COTS - 1809 by RTC Media

September 2018, Volume 20 – Number 9 • cotsjournalonline.com

JOURNAL

The Journal of Military Electronics & Computing

Flexible Shafts in Aerospace Applications

A Tale of Two Computers

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The Journal of Military Electronics & Computing JOURNAL

COTS (kots), n. 1. Commercial off-the-shelf. Terminology popularized in 1994 within U.S. DoD by SECDEF Wm. Perry’s “Perry Memo” that changed military industry purchasing and design guidelines, making Mil-Specs acceptable only by waiver. COTS is generally defined for technology, goods and services as: a) using commercial business practices and specifications, b) not developed under government funding, c) offered for sale to the general market, d) still must meet the program ORD. 2. Commercial business practices include the accepted practice of customer-paid minor modification to standard COTS products to meet the customer’s unique requirements. —Ant. When applied to the procurement of electronics for he U.S. Military, COTS is a procurement philosophy and does not imply commercial, office environment or any other durability grade. E.g., rad-hard components designed and offered for sale to the general market are COTS if they were developed by the company and not under government funding.

SPECIAL FEATURES 16

Steve Grimes, Director, Sales & Marketing, S.S. White Technologies, Inc

SYSTEM DEVLOPMENT 20

DEPARTMENTS

Flexible Shafts in Aerospace Applications

06 Publisher’s Note

2019 Predictions for the Defense Industry

The Inside Track

A Tale of Two Computers Yazz Krdzalic, Trenton Systems

COT’S PICKS 26

Editor’s Choice for September

COVER Pictured is the Vanguard-class submarine HMS Victorious. The Royal Navy has operated the UK’s Continuous at Sea Deterrent since 1967 when the first SSBN – or Ship Submersible Ballistic Nuclear – HMS Resolution began patrolling armed with the Polaris missile system. In 1996 HMS Vanguard, the first submarine armed with the Trident missile system, arrived on the Clyde and took over deterrent patrol duties from the Resolution Class.

COTS Journal | September 2018

The Journal of Military Electronics & Computing

JOURNAL EDITORIAL INTERIM EDITORIAL DIRECTOR Glenn ImObersteg, glenn@convergencepromotions.com SENIOR EDITOR Rob Hoffman, rob.hoffman@highassure.com MANAGING EDITOR Bryan Ruiz, bryandruiz22@gmail.com

ART/PRODUCTION CREATIVE DIRECTOR & LAYOUT Designs by Dave, drdesignservices@ymail.com DIGITAL MARKETING MANAGER Kyle Mac, kmac038@gmail.com

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COTS Journal | September 2018

PUBLISHER’S NOTE

John Reardon, Publisher

2019 Predictions for the Defense Industry Each year about this time we feature editorial describing the 10 hottest technologies for the coming year or some other matrices that we hope will reflect positively on our Editorial knowledge of the industry. This year was no different – I reviewed breakthroughs in cyber-security and found a prediction that a major Cloud provider would be hacked in 2019. (I thought that won’t be good). I look at predictions from industry leaders and found that Marc Cuban is predicting the individual who becomes our first Trillionaire will be the one who has mastered Artificial Intelligence. Somehow I thought that was a pretty safe bet. I saw that Elon Musk was expressing fear over AI – something about it taking over the world. Years ago I hired Ray Kurzweil, Author and self-proclaimed “futurist” to speak at an event I was producing. I thought this is a good “Gig” if you can get it. As he spoke I couldn’t

COTS Journal | September 2018

help thinking about Gene Roddenberry and how his fantastic mind came up with things like the Communicator or the Transporter on Star Trek. Somehow the TV program made these concepts and ideas seem much more feasible. Although I don’t have a TV show and normally I shy away from writing about the future, here are a few of my predictions for 2019: Cyber security Three things will occur in this area over the next year. The first will be that sensitive data will continued to be pushed to the cloud. Artificial Intelligence will be used to determine anomalies that indicate possible threats and finally deployed systems will be discrete and isolated.

UAVs The current trend towards remotely piloted vehicles will continue. The economics and the ability to keep humans out of harms way is hard to deny. The issues that this will bring will surge counter drone measures in the same ways as the shark repellant industry surges after Shark Week. Unlike the might of an American Aircraft Carrier or F-18 aircraft, UAVs will allow foes that are bit short in the pocket book to cause fear and insecurity that will result in dynamic growth in counter drone measures. Big Data and Analytics My only experience in Big Data is a magazine’s subscriber list, but it seems clear that the old adage of “Garbage In, Garbage out” remains intact. For 30 years my parents lived in a house that had the same address and phone number – with no concerns. Today scientist and Engineers are hoping to use data to predict threats, battlefield simulations, likely enemy strongholds etc. In 2019, emphasis will be redirected towards the quality and not the quantity of data. The predictions that “Dark Data” – the 90+ percentage of data derived from sensors that are never used – being a multi-billion dollar market will evaporate. Predicting the weather and the stock market will remain examples of how far we have to go and terms like “fuzzy Logic” will creep back into our vocabulary.

be a technology looking for an application, while Augmented Reality will capture our attention and become a more comfortable euphemism for the space. Robotics This is a confused space and any prediction of growth would seemingly be an easy one, but it is the rate of growth that I believe will remain unchanged over prior years. Our imaginations have come alive with the possibilities of AI and Machine learning, but robotic assembly was introduced in 1913 by Henry Ford and will continue to evolve at a slow and progressive rate. To believe that lithium batteries and surgical robots have caused a Gold Rush would be an exaggeration. The exuberance that we feel will soon return to more normal levels felt in prior years. Conclusion I enjoyed the opportunity to become a Futurist – even if it is short lived. I hope that 2019 brings peace and prosperity and that we all find benefit in using technology to address applications for a more peaceful world.

Quantum Computing It would be easy for me to predict that Quantum Computing will continue to evolve – that is simple enough. The issue with Quantum Computing is that of economics. The lack of a financial destiny will continue to delay any marketable advancement in 2019. Multi-threaded software solutions, multicore processors and highly distributed composable architectures will continue to advance causing a narrowing value to the theoretical value of a Qbit. Virtual Reality The VR world ebbs and flows with many companies spending large sums to offer an application that gains a foothold. Google, with their Google Glasses seemed to be a sure thing – before they shut the project down. The term that softens the impressions of VR is “Augmented Reality”. VR will continue to

COTS Journal | September 2018

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Sikorsky Wins $717 Million Award To Sustain Super Stallion And Sea Dragon Aircraft For The U.S. Marine Corps And U.S. Navy Sikorsky, a Lockheed Martin company, was awarded a performance-based logistics contract with a value of $717 million. The contract will provide supply and logistics support to the entire fleet of in-service CH-53E Super Stallions and MH-53E Sea Dragon helicopters. The H-53E is a battle proven heavy-lift helicopter continuing to support the U.S. Marine Corps and Navy in missions at home and around the world. The scope of the performance-based logistics contract includes repairs, overhauls, spares, obsolescence mitigation and asset management services over four years. Contract performance is based on material availability metrics with additional incentives added for demand reductions, maintainability enhancements and aircraft readiness contributions. “We expect the expanded performance-based logistics to measurably improve material availability and reduce support cost while increasing overall aircraft readiness,” said Pierre Garant, Sikorsky senior program manager,

Marine Corps In-Service Programs. “Our support infrastructure and past performance-based logistics successes will result in Sikorsky continuing to reliably provide mission support critical to the warfighter.” As the Marine Corps’ heavy lift-helicopter designed for the transportation of heavy material and supplies, the CH-53E Super Stallion is compatible with most amphibious class ships. With four-and-one-half hours’ endurance, the helicop-

ter can move heavy equipment over rugged terrain in bad weather and at night. The H-53E has consistently proven its worth to the fleet commanders with its versatility and range. The contract will provide the vital and affordable support to the entire fleet – expanding a reliable base of long-term sustainment as the aircraft continue to fully operate until the introduction of the replacement aircraft, the CH-53 King Stallion.

CH53 King Stallion

Avion Solutions, Inc. Wins AMCOM EXPRESS Award for Logistics Support for Unmanned Aircraft Systems (UAS) Project Office Avion is pleased to announce its award of the AMCOM EXPRESS task for Logistics Support to the Unmanned Aircraft Systems (UAS) Project Office; an award valued at ~$80M over 5 years. Avion will provide systems, subsystems, systems integration, and program logistics support/sustainment activities to UAS PO managed products including: Gray Eagle, Medium Altitude Endurance/Extended Range/Multiple Purpose; Tactical Concepts UAS: Hunter, Warrior-A, and Warrior-Block-0; Tactical UAS: Tactical Unmanned Aircraft Systems (TUAS), Small Unmanned Aircraft Systems (SUAS); Common Systems Integration (CSI) OSRVT, universal products; and joint operational systems, external State and Federal agencies, US State Department and Foreign Military Sales (FMS) UAS programs, and emerging developmental or non-standard UAS.

Gray Eagle Drone

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Boeing Launches New Organization to Unleash the Power of Advanced Computing and Networks in Aerospace New Disruptive Computing & Networks organization will operate as part of Boeing Engineering, Test & Technology

Boeing [NYSE: BA] today announced a new Disruptive Computing and Networks (DC&N) organization to develop computing and communications solutions for advanced commercial and government aerospace applications. By leveraging core technologies in quantum communications and computing, neuromorphic processing and advanced sensing, the new organization will enable Boeing to develop breakthrough solutions in secure communications, artificial intelligence and complex system optimization. In addition to building internal capabilities, DC&N will also work closely with Boeing HorizonX, the company’s innovation cell, to identify external partners for collaboration to accelerate growth. “Advanced computing and communications technologies are increasingly at the core of all aerospace innovation,” said Greg Hyslop, Boeing’s chief technology officer and senior vice president of Engineering, Test & Technology. “We’re excited to stand up the Disruptive Computing and Networks organization because it will help us develop new businesses and partnerships in this rapidly-expanding field, delivering more value to our customers and helping further define our second century of aerospace leadership” DC&N will be based in Southern California and operate as a part of Boeing Engineering, Test & Technology. Charles Toups, formerly the vice president and general manager of Boeing Research & Technology (BR&T), will lead the organization as vice president and general manager.

ing Defense, Space & Security, vice president of engineering for Boeing Defense, Space & Security, and vice president of Boeing Satellite Systems, where he led multiple commercial and government communication satellite businesses. Toups earned a bachelor’s degree in engineering from the University of California at Irvine, master’s degree in mechanical engineering from the Massachusetts Institute of Technology and master’s degree in business management from the Stanford University Graduate School of Business.cx Naveed Hussain will serve as the new leader of BR&T, the company’s advanced central research and development organization. BR&T is comprised of nearly 4,000 engineers, scientists, technicians and technologists who create and collaborate with research and development partners around the world to provide innovative systems and solutions to the aerospace industry’s toughest challenges. Hussain will have oversight of five facilities in the U.S. and six international research centers. Hussain is currently vice president of Aeromechanics Technology and leads the BR&T facility in Southern California. He has held a number of key leadership roles at Boeing since joining the company as a Howard Hughes Doctoral Fellow nearly 30 years ago. His accomplishments include leading Platform & Networked Systems Technology for BR&T, launching the BR&T-India research center in Bangalore and directing BDS Flight Engineering. Hussain earned his undergraduate degree from Rensselaer Polytechnic Institute, as well as a master’s degree and PhD in mechanical engineering from Stanford University. He also completed his MBA at the Wharton School at the University of Pennsylvania.

Prior to leading BR&T, Toups served in a number of senior engineering management and business positions at Boeing, including vice president and general man- Charles Toups to lead new organization ager of the Network and Tac- Naveed Hussain to become new leader of Boeing Research & Technology tical Systems division at Boe10

COTS Journal | September 2018

Mercury Systems Receives $6.7M BuiltSECURE Memory Order for Airborne Computing Application Mercury Systems, Inc., announced it received a $6.7 million follow-on order from a leading defense prime contractor for BuiltSECURE™ high-density secure memory devices to be integrated into the command, control and intelligence system of an advanced airborne platform. The order was booked in the Company’s fiscal 2019 first quarter and is expected to be shipped over the next several quarters.

Mark Aslett, CEO Mercury Computers

The Company’s BuiltSECURE technology transforms a two-dimensional array of discrete memory devices into a single, vertically-integrated memory module offering enhanced ruggedization for extreme operating environments. With space savings up to 85% enabled by this innovation, system architects can integrate larger memory capacities to support processing-intensive applications while simultaneously reducing the overall footprint of the system. BuiltSECURE memory devices are designed and manufactured in the Company’s Phoenix, Ariz. Advanced Microelectronics Center (AMC). “Our Advanced Microelectronics Center is honored to receive this follow-on order for space-saving, high-speed memory devices designed to withstand the harshest operating environments encountered by our warfighters,” said Iain Mackie, Vice President and General Manager of Mercury’s Microelectronics Secure Solutions group. “Receiving this order further reaffirms Mercury’s leadership position in the design and manufacturing of state-of-the-art, SWaP-optimized digital microelectronics in a safe, secure and trusted environment.”

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USAF Completes First Auto-Land Using MQ-9 BLOCK 5 Signals USAF’s Move Towards Increased Flight Automation for RPA

The U.S. Air Force (USAF) completed the first-ever automated landing of an MQ-9 Block 5 Remotely Piloted Aircraft (RPA), followed by the first auto-takeoff on August 9. The new Automatic Takeoff and Landing Capability (ATLC) was developed by General Atomics Aeronauti-

Marvin Test Solutions, Inc. is marking its 30th anniversary in the test and measurement industry. Since its founding in 1988, Marvin Test Solutions’ singular focus has been to Make Test Easy for automated functional test customers by creating innovative solutions with unrivaled long-term support. With three decades of hardware, software and system design expertise, MTS has been at the forefront of the latest technology advances, providing ATE (Automated Test Equipment) hardware, software, and integrated test solutions that combine quality, performance, reduced footprint, and ease of use, while meeting and exceeding the demanding test requirements of today’s complex military, aerospace, and manufacturing applications. “From the beginning, we believed there was a need for powerful test solutions that were easy

“This new, all-weather capability greatly increases the autonomy, flexibility, combat effectiveness and safety of the MQ-9 Reaper for the USAF,” said David R. Alexander, president, Aircraft Systems, GA-ASI. “Adding this level of automation will reduce the deployment burden of the warfighter and expand the scope of missions that can be flown by Air Force MQ-9s.” By automating the takeoff and landing of the RPA, ATLC helps to increase the safety and efficiency of the air-crews. The auto launch and recovery during these critical phases of RPA flight also enlarges the operational envelope for cross wind operations as well as divert field landing. The ATLC development program remains on track for fielding in the fall of 2019.

USAF MQ-9 Block 5 RPA

Marvin Test Solutions Marks 30 Years of Making Test Easy

cal Systems, Inc. (GA-ASI) to enhance mission capability.

to use and provided the performance and quality sought for by customers,” said Loofie Gutterman, President of Marvin Test Solutions and one of the company’s founders. “We could sum up our philosophy in a single phrase that is still true today – We Make Test Easy.”

Today, the company’s GENASYS mixed-signal test platform and suite of semiconductor test solutions bring the advantages of the flexible, scalable, PXI architecture to leading-edge test applications for mission-critical, high-value products from sensors to vehicles, aircraft to satellites.

Originally founded as Geotest, the company designed and manufactured integrated systems while developing its first hardware and software products. Its first software product, the ATEasy® test executive and test development suite, was released in 1991. Early on, Geotest recognized both the emergence of PC-based instruments as the ideal future test platform, and the advantages of a modular approach to designing test solutions. This commitment to industry standard modular design led to early active participation in the PXI Systems Alliance (PXISA), of which Loofie Gutterman is currently the president. By 2004, Geotest’s PXI portfolio exceeded 100 products.

Universal O-Level Armament Tester for AIM-120 Systems COTS Journal | September 2018

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Draper Off-the-Shelf Solutions Retooled for the Battlefield

When the DOD announced its Additive Manufacturing Roadmap in 2016, technology companies saw endless possibilities. If they could harness the potential of additive manufacturing (AM) to add features like antennas and sensors to off-the-shelf military equipment such as phones and computers, the door would swing wide-open. But in time, realizing the promise of additive manufacturing turned out to be more of a challenge than many thought. Additive manufacturing, also referred to as 3D printing, is versatile, flexible, highly customizable and, as such, can suit most sectors of industrial production. Materials to make these parts and objects can be of a widely varying type. They include metallic, ceramic and polymeric materials along with combinations in the form of composites, hybrid or functionally graded materials. The challenge remains, however, to transfer making the shapes and structures into obtaining objects that are functional. A great deal of work is needed in AM in addressing the challenges related to its two key enabling technologies, namely ‘materials’ and ‘processes,’ to achieve this functionality in predictable and reproducible ways.

Jennifer Jensen - Vice President for National Security & Space

COTS Journal | September 2018

Military applications of additive manufacturing face a particularly high bar if they are going to be modified for the battlefield. Products must be ruggedized, fit the warfighter, hardened and secure, according to Chris DiBiasio, Draper’s group leader for advanced manufacturing, who says it is important to remember that, in many cases, the operators of the equipment are soldiers, and their primary function is protection. DiBiasio manages Draper’s Additive Manufacturing Center, and he is familiar with modifying commercial off-the-shelf (COTS) computers, networking equipment and various technologies for the battlefield and other defense and commercial uses. Among the top requirements is to work within the tight confines of already-adopted product and technology platforms.

Avalex Technologies announces that National Grid Line Inspection UK has selected its widescreen Quad head display and HD DVR as part of the upgrade program for the Airbus AS350 and the BELL 429 helicopter. Fleet-wide upgrade to Avalex 17” widescreen HD displays and HD DVRs will help increase the efficiency and accuracy of National Grid Line Inspection’s use of helicopters to inspect the safety and integrity of its 14,000 km of electrical transmission lines.

“The challenge in additive manufacturing is how to add capability and functionality to an existing device or technology platform without adding too much weight, changing the device’s size or compromising the device’s native systems,” he said. Draper recently put this idea to the test by using additive manufacturing to print sensors onto a COTS hand-held communicator. Draper produced a scanned image of the communicator’s battery pack to find nooks and crannies where the new technology layer could reside, ported the image into a 3D CAD model, processed the CAD model with Draper’s proprietary software, converted the data into instructions for the 3D printer and then printed an ultra-thin, multi-stack layer of electronics. “The scripts and algorithm streamlined the 3D printing process and reduced 3D printing and assembly from a week to only a day or two,” said DiBiasio. The result was a communicator with new capabilities but no discernable change in its profile or weight. Military use of COTS and additive manufacturing is on the upswing. The Air Force recently launched a trusted computing program to give military access to COTS microelectronics. Elsewhere, the U.S. Army has announced plans to merge its additive manufacturing technology roadmap into an overarching DOD roadmap.

Avalex Technologies has announced that National Grid Line Inspection has selected its AVM4178Q 17” widescreen HD display and AVR8411 single-channel HD DVR as part of its video monitoring system upgrade on its fleet of U.K.-based Airbus AS350 and Bell 429 helicopters. “We are extremely proud that National Grid Line Inspections has put their trust in our new-generation widescreen displays and DVRs as part of their system capability upgrade,” Tony Hatten, Vice President of Business Development for Avalex Technologies said. “The enhanced capabilities of our new-generation video equipment will help enable National Grid crews to more accurately inspect and record the condition of more power transmission towers in less time.” “Prior to introducing helicopter-based inspections, it would take three workers a full day of dangerous work to inspect three towers,” he stated. “Now with the combination of advanced cameras and the Avalex HD monitors and DVR, one helicopter can check as many as eight tower structures for damage in about an hour. Plus, they have the added benefit of being able to record and share HD video with engineers back at National Grid’s headquarters for post mission analysis.”

The U.S. Army Awards Oshkosh Defense $49 Million to Bring Autonomous Technology to the Battlefield Oshkosh Defense, LLC announced that the U.S. Army Tank Automotive Research, Development, and Engineering Center (TARDEC) awarded Oshkosh a $49 million contract to integrate existing Palletized Load System (PLS) vehicles with scalable autonomous technology as part of the U.S. Army’s Expedient Leader Follower (ExLF) program.

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can significantly reduce our soldiers’ exposure to enemy threats by taking them out of the vehicle altogether.”

Under the contract, Oshkosh will integrate an initial 70 autonomy kits for Program Development and Operational Technical Demonstrations (OTD). The contract holds an

option to procure up to 150 autonomy kits.

“We are committed to bringing this life-saving technology to the battlefield,” Williams continued. “Through nearly 15 years of Oshkosh research and development, including independent and government testing, we are very proud to see this technology reach the U.S. Army fleets.”

The ExLF program addresses the needs of the Leader Follower Directed Requirement and Program of Record by removing soldiers from the vehicle while operating in highly-contested areas. Oshkosh autonomous technology was designed with the flexibility to be operated in a variety of modes, including leader-follower, fully autonomous, and tele-operation, to support manned or unmanned operations. “The PLS has been an integral part of the U.S. Army’s resupply and distribution fleet for over 25 years,” said Pat Williams, Vice President and General Manager of Army and Marine Corps programs for Oshkosh Defense. “By equipping these vehicles with autonomous capabilities, we

Milpower is selected to Support the Technologically Advanced Gremlins Program Dynetics was the recipient of the 21-month, Phase 3 award worth up to $38.6 million Tim Keeter, Deputy Program Manager and Chief Engineer

Secretary of the Army, Mark Esper (left), received a briefing on the self-driving “leader-follower” autonomous vehicle, the Oshkosh PLS.

for Gremlins at Dynetics, said, “Rapid development of innovative and complex systems like Gremlins drives us to identify and use system components with the highest reputation for reliability and performance. We are proud to have Milpower Source on our Gremlins air vehicle team.” As the supplier of numerous mission-critical

power conversion solutions for the Gremlins program, Milpower Source is encouraged by the Congressional recognition of the program. A member of the Senate Armed Services Committee, Senator Jeanne Shaheen stated, “I am pleased to see Milpower’s innovative technology furthering cutting edge efforts that support American defense initiatives. Developing the next phase of the Gremlins program continues New Hampshire’s long tradition of bolstering the United States’ national defense goals and objectives,” said Shaheen. “As a member of the Senate Armed Services Committee, I’ll continue to reach across the aisle to support this program to ensure investments in our national defense always remains a top priority.” Speaking about the power conversion solution for the Gremlins program, Joseph Widman, Gremlins Program Manager at Milpower Source, said, “we addressed the operational requirements through our advanced engineering design processes to exceed stringent environmental and mechanical requirements, primarily weight, without sacrificing performance. Milpower Source is excited to be part of the team and provide our unique ability to offer tailored power conversion solutions.” COTS Journal | September 2018

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Leidos Australia Awarded Land 2110 Phase 1B Chemical, Biological, Radiological, Nuclear Defence (CBRND) Project

Leidos Australia confirmed that it received award of the contract for Land 2110 Phase 1 from the Australian Department of Defense. The total value of the contract is $243.5 million over the Acquisition and Initial Support phase of five years.

capabilities are to enhance support to other government agencies in domestic CBRN incidents, and to assist integration in a coordinated whole of government effort. The project will deliver and sustain capabilities in Detection, Identification and

WhiteFox impresses U.S. DoD at world’s largest counter-drone testing event The tests showed how WhiteFox technology could become a pillar of defense in mitigating drone threats. WhiteFox Defense Technologies, Inc., a drone airspace defense and security company, had their flagship product, DroneFox, participate as selected equipment by the U.S. Government for the prestigious Black Dart counter-UAS and Red Teaming exercise last month. It was the first time WhiteFox had performed testing at Black Dart, the largest counter-drone testing exercise in the world. After only a brief training, military personnel were able to operate DroneFox to effortlessly detect, identify and mitigate drone threats that were sent by a contracted Red Team. WhiteFox participated alongside several Department of Defense organizations and civilian companies after passing the rigorous nine-month down-selection process. As UAS pose a unique and complex threat 14

COTS Journal | September 2018

“Leidos has a long heritage of delivering complex logistics and CBRND capability globally, and we are delighted to be chosen to deliver this critical capability to the ADF,” said Christine Zeitz, Leidos Australia Chief Executive. Leidos Australia has maximized Australian industry involvement to create local jobs through this important investment working with 14 Australian-based companies of which five are SMEs who will support capability delivery under the contract.

In partnership with the Capability Acquisition and Sustainment Group, Leidos will deliver critical capability to Defense in the area of Chemical, Biological, Radiological and Nuclear Defense (CBRND). The primary objective of the joint CBRND capability is to provide Force Protection to deployed Australian Defense Force (ADF) personnel, assigned coalition personnel, and designated civilians, both offshore and within Australia, against extant and emerging CBRN threats including environmental hazards. Additional objectives of the ADF’s CBRND

Monitoring, Warning and Reporting, Physical Protection, Hazard Management and Medical Support.

Gerry Fasano, President of Defense Group

that requires multiple layers of defense to comprehensively protect, public and private entities were encouraged to work together. Representatives of the U.S. Government saw how WhiteFox engaged with the entities and helped evolve security modeling along with techniques, tactics and procedures. Through the DroneFox user interface, operators were able to perform threat assessments of individual unknown or hostile drones and “whitelist” their own “friendly” drones. The military personnel operating DroneFox then relayed this information to remote personnel

Forty new jobs will be created under the acquisition contract to support the Government’s Sovereign Industrial Capability Priority of Test, Evaluation, Certification and Systems’ Assurance, and will help to ensure a skilled and sustained Australian workforce to support Australia’s unique requirements. A further ten new jobs will be created to deliver the Initial Support Phase. performing various ground operations at the exercise. The Department of Defense has hosted the invitation-only exercise since 2004 to test the capabilities of Department of Defense and civilian companies as unmanned aircraft systems (UAS) have become easier to own and use. More than 70 countries now use UAS for government or military applications, according to the Joint Integrated Air and Missile Defense Organization. FBI director Christopher Wray recently told a U.S. Senate panel that the threat from commercial drones “is steadily escalating” even as Congress gives agencies new tools to address these threats. The comments came just days after President Trump signed into law legislation that gives the Department of Homeland Security and the Department of Justice new powers to detect and mitigate drones that pose a threat to government and other sensitive assets.

SPECIAL FEATURE

Flexible Shafts in Aerospace Applications By Steve Grimes, Director, Sales & Marketing, S.S. White Technologies, Inc

In the aerospace industry, the importance of creating problem-solving technologies to meet the challenges of manufacturing highly complex, critically reliable machines cannot be overstated. In the history of aerospace manufacturing, there have been several innovative technologies that have changed the shape of flight. Some of these technologies arenâ&#x20AC;&#x2122;t well known or hugely influential on their own, like the propeller or jet engine, but are instead innovations that occurred behind the scenes, quietly enabling steady, vital improvements to aerospace technologies in various ways. One case in point is the flexible shaft.

Figure 1: A look at the inner construction of a flexible shaft

A flexible shaft is a highly effective means of transmitting rotary motion and is more efficient than universal joints, gears, sprockets and chains, and belts and pulleys. It is typically lower in cost than these other devices and offers the added benefit of compensating

for misalignments. Flexible shaft assemblies are successfully used in everything from 787 airplanes to childrenâ&#x20AC;&#x2122;s toys. Their exceptionally long lives are not affected by continuous operation at speeds up to 50,000 RPM, and

Figure 2: Two looks at flexible shafts used in TRAS on commercial aircraft 16

COTS Journal | September 2018

they can withstand temperatures ranging from -300 degrees to 1000 degrees Fahrenheit. Aerospace Applications Flexible shafts are used in a great variety

of aerospace applications, as their characteristics perfectly meet the challenges of aerospace manufacturing. Some common or especially vital applications include thrust reverser actuation systems (TRAS), flap actuation, valve override systems, pedal adjustment systems, rescue hoists, afterburner nozzle actuation, canopy actuation, refueling tubes, and more. Flexible shafts are a key part of TRAS systems on many large commercial aircraft. TRAS systems are essentially an engine break for these aircraft. Located at the back of the engine, the thrust reverser of a turbo fan / jet engine essentially closes the by-pass and diverts the thrust forward to slow the plane. In forward motion, the thrust comes in the intake and out the exhaust and by-pass. In the stop motion, the thrust comes in the intake and since the by-pass is closed, the thrust reversers divert the by-pass flow through forward facing matrices, causing the plane to stop. There are four flexible shafts used in this system, which synchronize and connect the actuators that open both halves of the thrust reverser. There are two other flexible shafts used in the trans cowl lock, which keep the TRAS from deploying while in flight. Another notable application in which flexible shafts are deployed is in the flap and slat systems, especially on slightly smaller aircraft, such as business jets. Flaps and slats are moveable wing surfaces that extend during takeoff and landing to change the wings’ profile to produce “high lift” at lower airspeeds. During flight, flaps and slats retract to reduce wing area and drag at higher speeds, increasing efficiency. The configuration of a flap and slat control system is very similar in most aircraft. Each surface is driven by linear actuators, which are connected to a transmission system centrally controlled from a power drive unit. Flexible shafts transmit the rotary motion from the motor out along the wing to drive the actuators that enable the flap and slats to extend and retract. An especially demanding application in which flexible shafts are used is that of fighter jet afterburner nozzle control systems. A fighter jet afterburner is comprised of a set of fuel injectors, a tube, a flame holder that the fuel burns in, and an adjustable exhaust nozzle. The actuators controlling the nozzles opening and closing are driven and synchronized by a series of flexible shafts that ring the engine. These flexible shafts are highly engineered to withstand the extreme temperatures and torque loads presented by this demanding application.

Figure 3: A jet afterburner up close. Flex shafts drive the actuators that open and close it.

Why Flexible Shafts? While some applications in which flexible shafts are deployed appear extremely complex or demanding, other applications seem straightforward. However, flexible shafts are a constant in all these applications. In fact, flexible shafts are often the preferred choice in aerospace applications for rotary motion transmission over gear boxes, universal joints, and belts-and-pulleys.

Why is it that flexible shafts are the best technology to use in so many aerospace applications? There are a number of reasons, and while many of these reasons depend upon the specific application at hand, there are other, more general reasons for the flexible shafts’ superiority that hold true across almost all applications. In general, flexible shafts are the preferred COTS Journal | September 2018

rotary motion transmission device because they: • Eliminate alignment problems: Flexible shafts have no need for the tight tolerance that solid shafts require. • Are more efficient: Flexible shafts are typically 90 to 95 percent efficient. Gears, U-joints, belts and pulleys have much lower efficiencies due to greater frictional losses. • Are both lightweight and powerful: Flexible Shafts have a 3:1 weight advantage over other design solutions while transmitting greater power loads. • Are less susceptible to vibration: Vibrations, a constant occurrence on aircraft, do not affect flexible shafts performance. • Reduce parts cost: Bearings and housings for solid shafts and gears require precise machining operations. Flexible shafts eliminate the need for such demanding tolerance and their excessive costs. • Are easy to install: Flexible shafts can be installed without the need for precise alignment or special installation tools. • Have a lower installation cost: Flexible shafts install in minutes without special tools or skills. Solid shafts, gears, pulleys, and universal joints require precise alignment and skilled mechanics for their installations. • Allow large off-sets: Flexible couplings allow only five degrees of off-set and U-joints 30 degrees, but with a 40 percent-50 percent decline in efficiency. Flexible shafts permit a

COTS Journal | September 2018

full 180 degree off-set while maintaining their high efficiency. • Can be designed in the latter stages of a project: Unlike other rotary motion devices that need to be designed around because of their rigidness, defined configurations, and large mass, flexible shafts allow greater design freedom because engineers have only one piece to work on, eliminating complex coordination of multiple pieces. • Provide greater design freedom: Flexible shaft technology offer limitless possibilities in position motor and driven components. The last point is especially important. One company, S.S. White Technologies, has been designing flexible shafts since 1874 (interestingly, the first one was used in dental equipment) and are now a leading manufacturer of them for aerospace applications. Many of S.S. White’s flexible shafts are designed custom for each application to maximize their efficiency and effectiveness. This is part of the beauty of the flexible shaft. Each individual flexible shaft assembly can be carefully designed and created to meet the needs of a specific application. If one application needs exactly this much torsional strength or power, the flexible shaft can be made to match that exactly. This is not easy to do. Flexible Shafts are a surprisingly complex product and is not easily modeled by simple calculations. For example, one of the most challenging aspects

of designing a flexible shaft is balancing the opposing properties of bending flexibility and torsional deflection. For S.S. White technologies, this problem is solved with a program called Perflexion, a proprietary computer modeling software based on the pioneering work of Dr. Adam Black. It is a powerful tool that allows design engineers to optimize the performance characteristics of a Flexible Shaft. Prior to the use of Perflexion it was nearly impossible to optimize one of a flexible shaft’s characteristics. With Perflexion, S.S. White can now fully model the behavior of all the wires within a flexible shaft and arrive at a design that provides maximum bending flexibility while allowing minimal torsional deflection with 20 to 30 percent improvement above accepted industry standards. S.S. White can serve as an example of the limitless possibilities held by flexible shafts in aerospace applications. When transmitting rotary motion , especially in a tight space, the flexible shaft cannot be beat in its efficiency, effectiveness, cost, versatility, and durability. An argument can be made for the flexible shaft being one of the backbones of the aerospace industry, and it isn’t difficult to see why. From windshield wipers to TRAS systems to jet afterburners, flexible shafts are there, doing their job quietly and efficiently, unbeknownst to many, but indispensable to all.

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SYSTEM DEVELOPMENT

A Tale of Two Computers By Yazz Krdzalic, Trenton Systems

A story about the importance of hardware revision control

Your Project is finished! However, not long after you are done celebrating you find that someone downstream from you made a change that’s now causing computer failures in the field. How could this happen?

it is the worst of times…. Let’s explore the life of two industrial computers - one with hardware revision control and one without - and see how their lives change over time... Both Computers start out their lives the same. Months were spent carefully writing the specs and selecting the correct components. Even more time and effort was spent in the lab getting everything up and running and verifying that everything works perfectly. Maybe you even spent months getting the appropriate industry certifications and testing done (CE, UL, shock, vibration, etc.) You’re proud of your project. You were involved in that first whiteboard design and now you’re looking at this amazing thing that you invented! As a designer, you’re finished and ready to put a bow on it; time to pass it along to production and the customer. But Then…

Revision Control One computer was under proper revision control. Every component is considered locked down unless approved by an engineer. Proper BOM (Bill of Material) control and quality processes are in place so that purchasing, production, and even the repair department can request changes that must first be 20

COTS Journal | September 2018

approved. This revision control requirement is also pushed down to your critical suppliers so that they can’t try to make changes that they consider an “equivalent or better.” Proper quality control (both incoming and outgoing) processes and documentation are in place to ensure that nothing slips through. Quality assurance and revision control are ingrained into the culture…and it shows year after year in your consistently low failure rate and your consistently happy customers!

No Revision Control Once our computer was passed to purchasing and production there was little concern to lock down the exact components. Cost, lead times, alternate sources for components, and manufacturability are all important factors, but they should have been considered earlier when everyone is able to make “improvements” as they see necessary. Now the computer that you invested so much time in does not look the same as you intended. With the best intentions, people downstream from you made changes that they didn’t realize would impact the form, fit, or function…and now you are having failures in the field.

So, what exactly is Hardware Revision Control If any change impacts the form, fit, or function of your system, then that change falls under hardware revision control. Form - physical size and visual parameters of a specific component Fit - the component physically interfaces with the rest of the system correctly

Function - the intended action of the part or component is correct There are many common-sense changes to your computer systems that everyone would understand affects the form, fit, or function.

in your application or long-term reliability concerns. If somebody downstream from you decides for cost, lead time, or convenience to change to a spinning disk hard drive, then the long-term consequences could be hidden and catastrophic.

1. CPU - If someone buys a less expensive CPU with a lower frequency then there will likely be performance issues with your application.

Let’s Illustrate how important yet subtle revision control changes can be.

2. Hard Drive - You may have selected a solid state hard drive because of vibration issues

Take a look at the two computers below and try to spot the difference between them.

Can you spot the difference?

The model numbers are the same, the serial numbers are very close (only 5 numbers apart), but they were manufactured 3 months apart. The computers are different in a very important way. Still don’t see it? Let me help you… The computer on the bottom doesn’t have the power supply cables sleeved correctly (see closeup views on next page for better detail). I know what you’re thinking…

COTS Journal | September 2018

Power supply sleeved correctly

This is too insignificant of a difference – but although small, it can have a large impact in a customer’s application.

Consider this It’s going on a military ship where there will be long-term, consistent vibration and those power cables are not protected from rubbing against the metal chassis. This vibration would pass almost any extended burn-in and quite possibly pass any visual inspection (remember it’s been 3 months since that inspect or has seen that model number).

Power supply sleeved incorrectly

There are many more examples where the need for rev(s) on control is less obvious, but no less important. Lets say that your processor board supplier decided that the tolerance on the VRM (voltage regulator module) should be +/- 5% rather than the +/-3% that your originally approved. This save your supplier a dollar or to and may have extended the product lifecycle a little (In general these are very good things), but the ripple effect of this subtle change will not be found during your visual inspections or in your functional burnin testing… but eventually you’ll see a high failure rate from the field.

It’s important to note There are some changes that people downstream from you can make that would most certainly not affect your form, fit, or function. Processor Board Supplier Maybe the supplier for your processor board finds an alternate source from a second supplier on a 100uf cap that has the same specifications. You probably don’t want to be bothered with this type of change so long as your supplier has proper approval processes (an engineer signed off on the change) and traceability (when was the part approved and when did production begin using it). It’s important to remember that hardware revision control not only pertains to component selection, but also to manufacturing processes. A lot has changed in the way we manufacture computer boards over the past decade or two. RoHS (restriction of hazardous substances) requires higher temperatures with newer manufacturing equipment. Water-wash vs no-clean flux. X-ray vs AOI for inspection. Different PCB bareboard manufacturers use different stack-ups for the same board that result in variability in trace thicknesses. The bottom line, make sure to pay attention to manufacturing processes and not just component selection.

COTS Journal | September 2018

Hardware Revision Control Reliability Availability Serviceability No matter how well designed your system may be, it is inevitable that eventually something will fail. Now you need to go to stock or back to your computer supplier and get the exact same model number. Without stringent, long-term revision control processes in place are you confident that the new unit will act properly? We normally think of RAS as making sure that the computer does not fail (High-Availability) and if it does fail then how quickly can we get it back up and running. I would like to elaborate on RAS and argue that there is a direct correlation between the level of hardware revision control and RAS reliability. If your computer hardware remains consistent throughout the whole product lifecycle then you will certainly see improved reliability. You’ll never be able to quantify how bad your failure rate would have been without proper revision control; but with revision control processes in place you can rest assured that you created the best, most consistent product possible.

Your customer expects that their system will be operational 99.999% of the time. Inconsistencies in the components and manufacturing processes will directly affect your uptime and cause the system to be nonoperational. Any down time is unacceptable and your customer expects that you have control over all of the processes that are in your control and that is pushed down to your suppliers as well. No matter how well designed your system may be, it is inevitable that eventually something will fail. Now you need to go to stock or back to your computer supplier and get the exact same model number. Without stringent, long-term revision control processes in place are you confident that the new unit will act properly? So… how can I ensure proper revision control?

The effect on revision control on the product lifecycle Many engineering projects take months, or possibly years, to go from concept to produc-

tion. The problem is that the average computer is only available to buy for a year or two. Even industrial computer companies average 2-3 years for availability. Note that your development process probably didn’t line up exactly with the computer manufacturer’s initial release date… so that means that your actual availability / lifecycle is even shorter. This short product lifecycle does make revision control much easier. They do not need to worry as much about parts going EOL (Endof-Life), manufacturing processes changes, etc. Most likely you will want to get as much return on the development investment you made. It is important to note that some computer suppliers provide a much longer product lifecycle. Also, we typically think of computers always needing to be on the cutting edge and constantly refreshing the hardware, but many applications value consistency and longevity more than the latest and greatest technology trends. A longer Product-lifecycle exponentially complicates hardware revision control. Now there are long-term impacts when any one parts goes obsolete. The processor boards have a

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few hundred unique components that must be carefully controlled, Windows may stop selling the OS that was originally approved, check how long will this hard drive be available, how stable is the company that you have sourced the computer, etc.

el. Anything that is beyond your computer supplier’s control is at risk. Be careful when you select non-embedded, long-life 3rd party components (e.g. GPU card, hard drives, etc) since the level of control is typically very limited and will likely become obsolete before the other computer components.

1 Built into the Company Culture Quality Assurance and a revision control mindset must be built into the culture. I have joked that if I walked around Trenton Systems and said we were not going to worry about revision control then I would likely get a standing ovation. It impacts everything we do from the first whiteboard concept drawing/planning, inventory, repairs, and all the way through the EOL notice that we typically send out 11+ years later. Make sure that your computer supplier is ISO 9001 certified and has a long, proven track record of consistently building the same products. Your computer supplier should also welcome you to visit / audit their facility and processes at any time. Talk directly with their quality people and their engineers.

3 Technology availability Up front in the design be careful to not only select products with longer-life availability, but also consider which technologies will likely be around in 10-15 years. Spinning hard drives, DVD-ROMs, and PCI slots are already headed down a path where they will not be around much longer. Whereas PCI Express and USB will likely be around for a long time and hopefully remain backwards compatible when newer versions are released.

2 Bill of Materials Revision Control BOM (Bill of Materials) revision control from the chassis down to the resistor lev-

COTS Journal | September 2018

4 Processes and Documentation Processes and documentation cannot be emphasized enough. Thorough incoming inspection, automated programming (BIOS, firmware, etc), assembly pictures and procedures, automated functional burn-in, and thorough outgoing quality controls are all vitally important. Make sure that the engineering department is involved in any potential changes in form, fit, or function and

that everything is signed off appropriately by various departments (engineering, purchasing, production, quality, etc). Documentation is even more important with high-mix (the computer supplier builds many various model numbers) and sporadic assembly (your specific configuration is not being actively built every single day by the same assemblers). 5 Communication with your customers Communication with customer is key to long-term success. Make sure your computer supplier knows your expectations up front. Make sure they understand that your application must be consistent and reliable. Make sure that they have a proper process in place to officially notify you of any form, fit, or function revision changes.

At the end of the day Your project that you’ve created and nurtured will only be as reliable and consistent as the revision processes and procedures you put in place. I know it’s tempting to always push forward with the next design, the next technology, and the next application…but consistency and reliability are underappreciated, yet vitally important, virtues.

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September 2018

COT’S PICKS Microsemi RTG4 FPGAs Become Industry’s First High-Speed Signal Processing Radiation-Tolerant FPGAs to Achieve QML Class V Qualification Designation Enables Space Customers to Leverage RTG4 FPGAs’ Easy Prototyping and Fast Design Timess Microsemi Corporation, a wholly owned subsidiary of Microchip Technology Inc. announced its RTG4 FPGAs, a high-speed signal processing radiation-tolerant field programmable gate arrays (FPGAs) have achieved Qualified Manufacturers List (QML) Class V qualification by the Defense Logistics Agency (DLA). The designation, the highest level of qualification for space components and a necessary step to satisfy mission assurance requirements on many space programs, opens the door for Microsemi’s RTG4 FPGAs to be used on the most critical space missions with the highest standards for quality and reliability. As the first and only radiation-tolerant FPGA offering more than 150,000 logic elements to achieve a QML Class V qualification, Microsemi’s RTG4 FPGAs can now be used by developers in Class 1 space flight systems, bringing the cost and schedule advantages of FPGAs to the most demanding space missions. Many space programs

WIN Enterprises Announces 2U HPC Server with New Generation Intel Xeon Scalable Processors WIN Enterprises, Inc, announces the PL81970, a dual-socketed, high performance, high bandwidth 2U High Performance Computer (HPC). The server supports two scalable 64-bit Intel® Xeon Skylake-SP processors for use in Cloud and Call Center applications. Robust I/O capabilities provide application flexibility, easy manageability,

The PL-81970 26

COTS Journal | September 2018

are constrained to use these Class V-qualified components due to the need for the highest level of quality and reliability, and until now have been unable to use a high-speed radiation-tolerant FPGA in their signal processing systems. RTG4 FPGAs now fill this void in the marketplace, providing more signal processing bandwidth than has been previously available in radiation-tolerant non-volatile FPGAs and enabling designers of satellite on-board data processing systems to take advantage of the easy prototyping and fast design cycle times FPGAs provide. “We believe it’s critical to support our customers with the availability of our flagship radiation-tolerant FPGAs qualified to the stringent QML Class V standard—the highest qualification level for integrated circuits operating in space,” said Minh Nguyen, Microsemi’s senior marketing manager of space and aviation. “This designation is the culmination of hundreds of thousands of testing hours, and underscores the high reliability of these unique devices as well as our team’s deep experience in developing radiation-tolerant FPGGAs with industry-leading flight heritage.” Granted by the DLA, NASA and the U.S. Air power efficiency, and faster data throughput. Two Nvidia Tesla GPU cards are featured to support demanding HPC and hyperscale data center workloads. Redfish is supported to deliver simple and secure management for converged, hybrid IT and the Software Defined Data Center (SDDC). FEATURES • Dual-Socket Intel Xeon Scalable Processor • Support for two Nvidia Tesla GPU cards

Microsemi’s RTG4 FPGAs

Force Space and Missile Command (represented by The Aerospace Corporation), the QML Class V qualification is a strong endorsement by recognized subject matter experts on the quality and reliability of RTG4 FPGAs. This validation is increasingly important as a growing number of satellites are being built to perform a wide variety of missions, including imaging, communications, navigation, science and monitoring of weather, climate and natural resources. Many of these systems require the highest level of component quality, particularly when large revenue streams depend upon the satellites functioning correctly, or when there are national security considerations. Microsemi www.microsemi.com

• 12x 3.5” SATA 6G Drive Bays and 2x 2.5” SATA 6G Drive Bays • AST2500 BMC with Redfish Support • 850W/1300W/1600W 1+1 Redundant CRPS PSU • 6x GbE plus 4x 10GbE SFP+ ports The PL-81970 platform can be modified based on the customer’s unique market requirements. WIN Enterprises www.win-ent.com

September 2018

COT’S PICKS Embedded 3D image processing from Vision Components

Vision Components has developed new 3D laser scanners with powerful integrated electronics. The VCnano3D-Z-series embedded vision systems are compact, lightweight, and easy-to-in-

tegrate in OEM applications. They contain a Xilinx Zynq SoC, which comprises a dual-core ARM processor and an FPGA. In order to determine line coordinates in laser triangulation, a point cloud has to be calculated. In the new sensors, this is done in the FPGA – the programmable circuit processes large amounts of data without delay. Thus, full processor power remains available for application-specific tasks. The laser profilers provide scan rates of up to 2 kHz. Featuring a 1-Gbit Ethernet interface, they are ideally suited, amongst others, for real-time applications in robotics, for example, for welding robot guidance and adhesive bead tracking.

VadaTech Announces new Xilinx Zynq UltraScale+ FPGA board with TCI6638 Multicore DSP+ARM VadaTechannounces the AMC541. The AMC541 couples Xilinx Zynq Ultrascale+ XCZU19EG MPSoC FPGA with the TCI6638K2K communications KeyStone SoC to provide a high performance wireless infrastructure module.

Vision Components . www.vision-components.com

XIMEA announces Cooled range of sCMOS cameras including Backside illuminated models Increased challenges in Scientific field and industrial applications require further enhancement in camera quality and XIMEA is preparing a combination of models based on the newest Scientific CMOS (sCMOS) sensors divided into versions with Thermoelectric Peltier cooling or PCI Express interface which delivers their full speed potential. The whole range of cameras is equipped with sCMOS sensors handpicked from the extraordinary line introduced by Gpixel inc., concentrating on excellent low noise values, high Dynamic range and including Backside illuminated models with unbelievable Quantum efficiency numbers. To utilize these exceptional parameters the use of both

Rolling and Global shutter option is available. The Rolling shutter mode offers lowest achievable noise and highest sensitivity which results from the symbiosis of USB3 and TE cooling arranged through Peltier. The sensor models that are best for such combination are GSENSE2020BSI and GSENSE400BSIwith the Dark noise down to almost 1e- and Quantum efficiency up to 95%. The Global shutter capture presents a compromise of the sensor sensitivity values, but really shines at frame rates which are provided with the help of PCIe interface. This is particularly useful in case of high resolution and large format sensors streaming 2x 12bit ADC. Sensors suitable for such bandwidth boost are for example GSENSE5130 and GSENSE6060BSI. XIMEA www.ximea.com

Zynq Ultrascale+ XCZU19EG MPSoC FPGA includes embedded Quad-core ARM Cortex-A53 application processing unit, Dualcore ARM Cortex-R5 real-time processing unit, ARM Mali - MP2 GPU. The FPGA has Dual banks of 64-bit DDR4 memory (one bank to the ARM Core and one bank to the FPGA) and includes an SD card. The TCI6638K2K communications infrastructure KeyStone SoC is a member of the C66x family based on TI’s new KeyStone II Multicore SoC Architecture designed specifically for high-performance telecommunication, IoT and networking applications. It features eight TMS320C66x DSP core subsystems (C66x CorePacs). The TMS320C66x interfaces to dual 64-bit wide DRAM DDR-3. The flexible AMC541 architecture allows the FPGA and DSP to interface to the AMC connector in different configurations. The AMC connector ports 2-3 and 8-11 are linked directly to the FPGA for the core to interface with the host through protocols such as SRIO, PCIe or 10/40GbE. The ports 4-7 can connect directly to the FPGA in addition to ports 8-11, or connect directly to the DSP with SRIO protocol via MUX (DIP-switch selection). The module also routes GbE on ports 0 and 1 per AMC.2 and the DSP and FPGA are linked via PCIe x2 and GbE. The onboard, re-configurable FPGA interfaces to the AMC FCLKA ( fabric clock) and TCLKA-D (user clocks and triggers) via a clock and jitter cleaner. There is also a front panel TRIG IN and CLK IN to the clock and jitter cleaner – the three front panel SFP+ cages allow expansion via fiber or copper interface. VadaTech www.vadatech.com

COTS Journal | September 2018

September 2018

COT’S PICKS

Annapolis Micro Systems Integrates FireFly™ Optical System for Highest Density & Performance

Director of Marketing, Samtec Optical Group. “Our collaborative approach to system design enabled Annapolis as an early adopter of our new

28 Gbps per lane optical transceivers.” Annapolis Micro Systems Inc. www.annapmicro.com

Annapolis Micro Systems is not integrated Samtec’s FireFly Optical Systems into multiple high-performance COTS boards, for maximum signal density and speed over longer distances. “The FireFly enables our FPGA boards to rapidly process huge volumes of data from an optical network,” said Noah Donaldson, Annapolis Micro Systems Chief Technology Officer. “With converters increasingly positioned close to the sensor, optical I/O is becoming more prevalent in multi-function EW, phased array radar, cybersecurity network processing, and high performance financial computing.” “The Annapolis Micro Systems embedded computing portfolio maximizes FPGA bandwidth density with our optical FireFly™ Micro Flyover System™,” said Arlon Martin, Sr.

Acromag’s New Multi-function I/O XMC Mezzanine Modules Feature A/D, D/A, and Digital I/O Channels to Conserve I/O Slots The XMC730 provides flexible, high-density I/O with high-performance DMA to solve a variety of SWaP-challenges BAcromag expands their general purpose I/O offering with an XMC version of their very popular PMC730 multi-function I/O module. The

XMC730 performs analog input, analog output, digital I/O and counter/timer functions. Three models provide front 68-pin SCSI-2 I/O connection or rear P16 and P4 I/O connectors. These boards are designed for commercial off-the-shelf (COTS) applications providing an abundance of I/O options to save I/O slots. A variety of carrier cards are available to host up to two XMC730 modules on VPX or PCI Express computer platforms. A conduction-cooled version is also offered, and boards start at less than $1,800. I/O options include 16 differential or 32

single-ended analog inputs, eight analog output channels, 16 bidirectional input/output channels and 32-bit multi-function counter/timers. The DMA transfer support moves data between module memory this frees the CPU from the burden of moving data between Module memory and System memory over the PCIe bus. “With the ever-increasing use of 3U and 6U VPX, we saw the need to re-invent the PMC730 card in an XMC version,” stated Russ Nieves, Acromag’s Vice President of Sales. “This allows customers to take advantage of increasing speed requirements, but still maintain the flexible I/O configurations that the XMC730 will offer them at a very affordable price.” For connectivity with real time software application programs, Acromag offers C libraries for VxWorks®, Linux®, and Windows DLL Driver software. The libraries provide generic routines (source code included) to handle reads, writes, interrupts, and other functions. Demonstration programs enable the developer to quickly exercise the I/O modules before attaching the routines to the application program. This diagnostic tool can save hours of troubleshooting and debugging. Acromag www.acromag.com

COTS Journal | September 2018

September 2018

COT’S PICKS OpenVPX Platform Accelerates Development of Boards for DoD Tri-Service Convergence Initiative System includes new SOSA slot profiles developed for C4ISR convergence program To support the rapidly developing activities begun under the C4ISR Modular Open Suite of Standards (CMOSS) initiative, Elma Electronic has released a 3U OpenVPX Convergence Platform. The new platform serves as a complete test environment to enable the integrated development of common, modular hardware architectures across critical C4ISR and EW systems. Built on Elma’s sturdy, easy-access E-frame test chassis, the new development platform enables system engineers to test a range of boards that meet profiles designed for use in various DoD program requirements, significantly streamlining engineering efforts and reducing time and cost to deployment. Ken Grob, director, embedded computing business development, for Elma, noted, ”The military’s shift towards modular, open standards-based hardware and software is fueling

High Performance, Fast Graphics and Media Processing in a Small Compact Design Amplicon, the UK market leading manufacturer of industrial computers, has introduced the Impact-D 100AL – their first ever DIN Rail PC to feature Intel® ATOM™ processors. The new system comes equipped with an extensive range of I/O ports offering maximum flexibility as well as impressive graphics capabilities. The Impact-D 100AL is powered by the new Intel® ATOM™ Apollo Lake processors, offering exceptional performance, extensive expansion and unrivalled availability with an operational lifecycle of 15 years, all within a compact and reliable design. Designed to outperform in the most demanding environments, the Impact-D 100AL utilises a compact fanless design, protecting

the need for reliable methods to quickly test hardware components across different platforms. This new development kit enables system developers to cost-effectively test and validate a wide number of hardware configurations.“ Initially, separate program efforts were undertaken by the US Army under CERDEC (CMOSS), the U.S. Navy under NAVAIR (HOST) and the Air Force under AFLCMC (SOSA) to move away from costly proprietary systems to COTS-based open standards. Each initiative was created to facilitate the development of interoperable systems across several defense branches to improve subsystem SWaP, enable rapid technology insertion and promote reuse. Now managed entirely under SOSA, this collection of open architecture hardware and software standards is aimed at providing reconfigurable, upgradeable and cost-effective C4ISR capabilities in deployed platforms across sensor appli-

cations throughout all major military branches. One of the tasks of the SOSA and HOST working groups is to define 3U and 6U slot profiles required to build OpenVPX-based subsystems for the tri-service convergence initiative. The first series of profiles was developed and submitted for inclusion in the VITA 65.0-2017 specification. Additional 3U and 6U profiles are being developed to take advantage of the new VITA 67.3 connectors to meet the needs of SIGINT, EW and SDR system requirements. Elma Electronic www.elma.com

against dust and particles commonly found in manufacturing facilities. In addition, the new unit offers an impressive standard operating temperature of -20°C to 70°C, with options for -40°C to 80°C, making it ideal for outdoor operations such as Transport and CCTV surveillance. The Apollo Lake processors provide 4K immersive graphics and fast video acceleration, making the Impact-D 100AL an exceptional solution for the most demanding media output tasks including in-vehicle usage or on-board entertainment. The Impact-D 100AL also offers users a wide range of I/O, with additional Digital I/O on the front panel for more complex procedures, such as industrial automation. Furthermore, the Impact-D 100AL provides cellular and WiFi capabilities for applications requiring offsite connectivity or remote operation. Amplicon www.amplicon.com

COTS Journal | September 2018

September 2018

COT’S PICKS We are pleased to present DDC’s latest press release titled: “DDC’s NAND Flash Chosen for the NASA BioSentinel CubeSat Spacecraft

radiation hardened with radiation mitigation RADPAK® technology, offering best-in-class spot shielding. RAD-PAK® enables DDC to deliver the latest commercially available microelectronics in a space qualified package, providing designers with a high performance space grade solution at a reduced cost. RAD-PAK®-based solutions offer a total dose immunity of 100 krads or higher, and have been qualified by NASA, ESA, JAXA and thousands of missions for over 20 years without any flight failures.

Data Device Corporation (DDC) proudly announces that our radiation harden memory has been selected to be integrated within the Pearl Single Board Computer (SBC), that is used as the flight computer on NASA’s BioSentinel CubeSat spacecraft. The Pearl SBC, along with DDC’s flash memory, is baselined for use on multiple upcoming missions for both NASA and the DOD.

• Benefits: • Proven Reliability • Hermetically sealed ceramic flat package with RAD-PAK® radiation-hardened shielding • RAD-PAK® packaging technology has been qualified by NASA, ESA, JAXA and thousands of missions for over 20 years without any flight failures • Optimized Performance • High density – Based on up to eight 32 Gb x8 NAND flash die (256 Gb), supports higher speed designs with less capacitance and fewer I/O’s to drive • Single Level Cell (SLC) Technology – offers fast read and write capabilities and boot times, along with excellent endurance and reliability

BioSentinel is a NASA space mission designed to study the effects of solar radiation on organisms. BioSentinel will be deployed as part of the first flight of the Space Launch System (SLS). SLS is the largest rocket ever developed, and will enable astronauts to explore destinations far into the solar system. DDC’s 192 gigabit NAND flash provides the CubeSat spacecraft with compact, high density memory, along with the advantages that a 24-bit bus configuration provides, allowing the use of TMR (Triple Modular Redundancy) error correction, for seamless operation without failure. DDC’s NAND flash is

Mercury Systems Announces HighPerformance Compute Blade for Artificial Intelligence and Other Advanced On-Platform Processing Applications Scalable Xeon and UltraScale FPGA processing power, and extensive memory packaged in rugged, secure, small form-factor blade for deployment anywhere

ANDOVER, Mass. - Sept. 13, 2018 - Mercury Systems, Inc. announced the EnsembleSeries™ LDS3517 processing blade for advanced onplatform processing, machine learning and artificial intelligence (AI) applications. Each blade combines an Intel Xeon® D server-class processor, a Xilinx® UltraScale® FPGA and a mezzanine site in a 3U OpenVPX™ form-factor. Wafer-stacking and systemin-package (SiP) miniaturization technologies

“We have worked on many space projects with NASA, and we are pleased that they continue to value the high reliability of our space products, along with the advanced functionality and performance that DDC is able to deliver, utilizing our space proven and qualified RAD-PAK® technology”, stated DDC Space Business Unit Manager, Dan Veenstra. Data Device Corporation www.ddc-web.com

Dan Veenstra, Space Business Unit Manager

enable the latest general and FPGA processing capabilities, their extensive supporting memory and a versatile mezzanine expansion site to fit into this compact form-factor. The LDS3517 blade is ideally suited to on-platform cognitive electronic warfare (EW), next-generation radar, machine learning and AI applications that require small, powerful and scalable processing engines. Optionally configured with embedded BuiltSECURE™ systems security engineering and packaged with modified-offthe-shelf-plus (MOTS+) technology, the LDS3517 compute blade can support military missions anywhere. “Our customers are asking us for small, powerful processing blades they can run their most computeintense applications on and these resources need to be rugged and secure for deployment at the tactical edge,” said Joe Plunkett, Mercury’s Senior Director and General Manager for Sensor Processing Solutions. “The EnsembleSeries LDS3517 meets these needs, making all manner of new missions possible from advanced on-platform electro-optical/infrared (EO/IR) and EW cognitive processing to platform autonomy and AI.” Mercury Systems, Inc. www.mrcy.com

COTS Journal | September 2018

September 2018

COT’S PICKS

Ultra slim single board computers (SBC) expand possible applications

DATA MODUL reacts to the constantly increasing demand for faster, more efficient and, at the same time, well-designed boards with their own ultra slim SBC development, the eDM-SBCiMX6-PPC. In sensitive sectors such as medicine, these SBCs are used particularly frequently, as they are generally more vibration and shock resistant than module-based systems. With the SBC form factor, especially designed for slim PPCs, DATA MODUL is standardizing ARM boards for the first time, as these allow the slim implementation of particularly popular display formats such as 7’’, 10.1’’ 12’’ and 15.6’’. Standard kits, consisting of display, the easyTouch sensor, also developed by DATA MODUL, controller and corresponding cabling, also only require short lead times. DATA MODUL has specialized in mechanical integration and, to achieve an optimum casing construction, design and function aspects with regard to material, dimensions, production possibilities and feasibility must be analyzed. Speakers, cameras, light conductors, semi-transparent surfaces and specific surface roughness of the front frame are challenges when developing a casing concept.

COTS Journal | September 2018

The demanding EMC requirements and the heat management systems are taken into account at all times by the DATA MODUL construction department. Slim format for efficiency and design With its 130mm x 80mm dimensions, this format offers 30% more room in width and thus allows more leeway for interfaces than Pico-ITX (100mm). To be able to make use of the maximum installation space behind a 7’’ LCD, the height was increased to 80 compared to the Pico-ITX of 72 mm. The assembly can reach the extremely low depth of maximum 13 mm by using flat connectors, where the mating connectors are applied at the side. In this way, no installation height is lost through the connection of the interfaces and the network cable bushing (RJ45) remains the highest point of the assembly. To become even flatter, an integrated version was used which finally led to a top level of 8.2 mm from the top edge of the circuit board. Fitted with the NXPi.MX6 ARM Cortex A9 processor family, scalable from 1 to 4 ARM cores, the (long-term) availability of the CPU is guaranteed until 2028. It has a sophisticated high-end 3D-capable HD graphics interface. Single supply

DC was implemented as a power supply. A 12VDC +/-5% or a wide range input with 16VDC to 32VDC can be selected via the equipment option. The 2 x 24 Bit LVDS interface allows the connection of LC displays with a resolution of up to 1920x1200 pixels (WUXGA). The backlight supply with PWM dimming is already available. A micro HDMI socket was included as an external graphics interface. The assembly is designed for the extended temperature range and can also be delivered painted if required (conformal coating) to avoid short circuits in humid ambient environments. Up to 2 GB of main memory and up to 64GB of eMMC SDD can be soldered and a WIFI/ BT module (M.2 standard) can be optionally fitted. Along with the mPCIE interface for the optional extensions with standard modules, 4 x USB 2.0, 1 x Gigabit ethernet, audio with amplifier, SPI, 2 x CAN /UART and 8 GPIOs have been brought out. The micro SD card socket on the bottom side also enables to expand with cheap mass storage devices for data collection. DATA MODUL www.data-modul.com

A50_COTs_2_25x9_875.qxp_A45.qxd 7/23/18 11:12 A

September 2018

COT’S PICKS

Abaco Launches SRS6000 MultiChannel Synchronous Receiver System to Significantly Reduce Time to Market for Advanced Electronic Warfare Applications • Can synchronize up to 32 1GSPS ADC channels out of the box • Eight SRS6000s can be daisy-chained for synchronization of 256 channels • Features remarkable picosecond accuracy • Provides a migration path to VPX

Abaco Systems announced the SRS6000 Multi-channel Synchronous Receiver System. Designed for customers developing advanced, high channel density electronic warfare and SIGINT applications, it can significantly reduce time to market. The SRS6000 leverages Abaco’s leadership and brings a new level of application-specific functionality, helping customers accelerate their development process and get to a solution faster by obviating the need for in-house development that can be time-consuming and costly. The SRS6000 is unique in a number of ways. Out of the box, it delivers the ability to synchronize up to 32 1GSPS ADC channels with a remarkable picosecond jitter. It is also scalable, with the potential to daisy-chain up to eight systems for a total of 256 synchronized channels in the most demanding applications. The SRS6000 also features an auto-calibration capability, meaning that it will automatically adjust its calibration routine in response to changes in cabling or setup. Migration to a

deployed, rugged 3U VPX system is straightforward. Target applications include MIMO radar, beamforming, direction finding and multi-channel listening. “Multi-element arrays like those found in radar and other RF apertures are increasingly driving the requirement for tight synchronization between many channels – sometimes in the thousands,” said Peter Thompson, Vice President, Product Management at Abaco Systems. “The SRS6000 provides the precision and channel density required by many of these applications.”

“Ensuring synchronization and deterministic latency through calibration is critical in any system - but calibrating a system with multiple converters can be a challenge to achieve,” continued Thompson. “The SRS6000 is designed for customers looking to jumpstart an electronic warfare or SIGINT development and who need to accelerate their proof of concept. It provides a new degree of precision, performance and extensibility – while at the same time helping customers minimize the time, cost and risk involved in bringing advanced electronic warfare solutions to market.” With two Intel® 2.2GHz Xeon E5 processors and five Xilinx® Ultrascale™ FPGAs, the SRS6000 provides server grade processing for the most computationally-intensive applications. Additionally, PCIe™ Gen3x8 and FireFly™ x8 fiber optic interconnects provide extreme throughput for powerful streaming. Abaco Systems. www.abaco.com

DC-DC Converters Transformers & Inductors DC-DC Converters 2V to 10,000 VDC Outputs 1-300 Watt Modules

• MIL/COTS/Industrial Models • Regulated/Isolated/Adjustable Programmable Standard Models • New High Input Voltages to 900VDC • AS9100C Facility/US Manufactured • Military Upgrades and Custom Modules

Transformers & Inductors

Surface Mount & Thru Hole

• Ultra Miniature Designs • MIL-PRF 27/MIL-PRF 21308 • DSCC Approved Manufacturing • Audio/Pulse/Power/EMI Multiplex Models Available • For Critical Applications/Pico Modules, Over 50 Years’ Experience

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PICO ELECTRONICS, Inc. 143 Sparks Ave., Pelham, New York 10803 Call Toll Free 800-431-1064 FAX 914-738-8225

E Mail: info@picoelectronics.com

COTS Journal | September 2018

COTS COTS

Index

ADVERTISERS

Company Page# Website Atrenne Integrated Solutions ............ 34 ................................... www.atrenne.com Behlman Electronics ......................... IFC .................................. www.behlman.com Chassis Plans .................................... 15 .......................... www.chassisplans.com Interface Concept ............................... 23 ..................... www.interfaceconcept.com Mercury Systems ................................ 4 ................................. www.tms.mrcy.com MPL ................................................... 34 ............................................. www.mpl.ch North Alantic Industries .................... 25 ......................................... www.nail.com OSS ................................................... 19 ...................... www.onestopsystems.com Pentek ............................................. BC .................................... www.pentek.com PICO Electronics, Inc ........................ 33 ....................... www.picoelectronics.com Red Rock Technologies, Inc .............. 34 ............................ www.redrocktech.com SkyScale .......................................... 8 ................................... www.skyscale.com Supermicro ...................................... 31 ............................. www.supermicrot.com Trident infosol .................................. IBC ............................... www.trident-sff.com Vicor Cororation................................ 5 ............ www.vicorpower.com/defense-aero

COTS Journal (ISSN#1526-4653) is published monthly at; 3180 Sitio Sendero, Carlsbad, CA. 92009. Periodicals Class postage paid at San Clemente and additional mailing offices. POSTMASTER: Send address changes to COTS Journal, 3180 Sitio Sendero, Carlsbad, CA. 92009.

SFF Chassis Enables Mini-ITX Modules in Airborne Platforms

Add Removable SSDs To Your VME System

Atrenne Integerated Solutions has announced an extension to the Small Form Factor (SFF) 760 Series electronic packaging design which enables off-the-shelf Mini-ITX and PCIe commercial electronics CCA’s to be deployed in airborne applications that reach stratospheric altitudes, well above 50,000 feet. Commercial components are typically not designed to operate in reduced pressure environments. For example, standard aluminum electrolytic capacitors, are designed for atmospheric pressure corresponding to 10,000 feet and below. Atrenne created a hermetically sealed rugged enclosure which maintained an atmospheric pressure of one atmosphere at all times, essentially simulating a lab operating environment. In order to maintain a seal, Atrenne employed a gasket able to buffer mechanical occlusions between the two precisely machined aluminum surfaces of the enclosure. Atrenne also developed a creative solution to maintain a seal around fiber optic cables, I/O cables and connectors. The solution also incorporated workmanship standards, and design for vibration, shock, and temperature. With a robust enclosure design, the system was able to meet stringent application requirements by isolating sensitive internal electronics from the harsh external environment.

• VME boards with SATA, USB or SCSI interface • Fixed or removable options using COTS SSDs • Removable module rated for 100,000 mating cycles • Discrete controlled military secure erase options • P2 adapters available

Red Rock Technologies, Inc. Brocton, MA • (508) 588-6110 • www.atrenne.com 34

COTS Journal | September 2018

info@redrocktech.com www.redrocktech.com (480) 483-3777