient information transmission during critical
defense operations. Radar Systems, Electronic Warfare, Electro Optic
technologies, Navigation and Avionics, Weapon Systems, Air and Missile Defense,
Navy Systems, Public Safety Communication.
6.
History of the Company
Aselsan was established in 1975 to meet the
Turkish Army's electronic demands as a result of increasing demand during the
Cyprus War and ensuing sanctions. Initially producing military radios and tank
communication systems, the company quickly adapted to technology advancements,
eventually becoming one of Europe's top 50 Defense Electronics Companies by
1990. Its product line included battery fire systems and TV transmitters in
addition to radios.Aselsan's offerings evolved throughout time, expanding into
communication, space technology, unmanned systems, and transportation
solutions. This expansion won the company fame and appreciation in Turkey, as
seen by the company's rising stock value and expanding facilities. Aselsan's
desire to lead worldwide is obvious via new products, commitment to quality,
and ongoing growth, bolstered by great financial performance and investor
trust. Its trajectory demonstrates an enduring commitment to quality and puts
it as an essential participant in the international defense and electronics
spheres.
3.
Quality Assurance
As a NATO member, Aselsan adheres to
stringent quality assurance requirements and international military benchmarks
for its products sold in both domestic and foreign markets. The organization is
certified and adheres to different standards, ensuring the high quality and
dependability of its goods.
The following quality certifications are
held by Aselsan:
1. AQAP 160 and AQAP 2110-2110: NATO
Quality Assurance Certificates that confirm the company's production and
testing methods comply with NATO Quality Assurance Standards.
2. AS 9100: A standard that, in addition to
the ISO 9001 Quality Certificate, contains the criteria for Aviation, Space,
and Defense Organizations. This certification ensures that Aselsan's aviation
and defense-related activities fulfill strict quality and safety standards.
3. CMMI: Capability Maturity Model
Integration, a framework for assessing and improving organizational process
maturity levels, hence improving product quality and process efficiency.
4. ISO 14001: Environmental Management
System accreditation, demonstrating Aselsan's dedication to ecologically
responsible business operations.
5. ISO 17025: A standard addressing the
competence of testing and calibration laboratories, assuring measurement
accuracy and dependability.
Aselsan performs four types of measurements
for purchased products during the Receiving Inspection and Handling Storage
(REHIS) process:
1. Vision Control: Visual inspection
procedures are used to assure product quality and conformance.
2. Dimensional and geometrical analyses are
undertaken to ensure that items fulfill the specified criteria.
3. Metallurgical Measurements: This
category comprises nondestructive and destructive testing procedures such as
liquid penetration, radiographic imaging, and ultrasonic testing. Chemical
analysis and microstructure inspection are also utilized to evaluate the
qualities of the materials used.
4. Environmental circumstances Test:
Evaluation of product performance under various environmental circumstances to
ensure reliability and durability.
Aselsan
ensures that its products consistently meet the highest industry standards and
customer expectations by implementing these rigorous quality standards and
comprehensive measurement processes, reinforcing its reputation as a trusted
and reliable provider of defense and electronics solutions.
4.
Software and Hardware
Management Software
Suites:
1. SAP: A complete enterprise resource planning (ERP)
software that serves a wide range of management requirements, including
manufacturing, marketing, financial, and reporting demands. Purchase orders,
work orders, sales orders, sales forecasts, bills of material, routing, and
lead time management are all handled by it.
2. TEAMCENTER: An integrated suite of software tools
designed to meet the needs of the company's manufacturing, marketing,
financial, and administrative reporting. It functions as a centralized
management platform for different parts of the company, such as figure/sales
order follow-up, quotation processing, and sales order processing.
3. MANMAN, DBMS, SQL, RDB: Database management systems
that are used to efficiently store, manage, and retrieve data from company
databases.
4. FMS: A package for preparing and organizing data
collections or files.
5. DATA, TRIVE, UDSM: Data inquiry packages that are
used to access and retrieve specific data from the company's systems.
Packages of Technical Software:
1. Microsoft Office Applications: Engineers frequently
utilize Microsoft Office applications such as Word, Excel, PowerPoint, and
Outlook for technical documentation, data analysis, and communication.
2. SIEMENS NX, CATIA, and AUTOCAD: Design software
widely used by engineers. Within Aselsan REHIS Division, SIEMENS NX is
especially popular for CAD/CAM/CAE processes.
3. MATLAB: MATLAB is a versatile tool for numerical
computations and simulations that is used for a wide range of engineering
calculations. Engineers use Simulink for system modeling, particularly in
control systems, electrical, and hardware-specific applications.
4. ANSYS, FLUENT, NASTRAN-PATRAN, and ABACUS: Analysis
software used for complicated simulations and finite element analysis (FEA).
These technologies allow engineers to assess and improve diverse designs and
systems, resulting in superior product performance and reliability.
5.
Typical Projects of the Company
ASELSAN, a pioneer in
electronic defense technology, specializes in the design, manufacture, and
logistical support of modern weapon systems for both land and marine platforms.
Their product line includes remotely controlled machine guns, grenade
launchers, tank and artillery firing control systems, and other items. They
also produce intelligent munitions and active defense systems.
The VOLKAN fire control system for Leopard 1
tanks and the FIRTINA self-propelled artillery were ASELSAN's initial offerings
in this arena. Since then, the company's portfolio have extended to encompass
numerous weapon systems integrated with anti-tank missiles, considerably
improving the performance of small and medium-caliber weapons.
ASELSAN offers a
comprehensive portfolio of tank system solutions, including fire control
systems, electric gun and turret drives, remote-controlled weapon systems, and
active protection systems. They also provide communication, reconnaissance, and
surveillance systems to ensure that operations are efficient and secure.
ASELSAN has produced
"smart ammunition" with great precision and accuracy through
electronic subsystem assistance by using their knowledge in military electronic
design.
Furthermore, ASELSAN specializes at active
protection systems, which detect and intercept threats before they reach land
vehicles.
ASELSAN has established
itself as a prominent actor in the defense sector via its persistent pursuit of
innovation and excellence, significantly contributing to the security and
capabilities of Turkish armed forces and winning international acclaim.
They create distinctive approaches in
essential technologies ranging from the depths of the sea to outer space. their
experience began with communication systems and has since expanded to include
military technologies, microelectronics, electro-optic solutions, unmanned
systems, radar, and electronic warfare technologies. They have recently
extended into civic fields, delivering solutions in healthcare, security,
transportation, smart systems, and energy. They currently sell over 500 goods
and provide high-tech solutions to their stakeholders
The
Gökkubbe system was developed in response to the ongoing advancement of air
threats caused by rapid technical progress, which poses substantial challenges
to standard Ground-Based Air Defense (GBAD) systems. Because modern air threats
are now more accessible to asymmetric adversary groups, there is a greater
requirement for a diverse and all-encompassing defense strategy to protect
critical infrastructure.The Gökkubbe system was designed to address the
numerous issues of modern air combat, and it features adaptive modular
architecture and cutting-edge capabilities. This is accomplished through the
seamless integration of sensors and effectors, resulting in a
self-multi-layered defense system able to countering both symmetric and
asymmetric threats.
The
Gökkubbe system's primary goal is to protect high-value stationary assets, such
as military sites and key civic infrastructure, against a wide range of air
threats, such as rockets, artillery, and mortars. The system is constantly
upgraded to stay effective in the face of new threats, ensuring long-term air
defense capabilities for the protection of critical installations and
facilities.The Gökkubbe system intends to maintain a solid defense posture
against developing air threats, defending key assets and infrastructures even
in the face of more complex and dynamic security situations by combining
flexibility, superior technology, and comprehensive defense measures.
The
GÜRZ Air and Missile Defense System is mounted on a mobile 8x8 wheeled chassis,
displaying its cutting-edge technological capabilities. It is designed to
oppose unmanned aerial vehicles (UAVs), helicopters, fighter jets, and
air-to-ground bombs.
As
the demands of modern warfare evolve, there is a growing need for highly mobile
air and missile defense systems. The GÜRZ Air and Missile Defense System
efficiently satisfies this demand, providing airborne threat protection for
both stationary sites and mobile convoys.
The
system excels at target verification, diagnosis, and tracking, and it is
augmented by a comprehensive countermeasure suite, enhanced threat assessment,
and efficient weapon allocation methods. This allows the system to provide a
powerful destructive ability against threats while remaining cost-effective in
design.
The
GÜRZ Air and Missile Defense System, which consists of various components like
a 35-millimeter Air Defense Gun with various ammunition types, multiple low and
very low altitude air defense missiles, sophisticated Active Electronically
Scanned Array (AESA) Search Radars, firing control radar, electro-optical
sensors, and data links, provides a robust and formidable defense against
diverse threats.
6.
Detailed Analysis of a Project
Completed by the Firm
SIPER is a missile defense and long-range
zone defense system. It is the result of the cooperation of Aselsan, Tubitak
SAGE, and Roketsan. SIPER is a long-range air defense system that protects
strategic facilities from enemy attacks. It is capable of near and far
deployment, multiple engagements and consecutive firing, and operating in
adverse conditions. Transportation by land, air, sea, and rail, High Command
Control with Multiple Tactical Data Link integration, and Radar Network
Management System (RADNET) connectivity with HvBS.
Long Range SIPER Area The Air and Missile
Defense System is effective against targets that breathe air, cruise missiles,
air-to-ground weapons, and unmanned aerial vehicles. System Fleet Control
Center and Search Radar are examples of Fleet Level Equipment. Fire Control
Center Fire Control Radar, Missile Launch Systems, Missile Carry Loading
Systems, Full Launch Missiles, Communication Systems, Support Equipment, and
Class Type Training Simulators constitute Battery Level Equipment.
SIPER's general characteristics include air
defense planning and coordination, information management and distribution
within the purview of command control, unified air picture development,
multiple engagement and sequential fire. Manual/Semi-Automatic/Automatic
Engagement, Friend or Foe Identification (IFF), Threat assessment and weapon
distribution, Automatic diagnostic management, Multi-Target Multi-Radar fusion
Capability for bidirectional connection with missiles Terminal phase guiding
using an Active Radar Seeker, an RF Target Detector, and a High Impact Warhead
Vertical/Slipped Fire Capability, Wired/Wireless Communication Daytime, ability
to function at night and in inclement weather, Radnet connection capability,
HvBS Working with Turkish Air/Land/Naval Forces command and control components
via the tactical data link Link 16 and JREAP, Embedded simulation of the
Missile Launch System with six missiles It is a propulsion system that runs on
solid fuel.
Technical specifications;
·
System Maximum Interception
Range: 150 km
·
Prevention Altitude :
0.1-30 km
·
Side Coverage :
360°
·
Number of Targets to
Follow:
100
·
Number of Targets Engaged in
Battery Level: 10
·
Battery Level Number of
Missiles That Can Be Driven: 20
The dedicated
design team associated with the mechanical design directorate, stationed at the
REHS building, created the fire control radar component for the SIPER project.
The electronics section supplies an overview of the radar's electrical
component sizes, while the designs for cold plates and chassis are methodically
built using Siemens NX software, aligning precisely with these dimensions. In
the meantime, the thermal team investigates the coolant flow channels built
into the cold plate design. Simultaneously, the structural team conducts a
thorough structural analysis, carefully evaluating whether the proposed
parameters are met. When inconsistencies occur, the structural team gives
proactive advice for essential changes. This integrated and multifaceted plan
allows the successful development of the fire control radar component,
highlighting the project's commitment to precision and perfection.
7.
Explanation of Your
Contribution to one of the Projects
A
detailed explanation of the contribution of the student to one of the projects
during the summer practice (Scope and description of your assigned task,
literature survey, detailed calculations and technical drawings)
During
my internship, I worked in the Mechanical Design Department's Structural
Analysis Team, where I was tasked with determining the proper fasteners for the
radar chassis utilized in the Gökkubbe project. I was in charge of giving a
bolt presentation, explaining the fundamental concepts of bolt mechanics, and
presenting the VDI 2230 catalog.
My
goal in giving this information was to help design engineers make more informed
bolt selection selections and to aid structural engineers in precisely modeling
the chosen bolts. In addition, I will be participating in the setup of a test
instrument and, if necessary, the calibration of the Ansys program.
This
project is critical to the effective deployment of the Gökkubbe radar system.
Proper bolt selection is critical for ensuring the structural integrity and
stability of the radar chassis under a variety of operational scenarios,
including as high-speed movements and external loads. I hoped to educate the
staff with industry standards and rules by presenting the VDI 2230 catalog,
which will allow for more efficient and successful bolt selection operations.
Furthermore,
my participation in the setup of a test apparatus and the calibration of the
Ansys program will give the team with useful data and insights into the bolt
performance. This will allow us to model and analyze the bolts' behavior under
various stress scenarios, ensuring that they match the project's stringent
safety and performance criteria.
In
summary, my role in the Structural analysis team during my internship was
critical to the success of the Gökkubbe project. I hope that my efforts will
provide the design and structural engineering teams with the knowledge and
tools they need to make informed decisions and build a robust and reliable
radar chassis for this crucial defense project.
8.
Future Plans
Aselsan's
major purpose is to rapidly satisfy the Turkish Armed Forces' electronic
equipment and system requirements while minimizing dependency on foreign
resources. To sustain its growth rate under every circumstance, the company
attempts to adjust its operations to meet the needs of the Turkish Armed
Forces, civilian clientele, and international countries. In times of crisis,
Aselsan devotes its full manufacturing capability to military weapons. The
company focuses on helping the Turkish Armed Forces in crucial areas such as
electronic warfare and cryptography, leveraging domestic resources for
expansion.
Aselsan
is now working on a number of important projects, including electrical systems,
weapon control systems, and software for the major Turkish combat helicopters
ATAK and tanks Altay. In addition, the business is working on projects
including the electrical systems and cameras of Turkey's first unmanned
aircraft, THA. Aselsan has also created a number of radar systems, including
the 2011 Discharge Control Radar, the 2012 Air Barrier Systems Pursuit and
Shoot Control Radar, the 2014 Satellite SAR, and the 2016 Multi-Function Phase
Sequenced Radar.
Aselsan
wants to strengthen its position as a leader in the Turkish defense industry
and one of the top 50 defense industry businesses in the world through these
ongoing and future initiatives. The company is already placed 55th in DEFENSE
NEWS TOP 100, 25th in FORTUNE 500 TÜRKYE, demonstrating its market supremacy.
Aselsan hopes to reach even better rankings in the future, motivated by its
dedication to excellence, innovation, and satisfying the changing needs of the
defense and electronic sectors.
9.
Conclusion
ME 400 Summer Practice is a crucial
component of the mechanical engineering curriculum since it allows students to
witness and understand real-world scenarios in industrial settings. This
practice provides a larger range of options, allowing students to select
internships that best match their interests and future goals. It goes beyond
engineering departments, providing students with insight into managerial
divisions and their interactions, as well as all of the processes involved in
making a proposal in a tender to delivering a completed project. The
opportunity to engage with seasoned individuals in the relevant industries and
receive their valuable information and expertise was the most important
component of this practice. This experience has greatly influenced my future
aspirations and enabled me to make more informed decisions about my course
selection and job route.
I had the opportunity to work in the Radar
and Electronic Warfare Systems design department at Aselsan during my summer
practice. I monitored relationships between divisions attentively and attended
meetings to witness knowledge-sharing and decision-making processes. I got the
opportunity to investigate the full project lifetime, from conception to
completion. It was a pleasant and eye-opening experience to build something
that would be used in real-life applications. It also confirmed that the
ability to generate organized and structured reports is just as important as
technical engineering expertise.
I learnt to use SIEMENS NX software in the
design department, broadening my skill set from theoretical learning to
practical implementation. Aside from engineering responsibilities, I got the
opportunity to watch administrative work and office practices, getting insight
into how a company operates as a whole. In addition, I investigated the
elements influencing a company's location selection, extending my awareness of
the complicated decision-making processes in industry.
Finally, summer practices in our field of study are essential for pupils. They offer an intensive workplace experience, bridging the gap between theoretical understanding and actual implementations. These internships are critical in assisting students in determining their career pathways, selecting appropriate courses, and making educated decisions about their future. Additionally, these techniques establish engineering ethics and obligations in students, developing them into well-rounded and responsible professionals. Overall, the ME 400 Summer Practice is critical in developing the future generation of mechanical engineers and providing students with the skills, knowledge, and mindset needed to flourish in their careers.
Yorumlar
Yorum Gönder