Sistemas COTS integrales desplegados de Curtiss Wright

1 | June 22, 2015 | Proprietary | © 2015 Curtiss-Wright

Defense Solutions Division

Paul Garnett

Deployable COTS Integrated Systems


Some Examples


Example Systems


Integration Computer

Application

– Integrating new NATO IFF system with existing RADAR on P3-Orion Maritime patrol aircraft

– SBC + Graphics + 1553 + SSD + spare slots

System

– Fan cooled 5 slot 3U ½ ATR – MPMC-9355

Key Features

– Small, high performance system

– Custom video capture and two output formats

– XF07-523 on XMC Carrier – legacy IO, custom video output

– 64GB Embedded SSD

– 2.5” Removable SSD option (Up to 1TB; SLC, eMLC, MLC)

– 115V 400 Hz AC power input

– ½ ATR tray


Integration Computer - Block Diagram

VPX3-1257 Custom CarrierVPX3-215

XMC-2101XVideo Capture/Video Output

XMC-523Kintex 7 FPGA

RS3

43

No

n In

terl

aced

RS3

43

No

n In

terl

aced

RS-

17

0

3 x

USB

XMC-603MIL-STD-1553

MIL

-STD

15

53

B

Enco

der

Dat

a/G

ate

Enco

der

Clo

ck

Enco

der

Dat

a/G

ate

Enco

der

Clo

ck

AR

P/A

CP

DIR

(R

S42

2)

Dig

ital

Vid

eo

Tou

ch S

cree

n In

terf

ace

(RS2

32

)

Tou

chSc

reen

Vid

eo (

RG

BH

V)

9 xSN55110

2 xSN55107

3 xDS26LVS31

PCIe x8

Expansion Carrier 1

Not populated

PCIe x4

PCIe x4

Expansion Carrier 2

Not populated60GBSATASSD

SATA

3 x

Gb

E

1 x

RS4

22

1 x

28

V D

iscr

ete

Inp

ut

RemovableSATASSD

SATA

PSU50ms Holdup

115V AC

PCIe x4

5 x

LV

C D

iscr

ete

Inp

uts


Integration Computer

VPX3-1257 – Core i7 Quad core SBC

VPX3-215 – XMC Carrier

XMC-523 – Kintex 325 FPGA

XMC-603 – Dual MIL-STD-1553

Third-Party Video capture/display

Custom XMC carrier (Gen 2 PCIe)

115VAC PSU

Fan Controller

Option to support RMC 2.5” SSD carrier


Defensive Aids System Application

– Hostile Fire Indicator

– 2 x SBC + 2 x FPGA + PCIe/Enet switch

System


Key Features


– 7 x 10Gb fiber-optic interfaces

– 3U VPX Gen 2 PCIe Switch (5 x 4xPCIe)

– 12 port Gb Ethernet Switch

– 28V DC power input

– ½ ATR tray

https://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=https://shamazkhan.wordpress.com/category/large-aircraft-infrared-countermeasures/&ei=p8ZuVb3FG4izUbD8g8gO&bvm=bv.94911696,d.d24&psig=AFQjCNG_TQx0slp3CKKhavY5V5OZQMR6Dw&ust=1433409541238975


Defensive Aids System

VPX3-1257 - Core i7 Quad core SBC

3U FPGA

Custom XMC carrier (Gen 2 PCIe)

XMC-651 - Ethernet Switch

28VDC PSU

Fan Controller

Extensive modular IO arrangement: future-proofing


MPMC-9365-0001 - Side View


Advanced EW System Application

– ECM, SIGINT

System

– Quad 4GS/s 12bit ADC, Quad 5.6GS/s DAC

– Dual Xilinx VX690T FPGA, Dual Core i7 Quad core


Key Features


– 3U VPX Gen 2 PCIe Switch (5 x 4xPCIe)

– Optional 12 port Gb Ethernet Switch

– Option for removable SSD

– 28V DC power input

(U.S. Air Force photo/Lt Col Leslie Pratt)


EW System – Block Diagram


Processing Unit Application

– Sonar processing - Maritime patrol aircraft

– SBC + Graphics + Switch + SSD

System


Key Features

– 3 x Core i7 Quad core Single Board Computers

– 2 x DVI HD video outputs from E8860 GPU

– 115V 400 Hz 3 phase AC power input

– ½ ATR tray


Processing Unit

VPX3-1257 - SBC

VPX3-716 - Graphics

VPX3-652 – Ethernet Switch

115VAC 3 Phase PSU

VPX3-1257

EMPTY

VPX3-1257

EMPTY

VPX3-1257

EMPTY

VPX3-716 VPX3-652

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

CHASSIS CONNECTOR PANEL

DV

I

DV

I

US

B 2

.0

US

B 2

.0

Au

dio

RS

23

2

US

B 2

.0

US

B 2

.0

RS

23

2

US

B 2

.0

US

B 2

.0

RS

23

2

8 x 10/100/1000 Base T

PCIe Gen 2 x4

64GB

SSD

SATA

115VAC

3 Phase

(3P no N)

PSU

11

5V

AC

3P

PCIe

Switch

PCIe

Switch

PCIe

Switch

PCIe Gen 2 x4PCIe Gen 2 x4

Co

nfig

Co

nso

le

4x D

iscre

te In

pu

ts

RS

42

2

DV

I

DV

I


Processing Unit – Alternate Configuration – Four SBCs

VPX3-1257 - SBC

VPX3-652 – Ethernet Switch

115VAC 3 Phase PSU

VPX3-1257

EMPTY

VPX3-1257

EMPTY

VPX3-1257

EMPTY

VPX3-652

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

Ethernet 1000 BaseT

CHASSIS CONNECTOR PANEL

US

B 2

.0

US

B 2

.0

Au

dio

RS

23

2

US

B 2

.0

US

B 2

.0

RS

23

2

US

B 2

.0

US

B 2

.0

RS

23

2

8 x 10/100/1000 Base T

64GB

SSD

SATA

115VAC

3 Phase

(3P no N)

PSU

11

5V

AC

3P

PCIe

Switch

PCIe

Switch

PCIe

Switch

PCIe Gen 2 x4PCIe Gen 2 x4

Co

nfig

Co

nso

le

4x D

iscre

te In

pu

ts

RS

42

2

VPX3-1257

EMPTY

US

B 2

.0

US

B 2

.0

RS

23

2

PCIe

Switch

PCIe Gen 2 x4

Ethernet 1000 BaseTEthernet 1000 BaseT

PCIe Gen 2 x4


Processing Unit – Internal Construction

Power

inlet filter

GPU SBC SBC

Frontplane

Mezzanine

SBC Switch PSU

Fan

Fan

controller

Backplane Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6


Processing Unit

Application

– Image Processing

System

– Conduction cooled 3 slot 3U – MPMC-9335

– Core i7 Quad core SBC

– NVIDIA GPGPU

– Spare slot for SSD

– Extremely rugged, baseplate cooled

– Integral heaters for cold start at -50C

Key Features


– Image/Signal Processing

– GVA Compliant

– MilCAN support


Processing Unit - Internal Construction


Performance and Applications VPX3-1257 SBC

– 134 GFLOPS

VXP3-49x - Maxwell (TBC)

– 2300 GFLOPS

Total of ~2400 GFLOPS in 250in3

– >16 TFLOPS per cubic foot

Applications

– Radar

– Image processing

– SIGINT

– Hyper-spectral imaging


MMC Platform

– Mirage Jet

Application

– Mission Management Computer (MMC)

upgrade – form and fit with new functions

System

– 6U 5 slot ¾ ATR – MPMC-9655

Key Features

– Extensive IO including third party card

– Custom Voice and Tone generator

– Custom Power Supply


MMC - Components Custom content

– Chassis

– Backplane

– Front Panel

– 6U PSU

– Voice/Tone gen, with video crossbar

COTS content

– DMV-183 x2 (SBC)

– PMC-706 (Graphics)

– PMC-550 (Flash)

– PMC-601 (1553B)

Third party content

– Low speed analog and bit IO


Terrier

Vehicle

– Terrier Light Engineering Tractor

Application

– Vehicle electronics (Vetronics) Controllers

– Drive By Wire (DbW) controller

– Special to role (StR) controller

System

– 6U 7 slot 1 ATR

– DMV-183

– 5 customer Build-to-print cards


EuroHawk

o Vehicle

– Large UAV

o Application

– COMINT

o System

– Three air-cooled 19 slot VXS systems

– Power Architecture SBC

– FPGA Processors

– Ethernet Switch

– Third-party RF


MPMC-9105 - Versatile Mission Computer

System Features:

o Up to 16GB DDR3

o 8GB Embedded Flash

o 4 x 10/100/1000 BaseT Ethernet

o 8 x RS232, 4 x RS422

o 16 x 28V GPIO

o 6 x USB

o 16 x ARINC429

o 2 x DVI video output

o 1 x VGA video output

o 4 x 2.5” SATA SSD – 4TB total

o 1 x XMC + 1 x PMC/XMC

o 45-100 Watts

o 28VDC – 50ms holdup option

o Lead-Free design

o 38999 connectors

o L240 x W180 x H80mm

Intel Core i7 Quad Core

Comprehensive IO as standard config


MPMC-9105 - Versatile Mission Computer

Flexible IO configuration in addition to the standard IO

o XMC (1) and PMC/XMC (1) sites unoccupied

o Each site supports x8 PCIe (Gen 2) for high bandwidth

o Pre-configured option:

– XMC-270 – Frame grabber

– XMC-710 – GPU for additional video outputs

o IPM site (1) – additional to XMC/PMC sites

– Curtiss-Wright small form factor mezzanine

– 2 x MIL-STD-1553

Operating System support

o Windows 7

o Linux

o VxWorks on request


Why is this of interest?


Deployable COTS Integrated Systems

Why you should be interested

– Pre-integrated

– Pre-qualified

– Technical Readiness Level 8 or 9

– No risk

– No development cost


Input/Output not an exact match to requirements? Customise!

o Designed to be customised

– Modify connector type and pinout

– Unused IO brought to the front panel

– Different IO types

– Additional IO cards

o Some cost – still low risk

– Implemented a variety of IO types

– EMC/ESD proven – cut/paste from IP “store”

– Wide Curtiss-Wright portfolio

– Trusted/proven Third-party suppliers

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://eis.apitech.com/power_line.asp&ei=u_tyVf_MB4SAUc7ag8AH&psig=AFQjCNGf00Xa1C76rGzHXl1sj8QTEzu5sg&ust=1433685167681463


Compute Compatibility

o CPU Architecture

– Compatible pinout between SBCs

*Not every IO combination

o Between Generations

– Compatible pinout with previous generation of cards

– Technology Insertion

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAMQjRw&url=http://androidviews.info/freescale/freescale-logo.html&ei=5f5yVcigLMOxUZWJgbAL&bvm=bv.95039771,d.d24&psig=AFQjCNHEX-tazrrx4v9G96Utj2A-Qxa1IA&ust=1433686117761787


Power Options

o Modular power and filter arrangement

– 28VDC

– 115VAC 50/60/400Hz Single Phase

– 115VAC 400Hz Three Phase

o No change to backplane routing or clearances required

o Low cost, low risk


Completely new requirements

o Different backplane architecture

o Different chassis

o More cost BUT still low risk

– Proven design approach

– Proven design methodology

– Proven manufacturing methods

– Experienced Engineers

– Experienced Program Management


About us


UK Systems Engineering Overview

o Focus: Rugged, High Performance, Deployable COTS systems

o Location: Letchworth Garden City, UK (1 hour from Heathrow Airport)

Letchworth, UK


Capabilities Overview

Program

Management

System Design

Expertise Electronic Design

Expertise

Packaging

Expertise

Custom

Backplanes

Qualification

Expertise Quality

Assurance

Level

>80% >80% L M H H H

60-80% 60-80% L M M H H

40-60% 40-60% L M M M H

20-40% 20-40% L L L M M

<20% <20% L L L L M

1 2 3 4 5

Level Cost

1Minimal or

no impact

2 <5%

3 5-7%

4 7-10%

5 >10%

and/or

M MODERATE

Some impact. Special

action may be required.

Additional managem,ent

attenton may be needed.

L LOW

Minimum impact. Normal

oversight needed to

ensure risk remains low.

Risk Rating

H HIGH

Significant impact on cost,

schedule, and/or

performance. Significant

action required. High

priority management

attention required.

Acceptable, no remaining margin

Unacceptable

Schedule

Minimal or no impact

Additional resources required; able to meet need

dates

Minor slip in key milestone; not able to meet need

dates

Major slip in key milestone, or critical path impacted

Can't achieve major program milestone

Highly Likely

Likely

Unlikely

Acceptable, with significant

reduction in margin

Likelihood of Occurrence

Likelihood

Technical Performance

RISK RATING GUIDE

and/or

Remote

Impact if Risk Occurs


Acceptable, with some reduction in

margin

Near Certainty

Lifeccycle

Services


Program Management

o Integrated Master Plans / Schedule

o Risk Management / Mitigation

o Quality Assurance

o Configuration Management

o Earn Value Management

o Financial Reporting

o Subcontract Administration

o Special Provisions

o Certification

Level

>80% >80% L M H H H

60-80% 60-80% L M M H H

40-60% 40-60% L M M M H

20-40% 20-40% L L L M M

<20% <20% L L L L M

1 2 3 4 5

Level Cost

1Minimal or

no impact

2 <5%

3 5-7%

4 7-10%

5 >10%

and/or

M MODERATE

Some impact. Special

action may be required.

Additional managem,ent

attenton may be needed.

L LOW

Minimum impact. Normal

oversight needed to

ensure risk remains low.

Risk Rating

H HIGH

Significant impact on cost,

schedule, and/or

performance. Significant

action required. High

priority management

attention required.

Acceptable, no remaining margin

Unacceptable

Schedule


Additional resources required; able to meet need

dates

Minor slip in key milestone; not able to meet need

dates

Major slip in key milestone, or critical path impacted

Can't achieve major program milestone

Highly Likely

Likely

Unlikely

Acceptable, with significant

reduction in margin

Likelihood of Occurrence

Likelihood

Technical Performance

RISK RATING GUIDE

and/or

Remote

Impact if Risk Occurs


Acceptable, with some reduction in

margin

Near Certainty

Integral Risk Management Integrated Master Plan / Schedule

Program Manager

Juan Batista

Mechanical EngSystems Eng

Project Engineer

David W. Lee

Electrical Eng Software

Subcontract

Tracy Cosgrave

Contract Admin

Darcel Pertusati

Finance

Sandee Baker

Operations

Bill Spires

SIV

Bill Ratliff

(Chassis)

John Wagstaff

(Backplane)

Sam Martinez

(Power Supply, EMI)

Luis Zaldana

(Schematic, NED)

Dave Newton

(Power Supply, EMI)

Ken Leo

(Systems Lead)

Glenn Shintaku

(ATP S/W)

Lester Arnold

(ATP/DVT)

Component Eng

Robert Rainen

Gary Bremer

(Mfg Eng.)

Phil Caudill

(Planner)

Franklin Sykes

Program Manager

Juan Batista

Mechanical EngSystems Eng

Project Engineer

David W. Lee

Electrical Eng Software

Subcontract

Tracy Cosgrave

Contract Admin

Darcel Pertusati

Finance

Sandee Baker

Operations

Bill Spires

SIV

Bill Ratliff

(Chassis)

John Wagstaff

(Backplane)

Sam Martinez

(Power Supply, EMI)

Luis Zaldana

(Schematic, NED)

Dave Newton

(Power Supply, EMI)

Ken Leo

(Systems Lead)

Glenn Shintaku

(ATP S/W)

Lester Arnold

(ATP/DVT)

Component Eng

Robert Rainen

Gary Bremer

(Mfg Eng.)

Phil Caudill

(Planner)

Franklin Sykes

Dedicated Program Organizations


System Design Expertise

o Requirements Analysis

– Requirements traceability

o System Architecture Design

– Quick turn architecture design based on application needs (performance, environment, physical constraints, etc.)

– Quickly accommodate varying I/O or processing needs using previous solutions

o Architecture trades studies

– Selection of the right products for the solution (COTS, point solution, etc.)

– Selection of internal data bus based on near term and long term needs

o Interconnect design/optimization

– Data path analysis, minimize bottlenecks, etc.

– Optimize physical layout of data paths

o Test Capability/Verification

– Test to application conditions

– Full verification of all input requirements

0 .275 .400 .600 .725 1.000


Electronic Design Expertise

o COTS circuit card customization

o Custom I/O circuit designs

o Custom power supplies

o High speed signal integrity analysis

o Tailored EMI filter design

LRU Level EMI Filtering

High Speed Signal Integrity Impedance Matched Traces

Shield/Guard Traces

Backplane Stack Shielding


Packaging Expertise

PLUGGABLE PWA

• Control

• HV Conditioning

BACKPLANE

CCM

QUICK DISCONNECT

FITTINGS

ACCESS COVERS

SEALANT

SEALANT

10.6 lbf

.0008”

Non-linear

contact

condition

deflection

sandwich mount

grommet mount

force

Custom Assemblies

SWaP Optimization

Solid Modeling

Finite Element

Analysis (FEA) Shock/Vibration Analysis

Thermal Design / Analysis

Convection / Conduction

Forced Air (Fans / ECS)

Liquid Cooled


Qualification Expertise

o Temperature – Operating, Storage, Touch

o Vibration – Mobility and transportation induced

o Shock – Bench Handling, Basic, Mobility, Gunfire, Rail

o Acceleration – Static and dynamic loads

o Altitude

o Humidity

o Ozone

o Salt Fog

o Fungus

o Seal Integrity

o Sand and Dust

o Cleaning Spray

o Submergence

o Hostile Environments - Ballistic Shock, Acoustic Blast Overpressure

o NBC Washdown

o HALT / HASS

o EMI

MIL-STD-810 AND DO-160 QUALIFICATION STANDARDS


Quality Assurance

o AS-9100 certified by UL

o Recertification Jul 2017

o DAOS Approved

o Supplier to UK-MOD/MAA

o Approved supplier for:

o Thales

o BAE Systems

o Boeing

o Raytheon

o Agusta

o Selex

o Airbus


Continuum Lifecycle Services

o Provides complete program lifecycle predictability through

– Configuration management/revision control services

– Component obsolescence management

– Long-term supply and repair programs

o Minimizes the risk of obsolescence for COTS-based programs by matching world

class technology with Curtiss-Wright’s capabilities in program and lifecycle

management

o Provides customers with the procurement cost and performance benefits of

COTS products, complemented by a complete lifecycle support package to

minimize overall program Total Cost of Ownership


Longevity of Supply/Repair

Longevity of Repair (PLUS)

First Production

Delivery

Early Access Units Active Production

(5-7 years)

LTB

(1+ year)

EOL

(1+ year)

Obsolete Status

LTB Notice

Issued

Last Delivery

w/o LOS

Last Repair

w/o LOR

Lifecycle Visibility

Longevity of Supply (PLUS)

COTS PLUS (Std Product)

Lifecycle Control (PLUS)

Variant Creation/Storage Services


PLUS Services

o Example customer clauses we are addressing in our PLUS services:

– Seller acknowledges its counterfeit risk mitigation obligations…the goods to be delivered hereunder shall be and only contain materials obtained directly from the original component manufacturer (OCM) or the original equipment manufacturer (OEM)

– To further mitigate the possibility of the inadvertent use of counterfeit parts, the Seller may only purchase components and parts procured directly from the Original Equipment Manufacturers (OEMs), through the OEM’s authorized distribution chain, or if though an Independent Distributor, Seller must provide to Buyer OEM documentation that authenticates traceability of the components to that applicable OEM

We are a Leader in Counterfeit Prevention in the A&D Market.

Most A&D Companies do NOT have Processes in Place to

Satisfy Counterfeit Requirements.


Rapid Prototype

Air-cooled or conduction-cooled systems quickly

integrated for hardware and software development while

the rugged/deployed units are being built.


Built from the Curtiss-Wright Catalog

Single Board

Computers

Digital Signal

Processing FPGA Networking

Graphics &

Video Software

3rd Party

Hardware

?


Summary

PCOTS System Slot Count &

Form Factor

Volume /

Dimensions Weight* Max PWR

@ 55° ** Built-in Features

COM-Express 240 x180 x 80 mm 5kg 90W

CP/NC

Flexible IO options

50 ms power hold up option

3U 1, 2 or 3 Slot

cPCI or VPX

180 x 215 x 124

mm

4-6kg 90W NC

280W CP

3U 5 or 6 Slot

VPX

144 x 215 x 345mm ~10kg 350W FC 28VDC, 115VAC 400 HZ single and

three-phase power supply options

50 ms power holdup

RMC removable storage

6U 5 Slot

VME. VXS or VPX

190.5 x 194 x 353

mm

<12kg 170W FC MIL-STD-704A

50 ms power hold up

6U 7 Slot (1”)

VME. VXS or VPX

287 x 210.5 x 420

mm

<20kg 600W FC 50 ms power hold up

MPMC-9315

MPMC-9325

MPMC-9335

MPMC-9675

MPMC-9105

MPMC-9655

MPMC-9355

MPMC-9365

* Fully populated system weight

** CP= Cold Plate, NC= Natural Convection, FC= Forced Convection (Fan), LC= Liquid Cooled


Take - Aways

o ITAR Free – Developed in the UK

o Curtiss-Wright COTS, but will integrate 3rd party or customer cards

o Large portfolio of existing solutions

o But can design “missing” functionality if required

o We design and develop in partnership with the customer


Q&A

Thank You

www.cwcdefense.com

[email protected]

Date post:	16-Aug-2015
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