4 . .-J Western Electric

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T h i r d Q u a r t e r 1 9 8 3 Sugar Grove, Illinois Installation A Small Town Gets The Latest

Sugar Grove, III., site of our latest 5ESS* office, is a small village about 50 miles due west of the Chicago Loop. State Route 47 used to bisect the town, but since the by-pass was built about 15 years ago. Main Street is as quiet as a suburban cul-de-sac. Total population according to the sign at the town limits is an optimistic 1,400. Prior to World War II, Sugar Grove was a typical Mid-Western farm center. With a population of1,400, the vil It hasn't changed a great deal. The Village of Sugar Grove is bisected by lage has one church, one grade school main crops are still corn and soybeans. State Route 47 and old Chicago, and one restaurant that closes at 2 pm For a few years following the war, Burlington andQuincy Railroad practically all the villagers were re tracks tired farmers. Starting in the mid-50s, however, with the construction of the East-West tollway a few miles north of town. Sugar Grove became a bedroom community for Aurora and various o t h e r i n d u s t r i a l c o m m u n i t i e s t o t h e east; A number of the residents now work at Western Electric in Montgom ery, Caterpillar in Aurora and, before the strike, at the Federal Aeronautical Administration Training Center. Like many of the towns in north This community center was built in western Illinois, Sugar Grove is ap Illinois Bell's step-by-step office was 1930. The Police force and Village Clerk proaching its sesquecentennial. The located in this rented building hid have offices in the rear first settlers to arrive in the area den behind the village general store. crossed the Fox River at Oswego in the spring of 1834. There were five young men in the party. They came West from Medina County, Ohio, seek ing opportunity and farms of their own. They came with two wagons and two yoke of oxen, four cows, two axes and each man had a flint-lock gun. Until they could build cabins to h o u s e t h e i r f a m i l i e s w h o h a d r e m a i n e d "back East," the young adventurers t o o k s h e l t e r i n a n a b a n d o n e d I n d i a n shelter. The Indians called it "Sinqua- sip" meaning sugar camp. Apparently it was located in a grove of sugar maples although none grows in the area now. Main Street is lined with walnut trees. The settlers began plowing the fer tile, rolling prairie that summer of 1834. Even today, the soil is rich and black. Wives and children began arriv ing in the summer of 1835. And some of the current residents can trace their roots to those early arrivals. The land was not surveyed until 1839 and 1840. The settlers didn't pay for their claims until the great government land sale in Chicago in 1842.

' Tr a d e m a r k o f W e s t e r n E l e c t r i c Third Quarter Contents 35th Year

T h e 5 E S S ™ S w i t c h — A Special Issue A few comments on the 5 from WE President, Donald Procknow

4 A New Era in Switching Why the 5 will make things easier for telephone company planners

8 Why a Local Digital Switch? The rationale behind "going digital"

C e d a r K n o l l s — 10 A n I n s t a l l e r ' s V i e w What the 5 looks like to the people who install it

14 Making It Everything about the 5 is new and different—including the way we make it

18 Marketing the 5 The 5 is a "hot" item, but it still takes salesmanship to sell it

You Can't Tell it 22 from the Real Thing Simulation is the name of the game in training

Moving Towards a D i g i m I N e t w o r k T h e a i l - d i g i t a l n e t w o r k d r a w s c l o s e r

28 CombustionBurning Problem is a A new approach to the energy crunch

32 WE People—Del Nauman Science and an ancient mystery

WE WE is published for employees of George Gray Steve Tomczyk On the Cover Western Electric. President: D.E. Procknow; Editor Design Secretary; A.M. ZIgler; Saul Flngerman Leonard Stern This imaginative rendering of our Treasurer: R.E. Ekeblad. new symbol for the 5ESS™ switch Editorial office: 222 Broadway, NY NY 10038 Managmg Editor Photography Telephone: (212) 669-2621 Adele Donohue-Evans Thomas J. O'Donoghue o v e r l o o k s a s e a o f i n f o r m a t i o n - Associate Editor Production processing keyboards—themselves symbolic of the new system's ability Copyright © 1983 by Western Electric Co., Inc. All Rights Reserved. t o s w i t c h v a s t a m o u n t s o f Printed In the United States of America. information. Title "WE" Is a registered U.S. trademark. Western Electric 5

2 WE The 5ESS Switch I'm pleased to have the opportunity ing. It's an excellent product, so fea switch a reality. And, within WE itself, to add a few words about the 5ESS*- ture-rich that it will be the bench we have had exceptional efforts by our switch in this special edition of WE. mark, the one against which all others people in development, in manufac It's not often that a product comes will be measured for years to come. ture, in marketing and sales. And, of along that revolutionizes an entire I'm proud of the 5ESS switch, and course, we've been working very industry. Despite all the claims in I'm proud of the way it's being man closely with our telephone company advertising and television commer aged and coming on-stream. Our c u s t o m e r s t o m a k e s u r e w e a r e m e e t cials, most new products are just Pitches have always been at the heart ing all of their needs. 1 expect these evolutionary steps in a series. of the Bell System and, in many ways, cooperative efforts to continue and The 5ESS switch, however, is a have contributed to America's reaping intensify as the 5 approaches its full revolutionary switching system, the t h e b e n e fi t s o f t h e fi n e s t t e l e c o m potential. most advanced in all the world and m u n i c a t i o n s n e t w o r k i n t h e w o r l d . Western Electric today is in wonder the one that will change the telecom The 5ESS switch will ensure our suc ful shape to meet the challenges and munications industry for all time. The cess in this part of our business and opportunities of tomorrow. It's true we 5 is a wealth of firsts: the first central guarantees that we will remain at the m u s t c o n t i n u e o u r w o r k t o r e m a i n a t office switch to use lightguide for its heart of the nationwide switched net the very forefront of technology and, own internal communication and work and play a major role in the along with Bell Labs, to develop and transport; the first to use software that international marketplace as well. manufacture the new products that is growable, shrinkable and upwardly The cutover in Sugar Grove, Illinois, will be wanted and needed. But, today, portable; the first to use the 256K is an important milestone in terms of we have the right people to do the RAM. And we're the first to mass realizing at least a portion of the awe job. We have the right structure and produce the 256K itself. There's a some potential of the 5ESS switch. organization. We have the world's most whole world of brand-new technology This cutover represents a great coop advanced digital switch and a tremen coming together in the 5ESS switch. erative effort. Western and Bell Labs dous product line backing up that It's our flagship product and truly have been working closely and well switch. We're ready for whatever to represents a new era in digital switch together for years to make the 5ESS morrow brings.

President

T h i r d Q u a r t e r 1 9 8 3 • T r a d e m a r k o f W e s t e r n K l e c t r i c 3

By Kathy Fitzgerald

"The 5ESS* switch represents much more than Western Electric's entry into the local digital switch market." So says Bob Carlson, General Manager of WE's switching product line. "The development of 5 signals the begin ning of a whole new era in switching." A n d i n d e e d i t d o e s . F o r t h e fi r s t time, the same system can be used to provide the latest electronic switching and custom calling features for rural, suburban and metropolitan areas. "The 5ESS switch is a single-system solution to all switching needs," said Jerry Johnson, Product Manager for the switch. "And even more impor tantly, from a telephone company's point of view, it's the first switch that grows easily—^from a few lines to over 100,000 lines. " W e l i k e t o t e l l o u r c u s t o m e r s t h a t it's a switch that grows, shrinks, or travels according to their needs," John son said. "It's an area planner's dream." And it's easy to understand why Let's say a suburban area suddenly gets an influx of new businesses with large communication needs. The Morris- town, New Jersey area is a good example of exactly that situation— with the Bell System chiefly among the large businesses expanding in the area. With a 5ESS switch, the tele phone company can add capacity as it's needed by simply adding interface modules. No massive equipment or software changes are required—^which means meaningful savings in engineer ing and installation time. If the population of an area gradu ally decreases, a telephone company needn't sit around with unused switching capacity. They can remove the appropriate number of interface modules and shrink the system. And because of their common architecture, t h o s e m o d u l e s c a n b e u s e d e l s e w h e r e in their switching system. And a remote switch module of the

" T r a d e m a r k o f W e s t e r n E l e c t r i c . 5 On Main St., Ed Natanek, Mike Renz and Ed Radke pose outside the new Sugar Grove central office. 5ESS switch can travel up to 100 miles "They've got to figure out what new from a host switch to economically business to enter and new services to bring custom calling features to even provide since basic telephone service the smallest rural area. is almost universal in the U.S. "The beauty of the 5ESS switch is its "The 5ESS switch is designed to incredible flexibility," Product Man support new services," Johnson says. "1 can't foresee a day when we won't ager Johnson points out. "That have a new piece of hardware or flexibility is the result primarily of two major breakthroughs in switching software to add to the system." technology: distributed architecture The Remote Switch Module (RSM) a n d m o d u l a r s o f t w a r e c o n t r o l . " announced this year is a good exam Briefly, distributed architecture ple. "An RSM is nothing more than an means that the computer intelligence interface module located away from is distributed throughout the system the host switch," he explains. instead of being concentrated in a that what was originally perceived as a Able to be located up to 100 miles central processor. Therefore, each disadvantage has really turned into an from a host switch, the RSM allows interface module is capable of advantage. Our local digital switch is telephone companies to offer several performing functions independently. not just merely digital. It embodies widely separated rural communities T h e i n t e r f a c e m o d u l e s b e c o m e t h e every technology of the 80s. the same digital capabilities enjoyed building blocks that allow the system "And perhaps more importantly, all by major communication centers. The to grow. of those technologies are open-ended. operating costs of the offering are low M o d u l a r s o f t w a r e m e a n s t h a t t h e They allow this system—this one in and the potential for the telephone binary coding that makes up the com vestment of the telephone company— company to earn revenue is great. puter's instructions is produced in to grow with the changing tech That the 5ESS switch is an evolving relatively distinct and independent nologies; or to grow with the changing product is readily seen in the systems programs. Thus, to add new features telephone needs. Our system is not going into service this year. like Call Waiting or Conference Call just a lESS* turned digital. It's a major Late this summer, the first multi- ing, you just add a separate software technological leap!" module office was cut over in Sugar module. There is no need to repro- Karl Martersteck, Bell Labs Execu Grove, Illinois. "The Sugar Grove cut- gram the entire system. tive Director responsible for 5ESS over was the key 5ESS switch "The modular design of the hard switch development agreed, "The 5ESS development milestone," BTL's Charlie ware and software of the 5ESS switch switch is structured in such a way as Brown said. "It was what we were all m a k e s i t t h e w o r l d ' s m o s t a d v a n c e d to make it easy and inexpensive to working towards—the office in which digital switching system," said Bob keep the system modern, and able to the modular software became totally Carlson. "It really represents the deliver new services to keep the cus functional. With this office in place, second, or maybe even the third t o m e r s ' b u s i n e s s v i a b l e . W i t h t h i s we will be able to add new features in generation in electronic switching system, we expect change. It's de quick succession." technology." signed for it, in both hardware and Obviously, that's true. In September, In addition to its modular design, software. With small changes in the a 5ESS switch will cut over in Port St. the 5ESS switch is the first switch that software, or perhaps new circuit Lucie, Florida, which will have the first uses totally solid-state devices. A packs, you can simply plug in new application of automatic message tele unique Bell Labs creation, gated-diode capabilities." processing, a highly sophisticated crosspoints, replaces the traditional Jack Warner, a BTL supervisor in method of billing methods for the electromechanical switches and relays charge of site testing, had one of the customer. that are the industry norm. The result clearest explanations of the architec In October, the 5ESS switch starts i s a m o r e r e l i a b l e s o l i d - s t a t e ture of the 5ESS switch: "Think of an showing its real versatility with the connection. i n t e r f a c e m o d u l e a s a b o o k c a s e a n d cutover of the first local/toll digital "The 5 is truly state-of-the-art," said units with circuit packs as books. You switch in Bradford, Pennsylvania. Charlie Brown, BTL head of the first can add, remove, mix or change the And so the process will go on for application for the 5ESS switch units to fit any service that you need. years—^with the new applications and project. This means you only have to buy the features of 5ESS switch only limited by "Many industry observers felt that amount you need—then expand later. what the telephone companies decide we were late in developing a local Also, you can add new equipment they want to offer their customers. digital switch," Brown says. "There are easily, as it's developed, just like you One of the truly unique offerings of those of us who would still debate a d d a b o o k t o a b o o k c a s e . " the 5ESS switch is called Business and t h a t . I n t e r m s o f t h e e c o n o m i c s o f The ability to "plug in new ca R e s i d e n c e C u s t o m S e r v i c e s . T h i s digital technology, we're right on time. pabilities" will become particularly means that a telephone company will Just as we were right on time in important to telephone companies in b e a b l e t o o f f e r i t s c u s t o m e r s a m e n u developing the 4ESS* switch when a post-divestiture mode. "After January of all the traditional custom calling there were real economics for digital 1,1984, the telephone companies are and centrex features plus an infinite in the toll environment. But that's going to be even more aggressive in n u m b e r o f v a r i a t i o n s o n t h e m . water under the bridge. seeking new ways to generate reve For example, a telephone company, "The real point," he continues, "is nue," WE's Jerry Johnson explains. if it chose, could allow its customers

6 • T r a d e m a r k o f W e s t e r n E l e c t r i c WE to use and pay for Call Waiting or Three-Way Calling on a per call basis rather than only by monthly fee. This would allow customers who don't want the entire custom calling pack age to use certain services when they wanted. "We're going to be talking to our telephone company customers to see w h a t B u s i n e s s a n d R e s i d e n c e C u s t o m services they want to be developed in the future," Johnson says. "The tech nology is there. It now becomes a market research job to see what the consumer would like to get from his telephone system." The potential of the 5ESS switch is unlimited. "The 5ESS switch project is one of our top priorities at the Labs," says Doug Dowden, BTL supervisor in charge of 5ESS Switching System Ar chitecture. "We've got a truly impres sive team of very bright, enthusiastic designers on the job. With so much of Princeton Telephone's president, our resources focused as they are on C. Rightly Trippet with a gated-diode circuit board in his central office. digital technology, you're not just buy ing a switch. You're buying a committed laboratory. And when Princeton Telephone Company you're talking about Bell Labs, that In May, the Princeton Telephone We s t e r n E l e c t r i c ' s c o m m e r c i a l s a l e s m e a n s a l o t ! " Company of Princeton, Indiana be organization. And of course, when you're talking came the first independent tele James C. Henderson, Chairman about Bell Labs and Western Electric, phone company to purchase and a n d C h i e f E x e c u t i v e O f fi c e r o f you're always talking reliability. cut into operation a 5ESS* switch. Rochester Telephone Corporation, "We've put a lot of effort into The 5ESS switch, located in said, "This project represents a per developing a maintenance and recov Princeton Telephone's Fort Branch, fect application of digital switching ery system," Jerry Johnson empha Indiana office, incorporates several technology. Through the use of s i z e s . " O v e r h a l f o f t h e s o f t w a r e f o u n d important hardware and software remote switehes, it allows the Prin in the 5ESS switch enables the system improvements over previous ceton Telephone Company to t o m a i n t a i n i t s e l f . I t h i n k i t w o u l d b e switches while providing a variety expand and provide new services fair to say it's the most sophisticated of services to the telephone com for years to come, efficiently and maintenance system in the industry." pany's customers. economieally. Test after grueling test proved the Princeton Telephone Company "Princeton is the first indepen system reliable. It kept processing President C. Kightly Trippet ex dent company to install Western calls even after being wrapped in a plained the company's reasons for Electric's 5ESS switch, which we at plastic envelope and cooked for 24 choosing Western Electric's switch Rochester Telephone regard as a hours at 120°. Engineers fed garbled over its competitors. "It is the latest superior system. We are certain that data to the switch's central processor generation of electronic switching over the next few years many other and calls still went through. Circuit system and represents the most independents will elect the 5ESS packs were disconnected and the advanced technology available," switch basically for the same rea switch simply re-routed the calls Trippet said. "We were convinced sons as Princeton—performance, around the trouble. that we would receive superior reliabUity, and flexibility." "The system is designed to self- support from Western Electric and Princeton Telephone's Fort correct any system features without Bell Labs people before, during, and Branch office initially has been de service disruption," Johnson said. "And after installation." He added, "This signed as a single module switch that's what it does every time." electronic switching system has with the ability to expand to meet And that's Western Electric's 5ESS great features that will bring Infor the changing communication needs switch. More than a digital switch. mation Age telecommunications of area customers. The switch's Modular architecture, solid-state con technology to our customers." design allows it to grow with the nections, the latest in micro Rotelcom, Inc., a subsidiary of communities it serves by adding electronics, software and even Rochester Telephone Corporation, m o d u l e s . I t s f e a t u r e s c a n a l s o b e photonics. The tops in reliability The engineered and sold the switching expanded to provide services to 5 E S S s w i t c h — a n e w e r a i n t e l e c o m system to Princeton Telephone un a r e a s w i t h i n 1 0 0 m i l e s w i t h R e m o t e munication switching. der a contract agreement with Switching Modules.

T h i r d Q u a r t e r 1 9 8 3 Tr a d e m a r k o f W e s t e r n E l e c t r i c 7 5

Why a Local

By Don Leonard Digital Switch? The 5ESS* switchitig system, a sec to switching provided a cost effective ond-generation switch, is a product ness which permitted the design of a that uses to the best advantage ad toll (long distance) digital switch. In vances in software, lightwave, micro 1976, our 4ESS* system, known as the electronics and digital systems. It was "super-switcher," became the first time planned and developed as part of a division, digital toll switching system. digital product evolution in the Bell As more and more 4ESS switches System network. Systems engineering were introduced into the network, the and planning continues to be a major economies of digital trunks improved strength of Bell Labs, and the 5ESS and their number grew. This was switch is a benefactor of this planning. closely followed by fast-paced de Let's explore how "digital" has been velopments in the exploitation of planned. lightwave technology, leading to the It became apparent with the suc introduction of the world's largest c e s s f u l i n t r o d u c t i o n o f t r a n s i s t o r s t o laser-powered digital transmission sys circuit design by the mid 1950s, that tem—eventually to link switching digital, pulse-eode-modulation carrier o f fi c e s b e t w e e n M a s s a c h u s e t t s a n d Some insights into systems could be used for some ap Virginia. plications more efficiently and more Just as TI and lightwave systems economically than analog systems. digitize communications between cen why we're That is, representing voices in the tral offices switching systems, in the going digital ones and zeros of digital pulses—the late-70s, the SLC-96* system brought language of computers—^would "prove digits to the lines between switching in" economically o f fi c e s a n d b u s i n e s s a n d r e s i d e n c e Don Leonard is Vice President, Switching In 1962, Bell Labs and Western engi subscribers. n e e r s i n t r o d u c e d t h e D I c h a n n e l With trunks and loops going digital, Systems at Bell Laboratories. banks and TI carrier systems to capi the next logical step was the develop talize on digital opportunities. These ment of a local digital switch for tele systems convert telephone con phone calls and data communications. versations into digital form for In the late 1970s, Western Electric transmission between switching announced the funding of the Bell systems. Labs development of just such an Advances in integrated circuits cou office, to be known as the 5ESS switch. pled with digital circuit design re Today, the first three working switch sulted in more and more use of digital ing systems in Seneca, 111., Cedarville, T carrier. Soon it became more effi Ohio, and in Cedar Knolls, N.J., are cient and cost eflfective to digitize already setting standards for reliability other parts of the network. In the and ease of operation. early 70s digital technologies applied These installations are the first of a

8 • ' I r a d c m a r k o f W e s t e r n K l c c t r i c WE second-generation, time-division switching system. actual language they use to talk to the switch product line where one flexi Western Electric's 64K dynamic Ran system is a special international stand ble digital switching system meets all dom Access Memory (RAM), and later ard computer language called MML, the switching requirements of an oper this year, the 256K RAM, give the 5ESS developed especially for craftspeople ating company customer. switch the most advanced chips for to use. The key ingredient to 5ESS switch economically storing software in The 5ESS switch has been planned leadership is its modular design. The structions. as a broad range digital switching system can grow smoothly by adding Unlike any other local switching system. It handles a wide range of modules controlled by microproc system, the 5ESS system has totally traffic without blocking—no traffic e s s o r s t o s e r v e m o r e c u s t o m e r s . T h i s solid-state transmission paths. New de jams—as well as all types of traffic: system was designed with the unique vices that can handle lightning surges local, local/toll and toll. Area planning ability to serve anywhere from 1,000 as well as relatively high voltages used tools have been developed which per to 100,000 lines. for ringing and testing replace elec mit the planning of switching offices The software that operates the tromechanical relays still used in other for a whole geographic area. The switching system is also modular and systems, allowing size reduction, cost switching system's flexibility—its flexible, using a high-level language. and maintenance advantages. smooth growth capability as well as its T h e s e c o d e d i n s t r u c t i o n s a r e o f t w o Other call processing operations, remote capability, where switching k i n d s : i n s t r u c t i o n s t h a t c o n t r o l t h e such as tone generation, detection and modules can serve as remote call switching equipment and instructions signal filtering are handled by a com- processing systems, operating up to that provide calling services and new puter-on-a-chip called a Digital Signal 100 miles from a host processor features that can create significant P r o c e s s o r w h i c h c a n m a k e a m i l l i o n switch—^permit the cost efficient re revenue for operating companies. Be c a l c u l a t i o n s a s e c o n d . placement of older switches while cause of this, software used to provide Within the 5ESS switching system, providing advanced features for revenue-producing features can be lightguide fiber is used for internal smaller communities. In addition, we added without affecting the rest of the data transmission functions. Lightwave are planning to introduce operator system. The software architecture is is not at all affected by electromag services as well as Integrated Services good for fast feature delivery. netic interference and is very broad Digital Network (ISDN) features. Si T h e m o d u l a r h a r d w a r e a n d s o f t w a r e band, that is, it has the capacity to multaneous voice and data capabilities design philosophy controls not only transmit much higher volumes of in will make services from shopping to the overall design of the 5ESS switch, formation than copper links. Also, at banking to recreation as easy as using but also the 3B20D processor and its Cedar Knolls, a lightwave cable di the telephone. operating system, plus an array of rectly connects the 5ESS system with a As the 5ESS switching system goes impressive electronic and lightwave 4ESS toll switch. into mass production, it will play a components which make the concept While technological advances have vital part in the emerging end-to-end a reality. made this switching system very digital network that will make it possi The Western Electric 3B20D proc powerful, it has also made it much ble to provide information age essor and its operating system controls more "friendly." Craftspeople commu s e r v i c e s t o h o m e s a n d b u s i n e s s e s a d m i n i s t r a t i v e f u n c t i o n s a n d c o o r d i nicate with the switching system by throughout the country. It is the key n a t e s a u t o m a t i c m a i n t e n a n c e i n t h e using an easy-to-read color screen. The stone of the digital future. T h i r d Q u a r t e r 1 9 8 3 C e d a r K n o l l s 5 An Installer's View

By George Gray

Photos by Joseph Gazdak

Lots of computer jargon to learn, but a self-diagnosing joy to work on once ifs up and running "It's like starting a completely dif ferent career. Fascinating. Even though of late 1 seem to be spending most of my time on the phone trying to get updated packs." That's how Bill Sumski summed up his role as supervisor on the 5ESS* switch at Cedar Knolls, N.J., a few days before cutover on March 4. B i l l h a s b e e n a W E i n s t a l l e r f o r 1 8 years, with all of his service in the Garden State. He works out of Morris- town—only a few miles from where he was born and raised. A total of eight WE installers w o r k e d o n C e d a r K n o l l s i n s h i f t s — with no more than five on any one day. Bill Sumski, Frank Regan, Dick Schipper and Mike Drugac were involved pri '\\\ marily with testing; Rich Bonadonna was the power man; Mike Lyness, Roy w Koes and Kevin Svec helped out dur ing the ironwork phase. "Compared with, say, a No. 5 crossbar job, where 1 started," Bill said, "this job is relatively easy to all the time as new features were Cedar Knolls, like the 5ESS switch learn. Practically everything is self- developed and tested out. installations that preceded it last year explanatory. The documentation is "What made this job a little rough," in Seneca, Illinois, and Cedarville, very good. There are a lot of plug-ins. Bill said, "was that we were designing Ohio, is a single-module system. But Your biggest problem is learning what it and building it and changing it all at unlike its predecessors, which will packs do what." the same time. Of course, that won't become remote switch sites operating Frank Regan, who has also been an be true of any later installations, all of off a larger 5ESS master switching installer for 18 years, mostly in New which will be a lot more routine. office. Cedar Knolls will eventually Jersey, seconded that appraisal. Frank "Very early on," he continued, "1 grow into a large self-sustaining sys w a s o n e o f t h e fi r s t W E i n s t a l l e r s t o spent three days meeting with the tem. Additional switching capacity is take the 5ESS switching equipment testers and transportation people at provided in frames known as IMs course at Dublin. It was a 12-day Oklalioma City—all the people I'd (Interface Modules). Up to 29 IMs can program, but proved a little confusing gotten to know over the telephone. be added later on, enabling the Cedar since hardware and software were Support from manufacturing is what Knolls system to serve as many as changing, being updated and improved makes something like this go." 100,000 lines. Initially it will serve less 1 0 • T r a d e m a r k o f W e s t e r n E l e c t r i c WE Installer Frank Reagan inserting gated di ode circuit board in an Interface Module frame, heart of the local digital switch.

Closeup of gated-diode circuit board. Squares contain switching crosspoints

Knolls is also the first 5ESS switch to glance. "Diagnostics can be done by be connected directly to a 4ESS toll the numbers," Bill said. "You just hit a switch. The connection to the toll couple of keys. There is very little office in Newark is by lightguide. typing necessary." Perhaps the most notable enhance C e d a r K n o l l s w i l l b e u n m a n n e d . WE Installers Frank Regan and Bill ment in the Cedar Knolls system is its Everything that shows up on monitors Sumski at the maintenance console of use of the latest processor and operat a n d t e r m i n a l s a t m a s t e r c o n t r o l i s Cedar Knolls 5ESS* switching center ing system. The new processor and duplicated 20 miles away in a manned operating system—the 3B20D Model c o n t r o l c e n t e r i n P a s s a i c . S o m e o n e 2 and DMERT Generic 2—completely may have to stop by once a month to than 1,500 lines in a nearby industrial automate most administrative and change a pack, but after the initial park. maintenance jobs in the switching flurry of activity with Bell Labs trying Each of the early 5ESS switch in system. out software ideas, things should be stallations contains a number of "firsts" Maintenance craftspersons are kept relatively quiet. The machine diag to be tried out before the product informed on the status of the system noses itself every midnight, checking goes into mass production. Cedar by a color video monitor that is a kind every piece of equipment. It even has Knolls was the first 5ESS switch to o f t e c h n i c o l o r w i n d o w i n t o t h e h e a r t i t s o w n b u i l t - i n c l o c k . T h e r e i s a l s o a provide service for a new exchange of the switch. Color-highlighted dia read-only printer made by Teletype area. Its predecessors replaced older grams and messages tell craftspeople that reports on status every 15 electro-mechanical switches. Cedar the status of any part of the system at a minutes.

T h i r d Q u a r t e r 1 9 8 3 11 "From the point of view of time four weeks, from the end of November and a fifth containing miscellaneous elapsed," Bill said, "the biggest part of until the first of the year when we equipment for alarms, recorded an the job was bringing in the power. turned it over to Bell Labs for some nouncements and protection. Even with everything pre-assembled software updates," Bill said. "They had One unit of circuit packs in the and pre-tested at the factory, you still it for the month of January and then 5ESS switch takes the place of four have to put up cable racks and hang gave it back to us for a week of final processor frames in the lESS switch or rods down from the ceiling. There was testing. We actually turned it over to one frame of equipment in the lA. a lot of cable to run to the main dis New Jersey Bell for their tests on I n s t a l l a t i o n i s f a s t b e c a u s e a l l c a b l e s tributing frame. It's temporary. They're February 6." are conneetorized and just have to be talking about replacing it with a Cos The 5ESS switch at Cedar Knolls is snapped in place on site. Much of the mic* main distributing frame. For the set up as two rows of equipment bays. work involves checking out circuit

V*

I

To simplify installation, many wire connections use snap connectors This time being, the main frame is located Each row is about 18 feet long. The 3B is at the main distributing frame on this floor but way over on the Processor row contains the main proc other side of the building. We worked essor in a double bay frame, three a month on the cable racks and then memory units known as MHD (Mova packs. For this, installers must stand started testing after three days." ble Head Disc) bays, and a fifth bay on a special mat and wear a ground- Unlike Seneca and Cedarville, the containing the TMS (Time Multiplex w i r e b r a c e l e t o n t h e i r w r i s t s . T h i s New Jersey office came in pieces. It Switch) and other equipment that prevents the components on the cir had been fully assembled at the fac c o n n e c t s w i t h t h e I n t e r f a c e M o d u l e s . cuit packs from receiving a 30,000- tory and then broken down, because You need the TMS for anything above volt jolt that can be generated by the the location at Cedar Knolls is below 1,536 lines. It is the key to "grow- static electric charge on the body. It's a ground. It could not be slid in as a ability." Everything fits into time slots. new precaution that the installers have unit. Pieces had to come in through a The other row—referred to by the to learn. loading dock and then down a freight i n s t a l l e r s a s t h e N o . 5 — a l s o c o n t a i n s The memory disks—^which are lo elevator. five bays—one for power equipment, cated inside what look like top-load "We actually had the job only about three for the IM (Interface Module) washing machines—also have to be

12 • T r a d e m a r k o f W e s t e r n E l e c t r i c WE To prevent damage from static electric UWWmBUHL ity, installers must stand on a special Duflmi'iiiii mat and wear a ground-wire bracelet

Memory disk weighs about 20 pounds.

handled with care. They are kept vir other. This is a big plus. With the tually air tight. One speck of dust I ESS* switch it took eight hours with could destroy the whole program. In a four people working on eight program typical system like Cedar Knolls there stores to change a program. With the are three memory frames—one is run lA they eut it down to a little over an ning, a second is a "warm" spare that hour with one person, and now we're can take over instantaneously, and the down to 20 minutes." third is backup. If you visited an early lESS switch Memory disks come in 10 layers ing office prior to cutover, the load with a total depth of five inches and a box was a large equipment case that core diameter of 14 inches. However, looked like a 21-inch TV console. This you never see the core uncovered. load box simulated busy-hour traffic in Whenever it is outside the cabinet, it a central office to give the new switch is transported inside a screw-on blue a r e a l i s t i c w o r k o u t b e f o r e i t w a s a c t u plastic dome that looks like the cover ally cut into service. for a layer cake in a diner. "This can't Just like almost everything else, it Built-in fans air cool circuit packs. weigh more than 20 pounds," Bill said, now comes in smaller packages. The lifting one up. 'Tou should try hefting load box for the 5ESS switch is about memory mods in a No. 1. They weigh nection of the incoming line at the the size of an electric typewriter and at least 65 pounds." main frame and assign a number. s i t s o n t h e c o r n e r o f a d e s k . I t ' s c a l l e d Each layer of the memory disk has Then, at what is known as the Recent P r o c a l l a n d i t ' s m a d e a t t h e I l l i n o i s information on it. In all, it can hold up Change Terminal, a craftsperson types S e r v i c e C e n t e r . I t d o e s a l l — a n d to 300 megabytes. Only about half that in the assigned number and class of more—that the whole roomful of capacity is currently used at Cedar service. The system then takes over b o x e s u s e d t o d o . Knolls. If you lived in the neighbor and automatically assigns an address in "It's been an interesting job," Bill hood, your telephone would have an the memory disk and you're in said, "to say the least. And I can tell address in there somewhere, along business. you there is not one part of Western with your class of service and what "With the 5ESS switch," Bill said, Electric that is not totally committed your billing rate is. "you can change the entire program in to making it work." This makes it very easy to add a new 20 minutes. You don't have to shut subscriber to the system. The tele down anything. You just let one disk phone company people make a con- keep going while you change the

T h i r d Q u a r t e r 1 9 8 3 13 Making it

By Judy Seikel

Right. Al Swung T. J. McNeely and Bob Green study a Spearhead drawing detailing the latest factory layout —I

Above. Delbert Rains and Ray Rose at the soldering machine in Oklahoma A sign of the times: City's new "fast line." the shipping cartons for ESS parts now WESTEmtt£Ctiiicca,mc. mfcfOayXK CITY. 01^ TMg c a r r y i n t e r n a t i o n a l symbols. ItTf

^CTN. N'. mtemxTH

14 WE the established products to fill the be demoralizing for everyone 5 vacancies. Over the past year, roughly involved." two thirds of the people at the McNeely, Swang and Green have Oklahoma City Works changed jobs. worked hard to minimize the costs and domino effect for the past two and Planning a half years. At meetings every Thurs "Hardly a square foot of the 900,000 day they come up with a "Most square feet in the total factory was Wanted" list, a "Next Most Wanted" list untouched by the arrival of the 3B and, finally, a list for routine things that Processor and the 5ESS switch," says must be done. This approach has given T. J. McNeely department chief. Engi the trades people some flexibility in neering—Factory and Machinery managing their work load. Procurement. The 46 trades employees under A 28-year veteran with WE engi Department Chief Bud Bricmont neering, McNeely has lived the worked approximately 100,000 hours reorganization night and day for as per year during the transition on long as anyone at Oklahoma City. It Almost everybody was his responsibility to get input from the product engineering depart at Oklahoma City ment and consolidate its needs into a W o r k s h a s b e e n reasonable working package. Assisted by A1 Swang, senior engineer, and Bob caught up in the Green, engineering associate, they proposed plans which were chewed excitement of mak over endlessly. "Since 1 had the whole ing our most plant floor space to worry about," McNeely says with tongue in cheek, "1 important product. was very objective." The plans, which were formalized as Engineer Colin Elliott checking out ligbtguide on the 3B processor. huge colored drawings, were code It had to be one of the gargantuan named Spearhead 1,11, 111 and IV mechanical and labor jobs and about juggling acts of corporate history. The Spearhead 1, which began in October, 95 percent of it was in connection 5ESS* switch, a major product that 1980, included everything that had to with 3B and 5ESS switch installation. would eventually occupy some b e d o n e t o m a k e r o o m f o r t h e n e w From the onset of Spearhead 1 to 300,000 square feet of shop floor products. "After asking all of the prod Spearhead ly Roy Blasius, section chief space was coming to life. Most of the uct people what they needed to do for Trades, Electrical New Con initial operations were being moved the job, we added it up and found we struction, and Frank Cory, section f r o m I l l i n o i s t o O k l a h o m a . I n simply didn't have enough to go chief of Trades, Mechanical New Con Oklahoma, what had previously oc around. struction, spent many hours of cupied those 300,000 square feet, had "We had to make some very hard planning with McNeely They also to be consolidated, cleared away and, decisions about how much floor space worked closely with purchasing, oper in some cases, transferred out to other a group could be allocated and we had ating and the employees in their trades plants. The time frame: a scant two to stick by our guns," McNeely said. organizations who analyzed and wrote and a half years. "By the time it's all over, we will the orders for thousands of dollars All through the reorganization, pro literally have changed every square a s s o c i a t e d w i t h m a t e r i a l s n e e d e d f o r duction had to be maintained. There foot of the factory. All of these changes the jobs. could be no gaps simply because are intertwined and they all impact on Cory says that in his 22-plus years in additional machines were being in one another. There is a domino effect the company, all 900,000 square feet stalled. At the same time. Bell Labs was that can take place if moves are not of Oklahoma City's manufacturing at work redesigning and updating the precisely planned. " floor space were rearranged at least products being transferred. Some cir How hard is it to filter out real once, but nothing in those years pre cuit boards were subjected to many needs and work them into a master sented the kind of challenge brought design changes during the transition plan? "Very hard," says Swang. "It's by the introduction of 3B and 5ESS period, as new features were added or, dozens of product engineers holding switch facilities. Along with this job, in some cases, "bugs" were tracked their heads in frustration and trying to the 128,617 square feet of available down and eliminated. squeeze out a little more space. It's space in the office building had, or The cost of the move was considera trades working 60 hours a week. And will have, major rearrangements to ble—not only for purchase of new t h a t ' s n o t t o m e n t i o n t h e a d m i n i s t r a accommodate changing supervisory equipment, transportation charges and tive side." structures. In addition, a new switch overtime, but also in training a whole The cost of moves and rearrange ing office for a Dimension® PBX work force for new jobs. Thousands of ments is staggering, and if that isn't system had to be included. people at the Oklahoma City Works enough, timing is critical. "One illogi Discussion of capital/plant require have undergone extensive training not cal, poorly-timed move could easily ments for producing the 5ESS switch only for the 5, but for support jobs, as cost thousands of dollars. You can't first cropped up in long-range plan well. As senior people moved into the afford to make that kind of mistake," ning meetings at the Oklahoma City new technology, others shifted into McNeely says. "Too many changes can Works early in 1979. Other ESS*

T h i r d Q u a r t e r 1 9 8 3 ' Tr a d e m a r k o f We s t e r n E l e c t r i c . 15 switches had been allocated to the Works on short notice and the hope was that the new product on the drawing board—the 5ESS switch— could be assigned early so that every thing would not have to be done on an expensive, rush basis. However, it was not until December of 1979, that the 5ESS switch was formally allocated to Oklahoma City. At that time, the switch was still under development at Bell Labs-Indian Hill and early production prototypes were being built at Northern Illinois Works. I t w a s t h e c h a r t e r o f t h e O k l a h o m a City Works Long Range Planning Com mittee (LRPC) to utilize the plant's major resources—people, floor space and capital—to the fullest. The first meeting of the Works' technical-professional employees soon followed in February 1980. TThey be gan the work of getting the Oklahoma A typical Oklahoma City employee City Works in shape to produce what last year spent 38 hours in a was characterized as "the primary classroom. This is a course in Bellpac modernization vehicle of the mid and modification late 1980s." Sam Kysar, now an assistant manager in engineering for the 5ESS switch, and Dennis Partlow, a senior engineer, worked with the Northern Illinois Works engineers on the specifications for specific capital appropriations for the 5ESS switch covering circuit pack assembly, circuit pack test, unit assem bly and verification, cable assembly and test, and unit, frame and system assembly, wire and test. Kysar, the project coordinator at the Oklahoma City Works, had the equip ment personnel reporting to him while the apparatus personnel re ported to Paul Odor, an engineering Mel Gering and Bill Rigsby and department chief. The liaison engi Janet McReynolds Lewis McCurley neers spent 50 to 100 percent of their test Interface check gate array time in the Lisle area from early in c i r c u i t b o a r d s o n Modules for the 1980 until mid 1981 when they re 5ESS switch. these computer turned to Oklahoma to engineer the ized test sets. introduction of their specialties in their factory. "We worked much more intimately w i t h B e l l L a b s a n d L i s l e o n t h e 5 E S S switch than on any other product in my memory," says Ed Condron, depart ment chief. Engineering—5ESS switch C i r c u i t P a c k T e s t . " T h e r e h a s b e e n a lot of travel back and forth and inter n a l c o m m u n i c a t i o n s h a v e b e c o m e critical. Part of the problem has been the short lead time. The other part is "If its blue, it's the complexity of the product. My n e w . " F o r t w o department works with more than 200 years, con codes of circuit packs used in the 5ESS s t r u c t i o n w a s t h e s w i t c h . T h e n u m b e r i s s o m e w h a t name of the vague because it is still evolving as we game. combine and separate functions or add

16 WE new features." We are not interested in knowledge for agement function in the 1980s. We "The 5ESS switch is the system that the sake of knowledge. We teach only train here in the classroom only when has put us squarely in the midst of the what you need to know for the job. the magnitude of training exceeds the 'Information Age'," says Kysar. "It now "What we provide," Dr. Lepak said, ability of the functional shop." occupies about 35 percent of the "is high-tech training that you can't Gene Blalock, who teaches the 3B factory floor space and that percent find in most technical schools. Our system course in electronics, believes age will undoubtedly increase. The employees are getting something here one of the most important things in capital expenditure for new facilities, at company expense that would take his job is to establish credibility with primarily test sets, will run about $90 them two years in conventional the students "because you have to million by the time we get into full s c h o o l s — i f t h e s c h o o l s c o u l d a ff o r d t o teach them so much in so little time. production. It is an extremely high- get and keep updating the latest Our objective is to develop a course stakes game. equipment. that is straightforward and at the same "The first Oklahoma City-built sys "Our primary emphasis in 1982," Dr. time, includes all of the information tem was shipped to Cedar Knolls, Lepak said, "was on 'tester training' necessary to perform the job. Our N.J., in November 1982," says Kysar. and it is again the priority in 1983 " students are required to troubleshoot "About 50 systems are scheduled to be Last year, a total of 243 testers re down to the chip level. The technol shipped in 1983, and by 1985, produc ceived 44,000 classroom hours in ogy is such that installation people tion should be on the order of one courses on BELLPAC® power units and cannot repair them out in the field the 5ESS switch per work day." systems for the 5ESS switch and the way they used to." There are countless manufacturing 3B processor family. Through the first innovations that will be appearing in four months of 1983, 231 testers have A G r o w t h P r o c e s s trade journals after patent possibilities received 22,000 hours of training. David Orme, manufacturing man have been fully explored. There are ager for 5ESS switches, sees the also some adaptations of good ideas process of getting people trained, get f r o m o t h e r l o c a t i o n s . T h e f a s t - l i n e ting the right materials ordered and used at the Denver Works in the getting the product into manufacture production of PBXs has been adapted despite many design changes as for use with circuit packs for the 5ESS "growing pains." switch. "The kind of problems we are hav ing are ones that you can anticipate Training when looking at the growth of the Preparing people for work on the A component insertion machine. program, but we can deal with the 5ESS switch has become a major process—and we will," Orme said. operation at Oklahoma City. Technical Tester training involves more than "We've had a Long-Range Planning training classes are conducted on all just the new technology products. Committee for quite a while that's three shifts. The 4l people who work Many employees are entering the test always looking out five years from in the Managed Education and Train ranks for the first time to fill jobs on now. We aggressively pursued alloca ing Department, headed by Dr. Clem the new products. In 1982, there were tion of the 5ESS switch. We let the Lepak, conducted 168,207 hours of 247 moves in the tester universe, company know that we wanted it and classroom instruction in 1982. That's which meant that 54 percent of the that we were trying to get ready for it. an average of 38 hours for every testers at the plant shifted to new jobs. "The 5ESS switch is the future of the person on roll. And, the classroom Testers now make up 20.6 percent Switching Equipment Division," he hours represent only a small portion of the Oklahoma City shop production s a i d . " I t s e r v e s a l l o f o u r c u s t o m e r s of the training iceberg. w o r k f o r c e . B e f o r e e l e c t r o n i c s w i t c h from the small offices to the large In 1976, before the buildup for the ing arrived on the scene in the offices designed for major cities. 5ESS switch, there were only two mid-60s, testers represented only 7.3 T h e r e ' s a m a r k e t w i n d o w o f o r d e r s f o r people on the Works' roster as trainers, percent of the population. Testing is a equipment that the telephone com but the demands of the business and very strong indicator of the changing panies are going to be buying in any the nature of the product have esca c h a r a c t e r o f t h e w o r k a t We s t e r n given year. The orders are going to be lated the need for instruction of all Electric. filled by some company, and we want kinds. "Our charter is to keep the Dr. Lepak said testers must have to be that company. We're trying to Oklahoma City Works at the leading basic training in digital logic, hold as large a portion of that business edge of technology and to prepare BELLPAC® circuit pack logic and a s w e c a n . " management for continuing change," instrumentation. The shortest training Orme, who has worked with the says Dr. Lepak. "Requirements are path for a tester is a little more than 5ESS switch program from the begin changing every day. These courses are 200 hours for a sophisticated circuit ning, says he likes these "start-up kind just as alive as if they were living and pack test. The systems and testbed of jobs. I like to think that our systems breathing. testers require more than 300 hours have not totally been designed yet, " A l l o f o u r c o u r s e s a r e b e n t t o w a r d training, plus a lot of practice on the and that there's a high rate of evolu troubleshooting," Dr. Lepak said. shop floor. tion in our product and in our "Troubleshooting is recognizing, locat "Of course, there is a lot of training processes," he said. "Training people ing, analyzing and clearing defects. that goes on outside of this depart for new jobs, managing the growth of This same philosophy holds whether ment," he said. "Supervisors, especially the program and coping with all of the it's a course on 5ESS switching equip section chiefs, do the bulk of corpo design change activity are a part of the ment or an established product. We rate training and development. start-up process. That's the challenge are interested in applied knowledge. Training is and will be a prime man we accepted. We can do it."

T h i r d Q u a r t e r 1 9 8 3 17 Marketing the 5

B y A d e l e D o n o h u e - E v a n s W E v i c e p r e s i d e n t s J i m E d w a r d s a n d T o n y I z z o confer in the hall at Southgate. Edwards is responsible for marketing development, Izzo for market planning.

18 WE The way we sell the 5 will be different from the way we sell any other Western Electric product.

The 5ESS* switch is "a real winner by every measure" according to Mar keting Development Vice President Jim Edwards. "It's clearly a flagship product," says Edwards, who joined the company in January and has extensive experience in marketing and sales in competitive, high-technology companies. "The 5ESS switch is the result of an enormous investment in R and D and capital. It's the stuff that makes or breaks a com pany. And it looks like a success story is upon us." Of course, the customer will play the all-important leading role in the story of the success of the 5ESS switch. The prime customers for the system are the operating companies, or RBOCs (Regional Bell Operating Companies), as they will be known a f t e r d i v e s t i t u r e . Market Planning Vice President Anthony Izzo says, "In the future as in the past, the RBOCs will be our numher-one customers. We won't abandon them. We'll continue to work to increase their ability to enlarge their revenue streams and develop new and innovative features." Izzo has a first-hand knowledge of operating company problems and needs having spent most of his career in the operat ing company network services area before joining Western Electric. Although the RBOCs are the prime targets for the 5ESS switch as well as WE's traditional customers, selling the s w i t c h t o t h e m w i l l b e d i ff e r e n t f r o m selling any other WE product. This is true for a variety of reasons; First is the nature of the product itself.

• Tr a d e m a r k o f We s t e r n E l e c t r i c 19 t o m e r u n d e r s t a n d s . " Izzo adds, "The strategy for market ing the 5ESS switch must be different. It's WE's first major product to be introduced just prior to divestiture. So in a sense it is our first major product introduced into the new marketplace. "With the 5ESS switch, we will be facing competition for similar prod ucts—digital switching machines— that are already in the marketplace," Izzo explains. "This 'incumbency' is something relatively new to us." In addition to the RBOCs, the 5ESS switch is being aggressively marketed to international, independent and gov ernment customers. "The switch's adaptability to small and large com panies makes it a great product for independents as well as the Bell com panies," says Izzo. "Its 100,000-line capacity coupled with its new technol ogy and flexibility make it competitive for use by the AT&T interexchange Southern New England Telephone's The 5ESS switch is a clear technologi Elliot Wilcox (left) examines fiber entity, as well." Izzo also sees plenty of cal leader in electronic switching optics for 5ESS at the Network potential for application of the elec tronic switch and its technology in systems and marks a new era in Software Center. Guiding him were switching. After 1984, it will be Art Olsen, Jim Russell and Jim government business. Western Electric is counting on the Western Electric's principal switching V i d e t i c . C u s t o m e r v i s i t s t o t h e C e n t e r product. are part of the sales strategy for 5ESS. 5ESS electronic switch to make up an Another difference is that the prod increasingly larger portion of its sales uct is being introduced in the midst of The third factor affecting the way in the next few years. the divestiture of the operating com the 5ESS switch is being positioned is "The successful marketing and sales panies from AT&T. Western Electric that it is being introduced into a of the 5ESS switch is critical to the will be entering a new era and so will marketplace in which competitive dig future of this company," says Izzo. "It's our customers. In selling the 5ESS ital switching machines are already in t h e k i n d o f s w i t c h c u s t o m e r s h a v e e l e c t r o n i c s w i t c h t o t h e R B O C s i n t h e place. In order for our switch to been asking for. Its modular design post-divestiture environment, we will emerge as the leading product in the m a k e s i t a fl e x i b l e m a c h i n e f r o m t h e have to change our customer contacts field, WE sales reps must clearly dem standpoint of application and size. and the manner in which we approach onstrate its superiority to other "Using a combination of hardware them. In the affiliated environment of products. and software, the customers can mix the past, our sales representatives Jim Edwards and Tony Izzo agree and match and buy as they want, dealt mainly with telephone company that if the 5ESS switch is to be suc achieving cost reduction and en planning and operations people. Now, cessful, it will require a bold, aggres hanced revenue streams in manageable they must also address the telephone sive marketing strategy. pieces. With the full-feature package, companies' marketing concerns. "The intensity of the competition in t h e 5 E S S e l e c t r o n i c s w i t c h b e c o m e s After divestiture, the RBOCs, anx the marketplace for the 5ESS switch is one of the most versatile products our ious to increase their revenues, will be going to be much greater than in the c u s t o m e r s e v e r h a d . " looking for products that not only are past," explains Edwards. "And our style To develop an effective sales strategy cost-effective, but also generate signifi of dealing in such an environment will and appropriate sales message for the c a n t a m o u n t s o f r e v e n u e . I n a d d i t i o n also be different. A system does not 5ESS switch. Corporate Account Man to telling the RBOCs what the 5ESS sell itself—even a system as outstand agement brought together a team switch does and how it works, WE ing as the 5ESS switch. We have to known as a SalesJ'rogram Develop sales people will also be telling them translate the value of the product's ment Team (SPOT). The SPOT h o w t h e s w i t c h ' s f e a t u r e s t r a n s l a t e i n t o superior architecture and manufactur included representatives from WE's c u s t o m e r b e n e fi t s . ing quality into terms that our cus Product Line Planning and Manage-

20 WE ment, Service Line Planning and These and other sales aids and tools Account managers will be working Management, account teams, Public are part of a comprehensive communi closely with market planners to iden Relations, Legal, Market Operations, cations plan developed by the SPDT to tify rapidly and pass along information Market Planning and Bell Labs. The support the efforts of our sales repre on their customers' problems or team worked together to analyze the sentatives. The communications plan needs. selling situation for the switch, set also includes a media strategy de "We see ourselves as problem-sol program goals and objectives, and signed to convey the message to our vers for the account managers' develop sales strategies as well as a customers, the general public and customers," explains Izzo, referring to plan to communicate these strategies employees through advertising, press his Market Planning organization. "It's t o o u r c u s t o m e r s . coverage and company publications. our job to respond to a customer's "It was up to the team to come up Six distinctive ads on the 5ESS problem or need by coming up with a with strategic selling thrusts for the switching system are running in Tele unique application of a standard 5ESS switch and to decide what to say, phony and Telephone Engineer and product." to whom, and when," explains Ray Management magazines—^publications According to Izzo, his organization's DeMatteo, Manager, Sales Program De whose readership is largely made up top priority is to honor the commit velopment and Assurance. "The team of telecomunications company execu ments that have been made to had to address a dynamic buying tives. The ads talk about the new era customers on delivery of the 5ESS s i t u a t i o n i n w h i c h t h e c u s t o m e r i s in switching ushered in by the 5ESS switch and specific features. changing. This required a new selling switch and describe a host of oppor "We have no doubts about the prod language that translates product fea tunities and capabilities that it offers uct's performance," Izzo affirms. "Our t u r e s i n t o c u s t o m e r b e n e fi t s . " to the industry. Each ad highlights a number-one challenge is to make avail Adds Dick Crean, General Manger, particular customer benefit of the able first in 1983 and then in 1984 the Market Operations, "An important sell switch, such as its ability to grow, product and features called for by our ing step we are taking with this modular software, reliability, remote customer." product is writing the 'salesware' in capabilities, and revenue-generating Edwards adds, "We'll be shipping the language of the buyer and not the features. twice as many 5ESS switches in 1983 seller. This is the way we will be A special training session was held as originally planned. marketing and selling our products in in May for all the people involved in "Demand for the product is so the future." selling the 5ESS switch. It was par strong that our customers want more The key to the 5ESS switch's mar ticularly geared towards switching than we can make. Right now we are keting strategy is positioning. The sales representatives, network systems manufacturing-constrained. The strategy seeks to position the switch in sales managers, and managers of ac solution is to make more of this the customer's mind in three ways: count management. The session was product. And that's just what we're first, as the premier digital switch in designed to accomplish three objec going to do. the Information Age; second, as the tives: to give our sales people the most "Western is the premier manufac standard of excellence in switching, current information on the switch and turing company in the world and has both in terms of reliability and in ease its capabilities; to unveil specific sales been solving manufacturing problems of operation; and third, as the most strategies and tactics developed for for a hundred years. I have no doubt economical and versatile local/toll use with customers; and to present a that we can handle this manufacturing switch to meet the Information Age program designed to spread enthusi- challenge." needs of the RBOCs. To allay any asum for the sales mission to all our E d w a r d s s e e s t h e s u c c e s s o f t h e doubts about the switch's capabilities employees. 5 E S S s w i t c h a s v i t a l t o W E ' s f u t u r e a n d and availability, the strategies also at Sales representatives were given a t h e f u t u r e o f t h e w h o l e n e t w o r k l i n e tempt to build customer confidence in variety of materials prepared to sup of business. the stability of the project. port their efforts and were then "This switch is a winner, but we all The account management organiza instructed on how and when to use have to get behind it to ensure its tion will be putting those strategies them. For example: when to take a prolonged success," Edwards says. "It's into practice primarily through direct c u s t o m e r o n a t o u r o f t h e N e t w o r k a big job and represents a tremendous selling of the switch by sales repre Software Center or Oklahoma City challenge. It is important that every sentatives. Works to see the 5ESS switch in o n e i n W e s t e r n E l e c t r i c u n d e r s t a n d s Augmenting the efforts of the sales production; how most effectively to t h a t w e e a c h h a v e a n e n o r m o u s s t a k e reps will be sales presentations by the use the slide-supported sales presenta in the success of this product. We all seven regional vice pmsidents to tions with a customer; and which of have to work together as a team to RBOC executives; adWrtising; exhibits several new eye-catching brochures on ensure that the 5ESS switch will for use at trade shows; and other the switch to distribute to a particular continue to receive a winner's printed and audiovisual sales aids. telephone company customer. reception in the marketplace." 21 T h i r d Q u a r t e r 1 9 8 3 tion of the real thing. What exactly is it that does so much You Can't 5 for so little? Well, on the hardware side, it consists of a micro-computer system complete with two disk memo Tell It ries, all neatly packaged in a trim white box about the size of an orange crate. What makes this box such a F r o m t h e great simulator of real-world systems is, of course, its software. Developed at the Dublin Training Center, this inge Real Thing nious software can mimic just about every kind of problem an electronic switching office can run into and, Photos by Joe Gazdak Dick Cieklinski looks on as one of his students "talks" to a simulator.

S o m e o f t h e e c o n o m i e s a s s o c i a t e d with 5ESS* switching equipment don't actually come with the equipment. Take the matter of training for tele phone company craftspeople and We s t e r n E l e c t r i c i n s t a l l e r s . T h i s v i t a l function costs a lot less for 5ESS switching equipment than for any other electronic switching system. One reason is that its advanced tech nology has simplified maintenance so much that both doing it and learning how to do it take a lot less time. This means that courses at Western Elec- tric's Training Center in Dublin, Ohio, are considerably shorter—only 33 days for the 5ESS switch maintenance course compared to 64 days for lA ESS switching equipment, for example. But there's another reason, too, and it shows how the same kind of innova tive thinking that created the 5ESS s w i t c h e x t e n d s i n t o a l l t h e We s t e r n Electric activities that support it, in cluding training. This second reason goes by the name of machine simula tion, which is a good name, because it means exactly what it says. Machine simulation is a means of simulating the behavior of real telephone office switching machines, including the 5ESS switch and the 3B20 processor that provides most of its intelligence. With machine simulation, telephone company students can complete a significant portion of their training without ever leaving their home base. What's more, they can do it at exactly the same kind of terminal they would be using if they were at an actual 5ESS switching office. In fact, they can't tell it from the real thing. Even an experi enced craftsperson diagnosing an ailing 5ESS switching office at a sim ulator terminal can't tell that he is not dealing with an actual switching ma chine. The beauty of this is that craftspeople are learning their craft on something that costs only a tiny frac

22 • Tr a d e m a r k o f W c s c e r n E l e c t r i c WE then, in response to keyboard inter field how it motivates students, turns fenders on the car," he says, "and Bill's rogation from students, communicate them on and things like that." Reports group put the motor in." that vital information to them. do, in fact, confirm that students are Sticking to that analogy, he could This kind of keyboard maintenance often seen still working at their termi have added that his people have since is known as diagnostics. Basically it nals at lunch time and other breaks. come up with a whole new car to works like this; When a craftsperson "What's more," adds Malloch, warm cope with the space problem. Called punches in the right code on a termi ing to his theme, "the simulator hands-on enhancement, it is a nal requesting diagnostics of a e l i m i n a t e s a l o t o f c o m m u n i c a t i o n s customized software package that dou particular unit, the system's software problems between trainers and stu bles the training capacity of Dublin's begins comparing that unit's actual dents by replacing words with hands- 5ESS switching equipment. With the behavior with the way it's supposed to on training. The students learn a lot by ever-increasing popularity of the new behave. It does this on the basis of t h e i r o w n d i s c o v e r i e s a t t h e t e r m i n a l s . digital switcher, they may have to point-by-point logic, or voltage checks, They can get their own answers to come up with software to double even f r o m o n e e n d o f t h e c i r c u i t t o t h e ■what if?' type questions that instruc that capacity. other. Whenever there is a diJBference, tors can't always answer, and they can T h a n k s t o t h e s i m u l a t o r ' s m u l t i - it points it out on the terminal's TV get them fast." terminal capacity, the operating com- screen or on a printer. With further queries, the craftsperson can track the problem down to a particular circuit pack, which is then replaced. The simulator models this complex pro cess without actually running the diagnostic tests. T h e s i m u l a t o r ' s s o f t w a r e a l s o i n c o r porates all the rules and constraints that prevent craftspeople from making the kind of mistakes that would put a real ESS switching office out of action. For example, in a real 5ESS switching office, every piece of equipment is duplicated so that one unit can remain in action while the other is diagnosed. This kind of redundancy allows crafts Want to simulate a different machine? Just change the disk. people to take one unit out of opera tion for diagnostics while substituting Not surprisingly, the instructors are panies don't have any space problems i t s t w i n — a l l w h i l e s e a t e d a t a t e r m i learning almost as much as their stu at their training centers. Every com nal's keyboard. Real ESS system dents. "For many of them," says pany has bought at least one simulator software won't permit the accidental Malloch, "the simulator is like going so far, and, if enthusiasm is any indica uncoupling of both identical units, and back to Dublin for a refresher course." tion, things look bright for future sales. n e i t h e r w i l l t h e s i m u l a t o r. I t m i m i c s The capabilities of the simulator Dick Cieklinski, a New Jersey Bell the redundancy, and it mimics the belie its small size. Each unit can instructor at the company's Corporate safeguards that prevent maintenance handle several terminals simul Training Center in South Plainfield, is people from making costly mistakes. It taneously, and each terminal can an avid supporter of the simulator. "It e v e n m i m i c s t h e e x a c t i n t e r v a l s a r e a l handle several different kinds of pays for itself very quickly," he says. 5 ESS system takes to do a complete switching offices. If a student has to " O u r s t u d e n t s u s e d t o h a v e t o u s e diagnostic. break off in the middle of a problem, Dublin's simulator over telephone The only things not simulated are the simulator will remember where he lines. Our dialup costs alone ran to the time and money saved. For exam was and take it from there when he over $1,500 a month. Now, our only ple, 18 of the 33 training days needed returns. cost is a small yearly maintenance for 5ESS system maintenance are de Dublin's George Teasdale (Depart charge for the software." voted to its 3B20 processor. Of those ment Chief 5ESS Technical Training) T h e r e a r e t h r e e s i m u l a t o r t e r m i n a l s 18 days, students have to go to the points out another of the simulator's in Cieklinski's classroom, each a hive Dublin Training Center for only six. many advantages. "A 5ESS switching of activity between lectures. "Students They can complete the first 12 days' office is real small," he says. "A com enjoy the course a lot more now," he work at a local Western Electric or plete switcher doesn't even take up as says. "Without the simulator, the telephone company school. The sav much space as a lA processor. Because course wouldn't be as interesting, and ings in room and board expenses are it's so small, our system here at Dublin every instructor feels the same way. It substantial and effectively reduce the physically can't accommodate as many also makes it easier for me. My stu already low cost of the 5ESS switch. students for hands-on training as ear dents know they're going to an actual Department chief Bill Malloch, the lier ESS system gear. The simulator's hands-on assignment after each lec project manager of Dublin's Machine ability to handle a number of termi ture, so they listen better." Simulation Group, sees a host of less nals is a big help." Cieklinski's boss. Bill Wymbs, tangible, but equally important bene Teasdale's group includes some of couldn't agree more. "It was a cinch to fits. "First of all," he says, "the the course developers who worked install," he says, "and it has worked s i m u l a t o r m a k e s c o u r s e s a l o t m o r e with Malloch's programmers to create exactly the way it's supposed to. We interesting. We keep hearing from the the simulator's software. "We put the t h i n k i t ' s f a b u l o u s . "

Third Quarter 1983 23 A Digital Network

X - 1, .4:^ ■-fe-S> By Lewis Bayers

Other Corporations are planning for it. We're building it.

There is a vision of the future shared by most planners in the telecommu nications industry today. It is called ISDN, which stands for Integrated Services Digital Network. ISDN is a v i s i o n o f a n e t w o r k t h a t c a n h a n d l e voice, data, video; a network that can h a n d l e t h e n e e d s o f t h e I n f o r m a t i o n Age. In Geneva, Switzerland, a United Nations agency is laboriously working towards defining it. Manufacturers and telephone companies around the world are studying it. Large corpora tions everywhere are taking steps toward planning for it. In the Bell System, we're already building it. And the 5ESS* switch, our newest, is not only available for today's needs, but is also another major step toward fulfill ing the vision of ISDN. Why ISDN? Well, today, the Bell n e t w o r k h a n d l e s o v e r h a l f a b i l l i o n calls each day. These are primarily voice calls, that is, people talking to people. But increasingly, the network is being asked to do more. The Infor mation Age sees computers calling computers, special custom calling services, video teleconferencing, and m o r e . T h e n e t w o r k n e e d e d t o h a n d l e this must be a network of sophisti cated equipment providing sophis ticated services. It must be able to handle voice and data, simultaneously. It must be able to switch and trans port data, facsimile, video, and special services as easily as it handles voice.

• T r a d e m a r k o f W e s t e r n E l e c t r i c 25 e

Can today's Bell network handle this? most efficient way to handle the call. packs. It uses the existing loop. Our Of course! The vision of the future Today, Western's Local Area Data Trans 5ESS switch was designed and built called ISDN is little more than what port (LADT) system is a major step in with this experience under our belt, we in the Bell System have been that direction, able to handle both so 64 kilobit switched data will be a building for years—a network of voice and data with a single interface, snap on the 5ESS switch and all three stored program controlled switches, and handle both at the same time. systems will be compatible." common channel interoffice signaling Again, the 5ESS switch and LADT were The ISDN vision also calls for packet (CClS), and digital trunks; a network planned together. They will work to switching capability. Again, Western is being built to eventually provide any gether, each system building on the in the forefront. The Bell System's type of communications transport and strengths of the other. C C l S n e t w o r k h a s b e e n c a l l e d t h e service. It's been evolving, growing, The 5ESS switch was designed with "largest packet-switched network in improving, since the beginning. Now, evolution in mind. The goal was to the world." And our No. 1 Packet with new customer needs, and new build a switch versatile enough to Switching System (PSS) is the most technologies available, it will continue function in virtually any capacity in powerful packet switch available today. to grow As new products come out of today's network, while still being able It is based on the 3B20 processor, the our shops, and new designs come out to cope with the inevitable changes same processor that is the heart of the of the Labs, the network will in that the network or technology will 5ESS switching system Administrative Module. Furthermore, as Karl Mar- creasingly handle even more traffic, present in the future. provide even more services. And the The goal has been achieved. This is tersteck, the Bell Labs executive director responsible for the 5ESS sys 5ESS switch is a major stepping stone possible, in part, because the 5ESS tem explains, "Conceptually, internally, in that evolution. switch is designed as an assembly of The ideal ISDN is made up of three semi-independent modules, with a su the 5ESS system is a packet switch." There's another key reason why the network elements. First of all, the perior software operating system that ISDN vision calls for an integrated a d m i n i s t e r s a n d c o o r d i n a t e s t h e f u n c 5ESS switch will be our stepping stone switch. The bulk of today's traffic is tions of the modules. Each module has to the future: it has the necessary best handled by the traditional circuit its own processor and a modular, depth of development resources and switching method. Some traffic, how structured software architecture, giv total corporate commitment. It has ever, is most efficiently switched by a ing it independent capacity and been designed by Bell Labs, the pre method known as packet switching. In capability, lb create a new service, mier laboratory in the world. It's being the ideal ISDN, we see a single switch only a small part of the system needs built by Western Electric, the premier that will incorporate both circuit to be changed, perhaps only the soft manufacturer of telecommunications switching and packet switching ca ware. "Vbu just modify the module products. And both are committed, pabilities. A switch that can simul responsible for that service, plug in fully, to continued evolution. In some taneously handle voice, data, even some new circuit packs if necessary, ways, the 5ESS switch is really more video. A switch that will also provide and that's it. than just a switch. Working along with all sorts of special custom features. A In fact, a lot of ISDN capability is our lA ESS and 4ESS switchers, the switch very much like the 5. already "plugged in" in the 5ESS 5ESS switch is the hub of the ISDN. The second element of an ISDN is switch. For example, the 5ESS switch Jerry Johnson, Western's Product Man an adaptive link, sometimes called a modules are already interconnected ager for the 5ESS switch describes it as "the most important project in switch "digital pipe." These are the digital by fiber optic links, providing fast transmission facilities that will carry communication of internal control ing. Not just to Western and our ISDN traffic. Western's T-Carrier, light messages today, and the promise of customers, but to the public at large. wave, and Subscriber Loop Carrier broadband capability in the future. It'll do more than any other switch; systems will all be key components of The ISDN vision calls for a high provide more reliable service, more the evolving ISDN. The 5ESS switch is speed, 64 kilobits per second, data custom services, allow the real bene designed with integrated interfaces to communications capability—^that's 64 fits of the Information Age to reach all of these systems. thousand bits of information per sec more people. It's not only compatible The third ISDN element, in the ideal ond. The 5ESS switch has this capa with future visions, but also provides vision of the future, is a standard bility today, built into the trunk circuits. real expense savings, improved opera interface for all customers. Tbday, the "The breakthrough technology tions, and revenues, today." In other words, it does more for the telephone simply plugs into a wall here," says John Leary, Western's Prod outlet. Computers need another uct Manager for Special Networks, money—^not only for today, but for method to hook into the network. In "happened with the lA ESS* and 4ESS* t o m o r r o w a s w e l l . W i t h t h e 5 E S S the ultimate ISDN, this will all be switches. Circuit Switched Digital Ca switch, we're not just building switch integrated. The customer simply plugs pability (CSDC) will be available ing equipment anymore. We're in and starts communicating. The net shortly on those systems. All you need building the future of the nation's work itself will figure out the best, i s s o m e a d d i t i o n a l s o f t w a r e a n d c i r c u i t telecommunications network. WE 26 • Tr a d e m a r k o f We s t e r n E l e c t r i c T h i s m i c r o w a v e r a d i o s t a t i o n a t Berthoud Pass, Colo., epitomizes the new digital transmission look. Combustion i s A Burning Problem

By Saul Fingerman

Photos by Len Stem and Sandia Twentieth century m a n i s m o r e dependent on fire t h a n o u r c a v e m a n a n c e s t o r s w e r e

A recent movie devoted nearly two h o u r s t o t h e m i s a d v e n t u r e s o f t h r e e likeable, but not particularly bright, cavemen who had been sent on a "Quest for Fire" by their tribe. The tribe's own fire had been inadvertently quenched, triggering an immediate outburst of near total panic. Everyone knew that, without fire, life was going to be a whole lot more dangerous and uncomfortable. "Quest for Fire" was datelined 80,000 B.C. We've come a long way A c o m p u t e r - e n h a n c e d since then, but our need for fire hasn't photo of laser light scattered by a really changed that much. We may call it combustion rather than fire, but, in hydrogen flame. one form or another and by whatever name, we are even more dependent on it than the cavemen were. The fact is This time, however, the seekers are that we provide more than 90 percent scientists rather than cavemen, and of our civilization's energy needs by they are armed with lasers and compu burning something—oil, gas, coal, ker ters rather than spears and stone osene, wood and so on. knives. And, most importantly, they are If you doubt it, think of autos, looking not simply for fire, but for a truc^, buses, aircraft and rockets. better, more efficient and pollution- Think of power plants and steel mills f r e e fi r e . T h e i r w o r k i s c a l l e d C o m b u s a n d c e m e n t k i l n s a n d f a c t o r i e s a n d tion Research, and they're doing it in a virtually any industrial heat source. cluster of five closely-spaced buildings And, finally, think of how you heat a t t h e S a n d i a N a t i o n a l L a b o r a t o r i e s i n your home. At this point, you should Livermore, California. have a pretty good idea of how impor Heading this vital project is a slim tant combustion is to your life, so you and energetic PhD in aerospace engi won't be surprised to learn that our neering named Dan Hartley. An government has instituted a twentieth- articulate and highly enthusiastic ad century version of the quest for fire. vocate of combustion research. WE 28 Dan Hartley and laser at Sandia's Livermore Laboratory. back as far as the last century." He also laboratory building, and what makes it saw that, unless America instituted a unique is the economical way it han Hartley was probably the prime cata major effort, it would never catch up dles lasers. The building was, in fact, lyst in the creation of Sandia's newest with the extensive combustion re designed and built around two high- and most important energy research search going on in Europe. Marshalling power lasers, both of which are too facility. As he tells it, in 1973, Presi his considerable expertise on the sub large and expensive to be cloned in dent Nixon asked all of the govern ject, he wrote a proposal for a each of the facility's 14 laboratories. m e n t ' s N a t i o n a l L a b o r a t o r i e s f o r i d e a s N a t i o n a l C e n t e r f o r C o m b u s t i o n Instead, the output of each laser is on solving our nation's energy prob Research. "shipped" to any lab experiment lems. Hartley, who was using lasers to Washington got the message and through a complex system of peri solve fluid flow problems, suggested funded the project in 1978. In 1980, scopes and ducts. tackling combustion problems with Hartley and his group of about 90 Like some latter-day Houdini, the same techniques. scientists, technicians and support Hartley explains that, "It's all done "I was excited about it," he remem people moved into their brand new with mirrors." Actually, the mirrors are bers. "I saw that virtually all combus buildings—one of which was, and controlled by computers, and the only tion equipment existing today is based probably remains, unique in all the magic is in the millions of dollars on old technology—some of it going w o r l d . T h i s i s C o m b u s t i o n R e s e a r c h ' s saved by getting the use of 14 lasers

T h i r d Q u a r t e r 1 9 8 3 29 pumping a lot of nasty pollutants into that warms researchers' hearts—things The auto industry's our atmosphere. What we don't fully like temperatures, densities and ve understand is how this happens. Nor locities of gases at different points of long-cherished view do we understand the instant-by-in- time and space. of hydrocarbon s t a n t m e c h a n i c s o f t h e t u r b u l e n c e t h a t One of the lab's one-cylinder en makes combustion so violent a pro gines is like no other you've ever seen. e m i s s i o n s w a s cess. Complex almost beyond any In addition to its sapphire portholes, it known mathematical description, such has four spark plugs. Why four plugs flat wrong turbulence is largely what combustion for a single cylinder? "So you can tailor for the price of one. fluid mechanics is all about. This the flame spread to study a variety of The lab building is unusual, too, highly esoteric science is devoted to knock and pollution problems," an because it is so vibrationproof, it the study of gases in motion, and, swers Hartley. "Efficiency depends on effectively serves as one huge, optical flames—for all their special charac how, when and where you ignite the platform for the laser systems. Re teristics—are made up of moving, searchers are convinced that nothing ever-changing gases. short of a major earthquake can inter It's not too useful for producing rupt the piped-in laser beams around energy, but there is such a thing as a which almost all their experiments are n o n - t u r b u l e n t fl a m e . R o m a n t i c s c a l l i t based. candlelight; scientists call it laminar As Hartley's colleague, Dr. Peter flame. What makes it laminar is that Mattern, manager of Sandia's Combus the fuel (paraffin) mixes with oxygen tion Science Department, explained, by diffusion, and does it so slowly the reason laser beams are so impor there is no turbulence. What there is tant to combustion research is simple. instead is a lot of soot. The truth is They are the only medium in exis that, although candlelight may be the tence you can use to "probe" a flame stuff of intimate evenings and romantic without disturbing it. If you stick any poetry, it is based on the formation of other kind of measuring device, such soot. The lambent gleam reflected as a thermocouple, into a combustion across the dinner table in lovers' eyes system, you've changed it so much, actually consists of glowing particles the information you're extracting is of the stuff. bound to be misleading. And, combus Less romantic, but far more useful tion is tough enough to understand are turbulent flames, since they're the without introducing additional com only kinds capable of productive plications. It is not only a turbulent work. Interestingly enough, they are and highly transient process—things made up of lots and lots of little happen very, very fast—but it also laminar flames—^which is one of the i n v o l v e s i n t e r a c t i o n s b e t w e e n t w o s c i reasons they are so complex. entific disciplines that are difficult Fortunately, lasers are perfect for enough to master by themselves. unraveling the mysteries of turbulence These disciplines are chemistry and as well as of the intricate chemistry fluid mechanics. that accompanies it. As we already Ironically, everyone who has ever noted, their beams don't perturb the taken a course in elementary chemis gases under study. What's more, their try thinks he or she knows all there is light-speed velocities permit nearly to know about combustion. It's just a instantaneous "snapshots" of the vio Three laser beams probe a cone of chemical reaction between fuel and lent events that go on in combustion. These "snapshots" are actually long flame to provide Sandia researchers oxygen that generates a lot of heat and with vital information. light—right? Well, not really .... sequences of data, but to scientists For one thing, combustion is rarely they are just as graphic as photos. a single chemical reaction; it is almost Hartley's people have figured out a fuel. For example, the current location always a host of chemical reactions wide variety of ways to use their laser of spark plugs may be all wrong occurring sequentially at dizzying beams to extract all kinds of vital because the designers didn't know speeds. Just the chemistry involved in information. In one laboratory experi how to take into account all the the burning of a tiny lump of coal ment, for example, three laser beams processes going on. We're trying to could fill a thick volume—and proba are fired into a one-cylinder gasoline describe these processes well enough bly will before Hartley's researchers engine. The beams enter through to find the best location for ignition. are finished. The chemistry of pollu transparent portholes of thick artificial We don't know these details yet, but tants could easily fill another volume. sapphire and exit out the other side we'll find out." We know, for example, that ideally, through a similar porthole. Once out, In point of fact. Combustion Re all of a fuel's hydrogen and carbon however, the beams are no longer the search has already found out plenty. molecules should combine with oxy same. In the cylinder's turbulent in For example, Sandia scientists and gen to form energy and a harmless ferno of burning gases, the beams their co-workers have proved that the exhaust of carbon dioxide and water. c o m b i n e t o f o r m a f o u r t h b e a m o f a auto industry's long-cherished view of We also know that, like most ideals, it different wavelength. This beam is hydrocarbon emissions from engines doesn't happen that way, and we're loaded with the kind of information was flat wrong. "Prior to this work,"

30 WE says Hartley, "they assumed a flame everything from cold start to moun Electric runs Sandia for the govern propagated out to the cylinder wall, tain driving. The microprocessor chips ment. "It's also because we want all where it was quenched because the are smart enough to handle almost the input we can get." says Hartley wall was relatively cold. They were anything you can measure—but how Lately, he has been getting more sure this quenching left a thin layer of do you know which things you want than just cerebral input. In recognition unburned fuel that was exhausted as measured and how you want them of the good things that have already pollutants. We proved it doesn't hap controlled by the computer unless come out of his laboratories, the pen that way." you understand all the inter government has granted Hartley the What this team proved was that a relationships? researcher's ultimate accolade—in fuel's hydrocarbons difiuse into the Hartley is convinced that, even if creased funding. His lab building is flame (which isn't quenched, after all) the f^th to understanding is still being expanded; a new high-power and are consumed. That bit of hard- pretty dimly lit, his group's work will laser is being installed, and he will e a r n e d i n f o r m a t i o n h a s s e t a u t o i n d u s help light the way for others. "Our likely receive an additional S21-million approach," he says, "is to not only do in fiscal 1985 for the expanded lab research, but also to develop the space and equipment. special tools you need for that re That money isn't going to go into search." By special "tools," he means new engines or fuels. "That's not what more than laser systems, see-through we do," says Hartley. "Ours is the long- engines and other technological eso- term goal of inventing scientific meth terica. Primarily, he means the many ods for doing combustion research." computer programs and mathematical Even so, what those methods may models his researchers develop for l e a d t o i n t h e h a n d s o f i n d u s t r i a l other scientists who share their quest. researchers makes for exciting spec And there are many. The auto indus ulation. And the excitement is try isn't the only beneficiary of heightened by little tidbits such as the Combustion Research's work. Any in recognition that a mere one percent dustry involved with any kind of increase in auto engine efficiency can combustion is privy to their findings. save this country nearly one-billion If they want, outside companies can dollars a year in imported oil. e v e n s e n d t h e i r o w n s c i e n t i s t s t o "In addition," says Hartley, "our re Sandia to do their own research. "All search can lead to alternative fuels, the companies have to do is pay their s u c h a s c o a l d e r i v a t i v e s . T h i s i s a n a r e a salaries and living expenses," says that has been virtually ignored up to Hartley. "As long as their work is now" A firm believer in the promise of important and not proprietary, we'll coal. Hartley presented a paper on the provide the facilities. In our two years subject in 1982 to the House Subcom of operation we have had nearly two mittee on Energy Development and thousand daily visitors with over three Application. In it, he pointed out that, hundred staying for the better part of although America's coal makes up a w e e k t o s e v e r a l m o n t h s t o s o l v e a nearly 90 percent of our entire energy special problem in combustion. The reserves, its use accounts for less than system works." 20 percent of the energy we consume. In addition to state-of-the-art lasers This vast hoard of black gold holds and electronics, those facilities include the promise not only of easing our access to a Cray computer—the fastest energy problems, but also of improv and most powerful machine of its kind. ing our unfavorable balance of pay try researchers off looking in other I t t a k e s a v o r a c i o u s n u m b e r c r u n c h e r m e n t s s i t u a t i o n o v e r s e a s . H o w e v e r, directions for pollution sources. At the to cope with the convoluted mathe Hartley made no attempt to minimize moment, they are fairly convinced the m a t i c s o f c o m b u s t i o n . the enormous problems dimming culprit is fuel trapped in piston ring Not surprisingly, there are a number some of the luster of that promise. crevices. And, if they can understand of mathematicians on Hartley's staff. "Coal," he admitted, "is a dirty, nasty, it, they can flx it. There are, in fact, several disciplines inconsistent fuel, and it burns in a Some of the information Combus represented at Combustion Research, highly polluting, corroding, and unre tion Research regularly feeds to the including physics, chemistry, engineer liable manner." auto industry has already paid off ing and mathematics. Hartley Can these problems be solved? "Yes, handsomely in terms of significantly considers this interdisciplinary ap indeed," says Hartley. "If we can un improved gasoline mileage and pollu proach vital. 'Ton can't go to college ravel the chemical paths in coal tion control—a fact that was gra and major in combustion," he says by combustion, we may be able to find ciously acknowledged by General way of explanation. practical ways to interrupt them and Motors. The synergetics of the interdisci prevent soot formation and other "Right now," adds Hartley, "a big plinary approach are reminiscent of kinds of pollution." push in the auto industry is to come B e l l L a b o r a t o r i e s . " S a n d i a ' s C o m b u s With characteristic optimism, he up with computer-controlled engines." tion Research facility," acknowledges notes that, "We've already had some TTie missing link is a definition of Hartley, even has a Bell Labs' scientist promising results from our coal re combustion precise enough to tell on its advisory board." This is only search. We're on our way—^well on our computers what to do to correct partly due to the fact that Western way!"

T h i r d Q u a r t e r 1 9 8 3 31 Threads of Gold

A number of years ago, there was a Del used sophisticated equipment in great Hollywood epic called "The the WE laboratory to cross section the Crusades." In the climactic scene, King threads and analyze the metal overlays. Richard the Lionhearted, in the white This was done using an ultramiero- armor, comes face to face with Saladin, tome and a scanning electron micro the arch villain. scope/energy-dispersive X-ray. There was a minimum of dialog in "Hospitals use a microtome," he such epics, and so Richard, the strong said, "when analyzing biopsy samples. silent type, to demonstrate the For studying the fibers from the mu strength and technical superiority of seum, 1 first mounted the thread in the Christians, takes his heavy broad epoxy resin and then sectioned it with s w o r d a n d c o m e s d o w n w i t h a l l h i s the microtome using a diamond knife. might on a huge timber. Precut by the The specimen was then placed in the prop department, the timber breaks vacuum chamber of the microseope on cue. Saladin, in response, tosses a a n d s c a n n e d w i t h a n a r r o w b e a m o f silk scarf in the air, draws his sword, high energy electrons. A series of and as the gossamer material floats photographs of the thread, at magni across the curved blade, it is cut in fications of up to 10,000 times, and half. X-ray analyses were obtained for meas It's questionable that any such a urement and study." confrontation took place in real life, The electron microscope examina b u t t h e d r a m a t i c s c e n e d i d d e m o n tion of the cross sections showed the strate effectively that 1,000 years ago, gold to be a very thin layer on the w h e n t h e W e s t e r n W o r l d w a s i n v o l v e d outer surface, so the entire thread with wrought iron and cast bronze, in appeared gold. the desert city of Damascus, alloys An intriguing part of this work was were being made that could take an comparing the metal wrappings in the edge equivalent to our modern razor ancient textiles with the metal deposi blades. The secret of how that metal tion on contemporary products. was made has been lost for centuries. Del's X-ray investigation of the con Another metallurgical mystery that struction of metal overlays showed has intrigued researchers for years are that the gold layer thickness averaged the so-called "gold threads" in ancient only about 8 millionths of an inch. tapestries and ceremonial robes. Al "It is remarkable to me," he con though they look to the naked eye like tinued, "to see how thin ancient fine gold wires, the threads are actu artisans could make the gold. At West ally silk or linen cores spirally ern Electric, we cannot use the wrapped with incredibly thin strips of teehniques demonstrated in these fab gold-coated metal. The mystery is how rics. To get gold as thin. Western did artisans hundreds, perhaps even Electric turns to expensive equipment. 1,000 years ago, make the paper-thin A supplier uses a rolled method to metal, cut it into almost invisible strips l a m i n a t e a b o u t 2 0 0 m i l l i o n t h s o f a n and face it with gold. inch of gold on the frequency springs The answer is that we still don't for the Touch-Tone* telephone dial. k n o w f o r s u r e . B u t w h e n a n e w e x h i b i t Even though it's 25 times as thick as in called "Fabrics in Celebration" opens the threads, we have had trouble at the Indianapolis Museum of Art getting the gold overlay that thin on after Labor Day, visitors will be able to these parts." s e e t h e r e s u l t s o f o n e o f t h e m o s t T h e m u s e u m i s e x e i t e d a b o u t t h e thorough investigations of the subject team work that brought industry and ever made. About 100 major pieces in education together in this project. the exhibit, whieh spans the years This is the first time an analysis has from 250 BC to the present, incorpo b e e n d o n e o n t h e f a b r i e s i n t h e rate precious metal threads. Museum's eollection. The staff says it The investigators were Leon was only possible at this time because Stodulski, a professor of chemistry at of the generosity of Western Electric Indianapolis University/Purdue Univer in lending its resources under Del's sity in Indianapolis, and Del Nauman, a guidance. senior engineer at the Indianapolis The Western Electric Fund has pre Works. viously supported the Indianapolis After Prof. Stodulski completed his Museum of Art through Performing emission spectrographic bulk analyses. Arts grants. ,

• T r a d e m a r k o f A T & T WE ^5

^ « & < s s » ^ % • • * * * ^ " « . m ■ • » ' " • • . ^ • ■ - U ^ - r " ' - - ^ . . Del Nauman, Prof. Stodulski and the museum's Harold Mailand. %

I lArs^

Don Procknow in Oklalioma City test area with Mel Ciering.

See page 14.

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