COTS Journal by RTC Media

Tech Focus:

ATCA Blades and Systems Roundup

The Journal of Military Electronics & Computing

PLUS:

Distributed Power Evolves to Meet Complex Military Needs An RTC Group Publication

Efforts Gel for Soldier Communications and Networking

Volume 14 Number 11 November 2012

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The Journal of Military Electronics & Computing

New I/O and Format Standards for Box-Level Systems

CONTENTS November 2012

Volume 14

Number 11

SPECIAL FEATURE New I/O and Format Standards for Box-Level Systems

10 Small Form Factor System Approaches Vie for Military Mindshare Jeff Child

18 Creating Mobile Networks for Tactical Environments Kevin Holcomb, Cisco Systems and Mike Southworth, Parvus

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

Departments 6 Publisher’s Notebook The Dark Lords... 8

The Inside Track

COTS Products

66 Editorial Can’t Stop the Signal

24 MXM Standard Enables GPGPU Use in Rugged Systems Marc Couture, Mercury Computer Systems

28 Counterfeit Chips Cause Problems in Military Supply Chain Steve Martin, Components Direct

TECH RECON Power Conversion for High-Performance Computing

32 Complex Factors Drive Mil/Aero DC/DC Converter Choice Steve Butler, VPT

40 Distributed Power Evolves to Handle Diverse Needs Dave Proli, Marway Power Solutions

SYSTEM DEVELOPMENT Soldier and Vehicle Mounted Comms and Networking

44 Initiatives Come Together for Soldier and Vehicle Mounted Comms Jeff Child

TECHNOLOGY FOCUS ATCA Blades and Systems

50 ATCA Meets Rising Performance and Compute Density Needs Jeff Child

ATCA Blades and Systems Roundup Digital subscriptions available: cotsjournalonline.com

Coming in December See Page 64 On The Cover: The Virginia-class attack submarine has a command and control systems module (CCSM) that integrates all of the vessel’s systems—sensors, countermeasure technology, navigation and weapon control—and is based on open system architecture (OSA). Shown here, Pre-Commissioning Unit Mississippi (SSN 782) conducts alpha trials in the Atlantic Ocean. (U.S. Navy photo courtesy of General Dynamics Electric Boat)

U.S. Postal Service Statement of Ownership, Management and Circulation Required by 39 USC 3685. 1) Title of Publication: COTS Journal. 2) Publication Number 1526-4653. 3) Filing Date 11/01/2012. 4) Frequency of issue is monthly. 5) Number of issues published annually: 12. 6) Annual subscription price: n/a. 7) Complete Mailing Address of Known Offices of Publication: The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County. 8) Complete Mailing Address of Headquarters of General Office of Publisher: The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County, California. 9) Publisher: John Reardon, The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County, CA 92673. Editor: Jeff Child The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County. Managing Editor: Sandra Sillion: The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County, CA 92673. 10) Owners: John Reardon, Zoltan Hunor. The RTC Group; 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Orange County. 11) Known Bondholders Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities: None. 12) Tax Status: The purpose, function, and nonprofit status of this organization and the exempt status for federal income tax purposes have not changed during the preceding 12 months. 13) Publication Title: COTS Journal 14) Issue date for Circulation data: 9/1/2012. 15a) Extent and Nature of Circulation: average numbers of copies each issue during preceding 12 months (Net press run): 23,833. Number copies of single issue published nearest to filing date: (net press run) 24,000 15b) 1. Paid/requested outside-county mail subscriptions stated on form 3541. (Include advertiser¹s proof and exchange copies)/Average number copies each issue during 12 months: 20,867; number copies of single issue published nearest to filing date: 22,220 b)2. Paid in-county subscriptions (include advertiser¹s proof and exchange copies)/ average number copies each issue during preceding 12 months/number copies of single issue published nearest to filing date: n/a. b)3. Sales through dealers and carriers, street vendors, counter sales and other non-USPS paid distribution/average number copies each issue during preceding 12 months: n/a, number copies of single issue published nearest to filing date: n/a. b)4. Other classes mailed through the USPS/average number copies each issue during preceding 12 months: n/a, number copies of single issue published nearest to filing date: n/a. c) Total paid and/or requested circulation [sum of 15c. (1), (2), (3) average number copies each issue during preceding 12 months: 20,867 number copies of single issue published nearest to filing date: 22,220. d) Free distribution outside of the mail (carriers or other means)/ average number copies each issue during preceding 12 months: 1212; number copies of single issue published nearest to filing date: 1760. e) Total free distribution (sum of 15d. and 15e.)/ average number copies each issue during preceding 12 months: 1212, number copies of single issue published nearest to filing date: 1760. f) Total distribution (sum of 15 c and15e)/ average number copies each issue during preceding 12 months: 22,079 number copies of single issue published nearest to filing date: 23,980 g) Copies not distributed/ average number copies each issue during preceding 12 months: 20, number copies of single issue published nearest to filing date: 20 h) Total (sum of 15g and h)/ average number copies each issue during preceding 12 months: 22,099 number copies of single issue published nearest to filing date: 24,000 i) Percent paid and/or requested circulation (15c divided by 15g times 100)/ average number copies each issue during preceding 12 months: 94.5%, number copies of single issue published nearest to filing date: 92.7% 16) Publication of statement of ownership. Publication will be printed in November issue of this publication. 17) Signature and title of the editor, publisher, business manager or owner: Sandra Sillion (Managing Editor), Date: 10/23/2012. I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subjected to criminal sanctions (including fines and imprisonment)and/or civil sanctions(including multiple damages and civil penalties). Sandra Sillion Managing Editor

COTS Journal | November 2012

The Journal of Military Electronics & Computing

Publisher PRESIDENT John Reardon, johnr@rtcgroup.com PUBLISHER Pete Yeatman, mail@yeatmangroup.com

Editorial EDITOR-IN-CHIEF Jeff Child, jeffc@rtcgroup.com MANAGING EDITOR/ASSOCIATE PUBLISHER Sandra Sillion, sandras@rtcgroup.com COPY EDITOR Rochelle Cohn

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COTS Journal HOME OFFICE The RTC Group, 905 Calle Amanecer, Suite 250, San Clemente, CA 92673 Phone: (949) 226-2000 Fax: (949) 226-2050, www.rtcgroup.com Editorial office Jeff Child, Editor-in-Chief 20A Northwest Blvd., PMB#137, Nashua, NH 03063 Phone: (603) 429-8301 Published by THE RTC GROUP Copyright 2012, The RTC Group. Printed in the United States. All rights reserved. All related graphics are trademarks of The RTC Group. All other brand and product names are the property of their holders.

Publisher’s

NOTEBOOK The Dark Lords… …and, yes, there’s more than one. When this issue of COTS Journal hits the streets we’ll know who won the various elections and there will be euphoria amongst the winners and prophecies of doom from the losers. Irrespective of the outcome of the congressional and presidential elections, the defense industry will still be in turmoil with minimal hope that anything will change the situation any earlier than the end of the first quarter. Last February we were able to extol the virtues of finally getting a Defense Plan after two years. In March we did a casual review of what the new budget would impact; and in July we commented on “the dark lord”: Sequestration. As predicted in July, nothing has happened on the subject of Sequestration—well almost nothing. Let’s just do a quick review. Sequestration should kick in on January 3. Meanwhile we have a labor law in place called the WARN Act that requires defense contractors to provide a 90-day notice to their labor force of impending major labor reductions. Based on all current available information, any such WARN notices should be issued on November 3rd. This action would impact hundreds of thousands of voters and their families—and would definitely have an influence on any and all persons running for election. In an effort to avoid this situation, the Office of Management and Budget informed vendors that they could bill the government for costs if government contract actions forced them to impose these layoffs due to Sequestration—essentially a “Get out of Jail Free” card. This was followed by a “hint” from other government sources that although Sequestration was mandated to take effect on January 3rd, it would take time after that date to determine what programs to cut. This meant it was not necessary to initiate actions under the WARN Act on November 3rd. That also meant that if the courts were to initiate actions against a contractor for failing to give notice that the government would support their legal defense efforts—another “Get out of Jail Free” card. You have to wonder if there was an implication that if any prime acted in compliance with the WARN Act prior to the election they might be looked upon unfavorably by the government. For politicians the dark lord over this last year of politics has not been Sequestration but rather National Defense. Politicians up for election on both sides of the aisle have been willing to make general statements about the military’s future, but neither side has been willing to make specific statements of what they envisioned for it. Any specifics made by anyone up for election would then provide ammunition to the other side. As long as politicians only speak in generalities everyone just assumes it to be “party line” and nothing is lost…well, at least to the individ6

COTS Journal | November 2012

ual’s electability. That’s one reason nothing has yet to be done. Military procurement is in a state of paralysis. I’d like to sound more positive, but with the approval of the next military budget being delayed, Congress will have to put the Pentagon on a six-month continuing resolution, just extending the current budget. With the exception of short-term contracts, pre-approved upgrades and retrofits, it’s going to be extremely difficult for anyone to sign off on anything until we have clear leadership and direction by the government. The question is if and when this will be provided. Inaction by Congress prior to 9/11 was a major contributor for that catastrophe to develop. If this current inaction produces either an economic or political catastrophe, then I’m sure—just as after 9/11—Congress will again establish a committee to look for the causes outside of Congress rather than accept blame. Many people started to realize six years ago—some sooner— that something needed to be done to evaluate our defense mission and bring the military and its industrial base in line with that mission. It is the responsibility of government to bring change to the military in an orderly fashion with as little effect on national security and the nation’s economy as possible. Any reasonable observer would have to state that this has not happened. The politician’s dark lord National Defense should pass on November 6th, leaving only the dark lord Sequestration. And Sequestration will have to be addressed no later than Q1 of next year, irrespective of individual or collective election results of the White House or Congress. Without an early clear picture, industry will be forced to initiate individual corporate self-protection acts resulting in plant shutdowns and mandating major labor reductions throughout their organizations; changes much greater than those put into plans for the potential of Sequestration. These actions would severely impact the economy just as people are starting to feel that we may be on the verge of a recovery. Suppliers to the primes are still providing quotes and shipping on orders in place. Even here we’re seeing belt tightening and reluctant labor reductions. The environment for the military industrial base will change, and it will be our suppliers that will be asked to provide a quick response to the primes as they re-organize themselves.

Pete Yeatman, Publisher COTS Journal

The

INSIDE TRACK Army Awards General Dynamics $395 Million for Abrams Modernization The U.S. Army TACOM Contracting Command has awarded General Dynamics Land Systems an eight-year, $395 million contract for research, development and testing in preparation for the Abrams main battle tank Engineering Change Proposal 1 (ECP1) production. The contract has an initial value of $80 million over 12 months. There is no tank production work associated with this award. The Abrams ECP1 program is an engineering-development effort focused on integrating a group of system improvements into a single upgrade program for the M1A2 SEPv2 baseline tank (Figure 1). The objective of this research and development effort is to prepare the Abrams tank to accept additional Army-directed requirements in the future without impacting current vehicle performance. The Army plans to begin low rate initial production of tanks with ECP1 upgrades in 2017. ECP1 will reengineer internal systems to reduce size, weight and power requirements, creating capacity for additional upgrades in the future. The effort will include miniaturization of electronics; evolving to a Line Replaceable Module (LRM)based electronics architecture; and increasing electrical capacity through improved power generation, distribution and management.

Figure 1

The baseline M1A2 SEP tank modernization includes a commander’s independent thermal weapons station, position navigation equipment, improved fire control system and an improved AGT1500 turbine engine.

General Dynamics Land Systems, Sterling Heights, MI. (586) 825-4000. [www.gdls.com].

TECOM Tapped to Build Expeditionary Ground Control Station (EGCS) TECOM Industries has received an award of a firm fixed price contract from AAI Unmanned Aircraft Systems, an operating unit of Textron Systems, for approximately $12 million. The contract award is for the production of Expeditionary Ground Control Station (EGCS) portable command and control stations (Figure 2). The EGCS portable command and control stations will support AAI’s Aerosonde Small Unmanned Aircraft Systems (SUAS). This contract award is in support of the U.S. Navy Intelligence, Surveillance and Reconnaissance (ISR) services contract, encompassing both landand sea-based unmanned aircraft systems operations for the Navy, Marine Corps and Air Force.

The Expeditionary Ground Control Station provides command and control capabilities in a small, modular configuration. It

includes ruggedized workstations for the aircraft and payload operators, as well as a remote interface box and miniature ground data terminal. Man-portable, netcentric and built upon a scalable, open architecture, the Expeditionary Ground Control Station allows multiple unmanned platforms to be employed simultaneously. In addition, it provides on-the-move command and control capabilities for mission flexibility. TECOM Industries Thousand Oaks, CA. (805) 267-0100. [www.tecom-ind.com].

Figure 2

The Expeditionary Ground Control Station provides command and control capabilities in a small, modular configuration.

COTS Journal | November 2012

DARPA Contracts RFMD to Improve GaN RF Power Efficiency RF Micro Devices has been awarded a $2.1 million contract from the Defense Advanced Re-

search Projects Agency (DARPA) to enhance the thermal efficiency of gallium nitride (GaN) circuits used in high-power radar and other military systems. The award is in association with the Near Junction Thermal Transport (NJTT) effort of DARPA’s Thermal Management Technologies (TMT) program. The goal of the DARPA NJTT initiative is to achieve a 3x or greater improvement in power handling from GaN power amplifiers through improved thermal management of the near junction region. By combining thermally enhanced diamond substrates with RFMD’s industry-leading GaN-on-SiC high-power technology, RFMD expects to significantly improve power density and power handling capability. RFMD’s partners in the program include the Georgia Institute of Technology, Stanford Uni-

INSIDE TRACK

versity, Group4 Labs and Boeing. Georgia Tech is recognized for its leadership in thermal testing, modeling and micro Raman thermography. Stanford University is the world leader in thermal measurement of the critical interface layers within a transistor die. Group4 Labs is a pioneer in the development of diamond substrates. Finally, Boeing plans to evaluate the resulting technology to assess its projected impact on future defense systems. RFMD Greensboro, NC. (336) 664.1233. [www.rfmd.com]

ViaSat Receives SATCOM Services Award for Mobile Airborne Net ViaSat has received a multimillion dollar award from the U.S. government for broadband satellite services to support en route military aircraft. The all-IP service plan is designed to enable access to NIPR, SIPR and commercial Internet, as well as VoIP and VTC sessions during transcontinental or transoceanic flights. The initial one-year agreement is renewable for multiple years and includes options to add other aircraft, additional missions and supplemental service. For senior leadership, VIP and other broadband requirements, ViaSat is providing tiered service plans with a range of networking and

Figure 3

ArcLight terminals enable aircraft like the C-17 to conduct advanced ISR missions using ultra-small antennas.

performance levels. Most plans include worldwide roaming access as a complement to higher priority regional service. Terminals for the aircraft and on the ground will be based on ViaSat ArcLight technology, already on over 300 government aircraft with more than 500,000 flight hours. Military

aircraft using the technology include MC-12s, C-37s, C-130s and more recently larger aircraft such as the C-17 (Figure 3). The U.S. Special Operations Command (USSOCOM) was the first military organization to use patented ArcLight technology in a high-speed Ku-band network on its C-130 aircraft. ArcLight

terminals have enabled these and other aircraft to conduct advanced ISR missions using ultrasmall antennas with apertures under 12 inches in diameter. ViaSat Carlsbad, CA. (760) 476-2200. [www.viasat.com].

Military Market Watch Global Military Land Vehicles Market Faces Period of Transition According to Frost & Sullivan’s recent analysis, the global military land vehicles market is expected to witness a slow growth at a Compound Annual Growth Rate (CAGR) of 0.7 percent during 2012-2021 (Figure 4). The reason for the short-term slowdown is the decline in the Western defense markets. Currently the global military land vehicle market is dominated by the United States. However, expected cuts in major U.S. vehicle programs will result in a decline of 1.5 percent. Growth momentum will pick up again in the medium term as the APAC and Middle East markets reach procurement phase. The Western market will offer opportunities in the form Military Land Vehicles Market: Procurement Units Comparison, Global, 2012 and 2021 of upgrades and capability Increasing vehicle procurement numbers sustainment. Decreasing vehicle procurement numbers in the non-traditional defense markets The global military in the tradtional defense markets 6000 land vehicles market is undergoing a transition. 5000 Many countries have been forced to curtail their 4000 defense spending, and as a 3000 result, vehicle programs in the West are being delayed 2000 or are facing reduction in procurement numbers. 1000 Even though some notable land vehicle modernization 0 APAC Middle East Latin America Africa Europe North America programs are under devel2012 2021 opment and even deploySource: Frost & Sullivan Analysis ment, the market future is uncertain. Figure 4 On one hand counThe global military land vehicles market is expected to witness a slow growth at a tries in Europe and North America intend to get rid Compound Annual Growth Rate (CAGR) of 0.7 percent during 2012-2021. of legacy equipment, but the new vehicle procurement numbers in traditional Western defense markets will decline in the future. Meanwhile suppliers can no longer rely on one country and will be forced to focus on multiple markets in APAC and the Middle East to remain profitable. The changing nature of warfare and ever increasing cost of military operations are forcing military planners to rethink their future vehicle capabilities. Future military operations will be asymmetric, and forces will have to operate in urban environments. Mobility, modularity, protection and compatibility with other battlefield elements are key attributes for future vehicles to protect against contemporary threats in a cost-efficient way, according to the report. The need for agile vehicles will, in turn, boost demand for lightweight and hybrid vehicles. For further information about Frost & Sullivan’s new report “Global Military Land Vehicle Market,” contact Joanna Lewandowska, Corporate Communications, at joanna.lewandowska@frost.com. Frost & Sullivan, San Antonio, TX. (210) 348-1000. [www.frost.com]. November 2012 | COTS Journal

SPECIAL FEATURE New I/O and Format Standards for Box-Level Systems

COTS Journal | November 2012

Small Form Factor System Approaches Vie for Military Mindshare As demand rises for highly integrated, small form factor box-level systems, a slew of new alternatives have emerged. For the first time, standards-based rugged box systems are becoming a welcome reality for military platform developers. Jeff Child Editor-in-Chief

ugged box-level systems have become a staple in todayâ&#x20AC;&#x2122;s military embedded computing market. Because complete systems can now fit into a relatively small enclosed box-level system, such solutions are displacing traditional backplane-centric slot card system architectures in many military platforms. Slot-card technology upgrade programs are continuing to do brisk business, and such programs are expected to both expand and multiply. But the box-level system trend is dominating wherever size, weight and power are priority concerns. Rugged box-level systems span a wide range of formats, sizes and configurations. A number of new non-standard formats have emerged. Yet thereâ&#x20AC;&#x2122;s been little or no standardization on the format or I/O configurations between vendors of these products. The exception is in the so-called Small Form Factor segment, where a handful of VITA specifications have been underway for the past couple years.

Flat-Box Style Solutions Among the non-standard side of rugged box-systems, one relatively recent trend is the emergence of flat, enclosed box-level November 2012 | COTS Journal

SPECIAL FEATURE

Three Small Form Factor Initiatives

Figure 1

The A175 is a rugged, self-contained, EMC/EMI-protected Remote Interface Unit (RIU) I/O expansion subsystem that provides dynamic mission profile reprogramming. The subsystem can recognize its physical location within the platform and communicate with the main mission computer. systems that offer a much smaller footprint than ATR boxes for example. An example of this type of product is the A175 from Aitech Defense Systems (Figure 1). It’s a rugged, self-contained, EMC/EMIprotected Remote Interface Unit (RIU) I/O expansion subsystem that provides dynamic mission profile reprogramming. The subsystem uses platform location monitoring built into the onboard FPGA to recognize its physical location within the platform and communicate with the main mission computer, allowing the unit to alter its functionality “on-the-fly” or at power up. Also classified as a data concentrator unit (DCU), the A175 optimizes SWaP (size, weight and power) with dimensions of only 7” x 7” x 1.3” and a weight of less than 2.5 lbs (the approximate weight of one 6U conductioncooled VMEbus board), while drawing only 10W, or about the same as a standard household incandescent nightlight. A large variety of I/O interfaces and large user-programmable FPGAs make the A175 useful in highly data-centric environments such as a remote interface data concentrator or an engine and power train data monitor, as well as in vehicle prognostics data collection and condition-based maintenance (CBM). 12

COTS Journal | November 2012

On the standard-based side, three VITA draft specification efforts have been in the works in the past year or more: VITA 73, VITA 74 and VITA 75. Each are different in the vendors backing them and in their relative stages of product development and standardization. VITA 73, introduced and driven by PCI-Systems, offers a footprint 4.5 x 4 x 6 inches in an 8-slot configuration. It’s based off the VPX (VITA 46/48) electrical standard with no edge connectors used. It has a high-speed Gen2 PCIe backplane and offers 10 Gbyte/s module to backplane transfers. The spec has three passive backplane profiles and unlimited active backplane mezzanine capability. According to PCI-Systems, VITA 73 enables designers to connect and configure everything as they wish by only changing out the design of the backplane mezzanine. A designer can place anything from an FPGA to switches to optical module interconnects here to meet any customers demands without confusing them with backplane profiles for each and every different application. The VITA 73 workgroup does not define a chassis, only modules and backplanes. Describing only footprints, stackups and pin locations lets the integrator build chassis variants that fit into any space, all the way to making the chassis an integral structural component on any application. PCI-Systems offers a full line of VITA 73 products including the VITA 73 development kit (Figure 2). The kit enables system developers to begin development of systems according to the VITA 73 draft specification 0.5, which can be downloaded from the VITA website. The chassis is NEMA 4x rated and MIL-STD 810f tested if used with MIL connectors. The standard development kit is with 8 slots. Mechanical Carriers and general specs are included so you can begin design work immediately. Included is the eight-slot chassis, power supply, backplane, Rear I/O mezzanine carriers (in the standard “x” lightweight SATA version), and mechanical add-on carriers for

other slots. It has a PCIe Gen2 two part modular backplane with power supply slot on the left side and CPU slot on the right side. Four slots with x4 lane PCIe each are designed with Gen2 PCIe “NoStub” technology. Meanwhile VITA 74, created and driven by Themis Computers, provides a standard mechanical format for standardization of switched serial interconnects for small form factor applications, with specific concern taken to allow deployment in ruggedized environments. Now in the working group draft stage, the spec was inspired by the company’s NanoATR system. The unit has a fully sealed, conduction-cooled chassis with two 19 mm and two 12.5 mm payload slots, a storage slot, and a dedicated connector panel-PSU slot in a small, light footprint that optimizes size, weight, power and cooling. The front panel can be equipped with either circular MIL or standard rectangular connectors.

Rugged VITA 74 Approach Themis Computer’s most recent VITA 74 offering, announced late last month, is the NanoSWITCH small form factor network device (Figure 3). The NanoSWITCH device is targeted at military airborne and ground vehicle integration, and command and control. Optimized for high-density Gigabit Ethernet deployments, the device includes a diverse range of interfaces that meet access, aggregation, or small-network backbone-connectivity requirements. The NanoSWITCH device provides ten Gbit Ethernet ports that can operate at reduced rates of 10 and 100 Mbits and supports managed L2 and L3 functions. The device also includes a packet-processing engine along with a TCAM-based policy function for secure ingress egress access control. Also supported are sophisticated IPV4 and IPV6 routing and tunneling, and the latest L2 and L3 VPN services following IETF (VRF, RFC2547), IEEE (802.1ad, 802.1ag) and DSL Forum standards (Qin-Q), including OAM support for IEEE and RTU extensions.

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SPECIAL FEATURE

VITA 75: Collaboration More a collaborative effort than the other small form factor offerings, VITA 75 was sponsored by a group of vendors including Curtiss-Wright Controls Defense Solutions, CSPI, Elma Bustronic, GE Intelligent Platforms, General Dynamics Canada, Lockheed Martin, Mercury Computer Systems, TE Connectivity and Xellerix. The spec

MISSION-CRITICAL

has a base standard VITA 75.0 that describes overall subsystem attributes such as the envelope of the subsystem (box) and the organization of the dot specifications. A VITA 75.11 spec describes the standardization of front panels, connectors, I/O signal pin assignments and power for VITA 75 subsystems. Standardization of mounting and cooling

Figure 2

The VITA 73 development kit enables system developers to begin development of systems according to the VITA 73 draft spec 0.5. The chassis is NEMA 4x rated and MIL-STD 810f tested if used with MIL connectors. The standard development kit provides 8 slots.

PERFORMANCE-CRITICAL

Figure 3

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Untitled-3 1 COTS Journal | November 2012 14

3/1/12 9:41:55 AM

The NanoSWITCH provides ten Gbit Ethernet ports that can operate at reduced rates of 10 and 100 Mbits and supports managed L2 and L3 functions. The device also includes a packetprocessing engine along with a TCAMbased policy function for secure ingress egress access control. for free air-convection-cooled VITA 75 subsystems meanwhile is defined by VITA 75.20. And finally, the VITA 75.22 describes the standardization of mounting and cooling for conduction to a cold-plate-cooled VITA 75 subsystem. All these specifications are available for purchase from VITA as Draft Standard for Trial Use. Where VITA 75 diverges from VITA 73 and VITA 74 approaches is a focus on the box-level aspects such as size and the level of ruggedization of the operating environment. Also included in VITA 75

SPECIAL FEATURE

are the types of connectors to external devices. The focus is on enabling technology refresh at the box level. By keeping the physical size and connectors are constant, the same platform space can be used and the wiring harness can be retained. This enables system developers to balance I/O and processing upgrades. It’s too soon to tell whether any of

the new small form factor standards will dominate over another or whether they’ll co-exist. Each is a big step forward in a technology area that’s moved into the center of today’s military decision making—almost usurping single board computers—yet has lacked any sort of standards that users can leverage in their military platform designs.

Aitech Defense Systems Chatsworth, CA. (888) 248-3248. [www.rugged.com]. Curtiss-Wright Controls Defense Solutions Ashburn, VA. (703) 779-7800. [www.cwcdefense.com]. Extreme Engineering Solutions Middleton, WI. (608) 833-1155. [www.xes-inc.com]. GE Intelligent Platforms Charlottesville, VA. (800) 368-2738. [defense.ge-ip.com]. Mercury Computer Systems Chelmsford, MA. (866) 627-6951. [www.mc.com]. PCI Systems Silver Spring, MD. (301) 358-3621. [www.pcisystems.com].

Untitled-18 1 COTS Journal | November 2012 16

5/2/12 2:03:25 PM

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When sensor data volumes become overwhelming, rely on GE As multi-function sensor arrays become more plentiful on many platforms, valuable output may be rendered useless without the sensor-proximate, high performance computing and networking needed to turn disparate data into useful information. Our ruggedized COTS high performance embedded computing solutions are proven to manage massive data streams even in harsh military and aerospace environments. And our AXIS Advanced Multiprocessor Integrated Software optimized DSP and math libraries provide the performance necessary to reduce development costs and risks while shortening time-to-solution for turning sensor streams into actionable intelligence.

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SPECIAL FEATURE New I/O and Format Standards for Box-Level Systems

Creating Mobile Networks for Tactical Environments Creating a mobile ad hoc network for the military involves more than reliable advanced networking technologies. It also means packaging these networking capabilities into ruggedized hardware to withstand harsh military conditions. Kevin Holcomb, Technical Marketing Engineer, Cisco Systems Mike Southworth, Director of Marketing, Parvus

efense personnel rely on communications equipment to relay dynamic information, including biometrics, voice, location telemetry and real-time video to enhance situational awareness. The growing demand for increased collaboration on the battlefield is driving the need to network everything that walks, flies, drives, or sails. The delivery of IP-based data, voice and video to highly mobile soldiers, ground vehicles, aircraft and command centers is complicated by size, weight and power (SWaP) constraints, by radio bandwidth inefficiencies, and by the dynamic nature of emerging mobile operations. The highly variable nature of radio links means that the best route through the network can change rapidly. Visibility into radio events and real-time link conditions is critical to ensure optimal performance, especially for delay-sensitive traffic. As a result, there is a burgeoning demand for solutions that will deliver the right information, in the right place, at the right time, wherever military personnel are located. Mobile ad hoc networks (MANETs)—self-forming, self-healing clusters of mobile routers, or nodes, communicating over wireless 18

COTS Journal | November 2012

Simple Tactical Example

Low Bandwidth High Latency

Ethernet Ethernet

High Bandwidth

High Bandwidth Ethernet

Figure 1

Routing Protocol

To the routers, every link looks like 100 Mbit/s Ethernet in an “always up” condition. How does the router choose the best path? What if the radio links are constantly changing? links—are evolving to support the military’s wireless communication needs, and with the addition of ruggedization improvements, are ready for the battlefield. Advanced networking technologies, such as Cisco’s Radio Aware Rout-

ing (RAR) and IP Multiplexing, now available in Cisco IOS, are extending and optimizing enterprise networking infrastructure beyond the reach of traditional fixed-networks into mobile and embedded networking applications.

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SPECIAL FEATURE

Figure 2

The DuraMAR 5915 is a Cisco IOS-managed mobile router, which includes the latest Cisco IOS networking capabilities such as RAR and IP Multicasting.

Radio Aware Routing The most fundamental problem facing those who develop, deploy, or use networks employing Communications-onthe-Move has been how best to merge two very different worlds—IP routing and mobile radio—while taking advantage of the strengths of each. Mobile nodes typically communicate over wireless radio links, where bandwidth is at a premium. Radio link quality can vary suddenly and dramatically because of factors such as noise, fading, interference and power fluctuation, which in turn cause changes in the connection characteristics experienced at the IP routing layer. In such dynamic environments, Layer 3 IP routing concerns such as network convergence, route-cost calculation and congestion avoidance can become highly challenging (Figure 1). Effective Communications-on-theMove requires a method for radios to inform routers of current link conditions so that the router can make quick, intelligent routing decisions. As momentary blind spots in network connectivity 20

COTS Journal | November 2012

are undesirable in military operations, Cisco’s Radio Aware Routing, combined with third-party cooperating radios, has emerged as a viable solution. Cisco routers with RAR support, including the PCI104 form factor 5915 Embedded Services Routers, can use link metrics from radios, such as maximum theoretical data rate, current data rate, resources (such as battery power) and relative link quality when calculating route costs and determining the best route to a given neighbor. RAR also enables routers to recognize and adapt immediately to changes in network neighbor status based on radio feedback rather than waiting for routing protocol timeouts, delivering delay-sensitive traffic quickly and efficiently to those who need it most. Fast convergence and optimal route selection help ensure delivery of mission-critical, delay-sensitive traffic essential to effective Communications-on-the-Move.

IP Multiplexing Reduces SWaP For tactical networking, few initiatives are as important as decreasing

SWaP. From a networking perspective, combining as many functions as possible into one ruggedized unit not only reduces SWaP, but also overhead and support costs. Addressing this market need, Cisco developed IP Multiplexing, a licensed feature within Cisco IOS software that does not require any additional hardware and improves bandwidth efficiency on satellite links that have packets-per-second (pps) constraints. The solution improves bandwidth efficiency over a pps-constrained link by using multiplexing schemes to combine multiple small IP packets from a single stream, or multiple streams, into a large packet, and then sending this large packet over the pps-constrained link. A demultiplexing process is then executed by another Cisco router on the other end of the pps-constrained link. The solution can also reduce the CPU load associated with the IP Security (IPsec) encryption of many small packets; less overall packets means less IPsec header overhead, which also utilizes bandwidth more efficiently. Similar bandwidth efficiencies can also be achieved when using other types of encryption devices. IP Multiplexing is proving ideal for military users with satellite links that have pps constraints (typically around 2000 pps), and have traffic patterns that consist primarily of many small packets. Applications that create large numbers of small packets, such as VoIP, can fill the limited number of pps slots, limiting the throughput across the satellite link. In practical applications, IP Multiplexing has been demonstrated to increase the number of phone calls supported by a typical pps-constrained link by 20x. By adding this feature to the router software, Cisco has eliminated the need for a separate unit to perform this function, thus reducing the overall SWaP for the user.

Ruggedizing Mobile Networks With all the advancements made in mobile networking design to improve military efficiencies, the networks must first be ruggedized before being deployed in tactical situations. Through a Solution Technology Integration (STI)

SPECIAL FEATURE

partnership with Parvus Corporation, Cisco technologies are strengthened and hardened for use in all military platforms including ground tactical, aerial, missile defense, amphibious and satellite programs. To make the previously mentioned mobile networking capabilities viable for military use, they must be enclosed in subsystems that are SWaP-optimized as well as mechanically stable under extreme environmental conditions, and fully certified to MIL-STD-810G (thermal, shock, vibration, humidity, exposure to dust, water). Recently, Parvus announced the DuraMAR 5915 (Figure 2), a Cisco IOSmanaged mobile router that includes the latest Cisco IOS networking capabilities such as RAR and IP Multicasting. The following ruggedization and mechanical design procedures were implemented to ensure the latest developments in networking technology can be deployed in military applications.

In this example, imagine a radio path where enough bandwidth exists to transport video and voice traffic. Being a line of sight radio in a vehicle in motion, the path can become blocked or degraded (Figure A). With RAR, the traffic can be diverted to the back-up satellite path within milliseconds, and moreover, a QoS policy can be applied to allow the higher priority voice traffic to get through (in this example, the SATCOM link does not have enough bandwidth to reliably transfer the voice AND video). Without RAR, the router would have no way of knowing the line of sight radio path was lost EXCEPT by using routing protocol timeouts taking seconds…or even tens of seconds. With RAR, the radio notifies the router as soon as the link loss event occurs at the radio network layer. RAR provides a standard interface between radios and routers as well as improved performance in reacting to changes in the radio network.

Drop Video Continue Voice

64 Kbit/s Voice

SATCOM Link 512 Kbit/s

1 Mbit/s Video

Modular Network Subsystems A sought-after feature in many of today’s military networking subsystems is modularity. Modular designs provide superior longevity and flexibility as subassemblies can be upgraded in the future without a complete system redesign—an especially attractive feature to organizations faced with tightening budgets. For example, the DuraMAR 5915 incorporates a modular rugged enclosure with building block chassis segments that have pre-integrated PC/104 card sets, along with MIL connector interfaces and optimized thermal management devices. Depending on customer requirements, a particular functional card set can be configured for standalone use—for instance as a computer, router, or Ethernet switch—or attached to each other and consolidated within a single, compact mechanical solution. Compared to the traditional approach of working around a fixed-sized box with a pre-defined number of open card slots, this modular approach provides greater f lexibility, superior technology reuse and provisions for mechanical adaptations.

Ethernet 100 Mbit/s

Radio Link 2 Mbit/s

64 Kbit/s Voice

Figure A

Radio Aware Routing (RAR) offers a standard interface between radios and routers along with improved performance in reacting to changes in the radio network.

Thermal Management Techniques With heat issues often credited as the largest contributor to system failures, ruggedizing the DuraMAR 5915 to meet these thermal challenges was a critical step. Thermal management for defense applications has always been a challenge because of the high operating temperatures of the latest processors and dense packaging needed for environmental ruggedness. By incorporating conductioncooling techniques to maximize the heat transfer, the new DuraMAR unit can remain fanless and passively cooled with no moving parts, increasing the reliability of networking capabilities. Further identifying any potential thermal management issues, engineers

used thermal modeling software to analyze potential cooling issues, ensuring the ruggedized networking subsystem will meet specific military standards. Infrared imaging cameras were also used to locate any hot spots or thermal concerns. By running a variety of analyses, engineers can quickly determine where potential points of failure could exist when subjected to the extreme temperatures encountered by the military, and design the system to lessen the risk of component failure.

Ruggedizing for EMI Protection For any device to be military-ready, it must first prove itself through compliance testing to a number of Military November 2012 | COTS Journal

SPECIAL FEATURE

Figure 3

The Mine-Resistant Ambush Protected vehicle is an example of a tactical deployment that relies on ruggedized mobile hoc networks.

Standards (MIL-STDs). Of increasing importance are MIL-STD EMI filtering and power quality standards, such as MIL-STD-461, 1275 and 704,which provide protection against conducted and radiated emissions, input voltage inversion, voltage surges and overvoltage spikes. Compliance for the DuraMAR 5915 was accomplished through the implementation of a reverse voltage/overvoltage protection circuit and by implementing several improvements, such as designing a sealed enclosure with good EMI gaskets and creating proper test cables. Moreover, proper grounding techniques and good bonding between chassis surfaces were critical in creating an enclosure to act as a faraday cage. Since external power leads are typically unshielded in test and application, they can be the single largest point of noise and susceptibility. By including a welldesigned filter at the point where power enters the system, this ruggedized system complies with EMI requirements as the filter prevents internal noise from exiting the system and protects sensitive electronics from external noise that otherwise might enter the system. Military vehicles are an example where all these issue are significant (Figure 3).

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The fast convergence and optimal route selection available in today’s mobile ad hoc networks are helping ensure the satisfactory delivery of mission-critical, delay-sensitive traffic. When combined with proven ruggedization practices, mobile ad hoc networks are primed for tactical operations. As the military increasingly demands reductions in SWaP and increasing efficiency in delivering their rich stores of information, network solution providers and system integrators will continue to work together to provide ruggedized, mobile networks to ensure the military’s success. Parvus Salt Lake City, UT. (801) 483-1533. [www.parvus.com].

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SPECIAL FEATURE New I/O and Format Standards for Box-Level Systems

MXM Standard Enables GPGPU Use in Rugged Systems GPGPU technology offers attractive levels of performance for key military applications. The MXM standard packages GPGPUs for the SWaP-constrained requirements of the defense realm. Marc Couture, Director of Product Management Mercury Computer Systems

any products and technologies designed specifically for highvolume commercial applications are increasingly useful for embedded applications. But before they can add value they must be adapted for rugged, SWaP-constrained environments. While seemingly a daunting task, it is possible. Consider the advancement of compute power in the supercomputer market as new designs leveraged continually more powerful GPU compute nodes. Supercomputers have become exponentially more powerful by utilizing increasingly advanced technology, including GPUs, which debuted in the Top500. org most powerful supercomputers in 2008. The number one spot that year was claimed by the IBM Roadrunner QS22 BladeCenter cluster—and justly so. After all, it was the first supercomputer to sustain over 1 Petaflop. Debuting at #29 was the TSUBAME, which was created by the Tokyo Institute of Technology and was the first GPU-based supercomputer to break into the Top500 ranking. The following year, China’s Tianhe-1 was ranked #5 with the help of AMD Radeon HD 4870 GPUs. Seven months later (June 2010), China’s Nebulae came in at #2, using NVIDIA’s Tesla C2050. The 24

COTS Journal | November 2012

Relative GFLOP/Watt GPU Performance Improvement 3.0 2.5 2.0 1.5 1.0 0.5 0.0 2007–2008

2008–2009

2009–2010

2010–2011

2011–2012

Figure 1

GPU technology is evolving at such a rapid pace that the industry benefits from a significant bump in performance every year. Within a span of four years (from 2007-2008 to 20112012), the GFLOP/watt performance increased by almost a factor of 2.7x. trend continued in November 2010, as the Tianhe-1A—based on the same C2050 GPUs ranked #1 in the world, and Japan’s updated TSUBAME 2.0 ranked #4. In a most recent Top500 list, three out of the world’s top five supercomputers were built using GPUs. Admission into this exclusive club required a minimum performance of 2.287 peak theoretical Petaflops.

Applying Supercomputing in Embedded Within a span of two years, GPUbased computing progressed from simply cracking the preeminent computing list to dominating the top spots (Figure 1). This remarkable ascent was achieved in part through rapid advances in GPU compute performance. Leveraging shrinking semi-

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SPECIAL FEATURE

Figure 2

Through the use of industry-standard MXMs, embedded computer vendors can deliver the highest-performing GPU solution quickly, without having to conduct a lengthy redesign of the OpenVPX module.

Vibration Power Spectral Density (g2/Hz)

Random Vibration Profile 1 VITA 47 ECC1-4 (V3)

0.1

VITA 47 EAC4-6 (V2) 0.01 VITA 47 EAC1-3 (V1) 0.001

Standard MXM Connector

0.0001 1

100

1000

10000

Rugged MXM Connector +3dB

Vibration Frequency (Hz)

Figure 3

Random Sine Vibration Sweep (5-2000 Hz, 10G peak, 2 hour/axis). Performance of Standard and Mercury-developed Rugged MXM connector (solid lines) compared to the VITA 47 air-cooled (EAC) and conduction-cooled (ECC) standards (dashed lines). conductor process technologies—the latest push going from 40nm to 28nm— GPU vendors such as NVIDIA and AMD were able to squeeze more processors into a single die, while maintaining the same power envelope. Supercomputers tend to leapfrog each other in the performance domain by swapping out previous generation processing nodes for the latest generation processors, gaining the benefit of increased performance. Without this modular upgrade capability for processing cores, it would be very difficult for today’s top supercomputers to maintain their leadership positions. 26

COTS Journal | November 2012

In the embedded space, it’s not as straightforward. While GPUs are rapidly increasing in compute density, the lengthy design cycles required to build ruggedized boards out of GPU chips, plus the extensive qualification for SWaP-optimized systems, make it quite challenging for the embedded community to keep pace with the latest advances in GPU technology. Typically, by the time an embedded GPU solution is available, a new generation of GPUs is released, leaving the embedded community with a less-than-optimal GFLOP/ watt solution.

To maintain top performance and take advantage of the latest GPU releases, embedded applications must follow the same modular upgrade path that has been successfully used with supercomputers. Specifically, the only way to keep pace with the latest GPU technology is to leverage industry-standard plug-in modules developed for high-volume, commercial applications and to adapt them to perform in rugged, SWaP-constrained environments. The result is a higher performance per watt for each new generation of GPUs. With the help of Mobile PCI Express Modules (MXMs), an industry standard supported by both AMD/ATI and NVIDIA, it is now possible for embedded solutions to keep up with the latest generation of GPU technology. The MXM concept was born when laptop manufacturers needed an easy way to support different variants of GPU technologies without having to redesign the laptop motherboard. From a hardware perspective, laptop manufacturers such as HP and Dell are able to offer multiple variants based on performance, price and battery life, simply by changing out the GPU MXM module while using the exact same laptop motherboard.

Scalable Performance and Ruggedization Mercury Computer Systems adopted this scalable “rugged” approach for the embedded market through its OpenVPX GPU carrier card, which supports two GPU MXMs from either AMD or NVIDIA. Through the use of industrystandard MXMs, Mercury can deliver the highest-performing GPU solution quickly, without having to conduct a lengthy redesign of the OpenVPX module (Figure 2). Given that both the GPU MXM and 6U OpenVPX carrier modules are printed circuit boards (PCBs) designed with components using surface-mount technology, the boards by themselves will withstand the rigors of shock and vibration. The concern is whether or not the commercial MXM connectors that mate the two boards together and that are designed for modular flexibility in laptops, can withstand extreme environments. The answer

SPECIAL FEATURE

Mechanical Shock Levels 90 80

Standard MXM Connector

Rugged MXM Connector

Force (g)

60 50 40

ECC1-4 (conduction-cooled)

30 20

EAC1-6 (air-cooled)

10 0 X AXIS Figure 4

Y AXIS

Z AXIS

PRODUCT (REF.ANSI/VITA 47-2005 (R2007))

Mechanical Shock Levels for standard (red bar) and Mercury-developed rugged MXM connector (green bar) compared to the VITA 47 air-cooled (EAC) and conduction cooled (ECC) standards (dashed lines). is yes. While standard MXM connectors were not necessarily designed for rugged applications and are prone to long-term fretting challenges, Mercury has developed key mechanical technologies to support strict shock, vibration and cooling requirements (including conduction cooling), and has applied these technologies to both PCBs and MXM mating connectors. Figures 3 and 4 graph two mechanical tests that illustrate how standard and rugged MXM connectors perform in a representative harsh environment. One test is for random vibration and the other for mechanical shock. The connector results, represented by solid bars or lines, are compared to the VITA 47 standard, which is represented by dashed lines. The rugged MXM connector not only meets the VITA 47 specification, it performs beyond the requirements of the specification. In the case of random vibration, the rugged MXM connector is tested at +3 dB above the VITA 47 conduction-cooled specification (Figure 3). For mechanical shock testing, a force is applied on the rugged MXM connector in each of the x, y, z axis. Again, the rugged MXM connector exceeds the VITA 47 conductioncooled specification (Figure 4). Since the rugged MXM connector exceeds the mechanical specifications of VITA 47, MXMs can be deployed in harsh environments while offering numerous advan-

tages for use in embedded applications, as described below. Open Standards: The MXM standard is supported by both NVIDIA and AMD. Industry-wide Adoption: The MXM electrical and mechanical specification is an open standard. The highest performance laptops available from manufacturers such as HP and Dell rely on the MXM standard to quickly deliver a GPU-based laptop solution. This permits them to rapidly deliver the latest GPU technology from both AMD and NVIDIA without changing any other hardware component. Upgradeable and Scalable Performance: It is clear that GPU performance will increase as a higher density of parallel processing cores are stuffed into a die due to architectural and semiconductor process technology advances. For the embedded space, this translates into increasing GFLOPS/watt for each new generation of GPUs. Because MXMs are designed for modularity and follow an industry standard, developers can benefit from the latest generation GPUs simply by replacing the previous generation MXM. In addition, developers can support both NVIDIA and AMD GPUs without affecting the underlying system hardware, selecting the best GPU for the target application requirement. Rapid Access to Technology: The modular nature of the MXM standard

provides a quick path to accessing the latest MXM technology without having to wait for a board refresh cycle. The complex GPU System-on-Chip (SoC) and high-speed memory layout is already performed by GPU vendors. System developers can leverage this work and quickly provide updates for the latest deployable solutions. Ruggedization: A 6U OpenVPX GPU module consists of three main components: the GPU carrier card, developed by embedded solution providers; the GPU MXM daughter card; and the MXM connector mating the daughter card to the GPU carrier card. As is expected in the defense industry, each of these components meets the VITA 47 standard, with particular attention to the rugged MXM connector developed by Mercury that exceeds these standards. The modular nature of the MXM provides a rapid and reliable path to the latest GPU technology, and it is being used successfully in a number of defense programs. If more GPU processing horsepower is required, just like with supercomputers, a rapid upgrade path exists through MXM. Mercury Computer Systems Chelmsford, MA. (866) 627-6951. [www.mc.com]. November 2012 | COTS Journal

SPECIAL FEATURE New I/O and Format Standards for Box-Level Systems

Counterfeit Chips Cause Problems in Military Supply Chain The problem of counterfeit components finding their way into military supply chains continues to get worse. By being aware of how to identify the many counterfeit tactics used today, engineers can avoid problems. Steve Martin, Executive Vice President Components Direct

recent study by market research firm IHS found that over 12 million counterfeit components have entered the supply chain in just the past five years. Many of these parts make their way into mission-critical industries, such as defense and aerospace, where a malfunctioning counterfeit or non-conforming part can mean the difference between life and death. While the government and trade groups have made some progress toward regulating the supply chain to ensure that components are only sourced directly from the manufacturers or their franchised distributors, the problem has not abated. The militaryâ&#x20AC;&#x2122;s unique supply and demand lifecycles make it increasingly susceptible to the infiltration of counterfeit parts. While they often display telltale signs an engineer can identify when inspecting a component, most counterfeit parts are not easily distinguishable from authentic components. Identifying and prosecuting questionable sources and obtaining authentic parts from manufacturer-direct distributors are the best line of defense for restricting the flow of counterfeit components into the military distribution chain. 28

COTS Journal | November 2012

Counterfeit Components Threat There are several ways in which military-grade components such as integrated circuits, connectors and powermanagement devices are counterfeited, but five methods have emerged as the most often used. These methods vary widely in their sources of production, degree of difficulty in being identified, and performance when used in military applications, but all are a threat to missioncritical military and defense production. Empty shells: These are chips that have the same external form factor and top marks as authentic parts, but are empty inside. Since they are the most easily detectable, empty shells have not proven to be as much of a danger for military applications as more sophisticated counterfeit methods. If one was to make its way into the manufacturing process, assuming that testing was conducted, the result, while expensive and time-wasting, would not be a catastrophic failure. For this reason, counterfeiters have increasingly turned to less easily detectable methods. Pulls: Pulls may be legitimate parts that have been recycled and repackaged as new, authentic parts, often becoming damaged in the process. Discarded

electronics equipment such as laptop computers are collected and shipped to counterfeit centers, often in third-world countries where the process is not regulated and labor is inexpensive. Here, the products are disassembled in order to obtain the components. Printed circuit boards are heated so that the chips can be more easily â&#x20AC;&#x153;pulledâ&#x20AC;? off. Some have lot numbers altered to make identification impossible. There are many examples of roadside operations, where components are de-soldered in uncontrolled environments, then repackaged and sold as authentic military-grade components. The heating and handling processes often damage the component (Figure 1). If not detected, it can cause massive problems when utilized in military production. Blacktopping: Blacktopping is a process in which a thin black epoxy coating is applied to the top of a component so that a new part number and date code can be printed on it (Figure 2). This is typically done to non-military-grade components so that they can be reclassified as militarygrade. Because the blacktopped part has the same dimensions as the one it is intended to copy, it usually passes visual inspection. However, because it is not military-grade

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carded because they are obsolete products, test failures, or excess inventory. “Dumpster divers” make a business of retrieving these components and reselling them. They are also difficult to distinguish. In most of the above examples, if the counterfeit or non-conforming part is not detected and makes its way into the supply chain, the results can vary. Some items won’t work at all in initial testing, while others’ performances may degrade over time. The worst outcome is an abrupt and catastrophic failure of a counterfeit or non-conforming part. In a missioncritical application like a guidance system or a helicopter rotor controlled by a circuit board, the results will be disastrous.

Tracing Counterfeit Parts

Figure 1

Sometimes components are de-soldered in uncontrolled environments, then repackaged and sold as authentic military-grade components. The heating and handling processes often damage the component (see bottom chip). If not detected, this can cause massive problems when utilized in military production. (Source: Electronic Process Training and Consulting)

and is not designed to withstand the rigorous temperature, pressure and other conditions of military use, the counterfeit part often fails. Blacktopping can sometimes be detected through x-ray inspection, but it is prohibitively time-consuming and costly to inspect every part, so some make their way into production. Counterfeit parts can also be detected by examining their indents—cavities that are purposefully created during the mold process (Figure 3). Originally clean-edged, indents are difficult to protect during the counterfeiting process and often become unaligned or ragged. Indents are also affected by the sanding of original markings and by blacktopping, which fills the shallow cavities. Counterfeiters are becoming more aware of the need to maintain indents, and some have resorted to recreating them to pass visual inspection. 30

COTS Journal | November 2012

Uninspected/untested parts: These are legitimate components, not counterfeits, but are equally dangerous to military production. They are manufactured on the same assembly line as authentic parts. In this case, however, insiders at the packaging facility will run the assembly line after hours, producing parts that fall outside the official supply chain and that the insider then sells directly for his own profit. Because these non-conforming parts do not subsequently go through the manufacturer’s inspection and testing process, defective parts are not caught. These non-conforming parts are nearly impossible to detect from authentic parts, since production and markings are the same, and they pose a significant danger for military production. Sample/scrap parts: These are also legitimate components that have been dis-

Since detection methods are not foolproof, by the time an engineer is in possession of a part, it is sometimes too late for him to identify the part as counterfeit. Even if he does, there is little recourse, as the point of entry for the counterfeit part may be many steps away in the supply chain. Efforts are being made to stem the flow of counterfeit parts at or close to the sources, which vary throughout the supply chain. At one time, military-grade components were spec-manufactured directly for the military. Due to price pressures and the resulting outsourcing of parts production to other countries, many standards were relaxed. And despite some efforts at self-regulation, the volume of counterfeit parts has exploded, and lawmakers have taken notice.

Lawmakers Take Notice In November 2011 at the Senate Armed Services Committee hearings about the threat of counterfeit and “gray market” parts (those distributed through unauthorized channels) in American weapons systems, Senator John McCain declared that “the Chinese government can stop” their manufacture and sale. The hearings outlined specific technology that is finding its way into the military supply chain, which both exacerbates costs and threatens lives. For example, the U.S. Navy SH-60B helicopter, which provides surveillance and targeting support, was outfitted with counterfeit parts sourced from Raytheon through an equipment

SPECIAL FEATURE

Figure 2

Blacktopping involves a thin black epoxy coating applied to the top of a component so that a new part number and date code can be printed on it. (Source: Electronic Process Training and Consulting) subcontractor in Texas. The parts were traced through an additional four states and three countries, finally originating with a company in Shenzhen, China. The Department of Justice is also expanding its enforcement of certification and import/export compliance. An example is the case of VisionTech Components, a Florida-based distributor of components to the military, which was charged in 2011 with operating a $16 million counterfeiting operation. The supposedly “military-grade” components were actually counterfeit parts produced in Hong Kong and Mainland China. This is one of the first cases where employees of the counterfeit operation were arrested and sentenced to prison time, and it also illustrates the growing threat of U.S.based brokers that illegally import counterfeit parts, making them more difficult to detect. The May 2012 Senate report Inquiry into Counterfeit Electronics Parts in the Department of Defense Supply Chain found that 80% of counterfeit distributors were U.S.-based or had a U.S. business presence. Of the 20% that did not have a U.S. connection, many had a Canadian or UK presence, which is similarly unlikely to raise any red flags due to those countries’ status as military allies of the U.S. Investigators found that in almost all these cases, the U.S. or allied business was simply a transshipment point for distributors in well-known counterfeit centers. Of these,

Figure 3

Indents are cavities that are purposefully created during the mold process. Counterfeit parts can be detected by examining their indents. (Source: Electronic Process Training and Consulting) China is the source for over 70% of suspect parts, with others coming from known counterfeit centers such as India, Singapore and Mexico. The report also concludes that keeping counterfeit parts out of the supply chain is “increasingly difficult.”

Direct Manufacturer Traceability Although further legislation will enable better “crackdown” on countries most at fault, utilizing manufacturer authorized distributors is the best way to guarantee the authenticity of certified electronic components for mission-critical industries such as defense and aerospace. These distributors operate with established process controls and meet ISO 9001, ISO 14001 and ESD 20:20 certified warehouse and handling procedures. Today, franchised distributors such as Avnet or Components Direct possess the certified, standards-based infrastructure and experience in meeting the unique needs of mission-critical industries. The best guarantee against counterfeit parts is 100% direct traceability from the original manufacturers, eliminating the risks surrounding product quality, reliability and liability. Components Direct San Jose,CA. (408) 503-7770. [www.componentsdirect.com].

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November 2012 | COTS Journal

1/12/10 10:03:31 AM

TECH RECON Power Conversion for High-Performance Computing

Complex Factors Drive Mil/ Aero DC/DC Converter Choice Matching the proper DC/DC conversion technology with a military / aerospace design is less straightforward than may seem. A host of reliability, packaging and standards issues need to be considered. Steve Butler, Vice President of Engineering VPT

ost power systems for highreliability applications can be constructed from standard power modules. The typical scenario requires various DC output voltages and power levels and is usually met with standard DC/DC converters, EMI filters and accessory modules. A modular power system can be developed quicker and at lower cost than a full custom approach. This is true even for critical military applications, and reliability can often be as high as or higher than that of a custom design. Critical applications range from undersea to military ground to commercial and military avionics to deep space. DC/DC converters, point of load converters, EMI filters and other power modules are offered by various manufacturers, all claiming high reliability. The question is, how do you know what level of quality and reliability you are getting, and how do you select the correct level for your application?

Defining High Reliability High reliability is more than just a claim from the manufacturer. Highreliability DC/DC converters must meet certain standards for electrical and envi32

COTS Journal | November 2012

Figure 1

High-reliability COTS products are intended for cost-sensitive applications that impose harsh conditions and require high reliability including UAVs-based systems. ronmental performance as well as defined quality requirements. Those requirements depend on the reliability grade of the product. They can be divided into three categories: high-reliability COTS, Mil Spec and space grade.

The differences between these reliability grades can be subtle and can be concealed with clever marketing. The product literature must be studied carefully to determine exactly what the product is, and equally important,

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TECH RECON

what it is not. Basic things to look for are temperature rating, hermeticity, military specification compliance and a rigorous environmental qualification. The ultimate test of reliability beyond that is official qualification and certification by the U.S. Department of Defense.

High-Reliability COTS High-Reliability Commercial Off-the-Shelf (Hi-Rel COTS) DC/DC converters came about in response to acquisition reform spearheaded by Secretary of Defense William Perry in the 1990s, commonly referred to as “The Perry Initiative.” Perry’s COTS initiative sought to improve the Department of Defense’s access to state-of-the-art technology and reduce costs while foregoing military standards for commercial specifications and standards. The intent was not to use commercial hardware in military applications. Rather, the intent was to use commercially available or non-developmental hardware where possible and reduce the need for full Mil Spec compliance. Hi-Rel COTS products are intended for cost-sensitive applications that impose harsh conditions and require high reliability including avionics, UAVs (Figure 1), ground systems, ground vehicles, shipboard, weapons and other similar type applications. Several important considerations for COTS DC/DC converters are listed below. These characteristics will differ between manufacturers, so it is important to understand how that product can affect the final reliability of your system. Temperature Range: A wide operating temperature range is essential for most high-reliability systems. If the system is required to operate over a -40° to 85°C range, it is safest for the DC/DC converter to have a wider range than that. Full power, continuous operation to 100°C and startup at -55°C is standard for Hi-Rel COTS. Input Voltage: A wide input voltage range and high transient capability will greatly simplify system design, accommodating line drops, transients and 34

COTS Journal | November 2012

noise often present in military electrical power systems. No Optocouplers: It is difficult to design a linear optocoupler feedback circuit that can be shown with a worst case analysis to operate properly over the full temperature range and life required by Hi-Rel applications. Hi-Rel DC/DC converters typically use magnetic feedback isolation, usually in the

Figure 2

The Hi-Rel COTS converters, called the VPT Series, offer 5-100W of power with temps of -55° to +100°C, rugged environmental screening and six-sided metal packaging. form of a pulse transformer, whose properties vary little over temperature and life. Fixed Frequency: All DC/DC converters utilize a switching topology that generates EMI at the fundamental switching frequency. A fixed frequency is almost universally preferred over a variable frequency to simplify EMI compliance, input and output filter design, worst case analysis and interaction analysis with other parts of the system. Metal Packaging: A six-sided metal package reduces the radiated emissions of the DC/DC converter and the radiated susceptibility of the EMI filter. It will facilitate the system EMI design and greatly reduce the likelihood of board-level noise problems compared to open frame or plastic packaged DC/DC converters. Tin Whisker Mitigation Strategy: Tin whiskers are hair-like crystalline

structures that can grow from a pure tin finish, producing electrical shorts and device failures. Hi-Rel COTS products will invariably contain pure tin, often in the form of semiconductor or passive component termination finishes. A mitigation strategy that prohibits bright tin, uses tin/lead solder, restricts the use of fine pitch components and utilizes a conformal coating is essential. Compliance : When a DC/DC converter is designed into a critical application, it will be required to comply with system specifications. Common electrical specifications for DC/DC converters are MIL-STD-461 for EMI, MIL-STD-704 for aircraft electrical power and MIL-STD-1275 for military vehicle power. Always select DC/ DC converters and accessories that are designed to meet these specifications from the outset. Qualification: Hi-Rel COTS products are usually qualified to a manufacturer-specific qualification plan, which can include both military and commercial standards, such as MIL-STD-883, MIL-STD-810, MIL-STD-202 and JESD-22. In the absence of a governing military standard, the manufacturer’s qualification plan is critical. Look for a qualification plan that includes temperature cycling, mechanical shock, random vibration and a steady state temperature humidity life test. Quality System: Hi-Rel COTS products are assembled to commercial standards such as J-STD-001 and IPC-A-610. The manufacturer should have a quality system that is certified to ISO-9001, but experience with higher quality levels or additional certifications will directly benefit product quality. The manufacturer should also have an aggressive counterfeit parts control plan. There is one more important point to consider when selecting COTS DC/ DC converters. COTS does not imply using a commercial or telecom DC/ DC converter outside its recommended operating range, whether that range is voltage, temperature or another parameter. It also does not intend the

TECH RECON

upscreening of commercial DC/DC converters, which requires detailed knowledge of its internal stresses. Either of these practices can compromise reliability, including qualification failures, compliance issues, field failures due to vibration and temperature cycling, and erratic operation at cold temperatures. Instead, use a Hi-Rel COTS DC/DC converter specifically designed for avionics, military or other rugged applications. As an example, VPT’s Hi-Rel COTS DC/DC converter solution, the VPT Series, is based on VPT’s MILPRF-38534 hybrid converter designs

Logistics Agency (DLA) Land and Maritime, U.S. Department of Defense. A true military-grade DC/DC converter will be qualified to this specification and listed on a Standard Microcircuit Drawing (SMD). A true military-grade EMI filter will be listed on a DLA Land and Maritime Drawing. MIL-PRF-38534 governs not only the end product but also the components, materials and processes used to build it. This means the converter is built on a DLA qualified manufacturing line, it has passed a DLA approved qualification, and it is available to a DLA SMD. This strict process ensures that quality is

Figure 3

The military DV Series offers 1-120W of power with temps of -55° to +125°C and hermetic packaging to MIL-PRF-38534 with DLA SMDs.

with 20 years of heritage (Figure 2). The VPT Series meets the original intent of the Perry Initiative: It’s intended for military applications and is commercially available, but it is not fully Mil Spec compliant.

Defining True Mil Spec A true military-grade DC/DC converter is defined as a Mil Spec component. The governing specification for DC/DC converter modules is MIL-PRF-38534, General Specification for Hybrid Microcircuits. MIL-PRF-38534 certification is granted and audited by the Defense 36

COTS Journal | November 2012

built into the product from the start, not added later. Mil Spec DC/DC converters, governed by MIL-PRF-38534, are the default choice for any critical reliability application. Class H under MIL-PRF-38534 is the “go to” quality level for any application that imposes harsh environmental conditions or is required for high-reliability platforms, including f light-critical avionics, UAVs, ground vehicles, weapons, shipboard, high temperature, undersea, high altitude and other similar applications.

The military grade DC/DC converter brings several additional characteristics beyond what you will find in a COTS-grade product. Dictated by MIL-PRF-38534, these can drastically increase the long-term reliability of the system. Wide temperature range: MILPRF-38534 Class H devices are specified to operate continuously over the full military temperature range of -55° to +125°C. High temperature operation is enabled with bare die power semiconductors and high thermal conductivity ceramic and metal packaging. True continuous full-power 125°C operation is impossible to achieve with plastic encapsulated ICs and PCB construction. Make sure your supplier does not derate the power at 125°C. Hermetic Packaging: Qualified hybrid DC/DC converter modules are hermetically sealed, usually in welded metal packages with glass or ceramic seals. Hermeticity protects internal semiconductor devices from moisturerelated failures. Hermeticity is verified by MIL-STD-883 Method 1014 for fine and gross leak. Internal water vapor is monitored using MIL-STD-883 Method 1018. Hermeticity also allows the device to tolerate liquid cleaning processes during assembly. A true hermetic package should not be confused with packages that appear hermetic or with datasheets using ambiguous terms such as “sealed” or “near hermetic” that do not meet the hermetic definition of conditions in MIL-STD-883. No Pure Tin: MIL-PRF-38534 specifically prohibits the use of internal and external pure tin finishes, with >97% tin, which can produce tin whiskers. Ensure the manufacturer has in place an aggressive program to screen components and eliminate pure tin. Component Element Evaluation: All materials and components used in the DC/DC converter module are evaluated in accordance with MIL-PRF-38534 to verify they meet their specifications and are suitable for the intended application. Element evaluation is performed on each lot of material.

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TECH RECON

Figure 4

Designed for space use, the SV Series offers 6-120W of power with temps of -55° to +125°C and hermetic packaging to MIL-PRF-38534 Class K with DLA SMDs.

Qualification: True military DC/DC converter modules are qualified in accordance with MIL-PRF-38534. Test methods are dictated by MIL-STD-883. The qualification is reviewed and final approval is given by DLA, rather than that of a commercial manufacturer where the test plan and final approval are self-determined. Upon successful qualification, the DC/DC converter can be put on a DLA controlled SMD. Qualified Manufacturing Line: The qualified DC/DC converter will be built by a QML listed manufacturer on a qualified manufacturing line. All processes used in the manufacture of the product are qualified and audited by DLA. At the Mil Spec quality level, some of the characteristics mentioned for COTS products are taken as a given. Manufacturers are certified to ISO-9001 and above that, to MIL-PRF-38534. A counterfeit parts control plan is required. With regard to the products themselves, optocouplers are generally not used at this level, and fixed frequency and full six-sided metal shielding are standard. Mil standard compliance with regard to EMI and input voltage range and transient capability is also standard for this level of product. MIL-PRF-38534 qualified DC/DC converters can often be procured to a manufacturer datasheet with reduced 38

COTS Journal | November 2012

screening. This option can take advantage of the qualified manufacturing line and processes, and the reliability of the hermetic hybrid construction, without full Mil Spec compliance and therefore at a reduced cost. VPT’s hermetic hybrid DV Series of Avionics / Military DC/DC Converters are built on a DLA certified manufacturing line and are fully qualified to MIL-PRF-38534 class H and K (Figure 3).

Defining Space-Grade Converters Space-level hybrid DC/DC Converters, radiation tolerant or radiation hardened, are also governed by MILPRF-38534. The manufacturer will have a radiation hardness assurance plan certified by DLA to MIL-PRF-38534 Appendix G. Space-level DC/DC converters are available on SMDs and are typically procured to Class K. Space-grade DC/DC converters are intended for space applications including satellites, launch vehicles and other spacecraft from low earth orbit to deep space for both commercial and military applications. Typical characteristics of space-grade DC/DC converters include the following: Total Ionizing Dose (TID) radiation: All space applications will require some level of TID radiation guarantee, which is affected by shielding. For low earth orbits or where the DC/DC converter is adequately shielded, a 30 krad(Si) guar-

antee is often sufficient. For higher orbits or longer missions, a 100 krad(Si) guarantee may be required. TID performance should have been verified by the manufacturer with component test data or guarantees, worst case analysis and test data on the complete DC/DC converter. Enhanced Low Dose Rate Sensitivity (ELDRS): TID testing is normally performed at high dose rates to shorten test time and reduce test cost. However, testing at lower dose rates, closer to those seen in actual space environments, has shown increased sensitivity to radiation in some components, especially bipolar technologies. Modern space programs will almost certainly have an ELDRS requirement, usually to the same level as the TID requirement. Older DC/DC converter designs may not have an ELDRS guarantee, so be sure to inquire about this. ELDRS performance is proven through testing and analysis. Single Event Effects (SEE): Single event effects are caused by energetic particles that interact with the semiconductors internal to the DC/DC converter. SEE cannot be shielded and must be dealt with in the DC/DC converter design itself. SEE can cause simple transients on the output, dropout, shutdowns and restarts, latch offs or hard failures. An SEE rating of 44 MeV-cm2/mg covers most particles that a spacecraft may encounter in its lifetime and is sufficient for most programs. An SEE rating of 85 MeVcm2/mg covers essentially all particles a spacecraft will face over its lifespan. SEE performance is verified primarily with testing of the complete DC/DC converter. Testing should include high-temperature latch up testing. Worst Case and Radiation Analysis: A guarantee of end-of-life post-radiation performance of the DC/DC converter is usually required. The manufacturer will have completed a detailed worst case analysis for circuit performance including both end-of-life and radiation effects. MIL-PRF-38534 Class K: Space grade DC/DC converters are typically procured to MIL-PRF-38534 Class K. Class K includes additional element evaluation and additional screening beyond Class H.

TECH RECON

Most space level DC/DC converters are procured to an SMD. Procuring to a Class K SMD is less costly than procuring to a custom source control drawing (SCD). No Optocouplers: Although isolation of the feedback control in a DC/DC converter can be accomplished with an optocoupler operating in the linear region, the LED within an optocoupler is sensitive to displacement damage from proton radiation. A reliable space-grade DC/DC converter will not use optocouplers. Magnetic feedback, which is insensitive to radiation effects, should be used instead. Aerospace TOR: Some space programs are governed by the Aerospace Corporation report, “Technical Requirements for Electronic Parts, Materials, and Processes Used in Space and Launch Vehicles,” commonly referred to as the “TOR.” The TOR specifies additional quality requirements above and beyond MIL-PRF-38534 Class K. These requirements can often be met on a custom basis with a modified or modified flow Class K hybrid DC/DC converter. Space-level DC/DC converters are specially designed for radiation tolerance. Upscreening by test or even substituting a few radiation hardened components into an existing design will not meet the stringent analysis and testing requirements of modern space programs. VPT’s SV Series space-level DC/ DC converters are built on the electrical and mechanical designs of VPT’s proven DV Series of hybrid DC/DC converters, which already have an extensive space flight heritage and are backed up by full worst case analysis and radiation (Figure 4). Every SV Series DC/DC converter is guaranteed for TID including ELDRS. These products are ITAR controlled and subject to export restrictions.

plan to utilize in your design. Temperature range, performance specs, Mil Spec compliance and quality systems all must be considered. Design heritage and program heritage are also important factors to review. Select a reputable manufacturer with proven experience in high-reliability applications.

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Untitled-3 1

7/9/12 November 2012 | COTS Journal

3:51 PM

TECH RECON Power Conversion for High-Performance Computing

Distributed Power Evolves to Handle Diverse Needs As military systems get ever more complex, the task of configuring a power distribution system is only getting more challenging. Fortunately integrated power solutions are smoothing the way. Dave Proli, Director of Engineering Marway Power Solutions

hen it comes to power requirements, none are as crucial as those supporting the equipment of our armed forces. Whether on board a ship, aircraft, landbased vehicle or in the command center, keeping critical equipment operating at peak performance levels requires a reliable supply of power. When it comes to distributing that power within a facility, power distribution units (PDUs) are at the heart of making sure the proper voltage and current gets to downstream equipment reliably and efficiently. However, many installations of electronic equipment require more than one type of power. In these cases, the PDU design can be leveraged to handle one or more types of power conversion within a single chassis. PDUs are most often used to take a single facility power connection and distribute it out in a controlled and convenient manner to the various branch circuits needed to support a given application. However, in many cases one or more downstream devices require power in a different configuration than what is provided by the facility. In these cases, it is advantageous to use a PDU with power conversion features built in. 40

COTS Journal | November 2012

VAC

VAC 1

VDC

Conversion

VDC 1 Conversion

VAC 2

VAC

VAC Conversion

VDC 2

VDC

VDC Conversion

VDC

VAC

Figure 1

Shown here are examples of input voltages being distributed and converted for more than one downstream voltage requirement. Conversions can be mixed to accommodate virtually any voltage and current capacity need.

Many Different Scenarios In many types of equipment, the loads require different voltages or phase configurations from each other, or from the facility feed. In this situation, some type of power conversion is needed to

satisfy the discrepancy. This can be as simple as a step-down transformer to reduce the voltage provided from the facility so that it is compatible with the load. Sometimes a delta source is available, but the load(s) requires a wye supply.

TECH RECON

PDUs to feed power to each device in the system. Additionally, the required power configuration for each piece of equipment can vary from numerous AC configurations to various DC voltages. Since the PDU is a common point at which this equipment is tied together, it is often beneficial to resolve these challenges in the PDU itself. This is accomplished by using a PDU to help integrate the various connector styles and power configurations required by the equipment. The PDU itself should be configured to provide the appropriate mating connectors for each piece of equipment, thus avoiding the need for adapter cables. If DC power is required for some equipment, the PDU can also be configured with an internal power supply, thus eliminating the need for external power supplies. Both of these approaches help to simplify the overall system.

Power Distribution for Multiple Requirements

Figure 2

Marwayâ&#x20AC;&#x2122;s COTS Power Distribution design incorporates power distribution, conversion conditioning and control components inside a single chassis. Or the conversion may involve changing an AC source to a DC feed as needed by the load equipment. In legacy equipment, power conversion products were installed and wired as separate devices. But it is often convenient and cost-effective to implement the power conversion requirements inside the power distribution unit, especially when the requirements of the various loads differ from each other. Transformers can be integrated into the PDU to provide voltage scaling or phase reconfiguration. Power supplies can also be integrated to provide DC outputs when needed. And for situations where only a DC power source is available, DC to DC converters can be integrated to change the voltage as 42

COTS Journal | November 2012

needed, and in some cases inverters can even be added to provide AC outputs. With this philosophy, the PDU itself manages the task of accepting the available facility power, and then providing the specific power configuration needed by each load device without the need for external components. And of course PDUs can be specified to provide the specific connector type that is most convenient for each device in the system.

Challenge of Distributed Power Certainly, due to the large amount of equipment that must be plugged in and powered at a given location, power distribution is a perpetual challenge. Most installations utilize one or more

Power distribution units are usually thought of for branching single power sources to downstream equipment, all of which have a common power need (Figure 1). However, many installations of military electronic equipment require more than one type of power source. In these cases, there can be advantages to integrating more than one power source, and even power conversion, into a single PDU. Starting with AC and/or DC power sources, there are four types of power conversion. AC to AC Conversion: This is most often a straight conversion of one standard facility voltage to another voltage as needed for a specific application. There are three types of conversion. The first uses a simple step-up or step-down transformer for a single-phase power source to either step up (increase) or step down (decrease) the input voltage. The second type involves changing the phase configuration of a multi-phase power source. This is accomplished with a polyphase transformer. A common scenario is to start with a three-phase delta facility source such as 208 VAC 3É¸ and convert it to a 120/208 VAC wye. This is

TECH RECON

done to provide a neutral line to power equipment that requires it. Wye to delta and other configuration conversions are also possible. A third conversion type converts AC frequency. AC voltage normally operates at 50 or 60 Hz depending on the country where provided. There is also a 400 Hz power specification for many military and aerospace applications. From a conversion perspective, providing 400 Hz AC involves converting an AC source to DC, then back again to the higher frequency AC. However, it is also possible to use an electric motor coupled to a generator to create a 400 Hz power source. Both of these techniques involve components of significant size and cost, which are not typically suitable for PDU integration. Step up/down voltage conversion and power configuration changes are options integrated into PDUs where a transformer will be selected to meet the configuration, voltage and other requirements. AC to DC Conversion: Many types of military and avionics equipment require a stable DC power source. A power supply integrated into a PDU accepts common AC facility power and provides DC power as an alternative or additional power source for distribution. A switch-mode power supply is the most common technology used today. Multiple COTS products offer excellent efficiency and voltage regulation while also being available in lightweight configurations suitable for PDU integration. When specifying a solution for an EMI sensitive environment (for example a system needing to conform to MIL-STD-461), switch-mode supplies can be used. But often they need to be accompanied by a filter on the line side to prevent injecting the switch-mode noise into the supply line and causing conducted emissions problems. Linear power supplies may also be used. Multiple COTS products provide ample selection, but these tend to be larger, heavier and not as efficient as switch-mode supplies. However, linearmode supplies can provide an advantage for downstream equipment which

is very sensitive to the high-frequency noise created by switch-mode supplies. Lastly, we can also integrate a rectifier circuit directly into the PDU. This would typically be done where the DC power is used for signaling or control and not as a power source. DC to DC Conversion: If there is an available DC power source, a converter can be used to deliver one or more different output voltages for distribution to downstream systems. These are usually solid-state modules easily mounted inside the PDU. Thermal considerations may be a factor for packaging, as these systems can generate quite a bit of heat when power capacity gets large. And because these devices rely on switch-mode technology, care must be taken for EMI sensitive environments. Just as with power supplies, compliance with MILSTD-461 will likely require a DC filter on the input side of the converter. For very small loads, we can also integrate a simple regulator or voltage divider circuit directly into the PDU. This would typically be done where the DC power is used for signaling or control and not as a power source. DC to AC Conversion: For those circumstances where only DC power is available, a properly selected inverter can be used to provide AC power. Though not a very common need, this is done usually to provide a “convenience” outlet for ancillary AC needs in an otherwise DC-power environment. For higher power capacities, the inverter tends to get large enough that integration within most PDUs may not be desirable.

meet this goal and provides reduced space, reduced weight and reduced cost. There’s also the advantage of improved cable management.

Simplifying Complexity Today’s advanced PDUs, like those from Marway (Figure 2) offer a wide array of options for a variety of mission-critical military COTS applications. In addition to integrated power conversion, conditioning, control and monitoring are also key attributes that assure the highest level of power distribution and enable the convenience of a single solution to solve all power needs. The reduction of packaging space frees up space that would otherwise be consumed by one or more external power conditioning/conversion/control/monitor devices. The improvement in wire/ cable management reduces system complexity because all power is distributed by the PDU via appropriate connection types. There’s also a lower overall system cost by eliminating the cost of separate enclosures for separate external power conditioning/ conversion/ control/ monitor devices. Whether supporting critical equipment on land, air, sea or satellite-based, high-performance COTS-based power distribution and conversion are imperative to the highest level of operation uptime and mission success. Marway Power Santa Ana, CA. (714) 917-6200. [www.marway.com].

Advantages of Integration in PDUs In many military systems packaging space is extremely limited. Whether part of a ship-board, airborne, or land-based system, consolidation of multiple requirements into a smaller, simpler solution can provide great benefits. Ultimately, a reduction in packaging complexity and component redundancy is a goal of most COTS systems. The integration of power conversion into a PDU helps November 2012 | COTS Journal

SYSTEM DEVELOPMENT Soldier and Vehicle Mounted Comms and Networking

Initiatives Come Together for Solider and Vehicle Mounted Comms They’ve taken years to come together, but the DoD’s communications and network programs have emerged with deployable, effective gear for today’s ground and vehicle mounted soldiers. Jeff Child Editor-in-Chief

nder the broad umbrella of network-centric operations, the DoD continues to aim toward a goal of full interoperable operations. The segment of that involving outfitting ground soldiers and their vehicles with advanced communications and networking technologies can be rightly characterized as an uphill battle. These have taken nearly a decade to become real—with many hurdles along the way. For the DoD’s Joint Tactical Radio System (JTRS) program, many of the technology pieces are coming together with its organizational problems now in the past. Meanwhile, WIN-T—the Army’s on-the-move, high-speed, high-capability backbone communications network— is moving forward to become the network for reliable, secure and seamless video, data, imagery and voice services for the warfighters.

More Field Testing for JTRS The Joint Tactical Radio System (JTRS) program encompasses ground, airborne, vehicular, maritime and small form fit variants of the radio hardware; 17 Increment 1 waveforms for porting into the JTRS hardware; and network 44

COTS Journal | November 2012

Figure 1

The General Dynamics GD300 is an Android-based, full-rugged, wrist or body-worn computer. management applications. All JTRS products are being developed in a joint environment to ensure interoperability and the enhancement of hardware and software commonality and reus-

ability. The JTRS Ground Mobile Radio (GMR) program has been canceled, as the Army has revised its requirements and is seeking a more affordable solution. The FY2013 Budget funds the de-

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The Harris Falcon III AN/PRC-117G manpack is NSA certified for a Type-1 implementation of SRW. velopment, testing and manufacture of JTRS engineering development models (EDMs), low rate initial production (LRIP) and full rate production (FRP), to include hardware and software as well as sustainment of fielded radios and certified waveforms. Exemplifying the soldier-worn side of JTRS are devices like JTRS HMS Rif leman Radio (AN/PRC-154) and the General Dynamics Itronix GD300 wearable computer, both built by General Dynamics C4 Systems. In February both were deployed to Afghanistan with elements of the 75th Ranger Regiment. The Rangers are equipped with the Rif leman Radio for intra-squad communications, and with the GD300 running the Tactical Ground Reporting (TIGR) tactical “app,” to send text messages, situation reports and other information to individual solders. Feedback from planned operational assessments will be used to inform the future fielding of the Rif leman Radio to the Army as a whole. The JTRS HMS program office and the Ranger Regiment decided to conduct the operational assessment following three separate successful evaluations in 2011. The Rifleman Radio is part of the Joint Tactical Radio System (JTRS) Handheld, Manpack, Small Form Fit (HMS) radio family. The JTRS HMS Rifleman Radio provides reliable networked voice and data communications in austere and cluttered urban environments using the government’s Soldier Radio Waveform (SRW). The General Dynamics GD300 is an An46

COTS Journal | November 2012

Figure 3

Special Troops Battalion, 2nd Heavy Brigade Combat Team, 1st Armored Division, monitors tactical communication during the first phase of the Network Integration Evaluation (NIE 12.2). NIE 12.2 was a series of tests that evaluate emerging technology by using current Army equipment as a benchmark in order to assess and improve the Army’s tactical network. droid-based, full-rugged, wrist or bodyworn computer (Figure 1). When paired with the Rifleman Radio, the GD300 displays the position-location information of all soldiers in the network. Soldiers can also use the GD300 touchscreen display to place pictorial graphics and send maps to team members or their leaders using the TIGR “app.”

Satellite Comms on JTRS Defense communications technologies require not just tactical radios but also military satellite network-centric communications. In March, such efforts moved forward completing the first demonstration of secure voice and data communications via the Mobile User Objective System (MUOS) satellite-communications waveform. The demonstration used a Joint Tactical Radio System (JTRS) Handheld, Manpack, Small Form Fit (HMS) two-channel networking radio AN/PRC-155 manpack radio—running the MUOS waveform software—to transmit encrypted voice through a MUOSsatellite simulator to the MUOS ground station equipment.

MUOS is a military satellite-communications system that will enable secure, mobile networked communications worldwide, even in the most austere environments. Development of the MUOS waveform remains on track for completion in the third quarter of 2012. By year-end, the MUOS capability will be available on the AN/PRC-155 manpack radio, the first MUOS terminal that will be available to soldiers. General Dynamics developed the MUOS waveform using the PRC-155 manpack radio. With two channels in one radio, a soldier can use one channel for line-ofsight SINCGARS and SRW waveforms, and bridge to the second channel using the MUOS satellite system for unprecedented, dedicated global communications reach.

Soldier Radio Waveform Among the workhorse waveforms that make up JTRS is the Soldier Radio Waveform (SRW) for wideband tactical communications. In August, Harris was awarded a $26 million indefinite-delivery, indefinite-quantity contract to upgrade

SYSTEM DEVELOPMENT

and maintain the U.S. DoD Soldier Radio Waveform (SRW) for wideband tactical communications. The U.S. government will leverage Harris’ expertise in wideband networking to add greater capabilities to the open-standard SRW waveform software and make it more widely available to U.S. forces in next-generation tactical radios. Developed by the Joint Tactical Radio System (JTRS) program, SRW is a DoD voice and data waveform standard used to extend battlefield IP networks to the tactical edge. Under terms of the contract, Harris will deliver improved capabilities, maintenance and ongoing support for the waveform over five years. Key enhancements developed by Harris will be placed in the JTRS Program Information Repository (IR), which was established to facilitate software reuse in DoD tactical radios. The Harris Falcon III AN/PRC-117G manpack is NSA certified for a Type-1 implementation of SRW (Figure 2). Additionally, Harris has integrated the AN/PRC-117G and AN/PRC152A with the JTRS Joint Enterprise Network Manager to assure interoperability with tactical radios developed by other vendors.

On-the-Move Networking The Warfighter Information Network-Tactical (WIN-T) is the Army’s on-the-move, high-speed, high-capability backbone communications network, linking warfighters in the battlefield with the Global Information Grid (GIG). This network is intended to provide command, control, communications, computers, intelligence, surveillance and reconnaissance (C4ISR) support capabilities. The system is being developed as a network for reliable, secure and seamless video, data, imagery and voice services for the warfighters in the theater to enable decisive combat actions. The WIN-T program consists of four increments. Increment 1 (Inc 1) provides “networking at the halt” by upgrading the Joint Network Node (JNN) satellite capability to access the Ka-band defense Wideband Global Satellite (WGS). Increment 2 (Inc 2) pro-

vides initial networking on-the-move to the battlefield. Increment 3 (Inc 3) provides full networking on-the-move via air tier. Increment 4 (Inc 4) provides protected satellite communications onthe-move. The FY2013 Budget procures and continues to field WIN-T Inc 1 to the Army, with a Ka satellite upgrade. Fielding of Inc 1 will be completed by the end of 2QFY12, and Inc 1b Material Work Order (MWO) fielding will start in 4QFY12. WIN-T Inc 2 is currently in Limited Rate Initial Production (LRIP) in anticipation of its Initial Operational Test in FY2012 followed by Full Rate Production in FY2013. WIN-T Inc 3 continues in its Engineering, Manufacturing and Development (EMD) phase to deliver full networking on-the-move, including the airborne tier.

Increment 2 Authorized In recent months the DoD authorized the Army to continue fielding Warfighter Information NetworkTactical (WIN-T) Increment 2 (Inc 2) as part of the Army’s Capability Set 13 deployment. As a result, last month the Army has awarded General Dynamics C4 Systems a $346 million delivery order to procure the WIN-T Inc 2 network for additional Brigade Combat Teams and Division Headquarters units. Initial fielding of the WIN-T Inc 2 network as a key component of Capability Set 13 began Oct. 1 at Ft. Drum, NY and Ft. Polk, LA, with the training of two brigades of the 10th Mountain Division using previously procured equipment. Network modernization is the Army’s top priority, and WIN-T is its cornerstone program. WIN-T Inc 2 completed its Initial Operational Test and Evaluation (IOT&E) during the Army’s Network Integration Evaluation 12.2 this summer. The IOT&E was the largest tactical-network test of its kind, involving more than 4,000 soldiers dispersed over a 2,000-square-mile area. The soldier feedback following the evaluation enables General Dynamics to work with the Army to continue optimizing the system’s overall performance and effectiveness.

Field Testing JTRS and WIN-T Together Building on the extensive JTRS field test performed by the Army in 2011, this spring saw the largest deployment yet of the JTRS HMS Manpack and Rif leman Radios and the Warfighter Information Network-Tactical (WIN-T) network. The U.S. Army conducted realistic operational evaluations of the next generation of high-speed communications equipment developed for ground forces. WIN-T Increment 2 and the JTRS Manpack and Rif leman radios form the baseline for the Army’s on-the-move tactical network. These two networking programs of record completed operational testing at the Network Integration Exercise (NIE) 12.2 at White Sands Missile Range, NM, through the end of May (Figure 3). The PRC-155 Manpack Radio has been a part of all three NIE exercises and is the only Soldier Radio Waveform (SRW) radio undergoing Multi-service Operational Test and Evaluation at NIE 12.2. Over 700 JTRS HMS networking radios are deployed at NIE 12.2. General Dynamics is the prime contractor for the Warfighter Information Network-Tactical (WINT). Undergoing initial operational testing at NIE 12.2, WIN-T Increment 2 extends the network for Brigade Combat Teams down to company level and provides on-the-move capabilities to commanders and staff at division through company levels. General Dynamics C4 Systems Scottsdale, AZ. (480) 441-3033. [www.gdc4s.com]. Harris Melbourne, FL. (321) 727-9100. [www.harris.com].

November 2012 | COTS Journal

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Aitech’s rugged C660, the new 6U CompactPCI PICMG 2.16 compatible high-performance, single-slot Gigabit Ethernet switch, serves as a robust communications backbone for moving massive amounts of data around tightly coupled processing or I/O data concentrators, typically found in embedded telecom, military, aerospace and spacecraft applications.

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TECHNOLOGY FOCUS ATCA Blades and Systems

ATCA Meets Rising Performance and Compute Density Needs Though created for telecom initially, ATCA has won itself a strong niche in the military market. Shipborne and UAV control station systems are attracted to the size and features of ATCA that are unique to the form factor. Jeff Child Editor-in-Chief

n recent years ATCA has carved out a solid niche in military applications suited to its features. There’s no alternative aside from ATCA for a large-sized board form factor—larger than 6U slot card boards. Therefore ATCA shines in a military system where compute density and raw performance are top priorities. VME and CompactPCI are suited for managing heavy I/O, but their form factors offer limited networking and processing capability. The high-performance and bandwidth capabilities of ATCA bring the latest technologies to standards-based applications, such as command and control, aerospace surveillance, land mobile communications and maritime networks, which must collect and manage large amounts of data in real time. ATCA is the perfect fit for those requirements because it was specifically designed to address high-density network communications applications, and deliver up to eight times the performance of VPX and 40 times the performance of VME or cPCI. In addition, ATCA is a broadly adopted standard that has proven its in50

COTS Journal | November 2012

Figure 1

Northrop Grumman Space and Mission Systems was selected to develop and produce the Navy’s next-generation tactical afloat network, Consolidated Afloat Networks and Enterprise Services (CANES), which includes guided missile destroyer (DDG) variant first article. The guided-missile destroyer USS Porter (DDG 78) is shown here. teroperability through nearly six years of deployment in the communication segment. Among the major programs that have considered ATCA is the U.S. Navy’s Consolidated Afloat Networks and Enterprise Services (CANES). Earlier this year Northrop Grumman Space and Mission Systems Corporation was selected to develop and produce CANES (Figure 1). Open standards-based high-availability (HA) middleware on ATCA platforms provides further fault tolerance on an application level that allows continued operations of critical missions even with some hardware and software failures. This is one reason ATCA has gained entry into applications like UAV ground control stations. With ATCA it is easy to integrate new networks with legacy systems. Video and

audio are critical elements of these applications, which combine to create tremendous bandwidth requirements. Current ATCA technologies can fully support 10 Gbits of traffic on the system backplane to process voice and video traffic, while future ATCA solutions will handle 40 Gbits of traffic for video applications such as HD video. In August, PICMG, the standards body responsible for ATCA, announced the adoption and availability of the AdvancedTCA 3.1R2 specification. The new specification increases system bandwidth by four times, allowing a single chassis to handle data transfers up to 10 terabits per second for full mesh designs. This translates into transporting and switching over 2 million High Definition video channels at the same time.

TECHNOLOGY FOCUS: ATCA Blades and Systems Roundup ATCA Blade Sports Dual Intel Xeon Processors

ATCA Blade Serves Up Xeon E5-2600 Processor

ATCA Processor Blade Sports Intel Westmere-Based CPU

An ATCA processor blade features robust computing power, high throughput connectivity and accelerated packet processing capabilities. The aTCA-6250 from Adlink Technology incorporates dual 8-core Intel Xeon processors E5-2658 and E2648L (2.1 GHz/1.8 GHz) with the Intel C604 chipset, eight channels of DDR3 memory up to 128 Gbytes, and a 400W power supply subsystem. The aTCA-6250 also provides versatile connectivity, including dual 10GbE Fabric Interfaces, dual

Advantech is shipping ATCA blades employing the Intel Xeon processor E5-2600 family, formerly codenamed Romley-EP. Advantech’s MIC-5332 dual processor ATCA blade features increased performance, faster and adaptable I/O along with greater memory capacity—all requirements at the core of applications using Deep Packet Inspection (DPI) technology, such as policy enforcement,

Diversified Technology offers an ATCA solution that includes multiple processor blades, switches, systems and full integration capabilities. The ATC7000 is a dual socket node blade supporting 12 cores (24 simultaneous threads with HyperThreading enabled) of processing performance by way of dual Intel Xeon 5600 series “Westmere” processors. The ATC7000 provides support for up to 64 Gbyte memory and an optional RTM with additional network interface options. The board is a PICMG 3.0-compliant processor board that

GbE Base Interfaces, quad front panel GbE interfaces, dual front panel USB and COM ports, and onboard SATA DOM socket. Dual 10GbE ports and dual hot-swappable SAS bays on the optional ATCA R6270 Rear Transition Module (RTM) provide additional network throughput and storage capabilities. High-speed data transfer on the PICMG 3.1 Fabric Interface is enabled by a PCI Express 2.0-capable Intel 82599EB 10GbE controller, and Base Interface connectivity is provided by PCI Express 2.0-capable Intel 82576EB GbE controllers. Paired with the optional aTCA-R6270 RTM, the aTCA-6250 supports additional dual 10GbE SFP+ ports enabled by an Intel 82599ES 10GbE controller. The aTCA-6250 supports the Intel Data Plane Development Kit (Intel DPDK), a lightweight run-time environment for Intel architecture processors offering low overhead and runto-completion mode to maximize packet processing performance.

quality-of-service, mobile and video content optimization and subscriber analytics. Advantech’s MIC-5332 dual processor ATCA blade, one of several Advantech products announced today, comes with full support for the Intel Data Plane Development Kit (Intel DPDK) and Intel QuickAssist Technology to provide a seamless upgrade path for customer’s deploying the company’s previous two generations of Intel Xeon processor-based ATCA blades. The blade also incorporates a Fabric Mezzanine Module (FMM), a technology at the core of Advantech’s Customized COTS framework offering distinct differentiation advantages over COTS platforms and in-house designs. Advantech also offers their FWA-6510 Network Appliance Series using two Intel Xeon E5-2600 processors with 16 physical cores and offering outstanding I/O density scaling up to 64 Gbit Ethernet ports or 16 10GbE ports in a modular architecture. Network Module offerings allow many port configurations with or without network bypass, offload and acceleration.

provides high performance for LTE/4G and other next-generation wireless and wireline military systems. The ATC7000 boasts both a base fabric of 1 Gbit Ethernet and an extended 10 Gbit Ethernet fabric. The dual Intel Xeons are L5638, 2.0 GHz Hex Cores or dual Intel Xeon E5645, 2.4 GHz Hex Cores. The Intel 5520 (Tylersburg) chipset supports a QPI CPU bus and up to 64 Gbytes of registered DDR3 DRAM. There are two onboard solid state storage disks. I/O includes front panel I/O, two 1 Gbit Ethernet ports, a USB 2.0 port and serial and management LAN. The rear transition module has two SAS/SATA ports, two 1 Gbit Ethernet ports, a USB 2.0 port and serial and management LAN. The RTM supports TM7000 and TM7000HD. The board is compatible with the ATS1936 10G ATCA Switch and the ATS1160 1G ATCA Switch. The board is compatible with Targa-14 Series 14 Slot ATCA Systems, Targa-6 Series 6 Slot ATCA Systems and MRS-6 Mobile Rugged ATCA Systems. The board supports PICMG specification PICMG 3.1 Option 9.

ADLINK Technology San Jose, CA. (408) 360-0200 [www.adlinktech.com].

COTS Journal | November 2012

Advantech Irvine, CA. (949) 789-7178. [www.advantech.com].

Diversified Technology Ridgeland, MS. (800) 443-2667. [www.dtims.com].

ATCA Blades and Systems ROUNDUP

ATCA Platform Ready for Tough Field Deployment

High Density ATCA Blade Aims at IP Media Processing

ATCA SBC Blends Dual Xeon 5500s, 64 Gbyte RAM

A high-performance, multiprocessing system platform is designed to address computeintensive requirements in command and control data center applications. The ATCA7365 SystemPak from Elma Electronic combines the high-performance multiprocessing of an integrated ATCA platform with a ruggedized design capable of withstanding the high shock and vibration found in rugged mobile transport

The military’s Everything Over IP strategy has boosted demand for network gear aimed at IP-based media processing. An ATCA media processor from Emerson Network Power claims to have the highest density of digital signal processing (DSP) cores of any commercially available blade. With up to

An ATCA single board computer is designed for demanding military networks where it will enable significantly faster network performance than is currently possible. Typical applications include Control Plane functions for WiMAX, LTE (Long Term Evolution) and NGN (Next Generation Networks) networks. The A10200 ATCA SBC from GE Intelligent Platforms features two Intel Xeon Nehalem 5500 Series dual or quad core processors and up to 64 Gigabytes of DDR3 SDRAM memory,

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and it delivers a combination of unsurpassed applications. It has been successfully tested to 576 DSP cores and running sophisticated Get Connected is a new resource further exploration performance and low power dissipation. withstand a 36-inch drop shock test per MILmedia processing software, thefornew ATCAinto products, and companies. Whether your goal For LTE applications, the A10200 is suited STD-810G. 8320 willtechnologies enable communications equipment the latest company, speak Featuring three ATCA processor blades, is to research companies todatasheet simplify from and aaccelerate the directly for Mobility Management Entity (MME) and Engineer, or jump to a company's technical page, the Home Subscriber Server (HSS). MME has each with two 6-core Intel processors aswith an Application development and deployment of very highgoal of Get Connected is to put you in touch with the right resource. a stringent requirement for user handover standard, the ATCA7365 SystemPak offers density IP media processing applications. These Whichever level of service you require for whatever type of technology, latency, and the A10200 with its multiple high processing power that makes it an applications include session border controllers, Get Connected will help you connect with the companies and products processing cores, faster and less contentious ideal solution for use in rugged “comms media gateways and servers, media resource you are searching for. memory interfaces and high-speed Ethernet on the move” (COTM) applications such functions, mobile video optimization, video www.cotsjournalonline.com/getconnected connectivity options, is well suited for this as data center virtualization and networkcommunications and conferencing servers, and application. HSS holds the subscriber database centric environments. The new ATCA7365 interactive voice and video response systems. and requires fast and reliable storage options, platform has been successfully tested to meet The ATCA-8320 is the first ATCA blade in which the A10200 offers in the form of dual environmental requirements for operation in the market that uses Octasic’s asynchronous SAS drives. More demanding storage needs a command and control center. It is mounted DSP technology and also features Octasic’s can be addressed by the use of a customized in a lightweight transit case, can withstand a Vocallo MGW voice and video software. rearsolutions transition module (RTM) using dual Fibre 36-inch drop test on two axes, and can endureGet Connected The board’s unique “gateway-on-a-blade” with technology and companies providing now Channel interfaces. random vibration up to 25 Gs per MIL-STDarchitecture also makes it suitable for use as a Get Connected is a new resource for further exploration into products, technologies and companies. Whether your goal is to research th Also contributing to the A10200’s leading810G. Operating temperature is 3° to 37°C datasheetstand-alone gateway element, allowing a high from a company, speak directly with an Application Engineer, or jump to a company's technical page, the goal of Get Connect edge performance is its support for multiple in 5% to 95% non-condensing humidity. In in touch with degree of scalability from very small systems the right resource. Whichever level of service you require for whatever type of technology, and 10 Gigabit Ethernet addition to the three processor blades, theGet Connected up to very large. addition bank of up will help youIn connect with to theacompanies andtoproductsGigabit you are Ethernet searching for. interfaces, together with a Gigabit Ethernet standard configuration includes an Elma 24 Octasic OCT2224M DSPs, the ATCA-8320 www.cotsjournalonline.com/ge maintenance port for remote management and Type 11A, 6U six-slot ATCA chassis, a fully blade features an eight-core Freescale QorIQ troubleshooting. The A10200 benefits from its replicated mesh backplane, and a single system P4080 device for advanced IP flow management implementation of Intel’s new 82599 Ethernet management card with a provision for dual and distribution and a dual core Intel Core i7 controller, which includes a new 40 Gbit/s PCI management as well as redundant cooling and processor for local control and management Express interface and the ability to deliver up to power supplies. Four 300 Gbyte SAS (serialapplications. a 250% improvement in network throughput. attached SCSI) drives and a 10 Gigabit Ethernet Emerson Network Power fabric switch blade with RTM (real-time GE Intelligent Platforms Tempe, AZ. monitoring) are also part of the ready-to-run Charlottesville, VA. (602) 438-5720. unit.

Elma Electronic Fremont, CA (510) 656-3400. [www.elma.com].

Products

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(800) 368-2738. [defense.ge-ip.com].

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November 2012 | COTS Journal

ATCA Blades and Systems roundup

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ATCA Platform Supports Advanced Networking Schemes

ATCA GigE Switch Blade Puts RapidIO to Work

There’s more and more overlap between commercial communications infrastructure technologies and the requirements of backend military network systems. A 10 Gigabit Ethernet ATCA open modular platform is a starting point for system developers to build on a common platform a multitude of new equipment configurations using CPU, NPU, DSP, storage and specialized third-party ATCAbased line cards that meet the requirements for

The Ensemble BSW-201 AdvancedTCA RapidIO/GigE Switch Blade is the heart of the Ensemble AdvancedTCA (ATCA) Application Platform. This ATCA fabric and base switch blade provides a serial RapidIO fabric interface for ATCA systems with up to 14 slots, while also supporting Gigabit Ethernet communications via a GigE switch. The 10 Gbit/s system hub is ideal for next-generation base station, RNC and

3G, 4G LTE, WiMAX, GPON, IPTV and carrier cloud network elements. Each Kontron 10G ATCA open modular OM9141-10G platform includes redundant power entry modules, cooling infrastructure with hot swappable redundant fans, and second generation 10GbE switching capabilities. Shelf Management is built in with redundancy and interoperability tested Shelf Manager Cross Connects as per PICMG specification, and an optional COM Express dual-core module is available for centralized system management with a standards-based HPI implementation. A telco alarm panel provides telecom grade external system alarm notification. The mature and stable Kontron switch management software suite supports a comprehensive list of core features and protocols including, among others: QoS, IPv4 and IPv6 routing, IPv4/IPv6 multicast routing and selected protocols. A sampling of supported protocols includes: Ethernet multicast switching protocols and functions (such as GVRP, GARP, RSTP, LAG, IGMP Snooping, DiffServ, ACL); IPv4 unicast and multicast routing, unicast forwarding protocols & functions (such as ARP, OSPF, VRRP, RIP); multicast forwarding protocols & functions such as PIM-DM, PIMSM, DVMRP, IGMP; IPv6 unicast and multicast routing; and IPv6 unicast forwarding protocols and functions such as discovery, OSPFv3, MLD and 6to4/4to6 tunneling.

media gateway development. The BSW-201 Switch Blade is part of the Ensemble Serial RapidIO ATCA Platform, which is a standards-based solution built around the power, functionality and scalability of serial RapidIO, AdvancedMC, AdvancedTCA and MicroTCA. The platform supports a variety of I/O sources and heterogeneous processing endpoints, thereby reducing integration costs, improving efficiency and minimizing risks in design of next-generation applications. The blade sports three 8-port Tundra TSi578 serial RapidIO switches and supports 21 channels of Gigabit Ethernet communications via a GigE switch. Two mid-height, singlewidth, RapidIO-enabled AMC sites are provided along with an onboard MPC8548 PowerQUICC III host controller.

Kontron America Poway, CA. (858) 677-0877. [www.kontron.com].

Mercury Computer Systems Chelmsford, MA. (866) 627-6951. [www.mc.com].

ATCA Blades and Systems ROUNDUP

ATCA Platform Delivers 50 Percent Cost-per-Bit Reduction The next wave of military networking systems will need to show cost-effective design approaches. With that in mind, Radisys has added the T40, an ATCA-based 40G platform, to the Radisys T-Series family of ATCA solutions. Essential in helping operators profit

from the explosion of new smart devices, Radisys’ T40 addresses the operator’s need for efficient network elements that decrease delivery costs and improve performance. The T40 platform is a telecom-grade system built to Network Equipment Building System (NEBS) specifications. It is pre-integrated with the largest selection of ATCA blades, built on cutting-edge processors and software. Radisys’ T40 platform with high-density input/output (I/O) and throughput delivers the necessary connectivity critical for keeping up with increasing access speeds and is customizable to support specialized applications for any telecommunications environment, including deep packet inspection (DPI), security and Evolved Packet Core (EPC) functions. Radisys’ T40 platform provides the flexibility and performance critical for keeping up with increasing high-speed mobile data traffic. The T40 includes the T-Series Management Software, including platform management, load balancing and switch redundancy. It has 28 Intel processors with more than 1 Tbyte of memory in a chassis, and 160G of flexible I/O on the hub. The system has Radisys Trillium 3G and LTE protocol stacks, including passive monitoring versions.

RadiSys Hillsboro, OR. (503) 615-1100. [www.radisys.com].

ON I S S I M AL C I T I CR ICES DEV

Rugged Platform Targets Mission-Critical Tactical Operations The Defense Solutions Group of SANBlaze Technology offers the Rugged Compute Platform for Tactical Ops (RCP-Tactical Ops), a field deployable ruggedized ATCA Platform. The integrated application-ready platform incorporates superior computing density, inherent redundancy, class leading power efficiency, modularity and convenient serviceability, thus addressing both the COTS and SWaP-C requirements of Modular Open

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Systems Approach (MOSA) for new DoD acquisition programs. Target applications for the platform include: C4ISR, Mobile tactical operations centers (TOCs), Mobile network operations centers (NOCs), Net-centric converged solutions for voice, video and data, as well as ground, shipboard and airborne battle management and communications systems. The platform supports SIPERNet and NIPERNet. The Rugged Compute Platform for Tactical Ops is a flexible, open standards platform based on ATCA technology. It is a modular system of building blocks comprised of networked computing elements, best-in-class storage, and switch and payload blades that conform to the ATCA standard. The RCP-Tactical Ops is interoperable with a vast selection of RTM and aRTMs that mate with both SPARC and x86 processor blades. Choices include SVGA Video, Fibre Channel, USB, RS-232C 9-pin serial full Modem Control, and numerous SAS/SATA/SSD drive options. AMC choices include SAS, SATA, SSD, 10 Gbyte, Quad 1GE, FC, FCoE and PCI Express flash storage modules. Each platform features redundant 10 Gigabit Ethernet (10 Gbit/s) connections that are ideal for pipelined packet processing in virtualized OS environments. It boasts AC (120/240V) and DC (-48/60V) power supply options, and superior cooling capabilities.

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Intelligent I/O Communications Subsystem Shrinks to Nano Size

Get Connected mentioned in thisIndustries article. Reducing size, weight and power has become all important in today’s military system design world. Followingwith thatcompanies trend, North Atlantic www.cotsjournalonline.com/getconnected has announced the availability of the industry’s first integrated, compact, nano-sized subsystem with unprecedented I/O capabilities, which connects Get Connected with companies and products featured in this section. to existing platform Ethernet networks, making data available to any system on the network. The Nano Interface Unit (NIU1) easily adds sensor data www.cotsjournalonline.com/getconnected acquisition, distribution and communication interfaces to mission computers without expensive chassis and backplane redesign, for use in military and aerospace embedded applications. The NIU1 supports a wide selection of different Intelligent I/O, motion simulation/measurement and communications functions such as: A/D, D/A, TTL, RTD; Discrete I/O; Differential Transceiver, Synchro/Resolver/LVDT/RVDT Measurement, Simulation and Excitation; Strain Gage; Encoder; Dual Channel Dual Redundant BC/RT/MT MIL-STD-1553; high-speed Sync/Async RS232/422/423/485; ARINC 429/575 and CANBus. This approach provides a simple integration effort for dedicated I/O interface capability to existing or new applications, targeting specific interfacing requirements. and provides a complete I/O function subsystem. In addition, Power-over-Ethernet (PoE) is standard on the NIU1 making it easy to integrate where 28 VDC power isn’t readily available. Pricing in quantity 100 of the NIU1-P8 configured with four high-speed Sync/Async RS-232/422/423/485 serial ports, 28 VDC input, Power-overEthernet and Dual Gigabit Ethernet Ports starts at $2,568 each. North Atlantic Industries, Bohemia, NY. (631) 567-1100. [www.naii.com].

VPX Mass Storage Card Boots over SATA/SAS and PCIe

Embedded PC Marries Kintex7 FPGA and Configurable FMC I/O

Acromag’s new Xembedded XVPX-9756 is a SATA/SAS-bootable storage module, in a 3U form factor, suitable for use with any CPU. It supports dual slim SATA drives or a single 2.5” drive, either rotating or solid state. The module connects directly to the CPU via SATA signals or by means of PCI Express signals through an onboard controller. Given its connectivity options, the XVPX-9756 is an unequaled bootable storage solution. The operating range is 0 to 70°C or -40° to 85°C, dependent upon thermal options. The original product, not bootable over PCIe, was intended for use with their RAID controller module as a customized solution. However, the XVPX-9756 is a more versatile option. This module permits booting on SATA/SAS or PCIe signals, suiting either customized or standard backplanes, which allows all CPU boards to benefit. By employing dual slim SATA drives on the XVPX-9756, users can take advantage of a simple single-card RAID system. This drive module is RAID 0/1 configurable with the option to use RAID 0 striping for high data throughput, or RAID 1 mirroring so that data written on one disk drive is also simultaneously written to the other disk drive. List price is $1,345 for air-cooled, $2,025 for conductioncooled and $2,590 for REDI covers.

The FPGA mezzanine card (FMC) standard has caught on fast as technology for using FPGAs in a modular way. Innovative Integration has announced its SBC-K7. SBC-K7 combines an Atom or i7 PC running Windows/Linux/VxWorks with a Xilinx Kintex7 FPGA plus dual, industry-compliant FMC (FPGA mezzanine card) I/O sites. The SBC-K7 incorporates a Type-6 COM Express module that provides full PC software and hardware compatibility. Available variants support Intel dual-core Atom (consuming just 6W) or quad-core i7 processors (45W) and up to 16 Gbytes of DDR3 RAM. Gigabit Ethernet, USB, SATA, DisplayPort, touchscreen LCD, RS-232/485, ultra-lowjitter programmable sample clock generation and PCI Express connectivity are standard. The FPGA computing core features the Xilinx Kintex 7 FPGA family, from K325T to K410T. The K410T provides 1540 DSP MAC elements operating at up to 500 MHz and 400k logic cells. The FPGA core has two LPDDR2 DRAM memory banks providing 512 Mbyte x 16 bit and 1024 Mbyte x 32 bit, respectively. Two FMC I/O sites are provided. HPC (high-pin count)-compatible site 0 features 80 LVDS pairs connected to the FPGA, plus clocks, controls and eight lanes of PCIe gen2 connectivity. LPC-compatible site 1 provides eight gen2 PCIe lanes, 22 HB and 34 LB differential pairs pins.

Acromag, Wixom, MI. (248) 295-0310. [www.acromag.com].

Innovative Integration, Simi Valley, CA. (805) 578-4260. [www.innovative-dsp.com].

75W DC/DC Supply Offers DIN Adapter Calex has announced the 75W QCM Chassis Mount DC/DC converter now available with a DIN mount adapter. The QCM Series offers an input range of 18 to 36 VDC and 36 to 75 VDC with output voltages from 3.3 to 24 volts DC. The QCM is fully encapsulated with easily accessible recessed barrier strips. The package size is 2.65 x 4.20 x 1.00 inches. The QCM is fully isolated input to output. The isolation voltage is 1544 VDC. The operating temperature range of the QCM is -40° to +100°C. The storage temperature for all models is -40° to +120°C. All models feature remote ON/OFF as well as output voltage trim. The voltage trim range is +/-10%. The units are protected by reverse input voltage protection, pulse by pulse current limiting, dead short current limiting and over-temperature protection.

Calex, Concord, CA. (925) 687-4411. [www.calex.com]. 56

COTS Journal | November 2012

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Conduction Cooled OpenVPX Blade Boasts 1.5 Terabyte Storage Get Connected with companies and products featured in this section.

Critical I/O has announced the availability of its OpenVPX Conduction Cooled StoreEngine www.cotsjournalonline.com/getconnected scalable solid state storage blade. StoreEngine is a scalable storage server designed for highperformance embedded systems. StoreEngine provides the built-in capability to operate as a highbandwidth data recorder, embedded RAID or file server. The product is easily scalable in storage capacity and performance by simply adding additional StoreEngine blades that seamlessly work together. StoreEngine provides unmatched storage capability, ultrahigh-performance and high capacity all within a small size, weight and power (SWaP) footprint. StoreEngine is ideal for high-bandwidth data recording, file serving and general purpose RAID applications.

Critical I/O, Irvine, CA. (949) 553-2200. [www.criticalio.com].

Cable Adapter Card Supports Dual-Port PCIe Gen 3 PCI Express over cable marries the best of PCIe performance with the convenience of a cable interconnect scheme. One Stop Systems has introduced its latest PCIe x8 Gen 3 cable adapter. The versatile new dual-port adapter can be used as a switch in I/O expansion applications to fan out the PCIe signal to multiple I/O devices like storage devices and/or expansion enclosures. An optional mezzanine card can be added to the adapter card to add two more PCIe x8 cable connectors. The new adapters are also field-programmable for both host and target applications. The PCIe x8 cable adapter can also be used in networking applications with the addition of the ExpressNet 2.0 driver installed on each PC in the network. ExpressNet 2.0 is sold separately. The single board has one PCIe x16 edge connector and two PCIe x8 cable connectors on the slot cover. The switch is field-programmable to allow the different ports to receive or transmit data. Therefore, in an I/O expansion application, the card can receive data from one server and transmit it to two I/O points. In the networking application, the ports can be set to non-transparent (NT), allowing server-to-server communication. The PCIe x8 Gen 3 dual cable adapter lists for $1,595 and is available immediately. The four-port card consists of the two-port card with two cable connectors and a mezzanine card with two more cable connectors. This card supports communication between five servers with the addition of the OSS ExpressNet driver installed on each server. It can also be used in I/O expansion applications installed in a host server and cabled to four downstream end points. PCIe x8 Gen 3 quad cable adapter lists for $2,495.

SATA II 2.5-Inch SSD Provides up to 512 Gbytes of Storage With the Industrial SATA II solid state drive of the X 500 Series, Swissbit AG is extending its successful Industrial 2.5-inch SSD product line. This 2.5-inch storage solution achieves a data rate on SATA II of up to 260 Mbytes/s and an impressive 15,000 IOPS with 4k random accesses. Added to this are such features as NCQ, TRIM, the ATA security set and in-field update. To ensure the absolute reliability of the power fail protected X-500 Series, Swissbit combines sophisticated mechanisms and augments these with the S.M.A.R.T. (selfmonitoring, analysis and reporting technology) protocol, the lifetime monitoring tool or SDK and an efficient BCH-ECC (error correction code) unit. The X-500 Series is available in storage densities from 16 to 512 Gbytes as SLC (single level cell) and in MLC (multi level cell) versions.

Swissbit NA, Eagle, ID. (208) 938-4525. [www.swissbit.com].

One Stop Systems, Escondido, CA. (877) 438-2724. [www.onestopsystems.com].

240 Watt DC/DC Converter Achieves 94.5 Percent Efficiency Murata Power Solutionsâ&#x20AC;&#x2122; RBE series of fully isolated DC/DC converters are designed for a broad range of applications including 12 VDC intermediate bus architectures or distributed power-based applications. The RBE-12/20-D48 model will deliver a regulated 12V output at 240W from a nominal 48 VDC input. With an efficiency of 94.5 percent, most applications with forced air cooling will not require an external heat sink. For applications where there is no forced air cooling or the operating temperature range is high, an optional baseplate is available that will allow for attaching a heat sink. The RBE DC/DC converter has been designed to meet the requirements of the Distributed power Open Standards Alliance (DOSA) eighth-brick configuration measuring 58.42 x 22.86 x 10.16 mm (2.3 x 0.9 x 0.4 inches). Pricing in OEM quantities starts at $30.00.

Murata Power Solutions, Mansfield, MA. (508) 339-3000. [www.murata-ps.com]. November 2012 | COTS Journal

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6U OpenVPX SBC Features 3rd Gen CoreGet i7 Quad-Core Processor Connected with companies and products featured in this section.

Curtiss-Wright Controls Defense Solutions (CWCDS) www.cotsjournalonline.com/getconnected has announced the new VPX6-1957, a very high-performance rugged Intel Architecture-based OpenVPX processing engine that features the Intel 3rd Gen Core i7 Quad-Core (“Ivy Bridge”) processor, an unmatched range of high-speed I/O, and support for Intel AVX floating point libraries. Designed for optimal performance in harsh environments, the SBC’s latest generation Intel 22nm quad-core processor is supported with a 21 Gbyte/s (peak) DDR3 memory subsystem connected directly to the processor that maximizes data throughput to its AVX floating point units. The VPX6-1957 features the widest range of I/O support available on an Intel-based VPX SBC, including Serial RapidIO (SRIO), x16 PCIe, Gigabit Ethernet (GbE) and 10 GbE. With an unprecedented quantity of onboard cache memory, the SBC’s CPU is able to process larger vectors at peak rates than was possible with previous processor technologies. Available with either 16 or 32 Gbyte of flash, the VPX6-1957 is ideal for handling applications with demanding storage, data logging and sensor processing needs. The VPX6-1957 supports a wide variety of high-bandwidth fabrics including Serial RapidIO Gen2 and PCI Express Gen2 via the SBC’s P1 and P2 connectors. The VPX6-1957 also supports dual 10 GbE ports to enable connectivity with heterogeneous boards in a high-performance embedded computing (HPEC) environment. Ruggedized air-cooled, conduction-cooled and air flow through (AFT) variants are available.

Curtiss-Wright Controls Defense Solutions, Ashburn, VA. (703) 779-7800. [www.cwcdefense.com].

Rugged PDU Provides 300 Amps of Intelligent Power Control Data Device Corporation (DDC) has introduced its first Power Distribution Units (PDUs) in the RP-20S1X family of stackable, configurable devices for 28 VDC systems. The High Power Solid-State Power Controllers (SSPCs) provide four independent 75 amp load channels (300 amp total current capability) to distribute and control power to four independent subsystems. The PDUs offer channel paralleling for high current loads, and feature independent remote control of individual channels and groups. The rugged PDUs are available with MIL-DTL-38999 connectors or power stud interfaces and are tested to IP-67, MIL-STD-1275D, MIL-STD-461E and MIL-STD-810F. DDC’s Solid-State Power Controllers provide intelligent power management advantages such as accurate over-current protection, programmability, load monitoring and network control to simplify vehicle power management. DDC’s SSPCs provide Size, Weight and Power (SWaP) savings, with higher reliability and longer life compared to electromechanical circuit breakers and relays.

Data Device Corp., Bohemia, NY. (631) 567-5600. [www.ddc-web.com].

10G Media Converter Provides Point-to-Point Fiber Connection

256 Gbytes SATA SSDs Target Unique Requirements A new line of solid-state storage products includes 1.8- and 2.5-inch SATA, Slim SATA, mSATA and CFast form factors that are specifically designed for embedded systems that have unique capacity and workload requirements. The StorFly SSDs from Virtium are also optimized to meet the storage needs of a diverse range of embedded application form factors and usage models, which differ substantially from storage requirements of client or enterprise applications. Virtium’s new StorFly SSDs also provide the ruggedness and flexibility today’s embedded systems demand by offering extended temperature operation, low power at peak performance and wide range of capacity points. Virtium’s low-power StorFly 1.8- and 2.5-inch SATA, Slim SATA, mSATA and CFast products are available now in capacities ranging from 8 to 256 Gbytes.

Virtium, Rancho Santa Margarita, CA. (949) 888-2444. [www.virtium.com].

PCI Express Encoder Does Simultaneous Capture from 16 Inputs.

Aaxeon Technologies has announced the release of their newest unmanaged media converter, the first 10G media converter in their robust line. The FCU-5002SFP+ offers 2 SFP+ ports and supports 3R optical signal regeneration. The media converter provides a point-to-point fiber connection for long distance deployment with a reliable and stable link over 10 Gigabit devices. The FCU-5002-SFP+ complies with IEEE 802.3ae 10GBaseR, and is compatible with Aaxeon’s FCU-Rack16 Series. SFP plug and play modules are sold separately, and can reach up to distances of 40 km. The media converter’s 3R signal regeneration relays or regenerates the optical signal that may have been degraded during the transmission, therefore allowing the signal to reach longer distances without fear of instability or degradation.

A 16-channel H.264 PCI Express encoder can provide multiple output streams for each input video channel. With the Model 819 from Sensoray, this means two H.264 streams at independently set resolutions, frame rates, bitrates; a low frame rate JPEG stream, and an uncompressed (preview) stream. Each channel allows an individually configured multi-window character and graphics overlay and provides real-time motion data. An internal 16 x 4 analog crosspoint video switch is used to route any combination of four composite output channels to external video monitors. Individual scalers and deinterlacers facilitate optimal resolutions for each captured stream. The output streams may be formatted as elementary, MPEG-4 or transport stream. OEM quantity 2-9 pricing for the Model 819 is $785.

Aaxeon Technologies, Brea, CA. (714) 671-9000. [www.aaxeon.com].

Sensoray, Tigard, OR. (503) 684-8005. [www.sensoray.com].

COTS Journal | November 2012

COTS PRODUCTS Get Connected with companies and products featured in this section. www.cotsjournalonline.com/getconnected

ARM-Based Module Rides ULP-COM Factor Get Connected with companies and products featuredForm in this section.

A new ultra-low-power, low-profile ARM-based Computer-on-Module is specifically designed to extend the www.cotsjournalonline.com/getconnected proven and scalable Computer-on-Modules-based usage model to new modules with ARM and SoC processors. The ULP-COM-sAT30 from Kontron offers a low-profile solution that measures 82 mm x 50 mm and integrates the Nvidia Tegra 3 Quad Core ARM 1.2 GHz technology. The Kontron ULP-COM-sAT30 delivers an advanced, rugged and scalable building block for industrial tablet and imaging-centric applications where power consumption must be extremely low. The combination of the low-power Nvidia Tegra 3 ARM processor and ULP-COM’s optimized ARM/SoC pin-out definition enables designers to build fanless, passively cooled systems that dramatically reduce power consumption and costs of deployed systems.

Kontron, Poway, CA. (888) 294-4558. [www.kontron.com].

AMC Packet Processor Card Sports Broadcom XLP 300 Processor A new AMC card is a high-performance network processor-based acceleration card designed for use in ATCA- and MicroTCA-compliant systems. The RPM-100 from JumpGen Systems features the latest Broadcom XLP 300 Series processors with up to 1.4 GHz core frequency, enabling telecom customers to reach new levels of packet processing and deep packet inspection. The RPM-100 can be delivered with up to 16 Gbytes of dual-channel 72-bit wide DDR3 ECC memory. Two 10GigE SFP+ interfaces are provided on the front panel. There are two front panel SFP+ 10GigE sites with AMC.1 PCI Express to the backplane and an optional AMC.2 10G Ethernet to the backplane. The card comes in a full-size or mid-size form factor.

JumpGen Systems, Carlsbad, CA. (760) 931-7800. [www.jumpgen.com].

Revamped Development Tool Takes Extended Infrastructure Approach Complex software system development has gone through many changes over the years. Companies continue to change their business models to better fit the unique needs of the process. Taking a large leap along those lines, Real-Time Innovations (RTI) has released the next generation of its RTI Connext product family. With over 70 new features, the latest release of RTI Connext provides a much more versatile and scalable architecture for developing real-time and embedded applications that use a variety of enterprise integration patterns. New features include expanded enterprise integration patterns such as request-reply, which allows applications to receive information on demand, only when they need it. It also supports guaranteed delivery to ensure critical data gets delivered even in the presence of hardware and software failures; and application level acknowledgement, which ensures that critical data is processed completely, even if an application fails after the data was received. The new version also includes scalability enhancements for better performance across large-scale systems—as the number of subscribers increase, there is virtually no measurable degradation in performance. RTI has also announced a new Infrastructure Community (IC) licensing model, which, when combined with the next generation of the RTI Connext product family, offers customers an easy way to adopt common infrastructures within and across an organization to achieve cost, time-to-market and interoperability benefits. The next generation RTI Connext product family is available now with U.S. pricing ranging from $1,000 to $3,000 per developer or $500 to $1,500 per processor. Free-of-charge licenses are also available for evaluation and for qualified infrastructure communities, R&D projects and university use.

VME USB3 Carrier with Removable Drive Modules

Removable storage for VME systems

Fast USB3 transfer rates. Compatible with USB2

Drive modules rated for 100,000 mating cycles

Drive modules use COTs 2.5” SATA drives

SATA interface option also available

Red Rock Technologies, Inc. www.redrocktech.com 480Ͳ483Ͳ3777

Real-Time Innovations, Sunnyvale, CA. (408) 990-7400. [www.rti.com].

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November 2012 | COTS Journal

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COTS PRODUCTS Get Connected with companies and products featured in this section. www.cotsjournalonline.com/getconnected

VITA 62 3U Power Supply Can be Air or Conduction Cooled Get Connected with companies and products featured in this section.

A universal AC input VITA 62-compliant 6-channel 3Uwww.cotsjournalonline.com/getconnected OpenVPX power supply provides up to 400 watts output for air- or conduction-cooled systems. The VITA 62 power supply standard defines connector configuration, power generation requirements, utility, functionality and form factor requirements for power modules mating to a VPX backplane VITA 62 power supply slot. The PSC-6236 from Dawn VME products features a mission-critical wide temperature range at high power on a 1-inch pitch. Input range is 85-264 VAC, 47-400 Hz. The Dawn PSC-6236 can be special ordered to support high current single channel applications. The PSC-6236 offers current sharing with up to four power supplies in a system for outputs of 12V, 5V and 3.3V. Models are available for air cooled, conduction to bulkhead cooled and conduction to wedge lock cooled applications and configurations. The PSC-6236 is designed to be compliant with MILSTD-461, MIL-STD-704F and MIL-STD-810F. Dawn’s proprietary embedded RuSH Rugged System Health Monitor technology actively measures voltage, current and temperature on each rail for intelligent monitoring and protective control of critical power supply performance parameters. The PSC-6236 is interfaced to the Intelligent Platform Management Bus (IPMB) providing an I2C communication link with system cards. Onboard microprocessor and firmware provide real-time over voltage, over current and over temperature protective control, with factory programmable power sequencing and shutdown for all voltage rails.

Dawn VME Products, San Jose, CA. (510) 657-4444. [www.dawnvme.com].

Embedded Platform Speeds Development of Qseven-Based Systems

CompactPCI Ethernet Switch Is Suited for Harsh Environments

A new embedded platform is designed for the fast development of embedded systems with Qseven modules. The MSC Q7-MB-EP4 platform from MSC Embedded is designed to support the latest version (1.20) of the Qseven specification, and offers system integrators a ready-to-use carrier board with added functionality and I/O flexibility for easy customization. The MSC Q7-MB-EP4 embedded platform provides a broad range of the interfaces commonly used in embedded applications, such as a dual Gigabit LAN, five USB 2.0 ports (four external), an RS-232 (pin header), an AC97 audio port and Serial Advanced Technology Attachment (SATA) interfaces. CAN signals are also available via a special pin header. An RS-232 Debug port for a console output simplifies Linux software development, which is especially important for MSC’s Qseven modules using ARM technology. The platform supports the industrial temperature range of -40° to +85°C. The compact Qseven module is mounted via a proven MXM connection on the solder side of the MSC Q7-MB-EP4 baseboard, making it easy to thermally connect the Qseven heat spreader to a metal enclosure and provide fanless heat dissipation. Pricing for OEM quantities starts at $160.

Aitech Defense Systems offers the rugged C660, the first in a new series of high-performance, single-slot Gigabit Ethernet switches. The new 6U CompactPCI PICMG 2.16-compatible switch serves as a robust communications backbone for moving massive amounts of data around tightly coupled processing or I/O data concentrators, typically found in military, aerospace and spacecraft applications. This new full wire speed, non-blocking switch provides high-speed connectivity and traffic management for streaming video, audio and data. The C660 uses Marvell’s BobCat Gigabit Ethernet (BobCat-GE) switch controller and Marvell MTS management suite to perform Layer 2 and 3 routing and switching for 24 Gigabit Ethernet ports and up to four 10 Gigabit Ethernet ports. All switches will be available in vibration- and shock-resistant versions, compliant to commercial, rugged and military specifications with a maximum operating temperature range of -55° to +85°C. The mechanical and electrical design of these switches guarantees reliable operation over the full range of military and rugged application environments. The switches are available in industry-standard 0.8” pitch for the VME and CompactPCI versions. The VPX version comes in 0.8-, 0.85- and 1.0-inch pitch conduction-cooled or 1.0-inch pitch air-cooled form factors as well as in the VITA 48 (VPX REDI) format with ESD covers to support two level maintenance LRM requirements for the 0.85” pitch version.

MSC Embedded, San Bruno, CA. (650) 616-4068. [www.mscembedded.com].

Aitech Defense Systems, Chatsworth, CA. (888) 248-3248. [www.rugged.com].

Quad-Port Network Card Supports Bypass/Failover A new quad-port, two-segment bypass card uses the latest fiber switch module with board-to-board high-speed connection technology instead of an outside wired design. This new special fiber switch module design in the NIP-52240 from American Portwell can support easy deployment, longer product life and more reliable network traffic than other fiber bypass cards in the market. The NIP-52240 provides a complete intrusion prevention solution using a Portwelldesigned Generation 3 bypass function, which supports normal mode, bypass mode and open mode when the system crashes or encounters power failure. The NIP-52240 quad-ports GbE fiber bypass card is compatible with all of Portwell 1U/2U network security appliances.

American Portwell, Fremont, CA. (510) 403-3399. [www.portwell.com]. 60

COTS Journal | November 2012

COTS PRODUCTS

Atom-Based Fanless Computer Marries 3.5-Inch HDD and Rich I/O A new series of low-power fanless computers is based on the Intel Atom D2550 processor. The MXE-1300 series from Adlink Technology increases processing power by 44 percent and graphics performance by 90 percent over the previous Atom platform. The Adlink MXE-1300 series adapts a 3.5-inch standard height hard disk drive to a 210 x 170 x 58 mm containment. Featuring operating shock tolerance up to 100 G, an extended marketleading operating temperature range of -20° to 70°C, and unique thermal design with zero cable management requirements, the MXE-1300 provides reliable performance in mission-critical and harsh environments. The Adlink MXE-1300 supports rich I/O interfaces, including six USB ports, four serial ports, four digital I/Os, three Gigabit Ethernet ports and one each of Mini-PCIe and USIM slots for wireless operation.

ADLINK Technology, San Jose, CA. (408) 360-0200. [www.adlinktech.com].

PCI Express Mini Carrier Card Brings SIM Power to CompactPCI A robust PCI Express (PCIe) Mini Card carrier board features two PCIe Mini Card slots as standard with USB and PCI Express connections as well as two SIM card slots. The F223 from MEN Micro is a 3U CompactPCI board that can be used in virtually all wireless applications from GPS, WLAN and UMTS to GSM and HSDPA, and is expandable to 18 SIM slots. Each PCIe Mini Card incorporates two or three redundant SMA antenna connectors on the front panel to guarantee the most stable connection over different frequency ranges. The two PCI Express Mini Cards on the F223 can be reset and powered on and off separately without having to reset the whole system. The F223 is designed for -40° to +85°C operating temperature using qualified components and conformally coated for use in harsh and mobile environments. Pricing for the F223 is $514.

Join the growing number of programs that use LCR Electronics’ ATCA Chassis in the field for mission-critical computing. To learn more about LCR and our products, contact us today.

9 South Forest Avenue Norristown, PA 19401 (800) 527-4362 sales email: military-sales@lcr-inc.com

www.lcr-inc.com

MEN Micro, Abler, PA. (215) 542-9575. [www.menmicro.com].

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November 2012 | COTS Journal

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COTS PRODUCTS

Solid or Spin... we go both ways

Rugged COM Express Module Boasts Small Size, High Performance

Ruggedized VPX Driv Drive v e Storage S torage Module Whatever your drive mount criteria criteria, everyone knows the reputation reputation, value and endurance of Phoenix products. The new VP1-250X, compatible with both solid state or rotating drives, has direct point-to-point connectivity or uses the PCI Express interface with the on-board SATA controller. It is available in conduction cooled , conduction with REDI covers (VITA 48) and air cooled (shown) configurations.

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Intelligent Power

New Digital DC/DC from Calex

A conduction- or air-cooled Mini COM Express module (55 mm x 84 mm) supports the Freescale QorIQ P2041 quad-core processor. With a quad-core processor, 4 Gbytes of memory, a ruggedized design, and at less than 7.2 square inches, the XPedite5650 from Extreme Engineering Solutions can provide the processing subsystem for a wide range of industrial, communications and military applications where size, weight and power (SWaP) are critical. Designed and tested for harsh military, aerospace and industrial environments, the XPedite5650 includes enhancements above and beyond commercial COM Express modules. It provides a rugged and reliable COTS processor mezzanine solution that is designed and tested for operation from -40Â° to +85ÂşC. It includes additional mounting holes for increased structural integrity and provides extended shock and vibration capabilities for operation in harsh environments. Conduction-cooled and air-cooled applications are supported by a single design. Soldered-down memory replaces less rugged/reliable SO-DIMMs, and the module utilizes a tin-lead manufacturing process to mitigate tinwhisker effects. The RoHS-compliant process is also available. The XPedite5650 is a COM Express Mini form factor (55 mm x 84 mm) with an enhanced Type 10 pinout. It supports a Freescale QorIQ P2041 processor with four PowerPC e500mc cores at up to 1.5 GHz, 2 Gbytes or 4 Gbytes of up to DDR3-1333 ECC SDRAM, one x2 and two x1 PCI Express interfaces, two Gigabit Ethernet ports (one 1000BASE-T and one 1000BASE-X), two serial ports, two USB 2.0 ports and two SATA 3.0 Gbit/s ports. Linux, Wind River VxWorks and Green Hills INTEGRITY BSPs are available. Other RTOS solutions may be available on request.

Extreme Engineering Solutions, Middleton, WI. (608) 833-1155. [www.xes-inc.com].

Audio Controller Upgrade Boasts Flexible Options Cobham has added another removable legend panel to the N301A family of audio controllers, which enables installers to change control names without removing the controller from the cockpit panel. The N301A-3xx series includes a selection switch that allows operators to choose compatibility of the N301A between commercial and military headsets, making it one of their most popular audio components. Keeping the N301A within the aircraft minimizes downtime and saves money. Cobhamâ&#x20AC;&#x2122;s removable legends are available in kits with multiple text options, including international languages, and legends are customizable to suit any operator specification. The N301A is available in standard configurations, customized panel layouts, and with Night Vision Imaging System (NVIS) B & A with Blue/White backlighting colors.

WDE Series â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘

75 Watt Isolated 1/8 Brick 9 - 36 and 18 - 75 V Input Range Calex PowerTap â&#x201E;˘ Software Digital Power Management via Industry Standard PMBusâ&#x201E;˘ Interface User Friendly GUI Interface Conď&#x192;&#x17E;gurable Output Voltage and Fault Thresholds Internal Datalogging Capability Standard and Custom Solutions

800-542-3355 www.calex.com e-mail: sales @ calex.com

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COTS Journal | November 2012

Cobham Aerospace Communications, Prescott, AZ, (928) 708-1550. [www.cobham.com].

10/24/12 9:46 AM

Why Should Researching SBCs Be More Difficult Than Car Shopping? INTELLIGENTSYSTEMSSOURCE.COM IS A COMPARISON TOOL FOR DESIGN ENGINEERS LOOKING FOR CUSTOM AND OFF-THE- SHELF SBCS AND SYSTEM MODULES. Todayâ&#x20AC;&#x2122;s systems combine an array of very complex elements from multiple manufactures. To assist in these complex architectures, ISS has built a simple tool that will source products from an array of companies for a side by side comparison and provide purchase support.

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ADVERTISERS INDEX Get Connected with technology and companies providing solutions now Get Connected is a new resource for further exploration into products, technologies and companies. Whether your goal is to research the latest datasheet from a company, speak directly with an Application Engineer, or jump to a company's technical page, the goal of Get Connected is to put you in touch with the right resource. Whichever level of service you require for whatever type of technology, Get Connected will help you connect with the companies and products you are searching for.

www.cotsjournalonline.com/getconnected Company Page# Website

Company Page# Website

ACCES I/O Products, Inc................ 16...............................www.accesio.com

North Atlantic Industries, Inc.......... 13..................................... www.naii.com

Acromag.......................................... 39............................. www.acromag.com

Ocean Server Technology, Inc......... 31...................... www.ocean-server.com

Aries Electronics, Inc...................... 22.............................www.arieselec.com

Products Avionics Interface Technologies....... 5................................www.aviftech.com

End of Article62............................. www.phenxint.com Phoenix International......................

Ballard Technology, Inc................... 68......................... www.ballardtech.com

Pico Electronics, Inc........................ 55...................www.picoelectronics.com

Calex Mfg. Co., Inc.......................... 62...................................www.calex.com Get Connected with companies and

Real-Time & Embedded Get Connected with companies mentioned in this article. Computing Conference................... 65................................... www.rtecc.com

productsPlans, featured in this section. Chassis LLC......................... 29.....................www.chassis-plans.com www.cotsjournalonline.com/getconnected

www.cotsjournalonline.com/getconnected

Crenlo Cab Products, Inc................ 23................................. www.crenlo.com

Red Rock Technologies, Inc............ 59........................ www.redrocktech.com

Critical I/O....................................... 19............................. www.criticalio.com

RTD Embedded Technologies, Inc...... 2........................................www.rtd.com

Elma Bustronic................................. 7..................... www.elmabustronic.com

Rugged Box Gallery....... 48, 49......................................................... GetSystems Connected with companies mentioned in this article.

Get Connected companies featured in thiswww.xes-inc.com section. Extreme Engineeringwith Solutions, Inc...and .. 67.products ..............................

Sealevel Systems, Inc..................... 37.............................. www.sealevel.com

Galleon Embedded Computing....... 41.............................. ww.galleonec.com

SIE Computing Solutions, Inc......... 14................................. www.sie-cs.com

GE Intelligent Systems.................... 17.............................. defense.ge-ip.com

SynQor............................................ 35................................ www.synqor.com

Innovative Integration...................... 15................... www.innovative-dsp.com

TE Connectivity............................... 54............ www.thefutureunleashed.com

Intelligent Systems Source.............. 63......www.intelligentsystemssource.com

Trenton Systems, Inc....................... 45...................www.trentonsystems.com

LCR Electronics, Inc........................ 61.................................www.lcr-inc.com

WinSystems, Inc............................. 33........................ www.winsystems.com

www.cotsjournalonline.com/getconnected

Index

One Stop Systems, Inc.................... 51.................www.onestopsystems.com

www.cotsjournalonline.com/getconnected

Microsoft Windows Embedded Evolve 2012..................................... 25.................. www.evolve2012tour.com COTS Journal (ISSN#1526-4653) is published monthly at 905 Calle Amanecer, Suite 250, San Clemente, CA 92673. Periodicals Class postage paid at San Clemente and additional mailing offices. POSTMASTER: Send address changes to COTS Journal, 905 Calle Amanecer, Ste. 250, San Clemente, CA 92673. Ride along enclosed.

Coming Next Month Special Feature: Advanced Compute Payloads for Small UAVs The flight control, mission control and communications gear aboard Small UAVs—like the Raven, Dragon Eye, Shadow and Killer Bee—face some of the most rigorous size, weight and power restrictions. Selecting the right embedded electronics and embedded computers in those systems becomes a make or break decision. This section focuses on the electronics aboard UAVs under 1,320 pounds and range from Line-of-sight control UAVs up to those that fall under the “light sport aircraft” standards. Tech Recon: VPX and VME Tackle ISR Challenges In recent years demand for Intelligence, Surveillance and Reconnaissance (ISR) capabilities has driven a huge ramp-up in data collection capacity. While that shows no signs of slowing, the ability to process that data—in the form of radar captured video or images—presents major system design challenges for developers of military platforms. Makers of VME and VPX are easing these challenges with a variety of solutions that address the particular needs of moving image-based data at high speed and processing it for the demanding real-time needs of military applications. System Development: Open Architecture Computing in Airborne Recon Platforms Designing and re-designing a computing payload system for military aircraft is very costly—especially when you factor in upgrades. By using open architecture designs, new functionality and upgraded computing systems can be switched out every couple of years without a complete redesign of the aircraft. This section looks at the technologies and products available that supports this approach. Tech Focus: XMC and FMC Boards XMCs are becoming entrenched as the natural successor to PMC as the leading mezzanine form factor in military applications. Meanwhile the VITA FPGA Mezzanine Card (FMC) specification defines an I/O mezzanine module designed to work intimately with an FPGA. FMC modules enable I/O devices that reside on an industry standard (VITA 57) mezzanine card to be attached to and directly controlled by FPGAs that reside on a host board. This Tech Focus section updates readers on these trends and provides a product album of representative XMC and FMC products. 64

COTS Journal | November 2012

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COTS

EDITORIAL Jeff Child, Editor-in-Chief

Can’t Stop the Signal

he devastating effects of Hurricane Sandy last month are still hard to process. My thoughts are with those who suffered and continue to suffer from the storm’s destruction—especially those hardest hit in New York and New Jersey. I urge everyone to donate if they can to the various relief organizations that are helping those affected pick up the pieces. Though of course nothing compares to the tragic loss of life and property caused by the hurricane, the storm had a number of ripple effects that hit many industries including ours. Among these was the cancellation of MILCOM 2012. With numerous airlines having canceled flights and states of emergency already declared, AFCEA International and IEEE Communications Society together with the MILCOM Conference Board made the decision to cancel the event. Canceling a major event such as this is never an easy choice. But according to conference spokespeople, as much as 40 percent of attendees, speakers and exhibitors expected to have their travel disrupted, so it was the right decision. For us, and for many in our military embedded computing industry, MILCOM has been a key show for us for several years, so naturally we regret not being able to reap its many benefits this year. I feel compelled to relate some of the interesting company announcements that technology suppliers had planned to showcase at the event. Among those that most caught my interest were those related to security and encryption—topics that continue to ramp up in importance for military system developers. An example along those lines is Xilinx’s rollout of its fourth generation secure architecture with Information Assurance and AntiTamper IP core support for defense-grade All Programmable 7 series FPGAs and Zynq-7000 All Programmable SoCs. Based on 28nm process technology, the defense-grade products are fully pin-compatible to commercial-grade equivalents for low-cost prototyping and are offered off-the-shelf. The devices blend secure silicon, Information Assurance methodology and DoD 5000 Series-compliant Anti-Tamper Security Monitor IP core (SECMON) into what Xilinx calls its “fail safe heritage.” Fail safe heritage removes any single point of failure in systems that may compromise a mission. Microsemi meanwhile unveiled its new SmartFusion2 systemon-chip (SoC) field programmable gate array (FPGA) family. Designed to address fundamental requirements for advanced security, high reliability and low power in critical industrial, defense, aviation, communications and medical applications, SmartFusion2 integrates flash-based FPGA fabric, a 166 MHz ARM Cortex-M3 processor, advanced security processing accelerators, DSP blocks, SRAM, eNVM and communication interfaces all on a single chip. SmartFusion2 incorporates Differential Power Analysis (DPA) countermeasures that Microsemi has employed through 66

COTS Journal | November 2012

a license from Cryptography Research Inc. (CRI). DPA is a class of attacks discovered by researchers at Cryptography Research. According to CRI, DPA is able to extract secret keys and compromise the security of semiconductors and tamper-resistant devices by analyzing their power consumption. Simple Power Analysis (SPA) is a simpler form of the attack that does not require statistical analysis. In contrast to physical attacks, SPA and DPA attacks are non-invasive, easily automated, and can be mounted without knowing the design of the target device. CRI developed solutions for securing devices against these attacks. According to Microsemi, SmartFusion2 is the first example of an FPGA player introducing a product to the market with these countermeasures. DPA can be used to steal secret keys from FPGAs, which are oftentimes used for mission-critical and highly sensitive functions, particularly in the military and aerospace sectors. Security technology was also part of some end-user equipment slated for release at MILCOM. Among those were Agile Milcoms’ new ISR-Direct platform that delivers FMV (Full Motion Video) and data directly to the warfighter via handheld tablets and smartphones. ISR-Direct provides real-time video as provided from a multitude of the end-user sensors combined with map overlay and two-way data to the critical edge, allowing warfighters to have up-to-date ISR information during their mission. The system is compliant with military security requirements and features embedded AES encryption in addition to the end-user’s HAIPE security measures. Other interesting news that was scheduled for release during the MILCOM timeframe were some milestone communicationsrelated offerings. PrismTech released details of its support for the SCA 4.0 next-generation Software Defined Radio (SDR) middleware specification as part of its Spectra product suite. SCA 4.0 is a major revision of the Software Communications Architecture standard. It’s compatible with radio sizes ranging from small, single-channel radios to prime-power, multi-channel sets. PrismTech’s Spectra Common Data Bus (CDB) is a fully integrated and optimized SDR middleware stack. It can be deployed across multiple processor types, including GPP, DSP and FPGA environments. PrismTech announced that the Spectra CDB suite of CORBA ORBs will be fully SCA 4.0 compliant by the end of this year. While we regret not having the chance to see these and other technologies in person, I appreciate the various companies taking the time to brief me by phone. However, nothing beats face to face, which is why technology conferences continue to be vital institutions for our industry. We wish the organizers and fellow supporters of MILCOM all the best, and we will continue—as we have for several years—to participate and support MILCOM in the future.

Fully Flight Qualified

Our Application Ready systems keep development time and costs grounded. X-ES systems are fully flight qualified to MIL-STD-810, MIL-STD-461, MIL-STD-704, and DO-160 specifications. We design, develop, manufacture, test, and support the systems and perform qualification under one roof in the U.S.

You’re cleared for take-off with fully qualified systems. That’s Extreme. Visit www.xes-inc.com/qualified to see our flight qualified systems.

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Small size, big performance High I/O Density 2D/3D video, audio, Ethernet avionics databus interfaces, serial, discretes, and more

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Reliable Power Conforming to vehicle and aircraft standards

Optimal SWaP Minimal size, weight, and power

Installation Flexibility Models for horizontal or vertical mounting

The New AB3000 Rugged Computer The AB3000 from Ballard Technology is small, lightweight and loaded with capabilities for easy integration into today’s modern aircraft, UAVs, and ground mobile platforms. With an efﬁcient Intel® E680T processor, MIL-STD-1553 and ARINC 429/708/717 interfaces, Ethernet, USB, video, audio, and PMC expansion, this

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rugged, conduction-cooled COTS device is ready to take on all of your toughest computing and interface problems. Performance and versatility in less space ... that’s the AB3000. Visit our website or call 425.339.0281 for more information.

AB3000 at-a-glance · Intel processor · 2D/3D graphics and audio · MIL-STD-1553 · ARINC 429, 708, 717 · Ethernet, USB, CANbus · Serial, discrete I/O · IRIG, BIT, and much more

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