Aerospace & Defense

April 2014 Welcome to your Digital Edition of Aerospace & Defense

Technology The Attack-Counterattack Game Small Form Factor Strategies for Military Embedded Systems Covert Infrared Battlefield Combat Taggants More Electric, Integrated Fuel Systems April 2014 Inside the UK’s Advanced Manufacturing Research Center

www.aerodefensetech.com Supplement to NASA Tech Briefs

How to Navigate the Magazine:

At the bottom of each page, you will see a navigation bar with the following buttons:

➭ Arrows: Click on the right or left facing arrow to turn the page forward or backward.

Intro Introduction: Click on this icon to quickly turn to this page.

Cov Cover: Click on this icon to quickly turn to the front cover.

ToC Table of Contents: Click on this icon to quickly turn to the table of contents.

+ Zoom In: Click on this magnifying glass icon to zoom in on the page.

– Zoom Out: Click on this magnifying glass icon to zoom out on the page.

A Find: Click on this icon to search the document.

You can also use the standard Acrobat Reader tools to navigate through each magazine. ➮ Intro Cov ToC + – A ➭ RFID: Simulation of a reader-transponder pair for radio-frequency MHIRXM½GEXMSRETTPMGEXMSRW6IWYPXWKMZIXLIQYXYEPMRHYGXERGIERH WLS[XLIQEKRIXMG¾Y\JVSQXLIXVERWTSRHIVERXIRRE

VERIFY AND OOPTIMIZEPTIMIZE YOURYOUR DESIGNS WITHTH COMSOL MULTIPHYSICS ®

Multiphysics toolssletyoubuildsimulationsthataccurately let you build simulations that accurately replicate the important characteristics of your designs. The key is the ability to include all physical effects that exist in the real world. To learn more about COMSOL Multiphysics, visit www.comsol.com/introvideo

Product Suite

COMSOL Multiphysics ELECTRICAL FLUID MULTIPURPOSE INTERFACING AC/DC Module CFD Module Optimization Module LiveLink™ for MATLAB® RF Module Mixer Module Material Library LiveLink™ for Excel® Wave Optics Module Microﬂuidics Module Particle Tracing Module CAD Import Module MEMS Module Subsurface Flow Module ECAD Import Module Plasma Module Pipe Flow Module LiveLink™ for SolidWorks® Semiconductor Module Molecular Flow Module LiveLink™ for SpaceClaim® LiveLink™ for Inventor® MECHANICAL CHEMICAL LiveLink™ for AutoCAD® Heat Transfer Module Chemical Reaction Engineering Module LiveLink™ for Creo™ Parametric Structural Mechanics Module Batteries & Fuel Cells Module LiveLink™ for Pro/ENGINEER® Nonlinear Structural Materials Module Electrodeposition Module LiveLink™ for Solid Edge® Geomechanics Module Corrosion Module File Import for CATIA® V5 Fatigue Module Electrochemistry Module Multibody Dynamics Module Acoustics Module

© Copyright 2012–2014 COMSOL. COMSOL, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, and LiveLink are either registered trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and MXWWYFWMHMEVMIWERHTVSHYGXWEVIRSXEJ½PMEXIH[MXLIRHSVWIHF]WTSRWSVIHF]SVWYTTSVXIHF]XLSWIXVEHIQEVOS[RIVW*SVEPMWXSJWYGLXVEHIQEVOS[RIVWWII[[[GSQWSPGSQXVEHIQEVOW

Free Info at http://info.hotims.com/49744-864 ➮ Intro Cov ToC + – A ➭ April 2014

The Attack-Counterattack Game Small Form Factor Strategies for Military Embedded Systems Covert Infrared Battlefield Combat Taggants More Electric, Integrated Fuel Systems Inside the UK’s Advanced Manufacturing Research Center

www.aerodefensetech.com

Supplement to NASA Tech Briefs ➮ Intro Cov ToC + – A ➭

Free Info at http://info.hotims.com/49744-827 ➮ Intro Cov ToC + – A ➭

Free Info at http://info.hotims.com/49744-834 ➮ Intro Cov ToC + – A ➭ Aerospace & Defense Technology Contents

FEATURES ______40 Chrono: A Parallel Physics Library for Rigid-Body, Flexible- Body, and Fluid Dynamics 6 Weapons Technology 42 Terrain Model as an Interface for Real-Time Vehicle Dynamics 6 The Attack-Counterattack Game Simulations 10 Surveillance & Security DEPARTMENTS ______10 Covert Infrared Battlefield Taggants 4 What’s Online 16 Small Form Factor Computing 35 Technology Update 16 Small Form Factor Strategies for Military Embedded Systems 44 Application Briefs 22 Propulsion: Energy Storage 46 New Products 22 More Electric, Integrated Fuel Systems 48 Advertisers Index 26 Materials & Composites ON THE COVER ______26 Toward Smarter Manufacturing and Materials 30 RF & Microwave Technology Signals intelligence, radar and communications are just some of the military applications being support- 30 RF FPGAs for Multi-Function Systems ed with small form factor computers and software 33 3D Software Helps Development of Vehicle-Mounted Defense radio boards these days. To learn more, read the Systems feature article on page 16. Illustration courtesy of Pentek 38 Tech Briefs 38 Software for Material/Structural Characterization Across Length Scales 39 Model Development Using Accelerated Simulations of Hypersonic Flow Features

2 Free Info at http://info.hotims.com/49744-829 Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Welcome to our Satellite Office

With hundreds of space missions under our belt, Coilcraft CPS is well positioned for all your aerospace applications

Space is no place for commercial-grade components. We also offer comprehensive product testing and That’s why leading aerospace companies rely on validation services in accordance with established Coilcraft CPS for proven RF and power magnetics industry standards, as well as custom screening to featuring: your electrical and physical specifications. • Custom termination plating including Sn/Pb and Gold Learn more about how our deep • Extended temperature ranges (-55°C to +300°C) space experience can help your • Vibration testing to 80 G / shock testing to 1000 G design take flight. Call or • Low outgassing to NASA specifications visit coilcraft-cps.com today!

* Coilcraft CPS parts are available with or without ITAR compliance.

800.981.0363 847.639.6400 www.coilcraft-cps.com

Free Info at http://info.hotims.com/4974- ➮ Intro Cov ToC + – A ➭ What’s Online

Top products Top articles Engine fuel pump bushings Predicting cavitation in fuel pumps Metallized Car- Liquid ring pumps are used in aircraft fuel systems in bon Corp.’s Metcar conjunction with main impeller pumps and serve the func- carbon-graphite tion of removing fuel vapor and air from the fuel. Thus, bushings offer ad- their reliable functioning plays a critical role in the safe op- vantages over tra- eration of aircraft during flight. Read more at http:// ditional metals for articles.sae.org/12709. use in gear pumps that pump aviation fuel for aircraft engines. The carbon-graphite bushings are used to support both the drive gear shaft and the idler gear shaft. The bushings are preferred for this application because they can use aviation fuel as the bushing lubricant. The bushings are self-lubricating—they can run dry for short periods of time without catastrophic pump failure or significant wear. In addition, they are dimensionally stable, which permits close bushing-to-shaft running clearances. More detail at http:// articles.sae.org/12700.

Lightweight compression latch The E3 Vise Action Compression Latch from Southco Inc., The same mesh was used for both the multiple reference frame and the sliding delivers robust, vibration-resistant fastening. The latch is suit- mesh calculations to achieve mesh consistency between the two models for able for use in a variety of transportation applications and relative comparison and assessment. across numerous other industries. It features lightweight, aluminum construction and provides higher strength and supe- Boeing examines expanded metal foils for lightning rior cycle life for heavy-duty installations. Commonality with protection of composite structures existing products allows for simplified installation. More de- A widely used material for lightning strike protection of tail at http://articles.sae.org/12701. CFRP structures within the aerospace industry is expanded metal foil (EMF). An issue with EMF is micro cracking of the Microwave analog signal generators paint, which can result in corrosion of the metal foil and sub- Agilent Technologies Inc.’s N5183B MXG and N5173B sequent loss of conductivity. Read more at http:// EXG microwave analog signal generators provide the sig- articles.sae.org/12712. nal purity, output power, and modulation developers need for advanced radar, electronic-warfare, and satellite- Falcon 5X gets advanced avionics communications applications. The N5183B MXG analog Dassault Aviation has built into its upcoming Falcon 5X offers accuracy and efficiency in two rack units. Its best- flight controls and displays experience not only from the in-class phase noise of less than -124 dBc/Hz (at 10 GHz, Falcon family of business jets but also from the Rafale multi- 10 kHz off-set) and -75 dBc spurious enables module- and role combat fighter. Read more at http://articles. system-level testing up to 40 GHz. It also accelerates the sae.org/12728. calibration of complex systems with best-in-class switching speed of less than 600 μs. More detail at http:// SR-72 flies into 21st century at Mach 6 articles.sae.org/12702. Lockheed Martin recently confirmed that its Skunk Works engineers are developing a hypersonic aircraft that will go High-power TIG welders twice the speed of the SR-71 Blackbird, called the SR-72. Read The Dynasty 280 and Maxstar 280 TIG welders from more at http://articles.sae.org/12619. Miller Electric Mfg. Co. deliver more power and can weld metal up to 3/8 in thick, yet are significantly lighter, Thermal management for fuel-cell systems studied more portable, and use less energy than machines of sim- A cooling architecture should be designed in a way that ilar output capabilities. Weighing 52 lb and 47 lb, respec- cooling loops and heat sinks are used by different heat tively, the Dynasty 280 and Maxstar 280 deliver up to 280 A sources, researchers at the Hamburg University of Technology of output power along with a smooth, stable arc to handle say. Read more at http://articles.sae.org/12737. any job from small to large. More detail at http:// articles.sae.org/12698.

4 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Building Bright Ideas At Proto Labs, we accelerate innovation by turning brilliant concepts into real parts in days.

Proto Labs serves as a catalyst for product designers and engineers when real, functioning prototype parts are needed fast. Just upload a 3D CAD model for an interactive quote within hours. When ready, our Firstcut CNC-machining and Protomold injection-molding services can produce up to 10,000+ metal and plastic parts in as quick as one day. That means you can fail fast, iterate faster (and more often), and conﬁ dently launch your product to market before competitors.

Injection Molding Part Design for Dummies Request your free book at protolabs.com/parts Enter code DB14B2 Major Credit Cards Accepted | ISO 9001:2008 Certiﬁ ed | ITAR Registered © 2014 Proto Labs, Inc. | protolabs.com | 877.479.3680

Free Info at http://info.hotims.com/49744-831 ➮ Intro Cov ToC + – A ➭ The Attack- Counterattack Game Leveraging Digital RF Memory Electronic Jammers for Modern Deceptive Electronic Attack Systems

Modern aircraft feature a variety of electronic counter measures for protection.

n the world of electronic counter systems enable the testing and verifica- produces a false return signal by playing measures (ECM), there is a con- tion of weapon and defense systems back the recorded signal. This false sig- stant battle of one-upmanship, against an enemy’s ECM techniques. nal deceives the enemy system so that it Iwhere each side is continually in- Armed with this knowledge, you can sees the false return as a real target. The novating to stay ahead of the other. develop capabilities to counter any elec- enemy then tracks the false target in- ECM are typically developed and imple- tronic countermeasures they employ. stead of the real one. mented to thwart an adversary’s specific As an example, assume enemy radar radar technology. To be effective, Elec- Denial Jamming has detected a fighter jet and starts tronic Attack* (EA) systems must be able One EA technique is denial jamming. tracking it. If the fighter has an EA sys- to identify emitters in the environment Put simply, if an enemy system emits tem on-board using a DRFM-based jam- and then selectively attack with specific one frequency with a particular pulse- mer, this system can detect the enemy techniques. They must also possess the width and pulse interval, your system radar, ingest the signal and create a false ability to attack multiple emitters simul- detects and identifies that signal. It return to the enemy radar. This false re- taneously with a combination of non- then blasts a massive amount of noise at turn can take several variations includ- coherent and coherent jamming tech- that frequency, jamming the enemy ing “ghosting” so that the enemy radar niques. and preventing that frequency from thinks that the target plane is in a dif- As an example, assume a missile sys- being used. The next move belongs to ferent location. DRFM-based systems tem is targeting an enemy aircraft. To the enemy radar, which might simply are highly effective at accomplishing confuse the oncoming missile, the jump to another frequency. Think of it this based on their extremely low la- enemy aircraft triggers an ECM. The as a countermeasure followed by a tency and ability to faithfully reproduce goal of the ECM is to deny or deceive counter-countermeasure. Then the de- returns with all the signal characteris- the incoming missile’s targeting system tection game starts again. tics of the radar source. The goal is to so it will miss the aircraft. In order for make the enemy radar think that the re- the missile to succeed against various Deceptive Jamming turn signal is from the target rather ECM techniques, the missile’s targeting A step above denial jamming is de- than generated by a jammer. system must be “taught” to counter the ceptive jamming. Deceptive jamming In order to do this effectively, the countermeasure. requires a higher level of sophistication DRFM must faithfully reproduce the This attack-counterattack game has and this is where Digital RF Memory characteristics of modern radar systems given rise to the need to develop elec- (DRFM)-based jammers come into play. including frequency and phase modula- tronic attack (EA) systems that mirror A DRFM-based jammer receives and tions on signal pulses. An advanced enemy techniques in order to test U.S. records the frequency, pulse-width and DRFM-based EA system also adds the and allied systems performance. These pulse interval of an enemy system and necessary modulations to the return sig-

* Electronic attack (EA) or electronic countermeasures (ECM) involves the use of electromagnetic energy, or counter-electromagnetic radiation weapons to attack personnel, facilities, or equipment with the intention of directly affecting, degrading, neutralizing, or destroying an enemy’s combat capability.

6 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ s Precision Metal Stamping (High and Low Volume) s Welded and Mechanical Assemblies s Complex CNC Machining s Rapid Prototyping s Close Tolerance Grinding s Tooling, Fixtures and Gages s Laser Cutting and Welding s Wire EDM

Free Info at http://info.hotims.com/497- ➮ Intro Cov ToC + – A ➭ Weapons Technology

nal, such as Doppler frequency modulation to match the range rate of the false target. Lastly, an EA system using a DRFM follows any changes in signal characteristic produced by the enemy system in order to deceive the enemy system into “believing” that the false target being generated is real. This takes the focus away from the actual target and protects it.

Threat Analysis Anticipating the capabilities of an adversary’s ECM system is a key component to reducing the vulnerability of friendly radar systems to new techniques. Mean- while, adversaries are constantly attempt- ing to develop radar systems less suscepti- Various methods, such as anechoic chambers, are used to test the effectiveness of ECMs. ble to being jammed. This ongoing cat-and-mouse game is what pushes industry innovation forward. The best way to ensure that an adversary cannot counter friendly radar and weapons systems is to test against actual enemy jammers. In the U.S., that is where the test and evaluation (TE) community comes into play. The TE community is composed of various agencies within the Navy, Air Force and other governmental agencies. They assess and analyze any existing or future ECM weapon systems that present a threat to U.S. or allied systems and warfighters. It is the goal of the TE community to ensure that electronic systems are not vul- nerable to jamming techniques. The TE community collects signals intelligence data or predicts signal trends in order to identify the capabilities of enemy EA systems. Using this information, ECM techniques can be generated which mirror the behavior of enemy systems. The TE community then tests these techniques against U.S. and allied High performance EA systems are radars and weapons systems to deter- critical for producing DRFM decep- mine their level of jamming success. tive jamming.

Various Testing Scenarios Simulated RF Environments: There are multiple ways to test the effective- interrupt a radar system’s ability to ac- countermeasures can be generated to ness of electronic systems. In one testing quire and track a target. further simulate the RF environment. scenario, an EA technique can be posi- Some systems for test laboratories and Depending on the application, an ac- tioned against a radar system in a labora- anechoic chambers feature radar envi- tual plane or missile seeker can be tory or anechoic chamber. By running ronment simulators (RES). State-of-the- brought into a test chamber. Their the EA system in this type of setting, it is art RES systems generate targets, radars are tested to determine if they possible to safely and cost-effectively de- weather, and other obstacles that a radar can still track simulated targets amidst termine if a jamming technique is able to would normally encounter. Electronic standard ECM techniques.

8 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Weapons Technology

Flight Systems: A second testing niques, a jammer simulator can be pro- ments and to generate particular jam- method calls for the mounting of an grammed to mimic the capabilities of ming techniques. EA system on an aircraft. An adversary an EA system. The fidelity of the simula- ECM system, or an ECM system which tion can be evaluated for analysts to Conclusion simulates the adversary system, can be generate a validation report to be used DRFMs play a critical role in ECM and placed in a pod that is mounted on an- by the TE community for test planning. hence, in EA developments. By leverag- other plane’s wing. The two planes are Validated simulators can be used ing information captured from present then flown against each other in an ex- against radar to verify the radar’s ability and future enemy systems, DRFM-based ercise which allows military analysts to operate in the presence of a particular test systems can be employed to test and/or pilots to see exactly what the EA system and to minimize the system’s new EA systems and verify whether or aircraft’s radar displays in a real com- vulnerability to jamming. not these systems will succeed. With the bat situation. growing reliance on electronic attack ECM systems can also be placed in Roles and Responsibilities systems to protect warfighters and unmanned drones, which are then tar- It is important to note that the TE equipment, continuous testing and up- geted by actual missiles. In this case, if community is set up to coordinate the dating is required. And leveraging the missiles never reach the drone, it vulnerability testing for electronic sys- DRFM-based test systems fills this need would verify the effectiveness of the tems and then make determinations in a modular, programmable, and cost- ECM system. This level of real-life test- based on its findings. It is their job to effective manner. ing eliminates any suppositions or esti- identify which systems work against This article was written by Tony Girard, mations by engineers. which techniques, and to what degree. Director of Engineering, Mercury Defense Jammer Simulation: Jammer simula- Additionally, the TE community — not Systems (Cypress, CA) – a subsidiary of tion is the third EA testing method. the supplier of the EA test asset — is re- Mercury Systems, Inc. For more informa- When armed with the knowledge of sponsible for programming the EA sys- tion, visit http://info.hotims.com/49744- specific jammer methods and tech- tem to make specific signal measure- 500

,LPK!EK@A HS=UOKJPDABNKJPHEJA

From hi-rel specialty photodetectors to high power LEDs, Opto Diode products have been serving the military and defense industries since 1981. Every Opto Diode product is designed, manufactured, High Power LEDs, Silicon Photodetectors & High Level Assemblies and tested in our own U.S. facility to meet the most Ŗ#=OPLNKPKPULEJC rigorous functional and environmental standards possible. Ŗ%ECDHUNAHE=>HA=J@NALA=P=>HA Our wafers, manufactured in our state-of-the art wafer ŖQPKI=PA@LNK@Q?PEKJ fab, allow for cost-effective high-volume production. We Ŗ KILHAPAPAOPEJC?=L=>EHEPEAO can also provide comprehensive testing of chips, wave- Applications lengths, and output power. *EHEP=NU!ABAJOA Do what some of the most prominent military and REKJE?O ,J0DKNA,J1EIA,J Q@CAP defense suppliers in the world do. Call us. Opto Diode. EKPA?DJKHKCU For standard and custom products designed to serve. *A@E?=H 0?EAJPEł? /! Member of the ITW Photonics Group KIIAN?E=H 750 Mitchell Road, Newbury Park, CA 91320 805.499.0335 Fax 805.499.8108

Free Info at http://info.hotims.com/49744-833 www.optodiode.com ➮ Intro Cov ToC + – A ➭ Surveillance & Security

Covert Infrared Battlefield Combat Taggants

odern warfare often involves poorly defined battle lines accompanied by multi- Mlevel fire support systems that can deliver firepower with high precision and devastating lethality from a long distance. The ability to immediately and accurately discriminate through sight between friend and foe is of great importance to military operations for effectively destroying hostile forces while preventing fratricide. This ability is even more crucial for irregular and unconven- tional warfare such as anti-terrorism operations where US forces often engage enemy combatants well entrenched in urban settings or rugged terrains at night. In such battlefield conditions, using conventional daylight and thermal imagery often exceeds the ability to accurately identify targets as friend or foe, and more reliable battlefield identification methods are needed.

Tagging, Tracking and Locating Figure 1. Optical taggants can be used effectively in battlefield situations known as “identification friend Tagging, tracking and locating repre- or foe (IFF)”. Here a hyperspectral imager from the air identifies friendly soldiers in the general area where sent a valuable technology for both both sides are present. (Diagram courtesy Brimrose Corporation) commercial and military applications. For military operations, the tagging sys- tagging system consists of three essen- Organic dyes with fluorescence max- tems (taggants and detectors) must sat- tial parts: infrared emitting (or absorb- ima extending to far near IR and into isfy three basic requirements: covert- ing) taggants, photodetectors, and an short wave IR (SWIR) can be achieved ness, (i.e., signals cannot be easily intelligence interface. Certain materials by the formation of metal ion com- detected by common techniques), quick can emit infrared light through chemi- plexes. The most notable group of met- and accurate identification from a long luminescence, photoluminescence or als whose ions are capable of narrow distance (up to a mile or farther), and electroluminescence. band infrared emission is the lan- both lightweight and ruggedness suit- There are three general groups of in- thanide series with atomic numbers 57 able for field applications. Other impor- frared emitting materials: organic IR to 71 (lanthanum to lutetium). Lan- tant criteria may include two-way com- emitting dyes, lanthanide IR emitters, thanide infrared phosphors can also be munication, the ability to track and and semiconductor IR emitters. Many hosted in inorganic matrices. These in- identify a large number of subjects and pure organic dyes have been developed organic host materials include fluoride objects, and specific capabilities tailored especially for NIR bimolecular imaging. and oxyfluoride optical glasses, such as for unique battlefield conditions. The use of NIR fluorophores will elimi- NaYF, SiO2–Al2O3–NaF–YF3, and oxide Materials and devices emitting in the nate background noise caused by the glass/ceramics including SiO2, ZrO2, infrared region represent an important autofluorescence of biosubstrates. Com- Y2O3, and Y3Al5O12 (yttrium aluminum class of covert optical taggants. Infrared mon organic NIR fluorophores include garnet; YAG).These inorganic host ma- (IR) light (from 0.75 μm to 1000 μm) is cyanine, oxazine and rhodamine dyes. terials are generally optically transpar- electromagnetic radiation with wave- The fluorescence maxima of these dyes ent, especially in the IR spectral region. lengths longer than those operating in are between 700-850 nm. Organic near Infrared emissions of lanthanide are the visible region. For military applica- IR dyes can be used to make glowstick- often achieved through photolumines- tions, the IR wavelength is usually lim- type IR light sources through chemilu- cence. Photoluminescence of lanthanide ited to 15 μm. An integrated infrared minescence. cations are due to their abundance of 4f–

10 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ He Created the Future. Mark Wagner, President of Sensorcon, Inc. Grand Prize Winner of the 2012 Create the Future Design Contest.

Smartphones are getting smarter thanks to Sensordrone, a keyfob-sized device that dramatically extends the sensing capability of phones and tablets for applications ranging from medical to environmental monitoring. For the inventors at Sensorcon, Inc., entering the Create the Future Contest was another smart idea.

"Winning the Grand Prize in the 2012 Create the Future Design Contest validated the Sensordrone as a truly unique new product and helped bring additional positive attention to it, enabling a successful production launch in 2013," says Mark Wagner, President of Sensorcon.

Now it’s Your Turn. THE

To enter, get details at www.createthefuturecontest.com DESIGN CONTEST 2014

SPONSORED BY

CATEGORY PRIZE SPONSOR SPONSOR

Free Info at http://info.hotims.com/49744-828 ➮ Intro Cov ToC + – A ➭ Surveillance & Security

tion algorithm; the choice of detectors different emissions and excitation wave- that can only be fully identifiable to tag- and detection techniques; and the use of lengths can be blended into multi-wave- gant designers/manufacturers. A simpli- logical analytical tools such as comput- length compound-emitters or strategi- fied example of the compound taggant ers. For instance, through taggant cally distributed into patterns/layers to system can be illustrated by the excita- markup manipulation, materials with produce sophisticated signals and codes tion/emission behaviors of a two-component taggant mixture, Nd-doped ZrO2 and Er-doped ZrO2, as shown in Figure 4. Taggants based on electrically pow- ered emitters such as LEDs and laser diodes can be encoded with sequenced flashing algorithms to achieve a strobo- scopic effect. The design of taggant emission spectra can also be tailored for specific detector/imager systems. Most infrared detectors/imagers are only effective with certain wavelength ranges. Therefore, taggant systems emitting signals that cannot be fully detected with a single type of detector are more covert. Multispectral and hyperspectral tunable optical filters, such as MEMS optical modulators and Acousto-Optic Tunable Filters (AOTFs), can greatly enhance an Figure 4. Photon emissions of a mixture of Nd-doped ZrO2 and Er-doped ZrO2 excited at 1064nm. infrared detector’s capability for detecting

Performance advantages in the world’s hottest spots.

Mission-critical thermal solutions since 1970. For four decades, advanced military systems have When the heat is on, for land, sea or air, military and aerospace engineers relied on our thermal management solutions. turn to innovative, reliable Thermacore thermal solutions to protect the Find out why. Visit our Thermacore Design Center mission-critical components of today and tomorrow. Through partnerships at www.thermacore.com/design with military systems engineers, Thermacore continually discovers new ways to blend novel concepts and new materials with proven technologies.

AS9100 • ISO 9001 • ISO 14001 • DDTC/ITAR

14 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 836 Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Surveillance & Security

and de-convoluting complex optical sig- cryogenic cooling. Finally, IR emitters tectors and scarcity of available emitters nals such as clustered emission peaks. (such as LEDs and laser diodes) with var- in this range. Unlike other optical filter systems, AOTFs ious SWIR wavelengths are available at This article was written by Dajie Zhang, do not suffer from the mechanical con- relatively low cost. Although taggants in PhD, Senior Scientist, Brimrose Corpora- straints, speed limitations, image shift, the mid-infrared region (3-8 μm) are also tion (Sparks Glencoe, MD). For more infor- and vibration associated with rotating fil- highly desirable, their development has mation, visit http://info.hotims.com/ ter wheels, and can easily accommodate been hindered by the lack of low-cost de- 49744-501. multiple wavelengths. They are mechan- ically robust and lightweight, and are ideal for field and handheld applications. Acousto-optic technology can expand the capability of common infrared detectors in many aspects. When an AOTF is integrated with an IR camera, they together become a hyperspectral imager. With an AOTF-based hyperspectral imager, multiple LEDs with different wavelengths can be used in the taggant. This allows the taggant to emit messages coded with algorithms such as wavelength hopping and scrambling, enabling covert optical communication. Such signals can only be correctly recog- nized by the hyperspectral imager, while a broadband infrared imager cannot receive the valid message. Full-duplex communications between the taggant and AOTF imager can be achieved when a simple photodetector is added to the taggant, and an AO deflector (AOD) is added to the AOTF imager. The AOD can direct an eye-safe laser beam to the taggant’s photodetector and send a message by modulating the laser. This modulation function is an intrinsic feature of AOD. The AOD can also point a narrow laser beam on to an individual taggant to deliver a coded message. Optical taggants emitting in the near infrared range have been deployed for battlefield operations. These include infrared light sticks and the LED-based Tron system. However, with the global avail- ability of 3G IR goggles capable of seeing up to 1 μm, they lose their covertness. Fu- ture taggants should operate in an IR wavelength that cannot be detected with common night vision scopes or human body thermal imaging devices such as FLIR. Currently shortwave IR (SWIR) between 1-3 μm is a very attractive range for several reasons. First, it cannot be detected by either near IR wavelength night vision scopes or long wavelength IR FLIR systems. Secondly, IR cameras in this range are lightweight, compact, and operate at room temperature, not requiring

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p ://inf o. h ot ims . c o m/4 9 744- 8 4 0 15 ➮ Intro Cov ToC + – A ➭ Small Form Factor Computing

Small Form Factor Strategies for Military Embedded Systems

he proliferation of unmanned VITA 59 – military vehicles tasked with Rugged COM Express critical communications and The PICMG COM Express Tradar requirements drives the standard defines a series need for powerful data acquisition and of modules (cards) and signal processing products that must fit backplanes supporting pro- into increasingly tighter spaces. New in- cessors, memory, networks, and dustry standards meeting these needs specialized I/O. VITA 59 extends offer smaller circuit boards and enclo- COM Express for use in harsh envi- sures, optical gigabit serial links, and ad- ronments of extended temperature, vanced thermal management strategies. shock and vibration. As shown in Figure Figure 1. VITA 59 Rugged With new resources found in the latest 1, this is accomplished through relatively COM Express module processors and FPGAs, system designers simple mechanical modifications to the adds thermal tabs to the can now create powerful, compact sys- printed circuit board of the module, leav- sides of COM Express boards to pull heat out to a rugged aluminum frame. tems surpassing performance levels ing the central PCB design largely intact. (Image courtesy MEN Micro) achievable only a few years ago. This strategy allows developers to create two similar versions of each module, modules connect to the backplane Emerging Small Form Factor one for commercial, and one for rugged using the same connectors defined in Industry Standards applications. Software and firmware can VITA 57 for FMC modules and carriers, The VITA and PICMG organizations be developed on the commercial plat- with 200 or 400 contacts, depending on actively promote and maintain stan- form and then later deployed without the module width. Unlike VITA 73, dards for embedded systems suitable for changes in a fully ruggedized system. these same connectors handle all power commercial and military applications. and signal connections to the modules. Consisting of interested members from VITA 73 – Rugged Small Form Factor The gigabit serial pins support rates up industry, academic and government or- Based on the electrical specifications to at least 8 Gb/sec to support PCIe Gen 3 ganizations, each working group con- of VPX (VITA 46 and 48), VITA 73 aims interfaces commonly found in embedded tributes towards the development of a to shrink the modules and chassis as platforms. VITA 74 defines a comprehen- new standard. much as possible, while maintaining full sive IPMI (intelligent platform manage- Once adopted and put into practice, system-level performance in rugged en- ment interface) using the I2C manage- refinements, and extensions to these vironments. Definitions for single- and ment bus that maintains and monitors standards ensure the long life cycle sup- double-wide modules, both 101.5 mm system components and the identities of port required for most government pro- deep and 71 mm across, include a vari- FRUs (field replaceable units). grams. Customer acceptance of a new ety of backplane pin configurations sup- standard fosters an open community of porting various module functions. These VITA 75 – Rugged Small Form Factor vendors offering compatible products include power supplies, CPUs, 2.5 inch Unlike the other standards, VITA 75 compliant with the standards. Compet- disk drives, and payload functions such addresses SWaP-C challenges by defin- itive market forces help keep costs as digital and analog I/O. The backplane ing characteristics for the system chassis, down, encouraging customers to re- uses different types of pin/socket con- saving the details of module size and in- quest new systems based on successful nectors for power, SATA, analog I/O, and ternal connectors for later extensions. standards. data. Gigabit serial data pins are rated to VITA 75 stresses the importance of ther- Five new small form factor standards 10 Gb/sec to handle the latest versions mal management packaging techniques for embedded system modules and back- of popular serial standards. to place hot components as close as pos- planes are currently in draft or trial use sible to the cold plate or chassis walls. status awaiting final adoption. While VITA 74 – System Small Form Factor VITA 75 proposes two types of modules: each of these standards offers unique me- Module stacked and bladed. Stacked modules use chanical features, all of them are deriva- Like the VITA 73 specification, VITA a male connector on one side of the PCB tives of existing embedded system stan- 74 embraces all of the VITA 46 VPX and a female on the opposite side, so dards. They all combine the most electrical signal definitions for two sizes that adjacent modules can be joined by appropriate aspects of proven designs and of small form-factor modules. Both are pressing them together. Bladed modules leverage new technology to help reduce 89 mm deep and 75 mm across, with a are joined by a backplane with connec- size, weight, power and cost (SWaP-C). width of either 12.68 or 19 mm. The tors similar to those on VITA 46.

16 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Innovative design can make anything lighter.

Minimizing component weight with advanced engineering, technology and materials. Without sacrificing performance. It’s what we do. More at altair.com/lightweight.

Free Info at http://info.hotims.com/49744-835 ➮ Intro Cov ToC + – A ➭ Small Form Factor Computing fischer MiniMax™ Series

2 Connect Innovation VITA 75 defines many different When Less is More! types of rugged embedded system enclosures through numerous profiles for size, mounting and cooling options. Profiles for circular military connectors to handle power, signals, networks, and other inter- Figure 2. faces follow a well defined Rugged MicroTCA nomenclature inspired by VITA module incorporating an AMC module in a 65. Likewise, numerous front conduction-cooled enclosure panel profiles define various suitable for harsh environments. combinations of connectors to (Image courtesy VadaTech) meet requirements for a wide range of chassis sizes and system I/O requirements.

PICMG Rugged MicroTCA PICMG Specification 3.x defined ATCA (Advanced Telecom- munication Computing Architecture) boards, backplanes and chassis for the latest generation of commercial communications equipment. AMCs (Advanced Mezzanine Cards) are daughter- cards that attach to the main ATCA carrier boards. Widespread adoption of ATCA for high-volume commercial markets helps to keep product prices lower than equivalent functions from traditional COTS vendors. The MicroTCA specification converts AMCs to modules that can be plugged into a small form factor chassis with a backplane. Its well-defined backplane topology using gigabit serial interconnections and platform management strategies, presents a very capable architecture for high-performance embedded systems for government and military applications in benign environments. New Rugged MicroTCA extends these systems for deployment in harsh environments of temperature, shock, vibration, hu- ■ Miniaturization & high density midity, etc. Specified limits proven in qualification tests of ■ Unique combination of 24 mixed pins the latest versions of Rugged MicroTCA meet or exceed those (20 signal + 4 power) of VPX. As a result, vendors of Rugged MicroTCA are now se- curing design wins for ruggedized military system programs. ■ Waterproof to 120m mated and unmated Small Form Factor Enabling Technologies

Gigabit Serial Interfaces www.fischer-minimax.com A common theme pervades all five of these new standards: the use of gigabit serial interconnects to eliminate the parallel bus backplanes of previous generation systems like VMEbus and CompactPCI. Virtually all consumer, commercial, industrial, and military appli cations have enjoyed widespread adoption of these gigabit serial standards including Gigabit Eth er net (GbE), PCI Express (PCIe), SATA, SerialRa- pidIO (SRIO), and others. Fischer Connectors, Inc. Tel 800.551.0121 A single gigabit serial link can deliver high speed data over a [email protected] single differential pair at rates to 10 GB/sec, or more. This reduces the circuit board area and the number of connector pins required to sustain a given data transfer rate.

18 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 839 Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Small Form Factor Computing

FPGAs tion to external DDR3 memory chips, half compared to the previous genera- FPGAs offer designers more ways to essential for transient capture of radar tion Virtex-6. This eases thermal man- achieve smaller form factors than virtu- pulses, digital delay lines and signal agement and extends missions for bat- ally any other device. Built-in gigabit se- processing workspace. Sophisticated cir- tery operated or power sensitive rial interfaces and standard protocol en- cuitry automatically trains the memory applications. gines for PCIe and GbE eliminate the need timing signals for optimum perform- for additional interface chips. Custom ance at power up. Backplane Optical Interfaces protocol requirements, like SerialFPDP, Front end digital signal processing Initiatives by standards organizations can be configured using internal FPGA re- requirements, like digital down con- for optical interconnections are now sources. This technique extends easily to verters for software radios, are perfect yielding product offerings. Approved simpler tasks such as custom data format- candidates for the many DSP engines standards from the VITA 66 Fiber Optic ting, buffering and packetizing. found on most FPGAs. The largest Vir- Interconnect group define three back- Configurable I/O ports on FPGAs han- tex-7 device now contains 3600 plane optical interfaces for 3U and 6U dle direct connections to specialized pe- DSP48E engines, vastly outstripping VPX that are variants based on MT, ripheral interfaces for exotic sensors and the raw processing power of DSPs and ARINC 801 Termini, and Mini-Ex- transducers, like a 48-bit interface to a GPPs. This type of pre-processing can panded Beam optical technology, re- 3.6 GHz 12-bit A/D, for example. Tim- deliver two-fold savings: lower output spectively. ing, gating, triggering, and synchroniza- data rates and simpler downstream All of them support single- or multi- tion structures for critical applications processing engines. mode fiber interfaces by replacing one like phased array radars take advantage These many benefits result in smaller or more of the standard VPX bladed of configurable logic, state machines, circuit boards, fewer components, and connectors. Blind-mate connectors be- and counters, all inside the FPGA. simpler connections. At the same time, tween the VPX module and the back- FPGAs also feature built-in advanced power dissipation for a given function plane feature spring-loaded inserts SDRAM controllers for direct connec- within a Virtex-7 FPGA has dropped by containing optical cable assemblies Turn light years into light seconds.

If you’re not using FRED Optical Engineering Software from 520.733.9557 440 S. Williams Blvd., Suite 106 Photon Engineering in your prototype design-build process then, Tucson, Arizona 85711 frankly, you’re wasting precious time. www.photonengr.com

FRED is the most flexible, accurate and fastest optomechanical design and analysis tool available. FRED streamlines the design-build process, eliminating the need to develop multiple prototypes by helping you get it right the first time, every time. Learn all the ways FRED can speed up your So get more done, more quickly and with less effort. optomechanical design and analysis projects. Get to know FRED from Photon Engineering. Contact Photon Engineering today.

FRED — the right solution every time.

Coherent beam propagation • Stray light analysis • Illumination and non-imaging optical design • Imaging system analysis • Multi-wavelength characterization • Thermal imagery

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 83 7 19 ➮ Intro Cov ToC + – A ➭ Small Form Factor Computing

The unreleased bon cables and terminated in an MT VITA 66.4 stan- ferrule. dard based on the Figure 3 shows a 3U VPX carrier for high-density MT FMC illustrating these small form factor ferrule uses a half- enabling technologies including PCIe size metal hous- Gen 3 system interface, the Virtex-7 ing for a smaller FPGA, and the first implementation of module and back- the proposed VITA 66.4. plane footprint. It Optical interfaces benefit small form supports either 12 factor systems in many different ways. or 24 pairs of op- Optical cables are lightweight, smaller tical cable. First diameter alternatives to copper cables, Figure 3. Pentek Model 5973 3U VPX Virtex-7 FMC carrier uses Samtec FireFly™ Micro Flyover delivering 12 optical fiber pairs to versions of the especially important in unmanned ve- the proposed VITA 66.4 backplane I/O. (Image courtesy Pentek) connectors are al- hicles sensitive to weight and packed ready available tightly with electronic payloads. They that float within metal housings. from majo r vendors, including TE Con- are completely immune to electromag- Alignment pins and holes in each half nectivity and Molex. netic susceptibility or emissions for of the mating assemblies ensure exact To ease implementation of the opti- added reliability in electrically noisy alignment of the polished ends of cal interface, Samtec is now sampling environments such as antenna masts each optical path. The MT variant in its FireFly™ Micro Fly-Over system. and engine rooms, and for added secu- VITA 66.1 provides the highest density This small module interfaces 12 lanes rity against eavesdropping. with up to 24 pairs of optical fibers, of gigabit serial electrical signals to Optical cables can transport existing while VITA 66.2 and 66.3 both provide laser transmitters and receivers con- gigabit serial traffic at rates beyond 10 2 pairs. nected through 12-lane optical flat rib- Gb/sec, extending these interfaces between modules, chassis and racks. De- pending on the optical fiber mode, these links can extend from 100 meters to sev- Nano-D Bi-Lobe® eral kilometers, easily covering the length of the largest aircraft and surface vessels. Remote sensors and data acquisi- Connectors tion pods in small enclosures can be mounted close to antennas, sending dig- itized signals back to a central processing center across optical links.

• SPACE GRADE Choosing the Best Small Form Factor Solution • MIL-DTL 32139 With so many proposed approaches to small form factor embedded systems, • EEE INST-002 customers need to determine which technical aspects of each approach are INSPECTION most important for a particular application and carefully consider the compa- • LOW OUTGASSING nies backing each standard. It is highly MATERIALS likely that no single standard will emerge as the winner. However, system designers waiting for • RUGGED a final outcome will miss out on the significant, tangible benefits available • LIGHTWEIGHT today. New extensions to these standards will be inspired by customer-driven opportunities, helping steer the technology with real-world requirements. Omnetics Connector Corporation This article was written by Rodger Hosk- 7260 Commerce Circle East, Minneapolis, MN 55432 USA ing, Vice President, Pentek, Inc. (Upper Sad- Tel +1 (763) 572 0656 • www.omnetics.com • [email protected] dle River, NJ). For more information, visit http://info.hotims.com/49744-502.

20 Fr ee Inf o at h tt p : //inf o. h ot ims .c o m/4 9 744- 8 4 1 Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ SAE OFFERS LIFELONG CAREER SUPPORT TO OUR MEMBERS

Only SAE Members get continuous opportunities to engage a multi-industry global engineering community for personal and professional growth.

Exclusive Benefits Include: • Access to SAE’s Mentor Center, where you can expand your network and learn from the BEST in the industry

• Seven-day advance notice of new jobs through SAE’s Career Center

• FREE access to original industry studies, like the new materials, safety systems, and fuel efficiency reports

• FREE subscriptions for up to three of SAE’s award-winning magazines

• Discounts on SAE products and services

And much more! Visit www.sae.org/membership for a complete list of members-only career enhancement resources.

Upgrade your Membership Level: When renewing your membership, remember that you can upgrade from Classic to Premium or from Premium to Elite and get even more beneﬁ ts!

Not an SAE Member? Join today at www.sae.org/join.

www.sae.org/membership

P136731

Free Info at http://info.hotims.com/49744-842 ➮ Intro Cov ToC + – A ➭ Manufacturing/Materials

Toward Smarter Manufacturing and Materials At the U.K.’s new Advanced Manufacturing Research Center, engineers and innovators have at their disposal some of the world’s most advanced design and manufacturing assets for precision engineering. by Richard Gardner

or well over a century the word “Sheffield” has been syn- onymous with high-quality Fsteel products, ranging from cutlery to heavy engineering products for bridges, railways, and aircraft. Fol- lowing many years of industrial decline as much traditional large-scale manufacturing departed in the direction of low-wage Asian economies, the region suffered accordingly. However, high-quality specialist engineering and manufacturing continued to remain competitive, especially for very demanding sectors such as aerospace and energy generation. This has led to the creation of R&D facilities alongside Sheffield University, within a fast expanding hi-tech business park dedicated to innovation in manufactur- Laying down composite sheets in a clean area at the Advanced Manufacturing Research Center. ing processes, including composites, metallics, and hybrid components. This ft² facility, which will incor- has just been boosted with the an- porate “the highest envi- nouncement of a new $60 million proj- ronmental standards.” ect to build an advanced “showcase” Sam Turner, Head of the factory, Factory 2050. AMRC Process Technology Group, told Aerospace & Factory of the Future Here Now Defense Technology that in Professor Keith Ridgway, Executive the past a lack of invest- Dean at Sheffield University’s Advanced ment had resulted in a gap Manufacturing Research Center in the manufacturing food (AMRC), told Aerospace & Defense chain between those with Technology, “Our ambition is for Fac- special skills carrying out tory 2050 to be the most advanced fac- the R&D and those engaged tory in the world. It is part of our long- in manufacturing activity. term development in high value Fundamental research leads Just part of the extensive machining hall facilities. manufacturing in which we have an in- to core technology advan- ternational lead.” tages that can deliver new business. The it is managing a system rather than just The factory project will offer the lat- technology should not be a barrier to making parts. Design should be seen as est technologies in the field of advanced manufacturing but a key to unlocking a means of manufacturing, and greater robotics, flexible automation, an un- more efficient output. quality is needed right through the sup- manned workspace, and off-line pro- According to Turner, there is a need ply chain. Closer integration at all levels gramming in virtual environments. Ini- for a healthy interaction between acade- is vital, he added. Best practice is essentially around 50 researchers and mia and industry. The manufacturing tial, of course, but industry must be engineers will work in the new 14,400 industry should re-invent itself so that agile so that it can modify its products

22 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Manufacturing/Materials

and this means it must have “more testing new innovative processes and demonstration asset to attract new cus- headroom” in how it uses technology in methodologies. tomers and sales. manufacturing. In turn, this provides the suppliers “We are attracting new talent into with invaluable high-quality feedback Material Advances engineering,” said Ridgway. He ex- that helps them improve the product to The AMRC was originally envisaged as plained that setting up the AMRC was make it even more flexible and efficient an R&D center-of-excellence for hi-tech regarded as key to establishing a hi-tech and also serves as a highly visible machining technology, but with the in- engineering R&D cluster that would en- courage the repatriation of more high value manufacturing back to the U.K., where there is no shortage of young people looking for a more promising future.

Technology Benefits The AMRC is a true partnership and funding comes from the university, the U.K. government, the E.U., and 77 participating companies. From the outset Boeing has been a leading partner and other aerospace companies include Air- bus, BAE Systems, Rolls-Royce, Safran, Spirit, and Goodrich. Participating company partners, most of which are global in operation, all have a share in the technology benefits for they are involved in the overall goal of improving new means, methodologies, tools, and techniques that will advance materials and manufacturing technology within their own organizations. As an indication of the scale of savings that can be made possible by such innovation, Ridgway said that in some cases manufacturing costs had been cut by a factor of five. Both Boeing and Rolls-Royce have in- vested heavily in the AMRC site and its spreading campus. A huge futuristic There are many CMMs. Rolls-Royce single-crystal fan blade manufacturing plant is already on site One software makes and in production and is claimed to be them more powerful. the most efficient aerospace engine component manufacturing plant any- Whether you have an existing CMM device where, with very advanced processes or about to purchase one, Verisurf-X is that are kept well away from the eyes of the only software you need. With its 3D casual visitors. CAD-based architecture, ﬂ exible reporting A big attraction of being in partnership at the AMRC is the “win-win” sit- options, and ease of use, Verisurf-X uation for everyone. For the facility will reduce training time and increase managers, partner companies supply productivity, right out of the box. No matter free of charge their latest equipment what you are making or measuring, and systems for use in the various spe- Verisurf-X provides the power to drive your Learn more about the power of cialized work areas. These represent the devices, reduce cost, improve quality, and Verisurf-X by visiting our Website, very latest examples of hi-tech ma- streamline data management – all while or call for an onsite demo. chines and specialist equipment, so maintaining CAD-based digital workﬂ ow. WWWVERISURFCOMs they are suitable for evaluating and

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p ://inf o. h ot ims . c o m/4 9 744- 8 4 3 23 ➮ Intro Cov ToC + – A ➭ Manufacturing/Materials

creasing use of composite ma- Castings Technology Inter- terials, hybrid metallic/ national is wholly owned by composites, and now, 3-D AMRC and is a comprehen- printed components, as well sive casting research facility, as advanced metallics, the with a titanium casting capa- scope has been widened to bility as large as any in the cover all high-end manufac- world. Some 75 partners are turing materials and processes. involved and the facilities on Examples include casting and site include casting design, machining titanium and alu- patternmaking, cure making, minum and all methods of molding, preheating and as- fabricating composite struc- sembly, melting and pouring, tures and components. Sources inspection, machining, and claim this to be at least six finishing. There is a 1000-kg years ahead of any other simi- titanium melting capability lar facility. Europe’s largest The new apprentice school teaches young students basic workshop skills and high strength steel cast- electron beam welding facili- leading to more advanced specialisation and academic qualifications. ings can be manufactured in ties are also included on site. volume. The Composites Center in the AMRC shown a reduction of up to 80% is pos- All aspects of inspection and valida- has facilities for autoclave and out-of- sible. tion are covered and the production autoclave composites manufacture. In the AMRC Assembly Center the technologies are very wide ranging, Computer controlled automatic fiber latest laser scanners and robotic systems from titanium casting to additive lay- placement of layered materials repre- are capable of working to tolerances of ered pattern manufacturing, with be- sents the latest technology, but 15 micron, with huge reductions in op- spoke patterns grown from a laser using Sheffield has a 200-year old local legacy erational timescales. One program suc- light-sensitive resins. There is a unique of weaving skills and this has been ex- cessfully reduced a procedure that pre- capability in-house at CTI for making ploited to incorporate traditional inter- viously took one and a half days to just land-based turbines and this could be woven material patterns and techniques six minutes. expanded into aerospace structural that can be tailored very precisely using Creating a safe as well as hi-tech man- manufacturing. 3-D weaving machines for today’s hi- ufacturing and assembly environment In the Design and Prototyping Center tech requirements, especially in the is a key feature where operating bound- new designs for manufacturing are stud- aerospace sector. aries are being pushed further out all ied in close cooperation with many Using different woven patterns in the the time. The use of advanced virtual re- SMEs who are currently involved in material and different thicknesses can ality and simulation tools are used for some 120 active projects. The center is give added rigidity or flexibility and training as well as in other stages in the seen as a highly effective facility to edu- added density for strength where it is design, evaluation, and manufacturing cate personnel from smaller engineer- needed, and this includes using mixed stages of a project. ing companies who would not be able materials combining metallics with the As a part of a feasibility study with a to invest in such advanced design and carbon fiber. An aluminum matrix com- partner, a kinematic simulation of a pro- test tools and systems on their own. posite material has been developed and posed machine for 787 manifold assem- In the Structural Test Center there are tested for automotive applications. bly was completed to allow the center to the very latest facilities for component There is almost no limit to the permuta- validate the proposed design and easily testing and validation including 8-axis tions possible in preparing and making communicate the scope of the innova- loading system tools. There is also a mi- hybrid or all-composite structures and tion to the customer. During the visit to croscopy laboratory for micro structural components and the research, testing, the AMRC, this reporter was able to ex- evaluation where material changes re- and evaluating at AMRC extends into perience the latest 3-D virtual reality ca- quire very precise and accurate measure- next generation wing spar develop- pabilities, using a visor and hand con- ments with screening to determine the ments and highly complex molding troller to allow virtual components to be chemical composition within the mate- techniques. removed and relocated from a large rial. In another clean-room area within Other research activities include fila- aerospace engine that was complete in the AMRC, extremely accurate measur- ment winding for composite tubes and every detail. It was possible to accurately ing is undertaken with the aid of 3-axis microwave curing processes. An associ- manipulate the virtual hand movements touch-sensitive probes that record sur- ated aspect of all R&D work involves quite naturally after a few minutes and face touch points and can be used to factoring in the need to reduce energy to become completely immersed in the construct planes, surfaces or complex consumption at all stages in the manu- task. In reality the engine existed only in curves that are accurate to 5 micron. facturing process. In some cases a re- a virtual environment within an empty An indication of the strategic vision design of processes and methods has white-walled chamber. at the AMRC is the establishment of a

24 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Manufacturing/Materials

new Training Center where this past thinking future career in engineering. build their personal skills and shared February 250 young apprentices were These apprentices are sponsored by work experience on the basis of a admitted to join others already learning companies that will directly benefit sound “future-proofed” framework ap- basic engineering workshop skills, lead- from the high quality and motivation propriate for the needs of the 21st Cen- ing through a phased curriculum to of these young people. tury, and not restricted by legacy prac- more advanced training using the most The start they are being given at the tices and methods. modern CAD/CAM digital design and AMRC campus will ensure that they manufacturing tools and equipment, and classroom training aids, including virtual reality welding stations. From these educational building blocks the apprentice students can progress on to more specialist skills and academic qualifications, while having access to advanced equipment and systems that will equip them for a forward- Speeding up the Process GKN Aerospace is leading a project under the Structures Technology Maturity (STeM) program that aims to automate the assembly of aircraft structures with the goal of creating consistently high-quality wing structures 30% faster than is possible today. This STeM program is based around an advanced winglet as the demonstrator component, using this to progress a range of innovative assembly technologies. The complete assembly tooling and robotic COATED strategy for the winglet has been developed by GKN Aerospace in collaboration with the AMRC and NIKON AEROSPACE Metrology. Designed to be generic and therefore equally applicable to DEVICE many fu ture aircraft wing and fuselage structures, the process uses many emerging automated and robotic techniques that, as well as speeding assembly, will provide a consistent end product. The Leader in Coating Aerospace, Medical, and Industrial Components.

51 Parmenter Road, Hudson, MA 01749 (800) 258-0110 | www.boydcoatings.com/ADT

Aerospace & Defense Technology, April 2014 Free Info at http://info.hotims.com/49744-844 25 ➮ Intro Cov ToC + – A ➭ Propulsion

More Electric, Integrated Fuel Systems Engine system reliability can be improved by advanced electric architectures, while the reduction of hydraulic components, fuel tubes, and fittings can enhance the maintainability of the engine and minimize pilot workload.

lobal warming and envi- the conventional system, a fault-tol- ronmental friendliness erant design of the electric drive is considerations have re- mandatory. Gcently been key for multi- For the MEE fuel pump system cur- ple global industries. In the commer- rently being developed, IHI has pro- cial aviation industry, reduction of posed the use of a permanent magnet aircraft emissions, including CO2 blushless ac servo motor. In the servo and noise, is an urgent priority. Both motor control system, the electrical aircraft and aircraft engine manufac- current is adequately controlled corre- turers are striving to improve design sponding to the required torque from to accommodate the needs of com- the fuel pump. The control system mercial airlines. Engine manufactur- contains a limiter function to avoid ers in particular have worked long overload of the motor, and a motor and hard to improve each engine power-off function for emergency component, e.g., compressors, tur- shutoff of the fuel supply. bines, combustors, etc. In addition, IHI proposed the in- However, the need for another ap- troduction of advanced fault-toler- proach to further improve engine ef- ant technologies such as a unique ac- ficiency motivated researchers from tive-active redundant motor control IHI Aerospace to focus on the system system to the MEE. The active-active approach, including the control sys- control enables the supply of the tem, fuel system, or other engine sys- same amount of fuel to the engine tems, ultimately resulting in an MEE combustor in case a single open fail- (more electric engine). ure occurs in one of the redundant The MEE is a new engine system motor systems. concept that seeks engine efficiency improvements, which results in a re- Conventional vs. MEE Fuel duction of engine fuel burn and CO2 Systems emissions. The key concept of the In current commercial aircraft, the MEE system involves the architec- aircraft system consists of various sub- ture for the electrical power genera- systems, and each subsystem is inde- tion by the engine and changing the pendently designed to accommodate power source for accessories from the specific requirements or opera- mechanical/hydraulic to an electric tional conditions designated for each motor. Schematic of an MEE (more electric engine) electric fuel subsystem. The independency some- IHI focused on the electrification pump system vs. a conventional fuel pump system. times causes duplicated functions and of the engine fuel pump system be- complicated system design. cause of its contribution to fuel burn re- cooled oil cooler), which worsens en- One typical example of a segregated duction. The researchers conducted a gine efficiency. system is the engine fuel system. It is in- feasibility study of the MEE fuel system There are several technical challenges dependent from the aircraft fuel system for an assumed small-size turbofan en- for the practical design of the MEE and both systems are designed to ac- gine, and the result indicated an im- motor-driven fuel pump system. Failure commodate various conditions, which provement in specific fuel consumption of the engine fuel pump may induce are designated at the interface point be- (SFC) by about 1% during cruising. The IFSD (in flight shut down) of the engine tween aircraft system and engine inlet. SFC improvement would be accom- and result in catastrophic failure of the Integrating the aircraft and engine fuel plished by removing the fuel bypass cir- aircraft. To avoid such critical situations system would be helpful to construct a cuit and eliminating the ACOC (air- and ensure better reliability than that of more efficient and simplified system,

26 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Propulsion

but it seems not to be practical in the it is not necessary any more to attach ables the provision of proper suction of conventional aircraft system. the motor-driven fuel pump to the en- fuel from the tank, and a shutoff valve The aircraft system contains electric gine AGB. The location of the pump that shuts off fuel to the engine com- motor-driven fuel boost pumps, shutoff may be moved to an area other than the bustor. An integrated fuel system would valves, and cross feed valves as a mini- external surface of the engine. It means remove the burden of the aircraft and mum. There may be fuel transfer that the engine fuel pump is possibly engine interface condition, removing pumps, such as electric motor-driven considered as one of the components the duplicated function as much as pos- pumps or ejector pumps, for transfer- within the aircraft fuel system, and a sible and simplifying the system con- ring fuel between the tanks. In the case possible location would be in the na- struction. of a twin engine aircraft, the left- and celle, fuselage, or wing. right-hand engines are supplied with Current aircraft fuel systems and en- Integrated Fuel System Benefits fuel from the left and right wing tank, gine fuel systems have duplicated func- A reduction in fuel burn is expected respectively, during normal operation. tions, such as a boost pump, which en- through the introduction of the MEE If IFSD occurs in one of the engines, the cross feed valves would be activated to supply fuel from the opposite side tank to avoid an imbalance of fuel mass. The engine fuel system consists of an AGB (accessory gear box)-driven fuel pump, FMU (fuel metering unit), and FPV (fuel pressurizing valve) at a minimum. Performance characteristics of the fuel pump are determined so that the pump supplies sufficient fuel flow with the obtained fuel inlet condition and engine operating condition. Typically, the fuel pump consists of an LP (low pressure) impeller pump and HP (high pressure) gear pump. The LP pump increases fuel pressure at the HP pump inlet for the proper suction of fuel. A more electric architecture supports the integration, simplification, and re- construction of the aircraft and engine An example of a conventional aircraft and engine fuel feed system. fuel system because of increased con- trollability, a modular design, and flexibility of component installation. The MEE electric fuel system simpli- fies the engine fuel system by eliminating the fuel bypass circuit and complicated FMU. In addition, the MEE fuel system increases the flexibility of the engine fuel pump installation, because

IHI researchers propose integrating the fuel feed system between the aircraft and engine, as shown in this Schematic depicting the MEE fuel pump system. concept.

Aerospace & Defense Technology, April 2014 www.aerodefensetech.com 27 ➮ Intro Cov ToC + – A ➭ Propulsion

by the LP impeller pump in the electric fuel pump unit. The feasibility study of the small-size turbofan MEE fuel pump shows that the single shaft electric pump, which drives both the LP impeller pump and HP gear pump by the same shaft, can suction fuel during an aircraft boost pump failure. The submerged aircraft fuel boost pumps can be removed, which will not only con- tribute to a reduced number of components, but also remove the submerged components in the fuel tank. Another possible approach to reduce the number of components is to remove the cross feed valves and electric transfer pumps. In a conventional fuel sys- This proposed schematic of the integrated fuel feed system concept is for an assumed 150-200-seat sin- tem, the cross feed valve is necessary to gle-aisle aircraft with twin engines, such as a Boeing 737 or Airbus A320. have fuel mass balance between the left and right wing tanks in case one of the engines is shut down. In the proposed integrated fuel system, the left main pump unit has fuel inlets connecting to both left and right wing tanks. It is the same for the right main pump unit. The left and right main pump units always suction fuel from both the left and right wing tanks, so the fuel mass balance between the tanks will be maintained automatically, allowing the cross feed valve to be removed. In the integrated fuel system study for an assumed single-aisle aircraft, it was es- timated that the aircraft boost pumps, engine FMUs, and MFPs (main fuel pumps) in the conventional system would be replaced by four sets of electric fuel pump units. In addition, with the cross feed valves and aircraft shutoff valves re- Fuel connecting chart of the proposed system shows the fuel line among the tanks, electric pump units, moved, the total number of LRUs (line re- and engines. Redundant electric fuel pump units are connected to each engine. placement units) in the integrated aircraft system is expected to be reduced to about electric fuel system, which eliminates In the conventional system, electric half of the conventional system. the loss in fuel system efficiency caused motor-driven fuel boost pumps, which The proposed integrated system by the AGB-driven pump system. are usually submerged in the fuel tank, eliminates electric valves such as the Also, the number of components in pressurize fuel to provide the minimum cross feed and shutoff valves as much the fuel system would be minimized. pressure required by the engine fuel sys- as possible. However, in considering In the conventional aircraft fuel system. Typically, the aircraft boost pump is emergency situations—for example, se- tem and engine fuel system, which are the impeller type and adds about 50 psi vere fuel leakage from anywhere in the separated from each other, there is a to the tank pressure. However, the engine system—isolation of the fuel system duplicated function between the air- fuel pump also has a LP impeller pump to may be required to avoid loss of the aircraft components and the engine com- boost fuel pressure at the engine inlet be- craft fuel. For that purpose, the addi- ponents. One of the typical examples cause the engine fuel pump is required to tion of monitoring devices such as fuel is the pressure boosting function to en- supply fuel even though the aircraft pressure sensors, leak detectors, and sure that the engine fuel pump prop- boost pump is in operational condition. electric shutoff valves may be consid- erly suctions fuel from the aircraft fuel In the proposed integrated system, ered. Also, if the aircraft system wants tank. the boosting function is accomplished to control the fuel amount in the left

28 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Propulsion

and right tanks independently, that fuel in the tank, which is previously de- or boost pumps would not be necessary; would be accomplished by the addition termined to avoid heating of the pump. thus, reduction of pilot workload would of the electric shutoff valves in the sys- In the proposed integrated fuel sys- be expected. tem. Thus, the proposed integrated tem, the electric fuel pump units would This article is based on SAE Interna- electric fuel system has the flexibility to be installed outside of the fuel tank, in- tional technical paper 2013-01-2080 by incorporate additional electric devices stead of the submerged boost pumps. Noriko Morioka IHI Corp. and Hitoshi and will support aircraft system re- Pilot operation for the cross feed valves Oyori, IHI Aerospace Co. quirements. As mentioned above, the reduction in the number of LRUs will be achieved by introduction of the integrated fuel system. In addition, components that are submerged in the aircraft fuel tanks, such as the aircraft boost pumps, will be removed. One possible location for the electric fuel pump units is the fuselage, inside of the access door. Currently, LRUs are installed into distributed locations among the aircraft wing, aircraft tank, and the engine. In the integrated system, the LRUs may be installed in one place in the aircraft fuselage, so that replacement of the pump unit will be much easier than the current aircraft/engine fuel system components. Reduction in the number of LRUs, accessi- bility, and replaceability of the electric pump unit will improve the maintainability of the aircraft/engine fuel system. Because the integrated system allows maxon drives in arm prostheses. for the removal of the cross feed valves, adjustment of the tank balance by pilots would not be necessary anymore. On/off of the current submerged aircraft Maintaining control has boost pumps is usually conducted by pilots to maintain a minimum amount of never been easier.

If decentralized drive intelligence is maxon motor is the world’s leading sup- called for, maxon motor control provides plier of high-precision drives and systems the answer: All speed and positioning of up to 500 watts power output. Rely on controllers are designed to match with the quality of the highly specialized solu- DC motors up to 700 watts power. The tions which we develop with and for you. EPOS2 positioning controller can be www.maxonmotorusa.com used with CANopen and Interpolated Position Mode.

Table. LRU Comparison

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p ://inf o. h ot ims . c o m/4 9 744- 8 4 5 29 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology V+ G

RF V+

RF FPGAs for G RF RF

Multi-Function G Systems V+ A dynamically reconfigurable, wideband

programmable RF FPGA transceiver will provide RF

V+ reduced lifecycle cost, reduced redesign cost, and G Figure 1: service for multiple DoD platforms, while The 8-port phase maintaining near-optimal performance for each change RF switch design. application.

tate-of-the-art RF integrated RF FPGA to perform a wide variety of • An architecture that connects these circuits (ICs) achieve high per- functions. switches in a fully interconnected ma- formance via custom circuit Key elements of the RF FPGA ap- trix to allow total flexibility in inter- Selements with dedicated sig- proach are: connecting and switching between RF nal paths for application-specific func- • Extremely low-loss, high-isolation RF elements and to inputs/outputs. tions, but long design lead times and switches using phase change materials • Dynamically RF tuned banks of wide- non-recurring fabrication costs increase (PCM). Multiport RF switch designs (Fig- band, high-performance LNAs (low time-to-market for new applications ure 1) optimize thermal design to im- noise amplifiers), mixers, vector mod- and limit reuse. The key to developing prove PCM performance, and integrate ulators, driver amplifiers, and power an RF FPGA (radio frequency field-pro- arrays of these switches on thermally amplifiers using programmable circuit grammable gate array) is to provide RF and electrically optimized substrates. bias and circuit mission reconfigura- switching components with very low • Multiport switch designs with low tion techniques. insertion loss and high isolation that simulated RF losses of 0.1 - 0.2 dB up • Development of a family of RF FPGAs can be integrated with high-perfor- to 20 GHz, and 35dB - 60dB isolation that can be configured in a variety of mance RF circuits in silicon germanium between ports, based on measured and ways: as a standalone RF transceiver, as (SiGe) and gallium nitride (GaN) tech- extrapolated PCM data. They consume T/R (transmit receive) elements in an nologies, and integrating these circuits no prime power except for 100-nsec AESA (active electronic scanned array), in a reconfigurable topology to allow an heater pulses during reconfiguration. or as an IF (intermediate frequency) or baseband receiver. Packaging in 12 x 12-mm QFNs (quad-flat no-leads) pack- Low Loss Multi-port RF1 RF1 RF2/3 RF2/3 Fully Connected RF Phase Change Out In In Out Routing on Low-Loss ages with matched RF I/O for low pack- Switches Transmission Lines age insertion loss is used to allow multiple RF FPGAs to be integrated in flexible configurations. LNA Bank Baseband • Demonstration of the RF FPGA tech- • LNA 1 Down nology against multiple DoD system • LNA 2 Convert • LNA 3 applications with transition potential • LNA 4 • BB DCM 1 to a wide range of DoD systems. • LNA 5 Robust, Low-Loss Switch Technologies To produce an efficient RF FPGA, a compact, low-loss RF switch is the essen- Sub-Octave Filter Bank Vector IF Down-Convert tial technology needed. The phase change • • Filter 4 Filter 1 Modulator Bank Mixer Bank RF switches will be used to create a fully • • Filter 5 Filter 2 • IF DCM 1 interconnected switch matrix (Figure 2). • • Filter 6 • VM 1 • VM 3 Filter 3 • IF DCM 2 • Filter 7 • VM 2 • VM 4 These switches will connect banks of RF components (e.g., LNAs, mixers, filters, Figure 2: The flexible switch matrix connects RF circuit banks with each other and I/O for a high level of vector modulators) on the RF ICs to each reconfigurability. other, also allowing routing from any of

30 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

these circuits to the RF FPGA I/O. The RF the blocks and between the blocks. This switches are fabricated on separate silicon approach provides higher RF perform- (SiC) wafers, optimized for RF and ther- ance than a fine-grained architecture, mal phase change performance, and then and has the degree of flexibility needed flip-chip-bonded to the RF component IC. for a wide range of applications due to To further minimize RF losses due to the fully connected RF switch matrix. the switch matrix, the routing lines be- The receiver FPGA contains banks of tween switches are fabricated using high- LNAs, sub-octave filters for RF filtering, conductivity metal (such as copper), 50- vector modulators for beam steering, Ohm transmission lines on low loss down conversion mixers, and digital con- dielectric, such as BCB. The transmission trol. Jazz SiGe is used as the integration lines will be configured as microstrip, platform because the RF performance is with lines over and under the ground very good, digital control and power sup- plane to provide the isolated RF signal ply circuits for the phase change heaters Figure 3: The RF FPGA integrates the RF IC, inter- crossover capability required by the fully can be easily integrated into the same IC, connect matrix, and switches in a QFN package. interconnected matrix. The stackup and device fabrication is relatively inex- showing the integration of the RF IC, in- pensive. The number of RF elements and steering, filters, output amplifiers, and dig- terconnect matrix, and switches in a QFN their bandwidths in each bank have been ital control, and is baselined as a SiGe IC. package is shown in Figure 3. selected to provide the 0.4 to 18 GHz The power amplifier FPGA contains a range, based on previous SiGe designs. bank of GaN power amplifiers with up High-Performance RF Architecture Filter FPGAs contain receiver filtering re- to 8W output power, with controllable The RF FPGA uses a coarse-grained ar- quired for application-specific needs. The bias and switchable gain stages to serv- chitecture consisting of major functional transmitter FPGA contains banks of up- ice a wide range of frequency, power blocks with reconfigurability both within converters, vector modulators for beam output, and class of operation.

PRECISION PASSIVE COMPONENTS & ELECTRONIC PACKAGES PROVEN RELIABILITY. TRUSTED PERFORMANCE. Thick & Thin Film Resistor Products Electronic Package Products • Faithful scheduled deliveries under 2 weeks • Hi Reliability Hermetic Packages: • Values from 0.1 Ohm to 100G Ohm • Lightweight glass sidewall flatpacks • Abs. tolerance to ±0.005%, matching to ±0.0025% • Metal flatpacks, leadless chip carriers (LCC) • TCR’s to ±2ppm/°C, tracking to ±1ppm/°C and ceramic quad flatpacks (CQFP) • Operating frequencies to 40GHz • Surface mount and plug-in packages • High performance at cryogenic temperatures • Hermeticity per MIL-STD-883, Method 1014, -9 • Case sizes to 0101 Condition A4 (greater than 10 atm cc/sec) • Space level QPL’s, F.R.-“S”, per MIL-PRF-55342 • Plating per MIL-DTL-45204 and QQ-N-290 for standard packages (unless otherwise specified) • Zero failures with over 200 million life test hours • Custom design available • ISO 9001:2000 certified • RoHS and DFARS compliant • Full line of RoHS compliant products • 24-hour quote turnaround 44 YEARS OF EXCELLENCE

mini-systemsinc.com 508-695-0203 [email protected] 20 David Road, North Attleboro MA 02761-0069 SINCE 1968

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 8 4 6 31 ➮ Intro Cov ToC + – A ➭ What’s On RF & Microwave Technology

AEROSPACE CHANNEL

Sponsored by Wideband RF Building Blocks Relatively wideband RF components are used, and performance configurability is incorporated within these components. This gives high performance with wide frequency ap- Robonaut Gets Legs plication range. For example, very nearly equivalent NASA engineers are developing and performance can be achieved in 3:1 bandwidth SiGe LNAs, as that achieved in narrow-band LNAs. The mixers and vector testing climbing legs for the International modulators can function over even wider bandwidths with Space Station’s robotic crew member very good performance. Robonaut 2 (R2). These new legs will A small bank of LNAs, mixers, and vector modulators can provide R2 the mobility it needs to help perform over 0.4 to 18 GHz. Tuning is also incorporated with regular and repetitive tasks both within these components; for example, the LNAs have ad- inside and outside the space station. justable bias and switchable gain stages to optimize gain, www.techbriefs.com/tv/robonaut-legs noise figure, and TOI versus power dissipation as required by the application. NASA Telescope Reveals How Stars Explode Wide-Frequency, Scalable Transmit Power The power amplifier RF FPGA contains a bank of GaN re- One of the largest mysteries in astronomy configurable power amplifiers with >3:1 bandwidth capability — how stars blow up in supernova covering 0.4 to 18 GHz frequency. Using switched-in ampli- explosions and seed the universe with fier stages, it provides up to 8W CW RF output. High effi- elements like gold and iron — is being ciency of a class AB PA can be maintained as the input drive resolved with the help of NASA’s Nuclear is reduced by varying the drain and gate bias with the drive Spectroscopic Telescope Array (NuSTAR). signal. Greater than 40% efficiency over a 10:1 range of power Watch this simulation showing how shock levels was demonstrated. For an 8W RF output, thermal analy- waves likely rip apart massive dying stars. sis shows an acceptable <100 °C temperature rise in the final www.techbriefs.com/tv/ output RF switch due to self-heating. Lower power-level appli- NuSTAR-telescope cations (up to 100 mW) can be met with drive amplifiers in the transmit FPGA. Autonomous Landing Software Tested on Xombie Rocket Digital Configuration and Control The RF FPGAs are completely reconfigurable in the field via Jet Propulsion Laboratory has successfully control with digital control words coming into the SiGe RF tested new software called G-FOLD that ICs, based on the RS-232 standard. To control performance enables a rocket to select an alternate within a circuit block (e.g., LNA or mixer), there are embedded landing site, autonomously. The test was DACs and control registers to control bias and other settings. performed with Masten Space Systems’ The SiGe ICs also provide the controlled voltage pulses XA-0.1B Xombie rocket. You’re on-board needed for phase change switches. The power control cir- for the flight in this video. cuitry for each switch is located on the SiGe IC under the www.techbriefs.com/tv/ switch location to minimize parasitics and provide 20 nsec G-FOLD-software power turn-on and 20 nsec power turn-off, which provides for high-performance phase change switch operation and <1 mi- Opportunity Celebrates crosecond reconfiguration times. Ten Years of Exploration Conclusion A decade after it landed on Mars, the The RF FPGA approach uses arrays of these high-perfor- Opportunity Rover continues to explore. mance RF IC circuit elements, and achieves flexibility by re- The rover’s science team explains how configuring the signal path between desired elements with Opportunity traversed Mars, examined minimal degradation, due to use of low-loss phase change the diverse environment, and sent back switching technology. This enables multiple applications of data that transformed our understanding the same RF FPGA components with near-custom perform- of the Red Planet. ance. This shortens procurement cycles, improves affordabil- www.techbriefs.com/tv/ ity, and provides mid-mission reconfigurability. rover-anniversary This article was written by Mike Lee, Mike Lucas, Robert Young, Robert Howell, Pavel Borodulin, and Nabil El-Hinnawy of Northrop Grumman Electronic Systems. For more information, visit http://info.hotims.com/49744-541.

www.techbriefs.tv Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

3D Software Helps Development of Vehicle-Mounted Defense Systems

-3 Communications Linkabit (Melbourne, FL) develops de- implemented a mix of SolidWorks Professional, SolidWorks Lfense communications and electronic warfare systems to Premium, and SolidWorks Flow Simulation software, as well as protect soldiers and save lives on the battlefield. A division of the SolidWorks Enterprise PDM system. L-3 Communications, the sixth-largest defense company in “The seamlessness and range of tools in the SolidWorks de- the United States, Linkabit focuses on developing systems that sign environment make it the most capable development plat- safeguard troops in the field by obscuring visibility, jamming form at its price point,” Romanisko said. “SolidWorks software radar signals, intercepting communications, and disrupting has helped us to respond to our engineering challenges infrared transmissions. quickly, innovatively, and cost-effectively.” While Linkabit has always concentrated on the design of The M56E1 Motorized Smoke Obscurant System is repre- defense communications systems, the sophistication in- sentative of the products Linkabit develops with Solid- volved in innovating, creating, and manufacturing elec- Works software. Mounted on a Humvee, the M56E1 in- tronic devices has changed greatly, ushering in a new set cludes three types of obscurant systems: 90 minutes of of design and production challenges, according to Thomas smoke to obscure visual pinpointing, 30 minutes of A. Romanisko, mechanical engineering manager at Link- graphite powder to obscure infrared sighting, and 30 min- abit. “The complexity of the 3D shapes we are involved utes of carbon fibers to obscure millimeter-wave location. with today is simply beyond the capabilities of the 2D de- The system is designed to protect passengers from visual sign tools the company once used,” Romanisko pointed and electronic weapons sighting. out. “We used design configurations and sheet-metal capabili- Linkabit selected the SolidWorks 3D design platform from ties extensively on the M56E1 system,” Romanisko said. Dassault Systemes SolidWorks Corp. (Waltham, MA) because “Configurations capabilities and the tolerance analysis it is easy to use, is compatible with all major file formats, of- functionality really help us design assemblies efficiently. In fers robust sheet-metal capabilities, and provides seamless in- particular, configurations allow us to create exploded views tegration with productivity-enhancing simulation and prod- as well as show different modes of operation, which saves a uct data management (PDM) applications. The company lot of time.”

The SolidWorks 3D development platform helps L-3 Communications Linkabit develop sophisticated defense systems, such as the M56E1 Motorized Smoke Obscurant System shown here.

Aerospace & Defense Technology, April 2014 www.aerodefensetech.com 33 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

OUR DOMAIN: HYBRIDISATION

MoM (since 1991) MoM/PO (since 1992) MoM/UTD (since 1994) MLFMM (since 2004) MoM/FEM (since 2005) MoM/RL-GO (since 2007) FEM/MLFMM (since 2010)

UTD

PO/GO

MLFMM

MOM Electrical Size

FEM

Complexity of Materials One Product - Multiple Solvers Having the ability to simulate designs in software allows Linkabit to eliminate costly prototype iterations. FEKO includes several Simulation Minimizes Physical collaboration across the organization. computational methods, each Testing The system replicates vaults at all optimised for different problem Linkabit saves additional time and three locations, and enables the com- reduces its prototyping costs dramati- pany to automate its already well-reg- types. Due to a long history of cally with integrated SolidWorks Sim- imented workflows using automatic hybridising different techniques, ulation tools. “Studying the effects of email notification. In addition, Link- FEKO has been at the forefront of stress, vibration, and temperature is abit used its PDM system to standard- extremely important when develop- ize its parts libraries for commonly the efﬁcient analysis of complex, ing electronics packages for equip- used components such as connectors low and high frequency problems. ment used in combat,” Romanisko and fasteners, which eliminates un- noted. “We also use SolidWorks Flow necessary duplication of effort. Applications: Simulation to study the impact of air- “Linkabit is a zero-geography organi- flow on temperature to design cooling zation, which means we could have in- Antenna Design, Antenna systems for electronics.” dividual engineers in California, New Placement, Waveguide, RF Having the ability to simulate designs York, and Florida who are all collaborat- Components, Microstrip Circuits, in software allows Linkabit to eliminate ing on the same project,” Romanisko costly prototype iterations. The com- explained. “With SolidWorks Enterprise EMC, Cable Coupling, Radomes, pany also utilizes rapid prototyping to PDM managing revisions, access, and RCS, Bio-EM. produce SolidWorks component models user rights, working with someone on a 3D printer. “Instead of creating 10 across the country is like working with prototypes, we use simulation to com- someone next door.” plete 10 design iterations,” Romanisko Using SolidWorks eDrawings® files, said. “This approach has reduced our Linkabit has also improved communi- prototype development time by 75 per- cations with customers. “It’s great to be cent.” able to share a 3D design with a cus- www.feko.info tomer,” Romanisko said. “The ability to Worldwide Collaboration make cross-cuts, use transparency, and Global sales and technical With offices in Florida, California, spin the model makes eDrawings files a support network: and New York, Linkabit uses Solid- much better format than using PDFs.” Local distributors in Europe, North America, Works Enterprise PDM software to This article was contributed by Solid- South America, Japan, China, South Korea, manage design revisions, secure access Works Corp. For more information, visit Singapore, India, Israel, Taiwan, South Africa to sensitive design data, and support http://info.hotims.com/49744-542.

Free Info at http://info.hotims.com/49744-847 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Technology Update

ETS researchers develop new methodology for wind tunnel calibration

n recent years, the École de Technologie D coordinate inside the test section. contraction section, and a test section. ISupérieure (ETS) Research Laboratory in The 12-m open-return subsonic wind From the static pressure buildup the flow Active Controls, Avionics, and Aeroser- tunnel is a research apparatus used to is projected to an oval-shaped circular pat- voelasticity (LARCASE) has acquired sev- test airfoils and validate CFD models. tern flow straightener. Then the flow goes eral research apparatus—a research flight The wind tunnel allows for a safe con- through a series of five filters: the first is a simulator Cessna Citation X, an open re- trol of the flow conditions and makes honeycomb-shaped filter, and the other turn subsonic wind tunnel, and a flight measurements of pressure distribution four are nylon squared-shape filters posi- autonomous system (UAV)—making it on a wing shape possible. At the begin- tioned 0.5 m from each other. one of the few multidisciplinary research ning, the air pressure rises through the The settling section allows the flow to laboratories in Canada with a wide range centrifugal fan creating lateral mixing go from a turbulent state to a laminar of equipment with the capabilities of of fluid layers, then the turbulent parti- flow. simulating aircraft models, especially air- cles are straightened by the filters pro- LARCASE’s wind tunnel has two test foils, and validating the models with ex- ducing a laminar flow. The wind tunnel sections. The main one is 0.6 x 0.9 m perimental data collected on the ground consists of a centrifugal fan, a diffusing made in wood with Plexiglass remov- (wind tunnel) and in-flight (UAV). section, a settling chamber, a contrac- able doors able to reach 0.12 Mach. The LARCASE researchers have developed tion section, and a working section. second test section, half the volume of a new approach for wind tunnel calibra- The flow develops a 0.18 Mach maxi- the first one, is able to reach 0.18 Mach. tions using a limited number of dy- mum speed due to the engine and the LARCASE researchers used the Ex- namic pressure measurements and a double impeller centrifugal fan. The tended Great Deluge (EGD) algorithm predictive technique based on Artificial two inlets at the opposite side of the in hybridization with the neural net- Neural Network (ANN). Complement- rotor allow the air supply to increase works to find the predicted pressure in- ing the development of an ANN model, the pressure flow, and the use of the 24 side of the test chamber of the open re- a further objective of the research was small propellers by impeller allows the turn subsonic wind tunnel. to investigate an optimal method for fan to turn at a much higher speed than The hybrid NN-EGD method is pro- determining local flow characteristics normal fans with large blades. The en- posed to control the pressure distribu- by means of X, Y, and Z coordinates. gine and the centrifugal fan are located tion, by varying the coordinates of the Using a minimum of data collected inside the soundproof mechanical room point inside the test chamber, wing from the wind tunnel calibration for protected from debris and dust. speed, and temperature. The EGD algo- training, the ANN model would gener- The diffusing section consists of a wide- rithm is used to obtain the optimal net- ate the proper pressure for any given 3- angle diffuser, a large settling chamber, a work configuration such that the error is as small as possible. Qualitative performance measures are used that de- scribe the learning abilities of a given trained neural network. To train and test the NN, ANSYS Flu- ent software is used to determine the pressure values inside the test chamber. The coordinate (X, Y, Z), the wind velocity (V), and the temperature (T) of the test chamber represent the inputs of the model, the output is the pressure. A total of 81628 points are used to train, vali- The 12-m open-return subsonic wind tunnel consists of a centrifugal fan, a diffusing section, a settling date, and test NN-EGD. The validation chamber, a contraction section, and a working section. data represent 15 % of the data set, 15% of the data set to test the approach, and the rest to train NN. These points are selected randomly. Using the EGD algorithm, many architectures are tested. The objective was to obtain the simplest configuration to give the best results in a short time of compilation. After randomly trying different combinations of numbers of neutrons and layers, the best Configuration of used Neural Network (NN) taken from Matlab is shown. The number of neurons in each results are obtained using a NN architec- layer is 12, 15, 10, and 1, respectively. ture composed of four layers feed-for-

Aerospace & Defense Technology, April 2014 www.aerodefensetech.com 35 ➮ Intro Cov ToC + – A ➭ Technology Update

ward network. The number of neurons To test the approach, researchers used the dataset according to the coordinates in each layer is 12, 15, 10, and 1, respec- 14440 points. The average error of the of each point, the wind speed, and tem- tively. The NN inputs are X, Y, Z, V, and obtained results in plane 1 is equal to perature of the test chamber. T. The output is the pressure. 7.22%. In the plane 2, the error is 4.42%, This article is based on SAE Interna- The optimal architecture obtained and the error in the plane 10 is equal to tional technical paper 2013-01-2285 by using the EGD algorithm and obtaining 3.16% of the theoretic pressure. Abdallah Ben Mosbah, Manuel Flores Sali- the best results is composed of four lay- By using this approach, the re- nas, Ruxandra Botez, and Thien-my Dao ers feed-forward network. The NN-EGD searchers successfully obtained the of École de Technologie Supérieure, are implemented in Matlab. value of the pressure in each point of

Boeing advances automation with smart and portable orbital drilling tools for 787

ince robotic work cells have proven breakdowns due to a complex problem. tools. Workers are at their most efficient Sto be highly effective in certain ap- Since robotic systems are usually imple- when all information is available, no plications, and the technology is always mented at critical manufacturing flow decisions are required, and the risk of improving, some might dream of a day points, a breakdown can cause a stop in making mistakes is reduced. With when aircraft can be made like cars on production. The effect of a machine today’s information technologies inte- heavily automated assembly lines with breakdown must be considered when grated into the portable tools, all of all the associated benefits. Boeing has designing a process. The best insurance these issues can be addressed. made an advance in that direction. is redundancy, but it might be difficult This capability to have the process Robotic workcells are only able to to justify buying a spare robot. In the knowledge built into the portable tool achieve consistent quality because case of a smart portable tool such as a allows the positioning system (the everything in them is highly controlled; portable orbital drill motor, the cost of a human) to perform multiple activities every aspect of the operation is carefully spare is not prohibitive and any unit within the work area of the final assem- planned and tested and every workplace can perform the task of any other like bly. It also stabilizes the assembly must conform to a strict set of toler- unit—meaning that so long as one process by enabling the skilled mechan- ances to ensure quality. Luckily, there is motor is functioning the job gets done. ics to cover for team members who may an alternative: the fully autonomous ro- Another limiting factor to the robotic have an unplanned absence or might botic system. workcell, or even a fully autonomous just be stepping out for a minute. In the fully autonomous robotic sys- robotic system, is the lack of versatility. Boeing has traveled far down this tem, the robot is freed from the cell and The main challenge of a robotic applica- path by introducing smart portable tool equipped with a vast array of sensors. It tion is creating a robust process. In gen- can move about a large structure, iden- eral this involves developing a highly tify reference points, and perform oper- specialized process capable of perform- ations on an un-fixtured workpiece. The ing one job very well. In aircraft final as- only problem with this scenario is the sembly, the variety of jobs is great and astronomically high cost of developing necessitates the development of many such a system—including a highly tech- unique solutions. Robotic systems de- nical workforce required to maintain it. signed for one task might be useless on According to researchers at Boeing the next task and would undoubtedly and Novator AB, the smart portable tool need to be replaced or upgraded every is, at its core, indistinguishable from a time a design change is implemented fully autonomous robotic system in on the structure. The world’s scrap yards that a complex end effecter is used to are filled with yesterday’s specialized perform operation with high consis- tools, but every factory is equipped with tency while it is being positioned by a general tools that have remained un- hyper-capable entity; the only differ- changed for decades. Tool obsolescence ence with a smart portable tool is that is the enemy of agile assembly; tooling the entity is a human, not a super-ex- up for a new design should be a matter pensive imaginary robot. of adaptation, not invention. The benefits of robotic systems are The practical solution to increase the Front spar drilling on the Boeing 787 using the clear, but as with any complex system efficiency in final assembly is evolving automated orbital drilling technology. Here, two there is always the risk of protracted via the development of smart portable units are shown in operation.

36 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Technology Update

technologies for orbital drilling in the the work to maximize productivity. and the new work sequencing before wing-to-body join of its 787 Dreamliner. With the use of simulation software and the first airplane was drilled. Tapping into the depth of resources workcell mockups, the mechanics were The efficiency of the process is built across the corporation, the company completely familiar with the equipment into the smart motor’s programs, thus found a technology from scaling up production rates Sweden (Novator AB) being by bringing in new mechan- developed in California that ics for a second assembly line could supply a solution for proved to be painless. The their assembly lines in Wash- speed at which a technology ington state. With the “One can be expanded with the re- Boeing” philosophy, they sulting increase in productiv- were able to create a team that ity proves the smart portable worked together to address all tool philosophy to be the concerns of hole quality, right approach to take for manufacturing costs, equip- today’s aircraft and all final ment reliability, production assembly lines going for- support, and logistics. ward. Production mechanics and The article is based on SAE motor setup technicians International technical paper were brought in at an early 2013-01-2295 by Wesley stage to help design the lay- Holleman and Eric Whinnem out of the workcell. All input of Boeing Research & Technol- was used to develop the An orbital drilling motor setup bench was established prior to launch of the new ogy; and Madeleine Wrede of most efficient sequencing of automated drilling system. Novator AB.

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 865 37 ➮ Intro Cov ToC + – A ➭ Tech Briefs

Software for Material/Structural Characterization Across Length Scales A two-stage approach is used for element-by-element analysis of a micro-structure. Simpleware Ltd., Exeter, United Kingdom

ynthetic and natural micro-architec- Stures occur frequently, and multi- phase functionally graded composites are becoming increasingly popular for applications requiring optimized/tailored material properties. When dealing with such materials computationally, one issue that immediately arises is the analysis of the mechanical properties of macroscopically inhomogeneous multi-scale structures. The bulk response of these structures can be determined by performing full finite The process of Generating the Macro Mesh: Femoral head modeling (a) input dataset, (b) coarse tetra- element analysis (FEA); that is, with the hedralization, and (c) micro-element. entire geometry discretized at a resolution high enough to accurately model the element approach for each macro-ele- effective properties of a real-world struc- smallest length scale of interest. However, ment. The novelty here lies in effec- ture and compared to the results ob- these full models may easily exceed hun- tively discretizing the full 3D mesh into tained using classical methods. The dreds of millions, or potentially billions, larger tetrahedra and hexahedra, and Schoen Gyroid was chosen for this pur- of degrees of freedom, and solving prob- computing homogenized properties for pose as its periodic geometry allows peri- lems of this magnitude may only be pos- each macro-element based on exact odic boundary conditions to be used. sible with the use of supercomputing fa- meshed domains representing the full These boundary conditions are often cilities. microstructural complexity within the considered to be the exact solution. Additionally, in an iterative optimiza- macro-elements. Following the development of a tech- tion process where the performance of For the more general case, this work ex- nique to determine an effective constitu- the structure may be evaluated thousands ploited the use of robust, all-tetrahedral tive matrix for an arbitrary tetrahedral sub- of times, the use of full FEA simulations volume meshing as a method for divid- volume, the issue of multi-scale problems becomes highly impractical. When the ing an irregular domain into smaller sub- was addressed. Of particular interest is the performance of a structure is evaluated in volumes for homogenization. As each set of problems having an irregular (i.e. an optimization process, typically only sub-volume conformed to its parent non-cuboidal) domain. While problems of some aspect of the bulk response, such as macro-element, a method for calculating a more regular nature may be addressed deflection, is considered. For such proper- their effective properties was developed. with more conventional methods of deter- ties, the use of full FEA simulations to At the highest level, the developed ho- mining effective constitutive matrices, model the problem may be excessive. In mogenization process involves treating they are nevertheless addressable using the the present project, a novel, two-stage ap- the sub-volume as if it were the actual methods developed in this work. proach to solving such a large problem by macro-element. Appropriate boundary For many problems, it is highly im- performing element-by-element homog- conditions are applied based on the practical to attempt to include all enization of the micro-structure, followed shape functions of the macro-element length scales in a finite element model; by solving the global problem with a such that the sub-volume is constrained consequently, it is often desirable to coarser mesh, was explored. to the same modes of deformation. A se- only capture the coarser details. Rather The approach taken is based on creat- ries of finite element simulations is then than excluding the smaller length ing a coarse tetrahedral/hexahedral dis- performed in order to determine the sub- scales, a coarse mesh with appropriate cretization of the domain using tradi- volume’s effective properties. homogeneous material properties was tional volume meshing techniques, and As part of the validation of the devel- produced. The process of generating the assigning appropriate material proper- oped homogenization technique for macro mesh is outlined in the figure. ties based on a finite element homoge- tetrahedral sub-volumes, a homogeneous The homogeneous domain should con- nization based on high-resolution mesh sub-volume with fully anisotropic mate- form to the bounds of the original do- at the microstructural level of the macro rial properties was used as a “sanity test.” main as closely as possible, representing tetrahedra or hexahedra. In effect, two The input material properties were accu- the result of a “shrink-wrap” operation. length scales are decoupled by comput- rately recovered. More interestingly, the Each of the macro-elements in the ing effective properties using the finite technique was also used to recover the generated mesh is subsequently homog-

38 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Tech Briefs

enized using the developed technique. As each macro-element is considered as an independent sub-volume, the processing may occur in either series or in parallel, depending on the availab le computational resources. The final result is a Cryogenically Serviceable macroscopic homogenous model with varying material properties that can be exported to a traditional finite element Epoxy Adhesive package. This work was done by Philippe G. Young of the University of Ex- Two Component eter; and David Raymont, Joonshik Kim, and Viet Bui Xuan of Sim- pleware Ltd. for the Air Force European Office of Aerospace Research EP21TCHT-1 & Development (EOARD). For more information, download the Technical Support Package (free white paper) at www.aerode- ì Thermally conductive/electrically insulative fensetech.com/tsp under the Information Technology category. ì Cures at room temperature AFRL-0225 ì NASA low outgassing approved ì Halogen free Model Development Using 154 Hobart Street, Hackensack, NJ 07601 USA Accelerated Simulations of +1.201.343.8983ì[email protected]

Hypersonic Flow Features www.masterbond.com

This code enables more accurate models for Free Info at http://info.hotims.com/49744-848 computational fluid dynamics applications. Air Force Office of Scientific Research, Arlington, Virginia

urrently, the two main computational tools used by the Caerothermodynamics community to model hypersonic flows are Computational Fluid Dynamics (CFD), and the direct simulation Monte Carlo (DSMC) particle method. Both use essentially the same physical models for rotational-vibra- tional excitation and dissociation phenomenon, which are based on a limited number of near-equilibrium experiments performed at low temperatures. Rod Ends and Spherical The purpose of this work was to develop a new modeling Bearings designed and capability, based on computational chemistry, to provide a manufactured to Aurora's more fundamental understanding and develop more accurate thermochemical models for CFD and DSMC. A parallel exacting standards for quality DSMC code called the Molecular Gas Dynamic Simulator and durability. (MGDS) code, was developed that uses an embedded three- Registered and Certified to level Cartesian flow grid with automated adaptive mesh re- ISO-9001 and AS9100. finement (AMR). The refinement is arbitrary (non-binary) and enables accurate and efficient simulations with little user From economy commercial to input. In addition, MGDS contains a robust “cut-cell” sub- aerospace approved, routine that cuts complex 3D geometry from the background we've got it all ! Cartesian grid and exactly computes the volumes of all cut cells. Combined within a DSMC solver, these two features enable molecular-level physics to be applied to real engineering problems. Aurora Bearing Company In addition to the practicality for complex 3D flows, the 901 Aucutt Road DSMC code acts as a bridge between computational chem- Montgomery IL. 60538 istry modeling and continuum fluid mechanics. With exist- Complete library of CAD drawings and 3D models available at: ing parallel computer clusters, DSMC is able to perform near-continuum simulations using only molecular physics www.aurorabearing.com

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 8 4 9 39 ➮ Intro Cov ToC + – A ➭ Tech Briefs

models. Pure computational chemistry that dictates the interaction forces be- The methodology was validated with of simulation of shock waves and tween individual atoms as the model experimental data for shock structure in shock layers is computationally feasi- input. Thus, unlike DSMC or CFD, no mixtures of noble gases and diatomic ble with modest parallel computing re- models for viscosity, diffusion, thermal nitrogen. All-atom MD simulations of sources (100 core processors for a few conductivity, internal energy relax- nitrogen discovered clear “direction-de- days). Such simulations, which are re- ation, chemical reactions, cross-sec- pendence” of translational-rotational ferred to as “all-atom molecular dy- tions, or state-resolved probabilities/ energy transfer that is not captured by namics” (MD) simulations, require rates are required. Rather, every real existing models. Compressing flows in- only a potential energy surface (PES) atom in the system is simulated. volve fast rotational excitation, whereas expanding flows involve slower relax- ation for the same equilibrium temperature. A new model for both DSMC and CFD reproduces experimental data and is consistent among MD, DSMC, and CFD. A combined MD-DSMC technique replaces the collision model in DSMC with MD trajectories. The method reproduces exactly pure MD results. This is a significant advancement that enables simulation of axisymmetric and 3D flows where a potential energy surface is the only model input. Thus, the accuracy of pure MD is maintained for full flow fields, directly linking computational chemistry with aerothermody- namics. This work was done by Thomas E. Schwartzentruber of the University of Min- nesota for the Air Force Office of Scientific Re- search. For more information, download the Technical Support Package (free white paper) at www.aerodefensetech.com/tsp A three-dimensional solution for Hypersonic Flow of argon over a capsule geometry. This simulation under the Information Technology cate- required only 128 cores for 12 hours using the MGDS code. gory. AFRL-0226

Chrono: A Parallel Physics Library for Rigid-Body, Flexible-Body, and Fluid Dynamics This software enables 3D simulation of multi-body problems such as modeling granular terrain. US Army TARDEC, Warren, Michigan; University of Wisconsin, Madison; and University of Parma, Parma, Italy

he Chrono::Engine software is a In these applications, it is desirable to tional Inequality (DVI) formulation as Tgeneral-purpose simulator for three- model the granular terrain as a collection an efficient method to deal with prob- dimensional multi-body problems. of many thousands or millions of discrete lems that encompass many frictional Specifically, the code is designed to sup- bodies interacting through contact, im- contacts. This approach enforces non- port the simulation of very large sys- pact, and friction. Such systems also in- penetration between rigid bodies tems such as those encountered in gran- clude mechanisms composed of rigid through constraints, leading to a cone- ular dynamics, where the number of bodies and mechanical joints. These chal- constrained quadratic optimization interacting elements can be in the mil- lenges require an efficient and robust problem that must be solved at each lions. Target applications include simulation tool, which has been devel- time step. Chrono::Engine has since tracked vehicles operating on granular oped in the Chronosimulation package. been extended to support the Discrete terrain, or the Mars rover operating on Chrono::Engine was initially devel- Element Method (DEM) formulation discrete granular soil. oped leveraging the Differential Varia- for handling the frictional contacts

40 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Tech Briefs

A Furukawa Company

Your Optical Fiber Solutions Partner™ present in granular dynamics problems. This formulation Optical Fibers, Cables and Modules computes contact forces by penalizing small interpenetra- for Challenging Applications tions of colliding rigid bodies. Various contact force models can be used, depending on the application. Gyroscopes The core of Chrono::Engine is built around the concept of middleware; namely, a layer of classes and functions that can be Unmanned Craft used by third-party developers to create complex mechanical Avionics Systems simulation software with little effort. Given the complexity of the project, approaching half a million lines of code, the soft- LADAR & Directed Energy ware is organized in classes and namespaces as recommended by the Object Oriented Programming paradigm, targeting mod- ularity, encapsulation, reusability, and polymorphism. The libraries of Chrono::Engine are thread-safe, fully re-entrant, and include more than 600 C++ classes. Objects from these classes can be instanced and used to define models and simulations that run in third-party software, including vehicle simulators, CAD tools, virtual reality applications, or robot simulators. Chrono::Engine is platform-independent, so libraries are available for Windows, Linux, and Mac OSx, for both 32- and SPIE COME SEE US AT Defense, Security and Sensing 64-bit versions. A modular approach splits the libraries in Baltimore, Maryland | 6 - 8 May 2014 modules that can be dynamically loaded only if necessary, Booth #1150 thus minimizing issues of dependency from other libraries 860 678 0371 | www.ofsoptics.com /ofsoptics/ofs_defense /company/ofs /OFSoptics and reducing memory footprint. For instance, libraries were developed for MATLAB interoperability, for real-time visuali- Free Info at http://info.hotims.com/49744-850 zation through OpenGL, and for interfacing with post-processing tools. Most C++ objects that define parts of the multi-body model are inherited from a base class called ChPhysicsItem, which defines the essential interfaces for all items that have some degrees www.hunterproducts.com

MICRO-METALLIZER PLATING PENS MIL & QQ Standards GOLD 14K, 18K, 24K, SILVER, RHODIUM, PALLADIUM, NICKEL, COPPER, TIN, BLACK NICKEL, AND CHROME COLOR PENS AVAILABLE.

Environmentally friendly, these low-cost disposable applicators permit instantaneous selection from a variety of plating possibilities without the preparation of solutions. Specially formulated compounds and can be used for contact repair, prototype development work, electronic instrument repair, medical instrument repair etc.

Hunter Products Inc. 792 Partridge Drive, P.O. Box 6795 A simulation in Chrono::Engine Software of a Mars rover-type wheeled Bridgewater, NJ 08807-0795 vehicle operating on granular terrain. The vehicle is composed of a chassis and six wheels connected via revolute joints. The wheels of the rover are checkered s&AX blue and white to signify that the master copy of the rover assembly is in the [email protected] blue sub-domain and the rover spans into adjacent sub-domains. Shared bodies (those that span sub-domain boundaries) are white.

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 851 41 ➮ Intro Cov ToC + – A ➭ Tech Briefs

of freedom. A set of more than 30 me- Each sub-domain manages the simula- to the larger memory pool available on chanical constraints is part of this class tion of all bodies contained therein. distributed memory architectures. hierarchy. Furthermore, the architecture Bodies may span the boundary between Whereas a single node or GPU card is open to further definition of new spe- adjacent sub-domains. In this case, the may have about 6 GB of memory, a dis- cialized classes for user-customized parts body is considered shared, and its dy- tributed memory cluster may have on and joints. The software architecture has namics may be influenced by the par- the order of 1TB of memory, enabling been designed to accommodate an ex- ticipating sub-domains. The implemen- the simulation of vastly larger prob- pandable system for handling assets tation leverages the MPI standard to lems. (meshes, textures, CAD models), with implement the necessary communica- This work was done by David Lamb of multiple paths from pre-processing to tion and synchronization between sub- US Army TARDEC; Toby Heyn, Hammad post-processing. domains. Mazhar, Arman Pazouki, Daniel Melanz, Chrono has been further extended to This approach enables the simulation Andrew Seidl, Justin Madsen, Andrew allow the use of CPU parallelism for of large systems in two ways. First, it re- Bartholomew, and Dan Negrut of the Uni- certain problems. To efficiently simu- lies on the power of parallel computing versity of Wisconsin; and Alessandro late large systems, a domain decompo- since one compute core can be assigned Tasora of the University of Parma. For sition approach has been developed to to each MPI process (and therefore to more information, download the Tech- allow the use of many-core compute each sub-domain). These processes can nical Support Package (free white clusters. In this approach, the simula- execute in parallel, constrained only by paper) at www.aerodefensetech.com/tsp tion domain was divided into a number the required communication and syn- under the Software category. ARL-0158 of sub-domains in a lattice structure. chronization. Second, it allows access

Terrain Model as an Interface for Real-Time Vehicle Dynamics Simulations The vehicle terrain model interfaces with existing vehicle and tire dynamics models. US Army TARDEC, Warren, Michigan

n order to enable off-road vehicle dy- volved in the soil deformation. The ter- tlenecks. Parallel CPU and GPU hard- Inamics analysis simulations when rain takes a set of tire-terrain interface ware is utilized to accelerate these com- traveling on soft soil, a deformable Ve- forces from the tire model, applies it to putations. The model will be exercised hicle Terrain Interface (VTI) model that the surface of the terrain, evaluates the using a rigid tire with and without lugs interfaces with existing vehicle and tire terramechanics problem, and updates to demonstrate the ability to handle dynamics models was developed. It is the soil states and deformed surface complicated tire geometry. modularized to be interfaced to a multi- profile for the subsequent time step. The Vehicle-Terrain Interaction body dynamics vehicle that supports In the context of off-road vehicle sim- model involves three main compo- the Standard Tire Interface (STI). Any ulations, terrain models fall into three nents: (1) a surface loading mechanism tire model can be used that supports the categories of increasing complexity: due to 3D tire geometry contact with STI as well; currently, both rigid and rigid terrain where the main focus is an the terrain, (2) stress propagation of the flexible tire models are supported. accurate surface profile, use of empirical load through the subsoil, and (3) rigor- Geometry associated with the terrain relationships to find pressure and sink- ous vertical soil stress/strain relation- profile is a combination of low-fidelity age directly under the tire, or finite/dis- ship. terrain height measurements, with su- crete element approaches. Any off-road At the beginning of a time step, the perimposed NURBS for high-frequency vehicle dynamics simulation where the vehicle passes the tire wheel spindle content. The terrain model can effi- soil deforms considerably requires a ter- state data, which includes the position ciently query the current height by lo- rain model that accurately reflects the and velocity of the Center of Mass cally defining the surface as an equidis- deformation and response of the soil to (CM) in the reference frame indicated tantly spaced x-y grid, and using all possible inputs of the tire in order to by the Standard Tire Interface. The tire bi-linear interpolation of the nearest correctly simulate the response of the passes an updated geometry profile to four points. Points on the surface also vehicle. the terrain in the form of a height map contain information on the state of de- In this approach, fast simulations are query, and the terrain database returns formation of the soil, notably the possible due to the inherent parallel na- the collision information. Forces at the undisturbed terrain height, the type of ture of the subsoil stress calculations, tire/terrain interface are found at each terrain, and the energy and power in- which are the major computational bot- time step by using a combination of

42 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ e mode mode t c co va t T w t c w A no The so of affectedmate ments andc p t updated so subso r vo t t sumed tobe d demonst d sponse fo co second mode h ri h h equ h h r l h h i e i l hi ement i et sp r sp ast il e p ey a In o r e te but e te r at ri l t l ange r ese fo ce ont ospace &Defense Tec d umn ofso ume 3D Tire Geometry h mec ma i c ab l zed so l ir i acement ataconstantve soft-so h r i acement of7"tot ng tot l l i l c comp essu r il ed todefo rr . rr

r on

app r l l , e i e app i ands de es. T fo i st A nc a n tu , l a s causedbyanapp h r r i as i ate subso i comp , ces a i ate t n bu n w s mode r an te n mode r l ll h r il todete ude t e d li il ess equat owed bya e su vo i h r es Bouss rr h states li i h cs equat n p il li hil mp h r e outputsoft e t i r a ed tot anges toot st ri ess e passedf p fo l t l il e i r k dens umes r n su ir ri r ri ess e t g ir face oft asasystemofd ir ri r li m t l e-te i a oduces so but i ed us e-te l, g d app e bounda r f b l r r i , i m . T i ces w on/ il andpowe ave ili d w ed t r h used to determine collision points withtheterrain. , h i i face defo i rr p i andeac i nesq andCe on ons todete h rr e so h ne t ty h ons h e d , a i r i

li no e mode h ty oft o a e i ng v i ebound so r r ir n p li n conjunct h ng atasteady i r ri ee i essu r om t h i n l n t e t h il e sc e t e t es ano h ogy zonta e te l h l . e li e effectt i ’s effectson il at r r ➮ r nte h i h h ave w ed ve r essu et ir h so scoe d , h r y fo h

e vo e te i e te r rr A l es toa r e ove at l i ons h vo mat oc t e t i /ene zed so p r l sp a il e so w act r ril r r i eats a state l i i e d ir m rr rr n ac- r l l Intro r ty to asto- r l s as- il rr hi ume ume 20 t h h ace- i ma ces. e to i i i

a a on r i r ut ca ee on on r en h ne i gy ps i il, i i

e- s- s- 14 n n il 1 e i l l l , www.ae Tech Briefs Package (free white paper)at tion, downloadtheTechnical Support www.aerodefensetech.com/tsp under GPUs and the Information Technologythe Information category w US Army TARDEC.US Army to bes l fo ARL-0159. geomet t t s F st p p ment oft state ve pa at t r (ma t p d duced byw t m e e h un r li r h rl r l li i r ill ave ated aboutt r l r i acement-s sp o g at t This workwasdonebyAlexanderReidof Cov T Examp ox e te r y accountfo comput n ong ed tog m. T h h li ed tot , h enab i i w l n ma t e endoft i c acement e seconds l l mate h ) h l y rr hi i l , y e e mu r h

y pa l l y t l a i oc c va e te a r l nd l h i h i e nume e otat r l i n databasecan nf i l e so i ongated ge ve t h l

s ated. ty of h r r l y i i i rr ue ofs at s ea amete h ng us cat ToC l ee h r uenced byt h 1 a fo i ea r il e l ona h odefensetec i h i i i h l own tosca 5%. T -t m s comp s app n mode s

r i e s r e t i e i t ng t i r n t 1 st li mu ri me defo il ce vecto l h .5 MPH. ow-s l l p. i ca a i li r ir d oad ng bot mu e t r h r va For more informa- i p. ess e as tot l n t l h e ve li i h at

sp r r at t ed to l e tota l esu i act l li ex andnon-un at i + l ng a

h l r on examp ue. T l p s acement h r e eve li h i e d r l r t on h l i mab l e f h e we s w cm .com h i p at ts ve ve fo ca A e s h e c CPUsand r r ir ir l r

r i i and ages pa ea l i d ons p r ate ofap- esu mu h d s concen- ect st h h otat l ll, h e te en com- ri i , , ea e ir r o and sp except w ces fy t r l l i l ect i t e t e a on of at – i r ce of i l s ap- rr d hi ona l r ace- i e i op- n a i r h a i on ir on a c i n- i r at s- i i h n l i e e s s - - l . Fr A ee www.l F Lighting and Solid-State Advances inLEDs Discover theLatest Briefs maga te pr LEDs Inf r o ch o m duc o at

. r t V z , e INFRARED CONFERENCE h in Lighting Technology p t i i ➭ http://extension.ucsb.edu/ir3 (805) 893-4200 Enroll today! commercial applications. including thelatest advances inIRdetection, experts sharerecent Santa Barbara.Industry the UniversityofCalifornia, and SystemApplicationsat Modern InfraredDetectors annual shortcourseon colleague about,the47th Plan toattend,ortella SANTA BARBARA OF CALIFORNIA UNIVERSITY JUNE 16-20,2014 EXTENSION UC h e e g o n e tt w h r publi e ts, f p

t w e S fr : in //inf a ANTA s o ee o applica t gte ur s n o. h es e e h f B ch r

ot n charg s o ARBARA d e b ims t es rgy i OON ri f o ign NASA Tech n e . c N -e e

fs o n t m/4 a ffici otes . u c t digi : o to 9 m e 744- rial and n t . al t s, 85 4 2 3 Application Briefs

Vacuum Regulators to prove the accuracy of the simulated altitude. Working with Spectrum Sciences Simulate Altitudes aerospace engineer Curtis Stansfield and the Navy’s Dennis Gordge, Equilibar de- Equilibar signed three high-flow vacuum regula- Fletcher, NC tors. The design used high-resolution 828-650-6590 Proportion-Air electro-pneumatic regu- www.equilibar.com lators to pilot-operate the three vacuum regulators. The lightwe ight, sup ple di- o support air assets, the US Navy’s Al- aphragm moves only a few millimeters Ttitude Laboratory in Maryland is to modulate the vacuum regulator from tasked with testing On-Board Oxygen fully closed to fully open. The thin Generating Systems (OBOGS). The lab Viton diaphragm is sensitive to changes has three hypobaric chambers to assess in pressure as small as 0.001 psi. Equi- mechanical breathing simulators at alti- libar regulators pro vide stable pressure tudes up to 60,000 feet. The altitude in across flow rate changes of up to 1000:1 the chambers is simulated by precisely and adjust to changes in flow rate in regulating the vacuum pressure. less than 10 milliseconds. Testing oxygen generating systems The new system provides a significant presents unique challenges due to the reduction in altitude pressure variation. high flow rates created by aircraft sys- Even with non-steady air crew exhala- tems, the complexity of sinusoidal breathing, and the life- tion flows, the chamber altitude is maintained within +/- 50 and-death importance of a reliable system. Previously, the ft, an 85% reduction in variability. The system uses one bleed lab used traditional vacuum control valves to throttle orifice and two separate solenoid valves for three different flow between hypobaric chambers and vacuum pumps. modes. A very small orifice allows a low constant bleed rate While common throughout industry, such systems are for minor adjustments. A .25" sized orifice is used for con- not capable of responding quickly enough to oxygen sys- trolled descent, and a .5" orifice allows for rapid ingress of air tems’ frequent perturbations in pressure/flow balance. in a simulated emergency descent. The actual rate of descent Barometric swings of 2000 to 4000 feet were observed in in all cases is set by providing a matching ramping electronic some chambers. command signal to the electronic pilot regulator. In 2011, the Navy contracted with Research, Engineering For Free Info Visit http://info.hotims.com/49744-508 and Development, Inc., and Spectrum Sciences, Inc., to im-

Electronic Attack Capability on Unmanned Aircraft

Northrop Grumman Corp. Falls Church, VA 703-280-2900 www.northropgrumman.com

orthrop Grumman Corporation has integrated and em- Nployed an internal miniature electronic attack payload on the Bat unmanned aircraft, marking the first time that such a system was used in operation on a Group III (small, tactical) system. The Pandora electronic attack capacity, integrated in less than two months, is a low-cost derivative of Northrop Grum- Bat is a tactical, runway-independent, unmanned aircraft man's upgraded digital APR-39 systems. The lightweight, mul- that can be launched from land or sea. Its flexible design al- tifunction payload provides electronic attack, support, and lows for quick installation of a variety of payloads and enables protection. Northrup Grumman showcased the system’s capa- rapid, expeditionary deployment. During a 2013 Weapons bilities late last year in a demonstration that involved the jam- and Tactics Instructor (WTI) event, the Bat completed multi- ming of radars during the Marine Aviation Weapons and Tac- ple flights in collaboration with fixed wing and other un- tics Squadron One (MAWTS-1) Weapons and Tactics Instructor manned platforms. (WTI) event at Naval Air Weapons Station China Lake, CA. For Free Info Visit http://info.hotims.com/49744-509

44 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Application Briefs

Armored Response Vehicle for Bomb image camera, CBRNE equipment, and advanced communications sensors are also available to meet operator needs. Disposal Teams All Lenco-armored trucks are built with Mil-Spec steel armor, plate-certified to defeat multi-hit attacks from 7.62 AP / .50 Cal Lenco Industries BMG, while ceilings and floors provide enhanced blast and Pittsfield, MA fragmentation protection. Ballistic glass windows also offer 413-443-7359 multi-hit defeat. Additionally, BombCat models are built on www.LencoArmor.com heavy-duty commercial truck platforms, which allow upkeep and repairs to be performed at OEM dealers and truck centers. enco Industries has introduced the BearCat® EOD “Bom- For Free Info Visit http://info.hotims.com/49744-507 LbCat” armored response vehicle for bomb disposal teams and EOD and IEDD first responders. Designed with input from veteran explosive ordinance disposal experts, the Bomb- Cat accommodates a large tactical robot like the Andros F6A, which can be readily accessed using a fold-down ramp at the curb side door or deployed from a hydraulically controlled platform located at the front of the vehicle. The BombCat’s spool storage reel manages the robot’s fiber- optic cable, while technicians monitor progress via computer monitors from the safety of the vehicle’s interior. Secure radio signals also transmit robot audio and video feeds. The BombCat includes an optional, roof-mounted 24X zoom camera with high-intensity scene lighting that can be raised up to 10 feet for enhanced visibility. A thermal

The Crossroads of Manufacturing MAY 6-8, 2014 | CONNECTICUT CONVENTION CENTER | HARTFORD, CT | mfg4event.com

Mfg4 brings together three manufacturing industries; aerospace, defense (including arms) and medical, and one strategic technology; micromanufacturing under one roof.

Experience interactive exhibits and conference sessions

Discover ground-breaking solutions from other industries

Explore the latest techniques for creating micro features on parts of all sizes

Mfg4 is the perfect event for cross-collaboration, innovation and networking.

Visit mfg4event.com for complete event details and to register.

co-located with co-located with official media sponsor

produced by

Aerospace & Defense Technology, April 2014 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 853 45 ➮ Intro Cov ToC + – A ➭ New Products

Signal Acquisition Module Thermal Analysis Tool ADLINK Technology (San Jose, CA) A Thermal Analysis tool from Custom MMIC (Westford, MA) has released its PXI Express dynamic estimates the rise in temperature between the ambient sur- signal acquisition module, the PXIe- rounding and the bottom of a packaged MMIC when attached 9529, featuring up to eight 24-bit ana- to a printed circuit board (PCB). The online calculator does not log input channels simultaneously require a full 3D thermal simulation environment. Users select sampling at 192 kS/s and a 108 dB dynamic range. The PXIe- the package type, the power dissipation inside the package, the 9529 features a vibration-optimized lower AC cutoff frequency PCB board material, the via construction, and the base plate of 0.3 Hz, and all input channels incorporate 4 mA bias current. temperature (typically 85°C). The calculator then determines the The PXIe-9529’s built-in phase-locked loop (PLL) allows temperature rise through the multiple modules to lock to an external reference-timing sig- PCB to the bottom of the pack- nal; each module can perform measurements simultaneously. age, under the following as- In addition, the PXI star trigger ensures synchronization be- sumptions: the PCB is plated tween modules with less than 1 ns of skew. with 1 oz. copper (1.4 mils The PXIe-9529 provides flexible input ranges up to ±10V or thick), the package is attached ±1V, software-selectable AC or DC coupling, and both differ- to the PCB with solder (2 mils ential and pseudo-differential input configuration, with up to thick), and the base plate is an ± 42.4V over-voltage protection for positive and negative in- ideal heat sink. puts in both configurations. The module supports Windows 8, For Free Info Visit http://info.hotims.com/49744-513 Windows 7, Windows XP operating systems, and is fully compatible with third-party software such as LabVIEW™, MAT- Single Board Computer LAB®, and Visual Studio.NET®. The “Medusa” VPX3424 from For Free Info Visit http://info.hotims.com/49744-510 AcQ Inducom (Oss, The Netherlands) is a 3U Open- Single-Slot VPX Board VPX™ (VITA 65) single Elma Electronic (Fremont, CA) offers a board computer (SBC) featuring dual-drive VPX storage module that pro- the T4240 QorIQ® processor from vides more than 2 terabytes (TB) of stor- Freescale Semiconductor. The 12-core, age, but requires only one system slot. 24-thread processor, based on an e6500 core, The 533x family comes with either solid runs at up to 1.8GHz and 216 GFlops. The SBC state SLC, MLC, or 2.5" rotating drives. includes as much as 12GB DDR3 RAM. The 5330/1 boards feature a 4-port To add support for application-specific interfaces, the Medusa PCIe to SATA II 3 Gb/s controller, supporting two onboard and has a Xilinx Kintex-7, user-programmable FPGA and dozens of two external SATA 3G drives or four external drives. The con- customizable OpenVPX™ user I/O pins. A PCIe 4x communica- vection-cooled versions operate from -40°C to +85°C, and the tion interface enables pre-processing and video/image process- conduction-cooled versions operate from -40°C to +75°C. Op- ing. Other features include built-in AltiVec® technology accel- erating shock of all boards is 40 Gs at 11 ms, half-sine wave; erators; 2Mbit of FRAM; 256MB Flash for programs; and vibration is 2 Gs from 15 Hz to 2,000 Hz. multicore-debugging over AURORA and JTAG. For Free Info Visit http://info.hotims.com/49744-511 For Free Info Visit http://info.hotims.com/49744-523

-ARS 2OVER 4ESTED4ECHNOLOGIES 0)%:/!#45!4/23!.$-/4/2):%$0/3)4)/.%23

0)9OUR#OMPETITIVE!DVANTAGE "ROADESTPORTFOLIOOFPRECISION MOTIONTECHNOLOGIES %NGINEERSWHOUNDERSTAND YOURAPPLICATION ANDMATCHITTOTHE APPROPRIATETECHNOLOGY

WWWPI USAUS 0)0HYSIK)NSTRUMENTE ,0 INFO PI USAUS 0)4HE"ROADESTAND$EEPEST0ORTFOLIOOF0RECISION-OTION4ECHNOLOGIES

46 Fr ee Inf o at h tt p : //inf o. h ot ims . c o m/4 9 744- 85 4 Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ Product Spotlight New Products ACCUFIZ 6MP SHX1 LONG- HIGH RESOLUTION RANGE MULTI- LASER CHANNEL INTERFEROMETER TRANSCEIVER The AccuFiz 6MP provides Lemos International offers the highest available resolu- the SHX1 Long-Range Multi-Channel Transceiver tion for measuring steep slopes and small diameter that provides: optics. Its 2400 x 2400 pixel sensor lets you meas- • Unlicensed operation on MURS band frequencies Rotary Micro Drive ure surface shape earlier in the manufacturing (under FCC Part 95) process, to capture polishing marks despite high • Data rates up to 5 kbps for standard module New Scale Technologies (Victor, NY) fringe counts and to measure spherical/aspherical • High-performance double superhet PLL synthesizer has announced a prototype rotary piezo- optics and molds with unprecedented accuracy. • Usable range over 5km electric micro drive system. Unlike servo See us at Defense, Security and Sensing, Booth • Re-programmable via RS232 interface, fully 300. http://4dtechnology.com/products/ screened, low profile, small footprint. drives, the new rotary drive has no accufiz6MP.php www.lemosint.com measurable jitter, holds position without power, and generates no magnetic 4D Technology Corporation Lemos International fields. The 44 × 44 × 36 mm prototype Free Info at http://info.hotims.com/49744-855 Free Info at http://info.hotims.com/49744-858 operates at 350 degrees/second and has an acceleration of 3000 degrees/second2 CUSTOM RUBBER MULTIPHYSICS MOLDING TO EXACT SIMULATION SPECIFICATIONS PAPERS AND You probably know us best as pro- PRESENTATIONS ducers of rubber molded parts. Browse over 700 papers, However, you may not know that posters, and presentations we’ve produced many parts that from the COMSOL other companies considered nearly impossible to Conference, the world’s make. Our specialty? Precision custom molded largest event for multiphysics simulation. At this parts at a competitive price with on time delivery. event, over 2,000 engineers share their innovative Injection, transfer and compression molding of research in the electrical, mechanical, fluid, and Silicone, Viton, Neoprene, etc. Hawthorne Rubber chemical applications. Explore the innovative Manufacturing Corp., 35 Fourth Ave., Hawthorne, research presented at the COMSOL Conference NJ 07506; Tel: 973-427-3337, Fax: 800-643-2580, 2013 at www.comsol.com/ntblit www.HawthorneRubber.com A tiny rotating stage integrates a COMSOL, Inc. high-torque, direct-drive piezoelectric Hawthorne Rubber motor, precision ball bearings with low Free Info at http://info.hotims.com/49744-857 Free Info at http://info.hotims.com/49744-856 run out and wobble, optical encoder with zero reference mark, and New CRYOGENICALLY RUGGED Scale drive electronics and closed-loop SERVICEABLE FIREWALL/ control system. The device is PC-con- EPOXY SYSTEM ROUTER/ trolled using New Scale Pathway™ soft- EP29LPSP is a two compo- SWITCH/VPN ware. nent, low viscosity epoxy GATEWAY For Free Info Visit system for bonding, seal- The newly developed Firewall/Router/Switch http://info.hotims.com/49744-512 ing and coating. This epoxy not only functions at temperatures as low as 4K, but also withstands cryo- Solution is designed for an environment of -40°C to genic shocks. Additionally, it meets NASA low out- 85°C, and is produced 100% by MPL AG in Microwave Analog Signal Generators gassing requirements. EP29LPSP provides superior Switzerland. The product comes with the embedded Linux based OpenWRT OS and provides full func- Agilent Technologies (Santa Clara, physical strength properties, high chemical resist- ance, excellent electrical insulation and outstanding tionality. It includes a wide input power range and CA) has introduced two microwave ana- optical clarity. www.masterbond.com/tds/ep29lpsp can be customized according customer needs. log signal generators: the N5183B MXG and N5173B EXG. The MXG has phase Master Bond MPL AG Switzerland noise of less than -124 dBc/Hz (at 10 GHz, 10 kHz offset). The EXG offers +20 dBm at 20 GHz and low harmonics of Free Info at http://info.hotims.com/49744-859 Free Info at http://info.hotims.com/49744-860 <-55 dBc to characterize broadband mi- AVIATION crowave components, such as filters A WORLD OF FIBER OPTIC PANEL SOLUTIONS METER (APM) REPLACES NSN 6620-00- 083-8811. The APM is qualified to RTCA-160F, MIL 461, 810F, • T1/E1 & T3/E3 Modems, WAN 901C, 167-1, and EPRI 102323R4 standards. The • RS-232/422/485 Modems and Multiplexers APM is available in loop power or 5-45VDC power. • Profibus-DP, Modbus and amplifiers. The generator also sup- With a 4 digit digital display, unlike an analog meter, • Ethernet LANs ports continuous-wave (CW) blocking there is no more guessing or stuck needles. OTEK • Video/Audio/Hubs/Repeaters for receiver testing or basic local-oscilla- products carry a lifetime warranty. www.otekcorp.com • USB Modem and Hub • Highly shielded Ethernet, USB (Tempest Case) tor upconversion for point-to-point mi- • ISO-9001 crowave backhaul links. OTEK Corporation http://www.sitech-bitdriver.com/ For Free Info Visit S.I. Tech http://info.hotims.com/49744-518 Free Info at http://info.hotims.com/49744-861 Free Info at http://info.hotims.com/49744-862

Aerospace & Defense Technology, April 2014 www.aerodefensetech.com 47 ➮ Intro Cov ToC + – A ➭ Production/Circulation ______Adam Santiago Marilyn Samuelsen Production Manager (TBMG) Audience Development/Circulation www.aerodefensetech.com Lois Erlacher Director (TBMG) Published by Tech Briefs Media Group (TBMG), Art Director (TBMG) Jodie Mohnkern an SAE International Company Bernadette Torres Circulation and Mail List Manager (SAE) Designer (TBMG) Martha Saunders ______Audience Development/Circulation Editorial Assistant (TBMG) Thomas J. Drozda Kendra Smith Sales & Marketing ______Director of Programs & Product Managing Editor, Tech Briefs TV Development (SAE) Scott Sward Marcie L. Hineman Matt Monaghan Publisher, Periodicals & Electronic Global Field Sales Manager (SAE) Linda L. Bell Assistant Editor (SAE) Media (SAE) Lorraine Vigliotta Editorial Director (TBMG) Lisa Arrigo Joseph T. Pramberger Marketing Client Manager (SAE) Kevin Jost Custom Electronic Products Editor (SAE) Publisher (TBMG) Felicia Kennedy Editorial Director (SAE) Kami Buchholz Debora Rothwell Marketing Assistant (TBMG) Bruce A. Bennett Detroit Editor (SAE) Marketing Director (TBMG) Editor (TBMG) Richard Gardner Jean L. Broge European Editor (SAE) Tech Briefs Media Group, an SAE International Company Managing Editor (SAE) Jack Yamaguchi 261 Fifth Avenue, Suite 1901, New York, NY 10016 Lindsay Brooke Asian Editor (SAE) (212) 490-3999 FAX (212) 986-7864 Senior Editor (SAE) Terry Costlow, John Kendall, Billy Hurley Bruce Morey, Jenny Hessler, TBMG Sales Representatives Associate Editor (TBMG) Jennifer Shuttleworth, Linda Trego, www.techbriefsmediagroup.com/home/sales Patrick Ponticel, Ryan Gehm Steven Ashley Associate Editors (SAE) Contributing Editors (SAE) SAE International Sales Representatives http://sae.org/reps

For free product literature, enter advertisers’ reader service numbers at www.techbriefs.com/rs, or visit Ad Index the Web site beneath their ad in this issue. Reader Service Reader Service Company Number Page Company Number Page

4D Technology ...... 855 ...... 47 Maxon Precision Motors, Inc...... 845 ...... 29 ACCES I/O Products ...... 840 ...... 15 Mentor Graphics ...... 834 ...... 1 Altair ...... 835 ...... 17 Mini-Systems, Inc...... 846 ...... 31 Aurora Bearing Company ...... 849 ...... 39 MPL AG Switzerland ...... 860 ...... 47 Boyd Coatings Research Co. Inc...... 844 ...... 25 OFS | Specialty Photonics Division . . . . .850 ...... 41 Coilcraft CPS ...... 830 ...... 3 Omnetics Connector Corporation ...... 841 ...... 20 COMSOL, Inc...... 856, 864 . . . . .47, COV IV Opto Diode Corporation ...... 833 ...... 9 Create The Future Design Contest . . . .838, 828 ...... 11, 13 OTEK Corp...... 861 ...... 47 CST of America, Inc...... 863 ...... COV III Photon Engineering ...... 837 ...... 19 FEKO - EM Software & Systems (USA) . .847 ...... 34 PI (Physik Instrumente) LP ...... 854 ...... 46 Fischer Connectors ...... 839 ...... 18 Proto Labs, Inc...... 831 ...... 5 Gage Bilt Inc...... 865 ...... 37 S.I. Tech ...... 862 ...... 47 Hawthorne Rubber Mfg. Corp...... 857 ...... 47 Hunter Products Inc...... 851 ...... 41 SAE International ...... 842 ...... 21 Lemos International ...... 858 ...... 47 Tech Briefs TV ...... 32 Lyons Tool & Die Co...... 832 ...... 7 Thermacore, Inc...... 836 ...... 14 M.S. Kennedy Corporation ...... 829 ...... 2 TRUMPF Inc...... 827 ...... COV II Manufacturing 4 The Future 2014 ...... 853 ...... 45 UCSB Extension ...... 852 ...... 43 Master Bond Inc...... 848, 859 ...... 39, 47 Verisurf Software, Inc...... 843 ...... 23

48 www.aerodefensetech.com Aerospace & Defense Technology, April 2014 ➮ Intro Cov ToC + – A ➭ CST STUDIO SUITE 2014

CST of America®, Inc. | To request literature, call (508) 665 4400 | www.cst.com

Free Info at http://info.hotims.com/49744-863 ➮ Intro Cov ToC + – A ➭ RFID: Simulation of a reader-transponder pair for radio-frequency MHIRXM½GEXMSRETTPMGEXMSRW6IWYPXWKMZIXLIQYXYEPMRHYGXERGIERH WLS[XLIQEKRIXMG¾Y\JVSQXLIXVERWTSRHIVERXIRRE

VERIFY AND OOPTIMIZEPTIMIZE YOURYOUR DESIGNS WITHTH COMSOL MULTIPHYSICS ®

Product Suite

Free Info at http://info.hotims.com/49744-864 ➮ Intro Cov ToC + – A ➭