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com April 2016

Welcome to
your Digital Edition of
Aerospace & Defense
Technology Next Generation FPGAs for
Electronic Warfare Systems

April 2016
Turbine Flow Meters
Designing a Power Generation
System for a More-Electric Aircraft
Managing the Impact of Nanomaterials
in Aerospace Manufacturing
Show Preview:
XPONENTIAL An AUVSI Experience

From the Publishers of

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www.aerodefensetech.com April 2016

Next Generation FPGAs for


Electronic Warfare Systems
Turbine Flow Meters
Designing a Power Generation
System for a More-Electric Aircraft
Managing the Impact of Nanomaterials
in Aerospace Manufacturing
Show Preview:
XPONENTIAL An AUVSI Experience

From the Publishers of


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Aerospace & Defense Technology

Contents
14

38
26

FEATURES ________________________________________
4 Electronic Warfare
4 Next Generation FPGAs for Electronic Warfare Systems
10 Materials: Composites
10 Managing the Impact of Nanomaterials in Aerospace
Manufacturing
14 Aerospace Materials/Manufacturing
14 Turbine Flow Meters
20 Alternative Power Sources
20 Designing a Power Generation System for a
More-Electric Aircraft
26 Show Preview
26 XPONENTIAL An AUVSI Experience
28 RF & Microwave Technology
28 International Microwave Symposium Preview
30 Developing an Auto-Synchronized Multi-Avionics Protocol Data
Bus Acquisition System
32 Tech Briefs
32 Creating Simulated LIDAR Images of Human Poses in a Virtual
Laboratory
33 Advanced Sensors for Traumatic Brain Injury (TBI)
34 Multifunctional Core-Shell and Nano-Channel Design for
Nano-Sized Thermosensor
36 Molecularly Imprinted Polymer (MIP)-Coated Microbeam
MEMS Sensor for Chemical Detection

DEPARTMENTS ___________________________________
38 Application Briefs
40 New Products
44 Advertisers Index

ON THE COVER ___________________________________


Virtually all electronic warfare systems
exploit CPUs and FPGAs, each of which
offer unique strengths and advantages for
handling a wide range of tasks. Choosing
between the two often involved making dif-
ficult tradeoffs, but that may no longer be
necessary. Because of their complementa-
ry relationship, many FPGA vendors now
offer SoC (system-on-chip) devices combin-
ing CPU and FPGA resources within a single
monolithic silicon device. To learn more,
read the feature article on page 4.
(Image courtesy of Pentek, Inc.)

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Next Generation FPGAs for
Electronic Warfare Systems

D
esigners of virtually all elec- which countermeasure to deploy, and The choice of using an FPGA or a CPU
tronic warfare system applica- then transmitting the jamming signal at for a given task may be obvious because
tions exploit CPUs and FPGAs, the correct frequency and bandwidth, of its nature, but other times it could go
each offering unique strengths all must conform to an extremely strict either way. If so, the decision is often
and advantages for handling a wide time schedule. Thus, orchestrating the made for the CPU because a C program
range of tasks. This diversity arises from necessary FPGA and CPU resources be- is easier to develop, maintain and up-
fundamental differences in the devices. comes a critical design effort. grade. And, from a human resource per-
FPGAs consist of hardware logic, regis- High level decisions and complex data spective, it is often easier to hire a C
ters, memories, adders, multipliers and analysis are usually easier to implement in programmer than an FPGA designer.
interfaces connected together by the a CPU. If a complex signal processing task
user to perform a specific function. CPUs can be handled by the CPU, it is usually Next Generation SoC FPGAs
consist of ALUs, instruction execution easier to develop a C program for it in- Over the years, CPUs and FPGAs have
engines, cache memory, dedicated I/O stead of trying to develop IP for an FPGA. proven their effectiveness as team play-
and memory ports all connected in a An FPGA is typically much better at ers in electronic warfare systems. Be-
fixed architecture, whose resources are handling compute intensive signal pro- cause of this complementary relation-
driven by program execution. cessing or data crunching tasks because ship, many FPGA vendors now offer
Electronic warfare systems impose of its DSP blocks. Tasks like FFTs, matrix SoC (system-on-chip) devices combin-
some of the toughest restrictions on la- processing, and digital filtering can ex- ing CPU and FPGA resources within a
tency within the landscape of military ploit the benefits of thousands of DSP single monolithic silicon device. The in-
electronics. For example, systems to de- blocks operating in parallel. Further- dustry leaders in this market are Xilinx
feat RCIEDs (radio controlled impro- more, FPGA hardware surrounding and Altera.
vised explosive devices) must identify a these blocks can be tailored for each ap- Xilinx offers its Zynq family of SoCs
signal that could detonate the device, plication. This includes local data that combine ARM processors with Xilinx
and then immediately disable that com- buffers, specialized FIFOs, and opti- FPGA resources. Their most recent offer-
munication through countermeasures. mized interfaces to and from external ing is the Zynq UltraScale+ series, whose
Essential tasks in the chain from receiv- sensors, storage devices, networks, and CPU resources include a Quad-Core ARM
ing the signal, analyzing it, deciding system components. Cortex-A53 application processor, a Dual-
Core ARM Cortex-R5 real-time processor
and a Mali GPU (graphical processing
unit). The FPGA section includes a differ-
ent mix of 16 nm resources in each of the
eleven members of the series to cover a
wide range of complexity. The largest
member offers significant computational
power with nearly a million logic cells and
over 3,500 DSP slices.
A competing family of SoCs devices
from Altera is the Stratix 10 series, also
using the Quad-Core ARM Cortex-A53
Figure 1. Typical electronic warfare system task allocation for CPUs and FPGAs. CPU. Based on advanced 14 nm FPGA

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Electronic Warfare

technology, the Stratix 10 offers ten


different resource-balanced versions,
with over 5 million logic cells and
5,760 DSP blocks in the largest device.
As a major benefit over Xilinxs SoCs,
the Stratix 10 offers DSP blocks that
can handle not only single- and dou-
ble-precision fixed point operations,
but also single-precision IEEE 754
floating point functions. Floating
point math saves the often tedious
task of scaling optimization to avoid
saturation and underflow conditions
which often plague fixed point hard-
ware. Thus, designers can more easily
boost dynamic range for sensitive sig-
nal processing applications.
FPGAs excel at processing and deliv-
ering high-rate continuous streaming Figure 2. Different types of possible AXI connections for a software radio transceiver.
data because of parallel hardware struc-
tures connected through FIFO buffers to ory mapped status and control registers, by judgment to either the CPU or the
sensors or dedicated links. CPUs are often fully satisfying the needs of most FPGA. During system integration, mod-
much more effective when processing small peripheral devices. Still another eling and testing, it may become appar-
blocks of data located in system mem- derivative is the AXI4-Stream specifica- ent that a task should be reassigned to
ory. Because they must be intercon- tion, which eliminates the addressing the other resource. This is an iterative
nected, this disparity in the way CPUs overhead of AXI4 and AXI4-Lite. AXI4- process until all tasks are appropriately
and FPGAs prefer to accept and deliver Stream supports only unidirectional allocated to the CPU or FPGA for opti-
data poses a fundamental challenge transfers from the master device to the mum system level performance. Tools
within SoCs. slave device. from Xilinx and Altera rely upon AXI4
Figure 2 shows how AXI4 connection interconnects to facilitate changes in
Making the AMBA Connection can be used to join functional blocks of connections between the task modules
In order to mitigate this problem, the a typical software radio transceiver. Full as they are reassigned.
Advanced Microcontroller Bus Architec- AXI4 links join the CPU to external The SDSoC Development Environ-
ture (AMBA) was developed by ARM, memory and complex FPGA resources, ment from Xilinx supports their Zynq
Ltd. nearly two decades ago. AMBA is while AXI4-Stream interfaces are more SoC devices. C/C++ design inputs to
now widely adopted as an open source, appropriate for the data converters. Eclipse compiler tools help developers
well documented, license free interface AXI4-Lite easily handles the simpler determine which tasks dominate the
protocol between CPUs and peripherals, transfers to and from the operator inter- CPU workload, identifying possible can-
including FPGAs. face. didates for offloading to the FPGA.
A popular derivative of AMBA is the SoC developers can take advantage SDSoC coordinates execution of both
AXI4 (Advanced eXtensible Interface of AXI4 protocols to handle connec- the CPU and FPGA tasks, showing the
Rev 4) specification. It defines a com- tions among a diverse range of compo- effects of different partitioning and dif-
prehensive standard for transferring nents using this common interface ferent implementations of tasks within
data between master and slave devices standard to implement system topol- each partition.
for data widths from 32 to 1024 bits in ogy and reconcile data widths. AXI4 FPGA tasks are handled by the Xilinx
burst lengths of 1 to 16. A master and a can also be extremely effective in re- Vivado Design Suite, which uses HLS
slave device, both having AXI4 compli- ducing power and boosting transfer (high level synthesis) to create IP from
ant interfaces can be connected to- rates compared to competing strate- the C/C++ design input. Vivado also
gether and communicate, regardless of gies. This is critical for high perform- accepts HDL using Verilog or VHDL
the nature or function of the devices. ance FPGAs in real-time military em- and System Generator output from
Because simple devices may not need bedded computing systems. MATLAB block diagrams. In addition,
the extra interface overhead required to the Vivado IP Catalog offers an exten-
meet the full AXI4 specification, the SoC Development Tools sive collection of plug-and-play IP
AXI4-Lite specification restricts data A common methodology for SoC de- modules for signal processing, commu-
widths to either 32 or 64 bits and limits sign is presented in Figure 3. To start, nication, imaging, matrix processing,
the burst length to single transfers. This tasks are defined to satisfy system re- data manipulation, coding and format-
is ideal for reading and writing to mem- quirements, and then initially assigned ting. The Vivado IP Packager creates

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Electronic Warfare

Figure 3. Development tool methodology for SoC Design.

compatible IP modules from third- modeling, analyzing and debugging the


party IP and RTL design entries. interaction between the ARM CPU and
Since the existing IP Catalog mod- FPGA resources. It optionally includes
ules and the newly-created IP modules DSP Builder and support for OpenCL.
all use AXI4 compatible interfaces, the
Vivado IP Integrator can streamline the The SoC Landscape
installation of AXI4 interconnects as The latest generation of SoC FPGAs
required to ensure interoperability. represent major initiatives and invest-
SDSoC links these AXI4 IP interfaces to ments from both Xilinx and Altera.
compatible AXI4 links on the ARM These companies compete directly for
CPU, for a fully synthesized modular the high-end SoCs designs required for
SoC design complete with memory military applications by offering power-
mapping, modeling, debugging tools, ful ARM CPUs tightly coupled to power-
test benches, and timing analysis. ful FPGAs. In addition to impres-
Altera offers its SoC Embedded De- sive silicon, both companies offer com-
sign Suite that includes the Altera edi- prehensive and ambitious design tool
tion of the ARM DS-5 Development suites. They realize that system integra-
Studio to support the ARM CPU on tors may be influenced to choose their
Arria and Stratix SoCs. Based on SoC vendor based upon the effective-
Eclipse Tools, this open source extensi- ness of the tools, more so than on sili-
ble development environment in- con features.
cludes compiler, debugger and execu- In spite of the many devices avail-
tion tracer. able today, we are still in the early days
For FPGA development, Alteras QSYS of SoC offerings. Developers of elec-
System Integration Tool allows design- tronic warfare systems can expect sig-
ers to graphically connect AXI4 IP mod- nificant advances in performance over
ules from Altera and IP partners. QSYS the next few years as vendors continue
automatically configures the required to boost silicon resources and race to
interconnects to implement the subsys- provide tools to most easily take ad-
tem by creating custom IP from vantage of them.
schematic or HDL design inputs. This article was written by Rodger
Altera integrates the SoC Embedded Hosking, Vice President, Pentek, Inc.
Design Suite with QSYS using Quartus II (Upper Saddle River, NJ). For more infor-
System Level Software. It includes Al- mation, visit http://info.hotims.com/
teras IP modules, and resources for 61060-500.

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Managing the Impact of
Nanomaterials in Aerospace
Manufacturing

A
s the aerospace industry con- (NIOSH), demonstrate that some nano- ability to commercialize nano-enabled
tinues to make improvements materials have the potential to cause ad- products and extend far beyond those
to safety, comfort and afford- verse human health effects. Occupa- that are normally associated with chem-
ability of aircraft, nanomateri- tional health risks associated with ical exposures in the workplace.
als are making their way into more ele- manufacturing and using nanomateri-
ments of aircraft structure, electronics, als have been under study for at least Developing a Risk Management
glass, textiles and other components. two decades and the understanding of Approach
While these materials provide tangible their impact is still evolving. For exam- An integrated, enterprise-wide risk
advantages in terms of weight, strength, ple, inhalation toxicology studies of management approach is essential to
speed and comfort, their effect on the nanomaterial composites have shown a ensure that occupational risk is con-
humans that come into contact with real possibility for lung inflammation trolled throughout the supply chain;
them is still being studied and debated. and fibrosis. from those that supply the nanomateri-
With dimensions between approxi- Workers handling nanomaterials or als, to the technology manufacturers
mately 1 and 100 nanometers about products containing them may be at using the materials, and on to those de-
the size of a virus nanomaterials have risk for inhaling fine dusts or aerosols, veloping and using the innovative
unusual physical, chemical and biologi- either during the production of the products this technology supports.
cal properties that can differ significantly nanomaterial or during the manufac- The first step is to establish a clear risk
from the properties of bulk materials, in- ture or use of products containing control policy. An executive positioning
cluding single atoms or molecules. nanomaterials. Published exposure as- statement addressing all activities, from
These differences enable the aerospace sessments, such as those conducted by procurement of the nanomaterial or in-
industry to do a number of things in- NIOSH, indicate the need for high-in- termediate product, to production, and
cluding: engineer aircraft structures that tegrity process containment and con- including distribution and use, clearly
are flexible and adaptive; develop inno- trols when handling nanoparticles. demonstrates managements commit-
vative energy generation and storage sys- However, the number of nanomateri- ment to ensuring worker health
tems for air travel; and manufacture sen- als already in commerce far exceeds throughout the supply chain. Worker
sors that monitor virtually every element NIOSHs ability to a) characterize the health and safety exposure controls
of air travel. However, these differences potential hazards associated with may not be considered during product,
also create challenges for ensuring that worker exposures and b) establish safe process, and facility design because reg-
an aerospace manufacturing workforce exposure levels. Organizations develop- ulations requiring the control of worker
and those supporting its supply chain are ing and using innovative nano-enabled exposures to nanomaterials do not yet
not inhaling unhealthy concentrations products must develop internal exist, and codes and standards to in-
of nanomaterials. processes to manage the potential risks clude appropriate engineering controls
Published research studies, such as to their enterprise. Such risks will not into the design of facilities, processes,
those conducted by the National Insti- only affect the health of their work- and equipment have not been estab-
tute for Occupational Safety and Health force, but also delay or impede their lished. However, a wealth of authorita-

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Materials: Composites

tive guidance is available, such as Cur- Protecting the health and safety of the
rent Strategies for Engineering Controls supply chain workers will also ensure
in Nanomaterial Production and Down- that preventable health and safety is-
stream Handling Processes (NIOSH Pub. sues wont disrupt the business flow.
2014-102), and General Safe Practices Monitoring supply chain activities, dis-
for Working with Engineered Nanoma- seminating new information about
terials in Research Laboratories (NIOSH nanomaterial hazards and appropriate
Pub. 2012-147). risk-based controls, and measuring
Next, allocate appropriately-skilled re- health and safety performance globally,
sources, such as industrial hygienists, that will create business value and ensure
can identify and characterize the nano- the health and safety of all the workers
materials hazards. Nanomaterial hazard potentially exposed to nanomaterials or
characterization is one of the most chal- nano-enabled products.
lenging tasks due to the unusual physical, Finally, the enterprise risk manage-
chemical, and biological properties that ment system must seek out opportuni-
can affect the toxicity of the material if it ties for continual improvement, an im-
enters the body through the lungs, by in- portant step due to the rapidly
Scanning electron microscopy image from a der-
gestion, or through the skin. mal sampling of skin showing a carbon nanotube. expanding number of nanoparticles
Assessing exposure risks to nanoma- (Bureau Veritas) and nano-enabled products, as well as
terials begins with the collection of data the publication of new toxicity data.
about the workplace, workforce, and
the nanomaterials and nano-enabled Third-Party Expertise
substances. The workplace is character- Manufacturers new to using nanoma-
ized by understanding the process terials in their construction process
equipment containment including: the should consider using experienced
ventilation system exchange rates and third-party industrial hygiene experts
filtration; the air, materials and people who can help design and implement a
movement throughout the facility; holistic risk management approach for
local exhaust ventilation and dust col- the handling of nanomaterials and
lection systems; the room finishes nano-enabled products. These experts
where nanomaterials will be handled; pride themselves on providing certified
and areas for workers to put on and re- and qualified risk management support
move personal protective equipment and services including: material charac-
and clothing. The workforce assessment High resolution transmission electron microscopy terization, exposure limit and analytical
must also define the tasks performed by image of a carbon nanotube. (Bureau Veritas) method development, exposure assess-
each worker and how they might be ment, exposure control, waste mini-
performed differently by various indi- ties to establish acceptable ranges of oc- mization and management, and supply
viduals, which will significantly impact cupational exposures, commonly re- chain assessment. Leveraging a third-
worker exposure risks. ferred to as occupational exposure party expert also gives manufacturers
The final contributor to the exposure bands (OEBs). Combined with the added assurance that they will be able
risk is the nanomaterial itself. Again, workplace and workforce characteriza- to protect workers from nanomaterial
identifying the presence of a nanomate- tion, these nanomaterial OELs and exposure to the very best of their ability.
rial or nano-enabled products may be OEBs allow the industrial hygienist to Supporting the aerospace industrys
difficult since hazard communication identify the job tasks for each job title leadership in using advanced materials
and labeling requirements are still in with potential exposure risks above the and advanced manufacturing methods
development, and health effects data OEL or OEB, or those that result in un- to achieve our vision of commercial air
on most nanomaterials are still lacking. certain assessment of risk. travel is both exciting and challenging.
In the absence of nanomaterial-spe- It is also vital that the enterprise risk It requires that risk be assessed and
cific data, progress is being made on de- management system include the orga- managed throughout the enterprise,
veloping a process for grouping these nizations manufacturing and distribu- keeping workers safe and healthy, and
un-studied nanomaterials with other tion supply chain. The unique hazards supporting a companys ability to bring
materials. They are categorized as either and rapid development of new informa- new technology to market.
nanomaterials with adequate toxicity tion about the toxicity of nanomaterials This article was written by Donna S.
information to develop occupational means the supply chain will look to the Heidel, CIH, FAIHA and John Baker,
exposure limits (OELs), or normal-size manufacturers organization for infor- CIH, Bureau Veritas (New York, NY). For
materials with a similar mode of action, mation on how to safely handle nano- more information, visit http://info.
toxicity, and physical-chemical proper- materials or nano-enabled products. hotims.com/61060-502.

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Turbine Flow Meters
Technology-of-Choice for Measuring Critical Fluid Flow Applications

T
he aerospace industry has some Typical Flow Applications ufacturers can perform precise metering
of the most difficult operating From monitoring the fuel consump- of fuel flow in engine test cells, fuel and
conditions imaginable. Sensors tion of rotary and fixed wing aircraft, hydraulic fluid flow in component test
of all kinds used in this indus- missiles and drones, to evaluating the stands, and hydraulic fluid flow in hy-
try must stand up to the environment performance of hydraulic fluid and lu- draulic mules.
and be able to perform under harsh con- bricants, aerospace applications place Qualification and Acceptance Test-
ditions, fit in extremely tight spaces, high demands on flow sensing technol- ing: During the development process
and have electronics that can compen- ogy. Accurate and dependable flow me- for new flight-qualified components or
sate for variable conditions in order to ters are required for numerous fluid systems, turbine meters can be used to
provide precise, repeatable results. measurements on board aircraft and in validate compliance with performance
In particular, flight instruments meas- component test stands, such as: requirements over a wide range of oper-
uring fluid flow in aircraft fuel and hy- Fuel Management: Aerospace compa- ating conditions. In the process of ac-
draulic systems are required to operate nies rely on flow transducers to provide ceptance testing, the excellent accuracy
over extreme temperature ranges, while accurate, instantaneous fuel flow rate and achieved by turbine meters prevents
enduring heavy vibration and shock, and total fuel consumption data. Paired with manufacturers from narrowing the win-
withstand electromagnetic interference cockpit displays, flow meters must offer dow of acceptance due to the uncer-
and voltage transients. And, as aerospace easy installation and high reliability. tainty of the flow measurement. For ex-
test environments become more severe Fuel Ballast: As fuel is consumed, ample, a 100 pound per hour (PPH)
(higher temperature, greater vibration) there is a ballast issue that can be re- flow requirement can be narrowed to
and test application requirements for solved by fuel manipulation. This is 90 PPH by a flow measurement with
measurement devices grow more strin- often accomplished by pumping the 10 PPH uncertainty, thereby increasing
gent (smaller, lighter, more stable, higher fuel to different tanks, which requires the risk that a good part will be rejected.
accuracy), obtaining meaningful data can measurement of the fuel transferred to Performance Evaluation: Unmanned
be challenging. balance the aircraft. aerial vehicles (UAVs), drones and mis-
Hydraulic System Verification: siles are frequently called upon to stay in
Measuring hydraulic fluid leakage or dis- flight for extended periods of time, or
placement during a flight test requires a even loiter over an area. Aerospace de-
flow meter that is highly repeatable, ca- signers developing these and other ad-
pable of differential flow, and extremely vanced platforms seek instantaneous fuel
compact and rugged. Instrumentation flow rate data that can be used as feed-
suppliers are called upon to answer the back to control engine performance.
size, safety and durability requirements Maintenance, Repair, and Over-
of flight test engineers in a wide range of haul (MRO): When flow specifications
hydraulic system applications. are involved, turbine meters offer a
Product R&D: By pairing a flow precise tool to verify that fuel and hy-
Figure 1. The turbine flow meter is a popular meas- meter with a flow computer or smart draulic components meet the original
urement device among aerospace engineers. transmitter, aerospace equipment man- manufacturers specifications follow-

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Famous last words:
Any calibration will do.
With Keysight calibrations, you can count on the
accuracy of your electronic measurement equipment
guaranteed. We test the actual performance of every
warranted specification and every installed option every
time. And if an instrument is out of spec, we zero in on
the problem and make all necessary adjustments. How
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Aerospace Materials/Manufacturing

ing maintenance, repair, or overhaul. Why Turbine Meters? compact, lightweight packages with
As with qualification test procedure One of the preferred types of flow me- rugged materials of construction, tur-
(QTP) and acceptance test procedure ters among aerospace engineers is the bine meters are used to measure diverse
(ATP), the accuracy of these meters re- turbine meter (Figure1). It is widely fluids ranging from aircraft fuel to hy-
duces the chance that a conforming used for obtaining precise flow meas- draulic fluid, lubricant, cryogenic fluid
component will fall out of the accept- urements in clean, known liquids with and coolant. They also offer a versatile
ance window. relatively low viscosity. Available in metering solution that can be designed
and manufactured based on custom
specifications for packaging, end-fit-
tings, mounting, electronics, etc.
Turbine flow meters employ a
proven measurement technology,
which is digital in nature and provides
exceptionally reliable outputs. The
meter functions by sensing the linear
velocity of the fluid passing through
the known cross sectional area of its
housing to determine the volumetric
flow rate. The fluid, as it passes
through the meter, imparts an angular
velocity to the rotor, which is propor-
tional to the linear velocity of the
flowing fluid. Since the linear velocity
of the flowing fluid through a given
area is directly proportional to the vol-
umetric flow rate, it follows that the
speed of rotation of the rotor is directly
proportional to the volumetric rate.
maxon product range The meters turbine rotation produces a
train of electrical pulses sensed by an ex-
ternal pickoff mounted in close proximity

The solution is to the rotor blades. The frequency of the


pulses can be converted to scaled pulse or

always a matter of the


analog output, and displayed as gallons
per minute, pounds per hour, cubic feet
per minute, or in other engineering units.

right combination.
Since the turbine flow meter is digital
in nature, the task of signal processing
is greatly simplified. The meter elec-
tronics are not subject to drift and elim-
inate the need for analog-to-digital con-
version. This is useful for monitoring
dynamic step-changes in flow for air-

If versatility and intelligent drive solutions As the worlds leading supplier of high-
are called for, the maxon product range precision drives and systems, maxon
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brushed and brushless motors up to 500 maxon precision motors, inc.
Watts, gearheads, sensors, brakes and Contact us at 508-677-0520
positioning controllers. A modular system info@maxonmotorusa.com
to meet your individual needs. www.maxonmotorusa.com

Figure 2. The dual-rotor turbine design extends the


lower flow range far below what has been possible
before.

16 Free Info at http://info.hotims.com/61060-772 Aerospace & Defense Technology, April 2016


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Free Info at http://info.hotims.com/61060-806

Intro Cov ToC + A



Aerospace Materials/Manufacturing

craft hydraulic systems, flight measure- have been successfully marketed. One
ments for telemetering flow rates, or version uses two rotors rotating in the
fast delivery fuel dispensing systems. It same direction. However, inlet swirl will
also allows linearizing and temperature affect both rotors, reducing or increas-
conditioning circuits to be adapted to ing the revolutions per minute (RPM)
military levels of temperature and elec- depending on the direction of the swirl,
tromagnetic interference (EMI) noise and shifting the accuracy of the meter
immunity, with all of the signal condi- output similar to that of a single-rotor
tioning electronics packaged in a com- device. An alternative approach uses
pact, rugged housing that is quiet to two closely coupled rotors, turning in
EMI susceptibility and emissions. opposite directions. The flow exiting
In addition, turbine flow meters can from the first rotor greatly affects the
withstand the extreme G forces encoun- inlet incidence angle on the rear rotor.
tered during the flight of high-perfor- The two rotors become hydraulically
Figure 3. Electronic processors can be packaged
mance or military aircraft. Their elec- coupled and their sum (or average) pro- with the turbine meter to meet any
tronics can operate in temperatures vides a cancelling effect on fluid swirl. installation requirement.
from -55C to 125C. The meters them- Therefore, flow straighteners are not re-
selves (when used with remote electron- quired in most applications, making it EMI/RFI and mismatching flow com-
ics) are used from cryogenic to 450F. possible to install the flow meter in puters to flow meters, and provides an
Safety and reliability considerations tight spaces where an added length of amplified signal for transmitting long
dictate the use of turbine flow meters in straight piping cannot be tolerated. distances. It also allows for meter inter-
some aerospace applications. The Another benefit of hydraulically-cou- changeability without the need for
meters in-line rotor configuration en- pled rotors is the RPM ratio can be mon- rescaling, and delivers multiple process
sures the presence of fluid flow (includ- itored to determine bearing integrity outputs for temperature, flow, and pres-
ing fuel, hydraulics and coolant) even if due to wear or particulates. Bearing di- sure (Figure 3).
its rotor is not rotating (locked). Other agnostics have many practical applica- Ceramic Bearings: In recent years,
flow sensing devices, such as positive tions in an aerospace environment (e.g., there have been major advancements
displacement meters, would not permit noting anomalies when securing test in turbine meter bearing technology.
the passage of fluid. The result would be data over long periods of time). Ceramic bearings have proven them-
engine overheating or fuel blockage. Helical Rotors: Additional turbine selves to be superior in wear and less
meter advantages are found in the use susceptible to particulates than stain-
Latest Technology Innovations of helical rotors, which optimize energy less steel bearings. Furthermore, ce-
Even though liquid turbine flow me- transfer over the entire surface of the ramic bearings can be used in water
ters have existed for decades, there have blade enhancing speed-of-response applications providing a low-fric-
been many design enhancements offer- to step changes in flow rate. Helical ro- tion bearing system with longer serv-
ing impressive flow performance. These tors also produce less pressure drop ice life than traditional journal bear-
improvements enable turbine meters to across the meter, as compared with the ings (Figure 4).
satisfy application requirements in ways traditional flat-bladed rotor design. Secured Internals: The repeatability
once considered infeasible. Advanced Electronics: Turbine flow of the turbine meter not only requires
Dual-Rotor Design: Turbine flow me- meters equipped with new, sophisti- high-quality bearing systems, but the
ters have traditionally offered a repeat- cated electronics provide total compen- rotor and supports (referred to as the in-
able flow range of approximately 100:1 sation to enhance flow measurement ternals) need to be rigidly mounted into
and a maximum linear flow range of accuracy, while extending linearity over the housing. In bi-directional applica-
30:1. This performance is adequate for their repeatable range. The electronics tions, it is important the method of se-
general-purpose applications, but may receive a signal from the rotor, temper- curing the internals prevents any move-
not be suitable for aerospace users. The ature sensor and, occasionally, a pres- ment changing the flow profile. This is
dual-rotor turbine design extends the sure sensor to correct for viscosity ef- best done with a rod-through clamping
lower flow range far below what has fects on the flow meter output. system that secures the internals on a
been possible before. These meters have Embedded Processors: Electronic machined step in the housing. This type
a wider turndown than single-rotor processors can be packaged with the of clamping system not only enhances
configurations, and offer a repeatable turbine meter for remote, direct, or em- bi-directional flow, but also provides a
flow range up to 500:1 and a universal bedded mounting to meet any installa- solution for high-shock applications.
viscosity curve (UVC) turndown range tion requirement. Modern meter de-
of 60:1 (Figure 2). signs generally employ embedded Finding the Right Solution
Hydraulically-Coupled Rotors: Al- electronic processor boards. This ap- Aerospace applications are among the
though several versions of dual-rotor proach allows for a small envelope, most rigorous for any type of measure-
technology are patented, only a few eliminates the problems associated with ment instrument; strict industry regula-

18 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Aerospace Materials/Manufacturing

tions, extreme environments, and the ment solution. The right approach es- New or existing technology
ability to customize devices are just a tablishes a joint venture between the Environmental conditions
few of the demands placed on sensors flow meter supplier and customer, Performance criteria (e.g., accuracy,
in these applications. which is based on clearly defined speci- pressure drop, flow range)
Aerospace projects frequently call for fications, expectations and costs. The Certification requirements
a flow meter supplier with the resources project should start by identifying the Standards compliance
to provide a custom solution based on following key parameters: Delivery schedule
specific needs such as: Product cost
Ambient requirements
High/low temperature operation Long development cycles and high
Lightweight materials (aluminum, qualification costs require aerospace
titanium, etc.) companies to identify stable, reliable,
Bi-directional flow cost-effective partners. Such firms value
High-pressure capability speed in prototyping and development of
Extreme shock loads flow measurement devices in specialized
Custom physical dimensions packages. The precision output of these
Special end connections products helps reduce risk and cost in key
Material traceability applications while also minimizing the
Specialized testing requirements need for unscheduled maintenance.
This article was written by
Experience has shown project man- Mike McCoy, Senior Applications Engi-
agement for development and testing is neer, Badger Meter (Milwaukee, WI). For
Figure 4. Ceramic bearings are superior to stain-
essential to a successful outcome when less steel bearings in wear and less susceptible to more information, visit http://info.
devising a specialized flow measure- pitting due to particulates. hotims.com/61060-501.

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-773 19


Intro Cov ToC + A

Designing a Power Generation
System for a More-Electric Aircraft

I
t is theorized that systems and equip- tween the propulsion system and elec- and the fuel for a heat sink is expected to
ment for an All Electric Aircraft (AEA) tric power system because an MEA inte- be a solution for the exhaust heat prob-
will be developed 20 years hence as a grates power management into the elec- lem of aircraft. Since the electric fuel sys-
More-Electric Aircraft (MEA) with no tric power generated by engines. In tem affects the engine thrust as the dis-
bleed system, which is a concept typi- addition, the MEE will also have to con- charge changes, a fault tolerant design in
fied by the Boeing 787, and electric pow- sider the importance for optimization of which the discharge does not change
ered propulsion (including electric dis- the aircraft in integrated management during a fault is necessary.
tributed thrust or electric hybrids by gas by advancing management of fuel burns A similar design concept must also
turbine power generation), which is ex- and the thermal control system, opti- be considered for the power supply of
pected to be realized after the 2040s. In mization of engine control and informa- the electric system. Although a
this trend, a More-Electric Engine (MEE) tion sharing with the entire aircraft, and starter/generator realized by the high
plays the roles shown in Table 1. the integration of flight control. power of the aircraft's generator con-
A conventional engine has two re- tributes to the reduction of the con-
sponsibilities: propulsion as a primary Low-Pressure Spool Power Generation ventional air starter and plumbing, it is
function, and a power plant for the sec- The conventional fuel control system considered a transfer mechanism that
ondary systems power source as a sub- wastes a lot of power because a fuel may become larger due to increased ex-
sidiary function. This article will focus pump driven by engine extraction power traction of power by a power take-off
on the expectation that MEE will be pro- through an accessory gear box delivers as the secondary power, which was
vided as a future key technology for the excessive fuel flow compared to the nec- bled of air, replaced with electrical
total energy management of MEA. essary fuel flow to acquire a specified power by an engine-driven generator,
Specifically, the engine will be an impor- thrust, which circulates in the bypass cir- disposal of the generated heat by the
tant factor not only for the conven- cuit of fuel metering. An electric fuel sys- enlarged starter/generator, and the lim-
tional role of high efficiency and low tem that eliminates excess flow improves itation of location and available space
emission, but also for optimization be- the unnecessary rise of fuel temperature, around an engine.

Electric Power Demand and Engine


Control
No-bleed systems of the MEA gener-
ate more electric power because they
transfer the secondary power by com-
pressed air from the conventional
compressor to power generation by the
rotational energy of a high-pressure
spool shaft. The AEA, with a single
aisle and 150 seats, may need 1MW of
electric power, or for an eight-hour
flight, 7.8MWh. In order to realize
these electric power demands, the en-
Table 1. Roles of the MEE of electric aircraft gine system plays a role in power gen-

20 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Alternative Power Sources

eration in the total energy manage- Integrated Propulsion Control energy management at normal times
ment system that consists of power The electric power management needs and provide safety and stability in an
generation, distribution, storage and to be linked with every status and situa- emergency (Table 3).
consumption. tion of the aircraft and requires a stable As described, the MEE shares a close
The power generation system is nec- power supply and quick response in an working relationship with the MEA and
essary for the engine system consider- emergency. A conventional fuel pump the AEA in every aspect. While the MEE,
ing the improvement of generating ef- driven by mechanical power needs to be especially the electric fuel system, is
ficiency for future increased power mounted on the engine AGB, but for the thought to play an important role in ther-
demand, stability of engine control, electric power system it needs to provide mal management and control of electric
and limits of mounting structures of flexibility upon being mounted on the aircraft in the future, it is also an essential
an extraction mechanism and genera- fuel pump, and fuel system integration system as well as a flight control system
tors. General aero-engines have a low- should be assumed from the point of a and requires high reliability and safety.
pressure (LP) spool and high-pressure holistic and optimized system.
(HP) spool in the compressor and the Tightening the information and com- Sufficient Emergency Power
turbine, respectively, and fans that ac- munication between the control system For the AEA, including an electric fuel
quire thrust are driven by a low-pres- of MEE and the aircraft system may en- control system, the electric power sys-
sure shaft and the generator and the able integrated control such as remov- tem is one of the crucial systems and re-
pumps are driven by the torque of a ing limiting conditions temporarily by quires high stability and fault tolerance
high-pressure shaft. The generator analysis of the information and the sta- that do not cause any power fluctua-
drive by the torque of a low-pressure tus in coordination with engine control tions or disruptions by a system fault.
shaft should be examined in consider- and aircraft control in an emergency. The authors propose electric bus designs
ation of weighing up the merits and Coexistence of aircraft control, electric such as a power interchange through
demerits of the high-/low-pressure power management and stability of en- the MEAAP (More- Electric Architecture
shafts shown in Table 2. gine operation must function as total for Aircraft and Propulsion) research.

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-774 21


Intro Cov ToC + A

Alternative Power Sources

Table 2. Merits and demerits of the extracting power shaft of the engine Table 3. Research targets of the integrated propulsion control

However, our targeting emergency ground operations, basically, the engine gines of a twin-engine aircraft are
power source capacity was merely as- generator provides power while the en- down in an emergency situation. If
sumed as a substitute of the power gine is turned over even if it is in a one or more engines work correctly,
source at normal times and has not ground idle condition. However, the sec- the capacity of the engine generators
mentioned the observation that the ondary power supply (for air condition- are thought to be designed to basi-
AEA is feasible under circumstances ing, starting avionics, galley, etc.) is nec- cally enable normal operation. In
such as generator failure and a disabled essary for ground operation before the these cases, the following need to be
bus, or while the engine is off. There- engine starts and generally electric power satisfied from the requirements of
fore, a backup or emergency power and compressed air are provided by the each certification.
source should be large and complicated. GPU or the APU. When the engine starts,
For example, the ram air turbine the air starter requires compressed air or The Control System can be Operated
(RAT) system has covered essential the starter/ generator requires electric and the Aircraft Can Fly and Land
power supply and the flight control power. A power supply source for them is Safely Even if Two Engines are Broken
drive for conventional aircraft in an required and the APU dedicates starter Applicable requirement;
emergency, but it may not be enough driving power to conventional aircraft. CFR(Code of Federal Regulation) Title
for the AEA due to increased power de- This power supply and demand needs to 14, Part25,
mand. The auxiliary power unit (APU) be met in order to consider the alterna- Subpart D - Design and Construction,
is also not sufficient to back up the AEA tive function of the APU. Those would be CONTROL SYSTEMS,
because it has a failure mode as com- considered normal operations. 25.671 General. (d)
mon as the engines, such as a disabled In terms of emergency and recovery In this condition, electric power must
fuel system. Therefore, alternative en- operations, first, it should be deter- be provided to the avionics, the flight
ergy sources such as batteries and fuel mined whether at least one or more control, a high lift device so that com-
cells (FC) will be required. In that case, engines work correctly, or if both en- munication, position and attitude, atti-
the problem is specific energy perform-
ance and it is difficult to mount those
batteries and fuel cells due to the
weight. Taking this into consideration,
weve focused on an LP power genera-
tion system as a high-performance
emergency source.

Definitions of Power System Operation

Electric Power Demand for Emergencies


There are two modes of power supply
system operation: ground operations
and in-flight operations.
For in-flight operation, generally, the
volume of an engine generator is consid-
ered to be set to satisfy the total electric
energy demand for the necessary equip-
ment. Therefore, the integration of the
total electric energy is calculated. As for Figure 1. Proposed power bus architecture for AEA

22 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Alternative Power Sources

tude control and lighting is complete, maximum electric power by the forego- surface operation. Especially, when the
but not to the ECS, the galley, the fuel ing calculations. For the AEA, all actua- peak current is provided from the
pumps (the engines are already down), tors for flight control are electric and power supply, the capabilities of the
on-board entertainment, anti-icing sys- the electric power system is required to power system affect not only the gener-
tems (it was impossible for conven- provide peak current and absorb regen- ator capacity and size but also the wire
tional aircraft to provide the electric erated current repeating powering and capacity and weight to prevent a volt-
power while the engines were down be- regeneration according to the control age drop by line impedance.
cause bleed air was used).

The Engines Can Restart at a High


Altitude Even if the Normal Power
System Cannot be Used
Applicable requirement; CFR Title 14,
Part25,
Subpart D, ELECTRICAL SYSTEMS AND
EQUIPMENT,
25.1351 General. (d)
The starter/generator needs to be
used for engine restart, which consumes
a lot of electric power. Since the time to
restart the engines is short, electric
power is provided only to the commu-
nication system, the attitude indicator,
the attitude control and the fuel pumps
but not to all other nonessential
and non-urgent-use equipment. After
restarting the engines, all the systems
are restored immediately.

The ETOPS Should be Satisfied Even


if a Triple Fault in the Electric Power
Equipment Occurs
Applicable requirement;
CFR Title 14, Part25, Subpart I - Special
Federal Aviation Regulations, APPEN-
DIX K TO PART 25-EXTENDED OPERA-
TIONS (ETOPS),
K25.1 Design requirements.
K25.1.3 Airplane systems. (b)
K25.1.4 Propulsion systems. (a)
Electric power is supplied to the com-
munication system, the attitude indicator,
the attitude control system, the lighting,
the fuel pumps and anti-icing systems so
that normal operation is available with
one engine. Table 4 shows the calculated
result of the necessary electric power of a
single aisle aircraft with 180 seats based
on the above conditions. Power demand
for each electrical load was estimated as-
suming the 180-seater AEA system.

The Peak Cut Operation


It is necessary to reduce the electric-
ity in an emergency and the electric
power for the flight control is estimated
at approximately less than 30% of the

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-775 23


Intro Cov ToC + A

Alternative Power Sources

As clarified by the typical current wave- generation and LP-SPOOL power gen- System Distribution
form, there is a big difference between eration. LP power generation is avail- The system distribution of a single
the maximum current, which is con- able to provide more electric power aisle aircraft with 180 seats is described.
sumed during acceleration and at maxi- than the HP power generation at the We assume 400kw electric power gener-
mum speed, and the average current. It time of the engine halting, which ation per engine through the combina-
means that the challenges regarding the means a windmill condition in flight. tion of two HP-SPOOL power genera-
increased capacity of the generator and It is expected that LP power genera- tions of 150kw 2 and one LP power
line impedance are solved for the entire tion can be used as an alternative generation of 100kw, considering the
power system by leveling the electric power generation system without function redundancy of the starter for
power with an accumulator and control- mounting the RAT by adding the same the conventional HP-SPOOL power gen-
ling the maximum current. We have pro- function as RAT to it. The FC (Fuel eration. Confirming the conformity by
posed electric accumulation and electric cell) is a part of the configuration as each condition, given that a windmill
peak-cut control using a flywheel battery an alternative system to the APU, but a power generation of the LP generator is
(FWB) as a countermeasure against the large weight disadvantage is caused 1/2 the rated capacity (assumed value),
above. A capacitor, which is superior in when the FC is requested to generate it is found that mounting an FC rated
the following points to an electro-chemi- the same volume of power as the APU. about 80kw enables operation.
cal battery, such as a lithium-ion battery, Therefore, the important point of this According to the current FC system for
is generally applied to the electric accu- study is to discuss how much the out- aviation, the weight is about 200kg per
mulator because: (a) it has a long life put of the FC can be reduced with the 25kw. Therefore, approximately 600kg-
(semi-permanent repetition), (b) it can be combination of LP power generation 800kg composition is assumed. Given
charged by a large current, (electricity can assuming the operational situation. that the RAT weighs 200kg including the
also be discharged by a large cur- structure and the APU weighs
rent), (c) it is an eco-friendly ma- 200kg (including fuel), the
terial and (d) it is able to accu- weight is increased by about
rately comprehend the residual 200kg-400kg. Since, on the
energy from terminal voltage. ground, the engines need to be
A capacitor, which saves elec- started only with the power
tric charge in the inductor, is from the FC, the FC must toler-
generally applied for the electric ate about twice the rating for
accumulator; however, FWB, power supply for a short time for
which saves the power by ki- engine starting, which should be
netic energy, is superior for an taken into consideration for the
application requiring both high thermal design of fuel cells.
power and energy. FWB is also There are several approaches
highly effective by being located to developing this power
close to the load whenever possi- source. The existing high-power
ble and therefore, superior to the ratio HEV lithium-ion battery
capacitor, which is inferior in (LIB) is 25 kg at a 30 kW rate
low temperature characteristics, (1.4Wh). If we assume a power
considering its mounting on a source capable of 150 kW, the
non-pressurized area. In addi- LIB system weight would be 125
tion, it is considered that both kg. This LIB would also incorpo-
the leveling and high reliability rate the engine starter current
of the electricity can be achieved design specifications. However,
by making use of the feature this LIB system limits the time
that FWB can transmit the elec- to operate the engine starter.
tricity and energy insulating The LIB system stores the
electrically through kinetic en- 7.0Wh at 150kW output power
ergy and configuring to distrib- and approximately 170-second
ute the electricity to multiple run times.
control surface actuators from
the multiplexed power system. Challenges of Generating
Power by a Low-Pressure
System Configuration Shaft
This system is comprised of The capacity of LP power
the combination of the con- Table 4. Considerations for the necessary electric power of a single aisle generation affects the feasibil-
ventional HP-SPOOL power aircraft with 180 seats. ity of the FC.The challenges of

24 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Alternative Power Sources

generating power with the low-pressure eral aero-engines changes within the hand, the front-sump area is limited in
shaft as opposed to the more common range of 60-100%, but that of a low-pres- mounting space. The method to
high-pressure shaft, are: sure spool changes within the range of mount on the AGB is thought to be an
1. Type of generator 20-100%. For the generator of the high- extension of the conventional tech-
2. Location of the generator pressure shaft, a field winding-type syn- nique and has fewer challenges, but
3. Proposal for a new aircraft electric chronous type is broadly used, but it is the increased weight by larger PTO
power system not suitable for power generation by a (Power Take-Off) and the influence on
wide rotation speed range because a engine performance by the decreased
The specific difference between a gen- built-in permanent magnet generator is area for air flow in the engine need to
erator driven by a low-pressure spool used as a field power supply and output be examined.
and that driven by a high-pressure spool voltage is in proportion to the rotation The maximum rotation speed of the
is rotation speed range. The rotation speed cubed in principle. low-pressure spool is about 1/3 that of the
speed of a high-pressure spool for gen- The PM (Permanent Magnet motor) high-pressure spool. Since the constitu-
type and the SR (Switched tion of generators become larger as rated
Reluctance motor) type speed becomes lower if they have the
are considered to be same output/method, the generator of
prospects for the genera- the low-pressure spool will become larger
tor of the low-pressure than that of the high-pressure spool. Al-
shaft. The features of though it can be smaller by adding a gear
these types are shown in and accelerating, the acceleration is lim-
Table 6. The PM type has ited by the magnetic saturation character-
advantages in efficiency istic of the magnetic body and mechani-
and output density cal strength. In addition, since the
(weight/ volume), but it efficiency of the generator becomes lower,
has a drawback relating to the fluctuation range of the efficiency by
fault tolerance in which it the rotation speed becomes large for the
cannot stop excitation generator of the low-pressure shaft that
when it breaks down. The has a wide range of rotation speeds. Since
SR type is comprehen- the generator of the low-pressure spool is
sively potent in terms of inferior to that of the high-pressure spool
fault tolerance, although in performance and efficiency, it is practi-
it has drawbacks in cal to think this for the relatively low
weight and constitution. power. For a test calculation, the volume
The current generator is set based on an assumption that a
of the high-pressure 100kw generator is realistic.
spool is mounted on an
AGB (Accessory Gear Future Challenges
Box). The generator of Downsizing and lightening is the
Table 5. Electrical power system distribution the low-pressure spool is most challenging matter and downsiz-
considered to be embed- ing of power electronics using a fuel cell
ded and directly linked and wide band gap elements is an essen-
to the engine shaft in an tial technique. Downsizing and lighten-
aft-sump space or a ing of generators is also important. For
front-sump space, in ad- the future, since lightening is important
dition to mounting on to realize LP power generation, research
the AGB as well as that of is expected to move toward an electric
the high-pressure shaft, motor with high temperature tolerance
and considering the re- that can operate under temperatures of
duced mounting space more than 400C for LP power genera-
around a fan due to a tion, aiming at a composition to mount
high bypass ratio and the LP power generator on an AFT-sump
AGB-less for any future that does not require a PTO shaft.
plan. The aft-sump area This article is based on SAE Technical
(tail cone) has a large paper2015-01-2408 by Hitoshi Oyori, IHI
mounting space but has Aerospace Co. Ltd., and Noriko Morioka
a relatively high temper- and Tsuyoshi Fukuda, IHI Corporation,
Table 6. The features and types of generators ature. On the other doi:10.4271/2015-01-2408.

Aerospace & Defense Technology, April 2016 www.aerodefensetech.com 25


Intro Cov ToC + A

XPONENTIAL
An AUVSI Experience By Bruce A. Bennett

A
t AUVSIs Unmanned Sys- systems into countless aspects of our ting-edge research in unmanned vehicles
tems 2015 in Atlanta Geor- lifestyles, economies and national secu- and robotics; and something called Be-
gia, it was announced that rity paradigms. Listen to what they yond the Booth Showcase, which is a
the conference and trade have to say and stimulate your imagina- specially selected assortment of the best
show was being officially rebranded in tion before heading off each day to the products and partnership opportunities
2016 to XPONENTIAL An AUVSI Expe- exhibit hall or to one of the many edu- this years crop of exhibitors has to offer.
rience. The event, which runs from May cational sessions being offered. New to the Innovation Hub this year
2 May 5 at the Ernest N. Morial Con- are Discussion Groups, specialized gather-
vention Center in New Orleans, LA, will Exhibit Hall ings of individuals with similar interests
feature more than 180 speakers, 335- Speaking of the exhibit hall, there is where you can share ideas, trade informa-
plus educational sessions, and over 600 certainly plenty to see and do. For tion, brainstorm, solve problems, or net-
exhibitors representing more than 20 starters, over 600 exhibitors spread out work. Each Discussion Group will be
industries in the commercial, defense over 350,000 square feet of exhibit moderated by an industry expert to keep
and civil arenas. space will be showcasing the latest tech- the dialogue focused and productive.
So, what can attendees expect nology and solutions in all aspects of Another popular attraction located
to find at XPONENTIAL 2016? unmanned vehicle and robotics design, on the show floor is Robots in Action, a
The event kicks off on Monday after- manufacturing and use including air, special area where exhibitors can show
noon, May 2, with educational program- ground, surface, subsurface, space sys- off their small unmanned vehicle and
ming and workshops from 1:30 to 4:30 tems, weapons systems, security sys- robotics technology by demonstrating
pm, followed by welcome receptions in tems, engineering and R&D, propulsion it live. Some of the companies who
the early evening. These receptions are a systems, sensors, electronics, fabrica- demonstrated their expertise during last
great venue for first-time attendees and tion, imaging and communications sys- years show were Aurora Flight Sciences.
veterans alike to mingle and network in tems, and much, much more. Lockheed Martin, Detroit Aircraft LLC,
an informal relaxed atmosphere. Centrally located in the exhibit hall is and Unmanned Cowboys LLC.
Tuesday, May 3, kicks off with the the Innovation Hub, a unique area The exhibit hall will also play host to
first of three General Sessions planned where attendees can avail themselves of a number of special interest and tech-
for that week. According to AUVSI, the a variety of resources such as panel dis- nology pavilions. For example, the Air
General Sessions bring together a host cussions, workshops and special interest pavilion will highlight products and
of industry leaders who are deter- sessions; technical poster presentations services specifically targeted to the UAS
mined to reshape our world with the where attendees can interact face-to-face market such as engines, guidance sys-
spread and integration of unmanned with people doing some of the latest cut- tems, cameras, flight testing, and regu-

Attendees can evaluate the latest unmanned vehicle and robotics technology AUVSIs educational sessions tend to attract standing-room only crowds. (Photo:
up close in the exhibition hall. (Photo: AUVSI/Robb Cohen) AUVSI/Robb Cohen)

26 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

AUVSI Show Preview

latory information. A new pavilion this Automated Commercial and Industrial


year will be dedicated exclusively to the Vehicles
Survey and Mapping industry. Accord- UAS Operations Management in the
ing to AUVSI, the FAA has issued over Oil and Gas Industry
2,000 Section 333 exemptions to date, Commercial Autonomous Ground
many affecting the aerial surveying in- Vehicles in Mining and Agriculture
dustry, so there will be a lot of interest Remote Sensors for Agriculture and
surrounding the technology on display Data Analysis Techniques for
in this pavilion. And for those who Improving Crop Health
want to learn more about whats going Bourbon Street is a popular music and nightlife des-
on in the industry beyond Americas Defense Track tination in New Orleans. (Photo: Bruce A. Bennett)
borders, China, France and the UK will Future Directions for Army UAS
have their own pavilions showcasing General Officers Perspectives on
what they have to offer. UAS Programs, Operations and
For those interested as much in the fu- Requirements
ture of the industry as the present, there Human Robotic & Autonomous
is something called the Startup Show- Systems Teaming (H-RAST) Beyond
down and pavilion where attendees can 2030
meet some of the newest entrepreneurs MCWL Robotic and Autonomy
on the scene and find out what theyre Experimentation; Past, Present, and
working on. This is a must-see attraction Future
Trumpeter Jamil Sharif performing at the Maison
for prospective investors who might be TerraMax UGV: The Next Generation Bourbon jazz club on Bourbon Street. (Photo:
looking to back the next hot technology. Convoy Bruce A. Bennett)
Basically, an AUVSI panel of judges eval-
uated proposals submitted by the Civil few parts not ravaged by Hurricane Kat-
founders of early stage startups and Disaster Robotics: Land, Sea, and Air rina in 2005. The French Quarter is
chose fifteen semi-finalists who were in- Application of Unmanned Vehicle where much of the citys nightlife occurs.
vited to attend XPONENTIAL and meet Systems to Wildlife Research and Great restaurants, old taverns and hot
with a panel of venture capitalist judges. Management music clubs abound on many of its
From that group, three finalists will be Bureau of Land Management: streets, the most famous being Bourbon
selected to compete in the Startup Show- Unmanned Aircraft Systems for Street. Regardless of what type of music,
down on May 4 from 4:30 to 5:30 pm in Natural Resource Applications food or libations you like, theres proba-
the General Session room. There theyll bly an establishment in the French Quar-
get six minutes each to make their pitch, Additional Program and Session Topics ter that can cater to your tastes.
and another six minutes to answer ques- According to AUVSI, in addition to By day, try prowling the streets and
tions, in front of not only the judges but the above, other session topics being de- alleyways and check out some of the
anyone else who cares to attend. All fif- veloped include: buildings and architecture, much of
teen semi-finalists will also have exhibit Unmanned Systems and Robotics which dates back to the 18th and 19th
space in the Startup Pavilion where they Testing centuries, giving this part of the city
can discuss their technology with inter- Counter UAS Technology Develop- an old European atmosphere. Wander
ested attendees. ments up to peaceful Jackson Square and
The Future of UAS Data Acquisition, marvel at the impressive equestrian
Conference Storage and Dissemination statue of Andrew Jackson and the clas-
Those seeking additional enlighten- UAS Propulsion: New Developments, sic beauty of St. Louis Cathedral. If the
ment can also attend a variety of tech- Research and Pathways Toward French Quarter isnt your cup of tea
nical sessions at XPONENTIAL 2016. Improved Performance (theres a phrase not used much in
The technical sessions have been sepa- Challenges of Integrating Large connection with New Orleans), you
rated into three tracks: Commercial, Ground Systems in the Battlefield can hop a streetcar to the Garden Dis-
Defense and Civil. Although the pro- trict, or maybe book one of the popu-
gram was still being finalized as we After Hours lar cemetery or voodoo history tours.
went to press, here are some of the ed- If youre not too tired after walking the Or perhaps youd like to cruise the
ucational programs being offered: show floor for hours or participating in mighty Mississippi aboard an old-fash-
the technical sessions, there is certainly ioned paddlewheeler?
Commercial Track no lack of interesting things to see and Given all that XPONENTIAL 2016 and
Drones in the Enterprise: The Skys do in New Orleans. For starters, theres its host city have to offer, youll experi-
the Limit the historic and colorful French Quarter, ence a lot of things, but boredom wont
The Technology Progression to Fully the oldest part of the city and one of the be one of them.

Aerospace & Defense Technology, April 2016 www.aerodefensetech.com 27


Intro Cov ToC + A

INTERNATIONAL
MICROWAVE
SYMPOSIUM PREVIEW

T
he 2016 International Mi- tains that, al- Next-Generation 5G RF and Microwave
crowave Symposium (IMS2016), though the Systems. His keynote will explore the
organized by the IEEE Mi- phone con- vital role of a software-based approach
crowave Theory and Technique tains amazing to enable the explosion of wireless com-
Society (MTT-S), is the annual interna- semiconduc- munications for high-data-rate voice,
tional meeting for technologists in- tor and other data, and video applications, from early
volved in all aspects of microwave the- technologies, prototyping and research, all the way to
ory and practice. Held in San Francisco the phone is fully deployed systems.
from May 22-27, IMS is part of Mi- still in its in- Some of most compelling applica-
crowave Week, which incorporates fancy. Per- tion domains of the Internet of Things
technical symposia and an exhibition sonal wireless and Swarm concepts relate to how hu-
Dr. James Truchard
focused on RF, microwave, millimeter- connectivity mans interact with the world around
wave, and THz frequencies. has the potential to revolutionize them and the cyberworld beyond.
Heres a preview of some of the healthcare and education; the health- While the proliferation of communi-
keynotes, sessions, and other special care revolution has already begun. But cation and
events taking place during Microwave the biggest contribution of wireless will data process-
Week. To learn more and to register, be in improving the very concept of col- ing devices
visit www.ims2016.org. laboration. has pro-
In his keynote address, The Birth foundly al-
Keynote Speakers and Death of the Cell Phone, Dr. tered our in-
The hand- Cooper will point out the irony that the teraction
held cell- ability to solve the problems associated patterns, lit-
phone was with these revolutions may well be en- tle has been
introduced hanced by collaborative tools that use changed in
42 years ago, wireless technology to improve itself. the way we
but the mod- Dr. Cooper conceived, and led the effort process in- Professor Jan M. Rabaey
ern smart- to develop, a personal, portable cellular puts (sen-
phone is less radio handset. The result was the intro- sory) and outputs (actuation). The
than 10 years duction of the first truly mobile tele- combination of IoT (Swarms) and
old. Dr. Mar- phone in 1973. wearable devices offers the potential
tin Cooper, Dr. James Truchard, President, CEO, for changing all of this.
referred to as Dr. Martin Cooper and Co-Founder of National Instru- Professor Jan M. Rabaey of the Uni-
the founder of the cell phone, main- ments, will discuss Softwares Role in versity of California Berkeleys keynote,

28 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

RF & Microwave Technology

"The Human Intranet Where Swarms data; ultra-low-power CMOS, and en- The Exhibition
and Humans Meet," will discuss the ergy-scavenging and energy-harvest- The Exhibition consists of over 600
Human Intranet, an open, scalable plat- ing designs; new materials, metamate- exhibiting companies who represent
form that seamlessly integrates an ever- rials, and 3D printing applications for the state-of-the-art when it comes to
increasing number of sensor, actuation, RF/microwave; low-cost, personal materials, devices, components, and
computation, storage, communication, satellites and technologies; and next- subsystems, as well as design and simu-
and energy nodes located on, in, or generation 5G, 100+ GBPS wireless, lation software and test and measure-
around the human body acting in sym- and Internet of Things (IoT). ment equipment. The Exhibition also
biosis with the functions provided by Panel Sessions are an hour and 20 includes Microwave Application Semi-
the body itself. minutes long and focus on topics such nars, or MicroApps 20-minute techni-
as software-defined radio, RF MEMS, cal seminars presented by exhibitors ad-
Sessions and Workshops system-on-a-chip, microwave photon- dressing state-of-the-art products,
Focus Sessions highlight emerging ics, and other subjects. processes, and applications of interest
new technical topics that are gaining Workshops and short courses in- to the microwave community. Visit
importance and may be of significant clude emerging topics such as terahertz www.ims2016.org/exhibition for a full
interest to the microwave community. technology, carbon-based electronics, exhibitor list.
The sessions encompass a wide range green microwave technologies, and
of topics, and may involve a specific flexible/wearable electronics, as well as
emerging technology or cover several 5G wireless systems, technologies for
technologies relevant to a common low-cost phased arrays, RF technolo-
application. Some of these areas in- gies and applications for autonomous
clude RF technologies for smart vehi- and distributed vehicles and drones,
cles and drones; personalized health- and the latest developments in test and
care through wireless sensing and big measurement systems.

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Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-776 29


Intro Cov ToC + A

RF & Microwave Technology

Developing an Auto-Synchronized Multi-Avionics Protocol Data Bus


Acquisition System
A modern aircraft includes multiple
intelligent subsystems that aid in
communication, navigation, and sur-
veillance. These subsystems, called line
replaceable units (LRUs), are modular
and easy to replace in the field. Typi-
cally, independent teams design and de-
velop LRUs. It is important to test the
LRUs with a test rig on the ground be-
fore integrating them on the aircraft. A
ground-based LRU integration rig
(LRUIR) facility uses state-of-the-art
hardware and software in a distributed
architecture to help completely inte-
grate the process of verifying the func-
tionality of the avionics subsystems. An
LRUIR provides a platform to test the
LRUs in an integrated environment on
the ground.
Real-time data acquisition of the test
rig is important to ensure reliable test-
ing of the LRUs. The data acquired pro-
vides insight into the behavior of the
units and the communication among
them. A large number of LRUs connect
to the data bus acquisition system,
which features 730 I/O points from dif- System implementation schematic diagram.
ferent LRUs, user-configurable data for-
mats for acquisition, different proto- Next, the user could design each pa- network time protocol (NTP) was used
cols for different data formats, and rameter from low-level to high-level to synchronize other systems within
multiple chassis. configurations. Low-level configura- the network. Finally, precision time
This was a validation system, which tions included sampling rates for analog protocol (PTP) was used to synchronize
made efficiency and calibration the top or transistor-transistor logic, and open the three chassis. NI-Sync helped avoid
priorities. National Instruments Meas- source for digital, start bits, stop bits, traditional coding techniques for time
urement & Automation Explorer was RS-422 baud rates, MIL real-time ad- stamping each event, which would not
used to first test the individual cards, dresses and sub-addresses, or port num- have been as precise.
applying the concept of self-test to bers in case of Ethernet. High-level Inspired by NI Diadem data man-
make sure the system checked all the configurations included encoding tech- agement software, the new custom
cards as soon as the software ran. The niques such as non-return-to-zero, software was made user friendly so the
following cards were used in the system: biphase, or even protocols like high- user could view the acquired data as a
NI PXI-6225 M Series DAQ board for level data link control in which the user graph or table, or with special tem-
analog acquisition could configure for start of frame, end plates for MIL and ARINC data. A cus-
NI PXI-6511 module for digital of frame, controls bits, or FCS. tomized coding format was developed
acquisition The main challenge was to synchro- for synchronous RS-422 using the
NI-8431 device for asynchronous RS- nize up to a millisecond among differ- FlexRIO FPGA module. The FPGA
422 measurements ent cards using different protocols Module offered extra flexibility for
NI PXIe-7962R FlexRIO module for spread across three chassis. This was customizing the format per the
synchronous RS-422 measurements not a single-step process. Any event oc- clients requirements.
NI PXIe-8234 Gigabit Ethernet inter- curring during the acquisition process The application software was divided
face device had to be captured by all three PXI sys- into two modules the real-time
Avionics Interface Technologies (AIT) tems with the same timestamp so the module and the host user interface
MIL-STD-1553 for MIL acquisition event could be recognized during module. The real-time module was de-
AIT ARINC 429 module for ARINC analysis. First, the network was syn- ployed in the PXI controller, and the
acquisition chronized with the GPS time. Next, host user interface module ran on the

30 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

RF & Microwave Technology
Reliable Data Storage
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AIT drivers to help acquire ARINC
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visit http://info.hotims.com/61060-542.

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-778 31


Intro Cov ToC + A

Tech Briefs

Creating Simulated LIDAR Images of Human Poses in a


Virtual Laboratory
Automated human activity recognition can provide clues about a subjects intentions.
Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio

L IDAR is a partial 3D standoff sensing


method that illuminates a target
with rotatory or flash laser beams, ana-
lyzes the reflected lights, and provides
both the distance to the targets surface
and the targets surface shape. An array
of laser reflections can be used to map
the facing-side surface of a target object
as a partial point cloud. Unlike a 360
surface model generated by a traditional
full body scanner, the partial point
cloud from a LIDAR is a viewing angle
dependent 3D representation of the tar-
get shape. The resolution of these maps
depends on the density of the laser de-
tector array; a good image of a human
may require hundreds of detection pix-
els to capture enough detail to clearly
detect changes in limb positions. Simulated LIDAR Point Clouds
A LIDAR sensor capturing a series of
human body poses over a period of time in a laboratory setting, the variety of an- his/her motion capture data, was intro-
can provide clues as to the observed gles from which they would have to be duced for synthetic LIDAR image gener-
subjects intent based on his/her activi- recorded would require a large amount ation. Since the original human sub-
ties. Human observers can often easily of time spent recreating and recapturing jects shape and motion were both
identify specific activities and some- said activities, unless one deploys a captured in the 3D digital model, the
times make a reasonable guess regarding LIDAR sensor at every viewing angle. virtual model can easily be rotated in in-
the subjects intentions. However, com- However, multiple LIDARs not only crements through 360 to capture the
puters do not as quickly, nor as easily, are expensive to acquire but also can simulated LIDAR images corresponding
achieve the same results. cause interference among each other. In to different viewing angles.
Automated human activity recogni- addition to being time-consuming, A software script called Shadows (ver-
tion typically requires development of working with live subjects carries the sion 1.5.2) automates the process so
complex machine learning algorithms risk that subjects would not be able to that after a brief setup, the computer
whose performance depends on the size replicate their poses consistently over runs the image data collection largely
and representativeness of available numerous trials. Alternatively, if previ- unattended. This is more efficient and
training datasets. A large 3D shape ously captured 3D body scan and mo- repeatable than using a live human sub-
database of human pose images with tion capture data were available to ject throughout the data collection.
multiple human subjects and viewing recreate a human subjects pose and ac- Moreover, if there are any errors in the
angles would help greatly in the devel- tivity for evaluation within a virtual data collection, it can be regenerated
opment of activity recognition software. LIDAR research environment, these lim- easily. The main mechanism of generat-
With the release of low-cost range cam- itations associated with live subject ing the simulated LIDAR image is based
eras, new datasets in the form of 3D LIDAR research could be avoided, while on the orthographic ray tracing which
depth images were generated for the preserving the authenticity of the poses traces a ray along the path defined by a
purpose of human action analysis and and activities being studied. mesh vertex normal and stores an array
recognition. A study completed in the AFRL 711 comprised of the locations where (i.e.,
Recording a large number of LIDAR HPW/RHXBs 3D Human Signatures upon which polygon) the simulated ray
images of various human activities with Laboratory (3DHSL) facility recorded hits the human models outer surface
actual research subjects would be unnec- the needed sets of scan and motion cap- mesh. In this dataset, the resolution of
essarily difficult and time-consuming. ture data. A virtual laboratory was cre- the simulated LIDAR images is roughly
While subjects could certainly be ated wherein a 3D digital model of a 100-by-100 pixels, which is in the range
recorded performing activities of interest human subject, animated based on of typical commercial flash LIDAR.

32 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Tech Briefs

This hybrid experimental/virtual ap- tion capture system, which tracks a set
proach enables us to generate partial of 68 retro-reflective markers affixed to
surface point clouds with a complete a tight-fitting garment worn by the vol-
spherical coverage of viewing angles unteer, based on a modified Helen
along different azimuths and eleva- Hayes type marker set. Marker trajecto-
tions. We can also create the same point ries are captured during the subjects ac-
clouds at different scales to simulated tivity trials using 18 cameras. The sub-
LIDAR images of distant human targets. jects performed a variety of specified
Unlike many common avatar anima- actions within the capture volume in-
tions produced by artists, each of our cluding digging, picking up and putting
action simulations is individualized down an object, throwing, limping with
with respect to one of the human test a weighted ankle brace, and running.
subjects. The accompanying figure The motion capture volume is approxi-
shows two examples of such point mately 20 feet long, 15 feet wide, and
cloud patches. eight feet high.
Sixty-eight human subjects whose Using 3D scans of the human
data were used for SLI generation were shapes to create mesh models, fol-
scanned and motions captured in the lowed by animating the models with
AFRL 711th HPW/RHXB 3DHSL facility. motion capture data, could yield con-
The raw data collection process consists sistent and repeatable digital human
of two parts whole-body scans and op- avatars. Coupled with an automatic
tical marker-based motion capture. A orthogonal ray- tracing script, the vir-
whole body scanner photometric sys- tual laboratory allows simulating
Precision Metal Stamping
(High and Low Volume)
tem with nine camera pods was used to LIDAR point clouds of human actions
capture the subjects shape in a standing quickly and consistently for different Welded & Mechanical Assemblies
pose. Each pod wa comprised of two viewing angles and scales, as well as
Complex CNC Machining
black and white cameras, one color for a large number of subjects. The
camera, and one (or two) speckle pat- simulated data can then be used in re- Close Tolerance Grinding
tern projectors. search on human pose shape retrieval
Tooling, Fixtures and Gages
The data from each individual pod is and action recognition from single-
used to generate one continuous 3D view 3D point clouds. Laser Cutting and Welding
point cloud, which is then merged with This work was done by Jeanne Smith and
Rapid Prototyping
the data from the other camera pods to Iaiah Davenport of Infoscitex Corp., and
create a textured high-resolution 3D Huaining Cheng of the Air Force Research Wire EDM
whole-body image. The subjects wear Laboratory for the Air Force Materiel Com-
tight-fitting, stretchy clothing for a true mand. For more information, download
body shape during scanning. the Technical Support Package (free white
The three-dimensional mocap data paper) at www.aerodefensetech.com/tsp
are gathered using a passive-optical mo- under the Sensors category. AFRL-0241.

Advanced Sensors for Traumatic Brain


Injury (TBI)
Implanted sensors could be used to measure intracranial pressure
in TBI patients.
Army Medical Research and Materiel Command, Fort Detrick, Maryland

T he objective of this work was to


use miniaturized, state-of-the-art
pressure/temperature sensors engi-
longer-term measurements of biologi-
cal ICP and intracranial temperature.
The experience gathered from this
neered at Lawrence Livermore Na- work provided valuable data on sensor
tional Laboratory (LLNL) to measure placement, long-term brain tissue re-
the immediate increases in intracra- sponses to implanted sensors, and sen-
nial pressure (ICP) combined with sor capability of dual measurement of

Aerospace & Defense Technology, April 2016 www.aerodefensetech.com Free Info at http://info.hotims.com/61060-779


Intro Cov ToC + A

Tech Briefs

sors have an ultra-thin form factor The first closed-diaphragm wafer sen-
(thickness 90 m prior to packaging, sors were received from LLNL and imme-
and 130 m after final packaging). The diately tested. Static calibration produced
new sensors were designed to measure a linear relationship between 5 and 25
absolute pressure by modifying the PSI with an R2 = 0.986. The closed-di-
original contact stress sensor design to aphragm sensor is 90 microns thick, and
create a reference cavity a trapped vol- the final product with Kapton packaging
ume of gas that is hermetically sealed is 130 microns thick. Dynamic compari-
within the device. The new sensors pre- son of the new sensor with the existing
define the pressure sensors reference fluid percussion pressure transducer pro-
cavity within the silicon-on-insulator vided close tracking of pressure events.
(SOI) wafer. Initial testing revealed the need for
Close-up of the sensor showing the diaphragm (A) Five new sensors with diaphragm di- shielding of cables and power supply for
and four connector contact strips (B). ameters of 200, 400, 600, 800, and 1000 subsequent applications.
m (see figure) underwent testing and This work was done by Bruce Lyeth,
biologic ICP and impact pressure tran- calibration to determine the optimum Ph.D., of the Regents of the University of
sients. diaphragm diameter for subsequent in- California, Davis, for the Army Medical
Test-ready sensors were produced animal testing. The new sensors were Research and Materiel Command. For
with a range of diaphragm diameters packaged with an encapsulating layer of more information, download the Tech-
(200 - 1000 m). Diaphragm diameter Kapton to protect the sensor diaphragm nical Support Package (free white
should affect sensitivity of the sensors. and electrical connections from body paper) at www.aerodefensetech.com/tsp
These wafer-scale, absolute pressure sen- fluids. under the Sensors category. ARL-0190

Multifunctional Core-Shell and Nano-Channel Design for


Nano-Sized Thermosensor
Effective temperature sensing is important for many military-related activities, including environmen-
tal sensing in a highly explosive event.
Defense Threat Reduction Agency, Fort Belvoir, Virginia

T his work focused on developing


novel nano-sized thermal sensors
based on a multifunctional core/shell
the Au film upon thermal treatment
was characterized using AFM, SEM, and
x-ray diffraction (XRD), and their opti-
by UV-vis-IR photospectrometer and
Raman spectroscopy.
The effects of thickness on the tem-
and nano-channel design that can be cal responses (localized surface plasmon perature sensitivity were investigated,
used to measure temperature and re- absorption and surface enhanced which allows the design of various
taining thermal history of the biological Raman spectroscopy) were investigated nano-sized dynamic sensors for desired
agents experienced during the testing of
agent-defeat weapons.
Au-based nanostructure in thin film
geometry was explored as potential
nano-sized dynamic thermal sensors.
The Au ultrathin films with different
thicknesses varying from 1 to 5 nm
were prepared by thermal vaporation
on silica substrates, and the film mor-
phology was characterized by atomic
force microscopy (AFM) and scanning
electron microscopy (SEM). Thermal
shock of Au ultrathin films was per-
formed using a tube furnace within the
temperature range from 200 to 700 C,
and the duration varies from 3 to 180 A 3D thermal model of the core shell nanostructure as a thermal sensor. The duration is within 100 ms to 1 second,
seconds. The morphological change of and temperature ranges from 400 to 800 C.

34 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Tech Briefs

temperature regimes. Based on the systematic structural inves-


tigation and optical characterization, the correlation among
the absorption band, FWHM, and the morphological charac-
teristics such as particle size, shape, interparticle spacing, and
fraction of open dewetting area was established. A simplified
model was derived to correlate the change of the absorption
band with the temperature and duration, which enable pre-
diction of the thermal profile sensor materials experienced
during a thermal event. The thermal history model was also
experimentally validated.
Significant advancement was achieved in developing a
core/shell nanostructure as ultrafast dynamic nano-ther-
mometers with extreme sensitivity and fast response to rapid
temperature variation. Particularly, silica/Au core shell nanos-
tructures with well controlled surface morphologies were syn-
thesized, and the surface plasmon resonance properties upon
thermal shock were investigated in order to explore their po-
tential as ultrafast dynamic thermometers. The correlation be-
tween different synthesis conditions and the surface plasma
resonance (SPR) was identified, and reproducibility of materi-
als synthesis was evaluated.
Thermal shock experiments were performed within the time
of 100 ms up to 2 seconds using a pyroprobe, and the proper-
ties variation of the SiO2/Au core shell nanostructures were in-
Free Info at http://info.hotims.com/61060-780
vestigated as a function of temperature and duration. The ther-
mal history model was also developed based on the dynamics
of the morphology changes as controlled by the thermal-
dewetting, and the potential of using SPR variation upon ther-
mal shock as effective sensing mechanisms was evaluated. A
3D contour map was developed that enables establishment of
the connection among the SPR peak shift, temperature, and
duration of a thermal event. This systematic investigation
leads to the development of an ex-situ, ultrafast, dynamic
nano-thermometer based on silica/Au core shell nanostruc-
tures with extremely fast response below sub-second and even
100 ms, and sensitivity at a temperature of 300 C.
A key issue for the potential application of the silica/Au
core shell nanostructure for real detection is the reproducibil-
ity and sensitivity in a real environment. The scientific prin-
ciple for temperature sensing for the core shell structure is
based on the thermal dewetting-induced morphology and the
associated optical properties variation. The debris of the deto-
nation event may affect the sensitivity and applicability as
sensor elements based on optical properties vary. To test this,
systematic studies were conducted to investigate the interfer-
ence and impact of heterogeneous phase or impurity with the
sensor elements with the focus on the reproducibility of the
absorption spectra. These results indicated that the optical
properties wont be affected by the second phase or impurity
as it relates to the intrinsic electrical structure and electron
field/nanostructure interaction. Therefore, the core shell does
show potential when used as a sensor in a detonation event.
This work was done by Jie Lian of Rensselaer Polytechnic Insti-
tute and Qingkai Yu of Texas State University for the Defense
Threat Reduction Agency. For more information, download the
Technical Support Package (free white paper) at www.
aerodefensetech.com/tsp under the Sensors category. DTRA-0004

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-781 35


Intro Cov ToC + A

ITAR-Registered Tech Briefs
To Build Your
Machinery
Some Assemblies
Required.
Magnet Applications has been supplying industries like yours
with magnetics and magnetic sub-assemblies for over 50 years.
Molecularly Imprinted
Our expertise incorporates precision design, exceptional
engineering and supplying complete sub-assemblies from our
Polymer (MIP)-Coated
own facility - delivered in any quantity with a fast turnaround. Microbeam MEMS Sensor
for Chemical Detection
This sensor enables rapid detection and
identification of chemical warfare agents and
energetic materials.
MADE IN
Army Research Laboratory, Adelphi, Maryland
Only North American Manufacturer

M
of Compression Bonded Magnets
onitoring trace gases is of great importance in a wide range
ITAR/DFAR & ISO 9001 Registered Engineering Design & Analysis Services of applications. Detecting a diverse range of chemical
Sensor Class Magnetics for Critical Applications Indexing Features for Alignment & Orientation
agents requires an adaptable sensor platform capable of identi-
fying threats before they cause harm. Research and develop-
ment in hazardous-materials detection technology focuses on
increasing speed, sensitivity, and selectivity while reducing size
and cost. Although the current state-of-the-art vapor detector
eMail: Sales@MagnetUS.com (Joint Chemical Agent Detector) is lightweight, handheld, and
(800) 437-8890 magnetapplications.com easily attaches to a belt, it still provides added bulk to a soldier
on foot. Recently, microcantilever-based technology has
emerged as a viable platform due to its many advantages such
Free Info at http://info.hotims.com/61060-782
as small size, high sensitivity, and low cost. However, microcan-
tilevers lack the inherent ability to selectively identify chemi-
cals of interest. The key to overcoming this challenge is to func-
tionalize the top surface of the microcantilever with a sorbent
layer (i.e., polymer) that allows for selective binding between
the microbeam and analyte(s) of interest.
Molecular imprinting involves arranging polymerizable func-
tional monomers around a template, followed by polymeriza-
tion and template removal (see figure). Arrangement is generally
achieved by noncovalent or reversible covalent interactions. In
both types of molecular imprinting, once the template is re-
moved, three-dimensional cavities are generated within the
final materials that are complementary to the template molecule
Rod Ends and Spherical
in size, shape, and functionality. Essentially, one creates a molec-
Bearings designed and ular memory within the imprinted polymer matrix. This al-
manufactured to Aurora's lows preparation of polymers that are selective for the adsorp-
exacting standards for quality tion of the target molecule of interest. Other advantages of this
and durability. technique include robustness and stability under a wide range of
Registered and Certified to chemical and physical conditions, and an ability to easily design
recognition sites for a plethora of target chemicals (e.g., pesti-
ISO-9001 and AS9100.
cides, energetic materials, pharmaceuticals, and proteins).
From economy commercial to The polymer materials of interest are sol-gel-derived xero-
aerospace approved, gels, which have been used as a platform for MIP-based sensor
we've got it all ! development. These materials are attractive because their
physicochemical properties can be adjusted by choice of pre-
cursor(s) and the processing protocol. Precursors were chosen
based on potential interactions with the explosive 2,4,6-trini-
Aurora Bearing Company trotoluene (TNT). These specific interactions allow for in-
901 Aucutt Road creased target recognition.
Montgomery IL. 60538 A MIP alone does not meet the requirements for a sensor
without some form of a transducer to convert the analyte in-
Complete library of CAD drawings and 3D models available at:
teraction into a measureable signal. There is evidence of a va-
w w w . a u r o r a b e a r i n g . c o m riety of gravimetrical detection techniques applied to convert

36 Free Info at http://info.hotims.com/61060-783 Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Tech Briefs

Template Polymer matrix


molecule
Removal of
Assembly Polymerization template molecule

Polymerizable Formation of Unoccupied


functional monomer imprinted sites template site

A simplified schematic of molecularly imprinted polymer fabrication.

a MIP into a sensor. Low-mass, high- tion of explosive compounds and warfare agents of interest to the Army. A
frequency, and low-cost micro/nano CWAs. To date, this is one of the only successful MIP-coated microbeam
sensors utilizing mass loading of micro- demonstrations of a MIP-coated mi- MEMS sensing format could reduce sen-
cantilevers have drawn increasing atten- crobeam MEMS sensing platform for sor cost and size, while maintaining the
tion in the area of gravimetric sensing, these targets. Although preliminary, the high sensitivity, selectivity, and porta-
and MIPs have become an attractive data suggests that this combination is bility needed for military applications.
thin film coating for many microelectro- an effective and robust chemical This work was done by Ellen L. Holthoff
mechanical systems (MEMS)-based sen- nanosensing scheme. Further investiga- of the Army Research Laboratory and Lily
sors. In this work, molecularly im- tions will focus on refinement of the Li, Tobias Hiller, and Kimberly L. Turner of
printed xerogel thin films have MIP (i.e., xerogel formulation) for im- the University of California Santa Barbara.
demonstrated selectivity and stability in proved selectivity. Finally, the MIP- For more information, download the
combination with a fixed-fixed beam coated microcantilever sensor platform Technical Support Package (free white
MEMS cantilever. evaluation should be expanded to in- paper) at www.aerodefensetech.com/tsp
The sensors are fixed-fixed beams of clude other explosives and chemical under the Sensors category. ARL-0191
varied lengths and widths. The beam
thickness was 2 m. The values were cho-
sen so that the natural frequencies of the
beams were less than half the natural fre-
quency of the shear piezo actuator (330
kHz) used to drive the device. The mi-
crobeams were fabricated using a standard
silicon on insulator (SOI) process. The SOI
wafer used was 2 m silicon (Si) device
layer with 1 m buried oxide and 520 m
Si handle. First, oxide was grown on both
sides of the wafer. Silicon nitride (Si3N4)
was deposited on the backside on top of
silicon oxide; together they serve as masks
to protect the backside for potassium hy-
droxide (KOH) etch in a later step. After
front side oxide removal, it was then spun
with photoresist and pattern was trans-
ferred. Then a deep reactive-ion etching
was used to define the device features.
Back side mask features were defined
using photolithography and inductively
coupled plasma. The front side was spun
with a ProTEK coating to protect features
during back side release etch. The back
side was opened by anisotropic KOH etch
and stopped at the buried oxide. The de-
vice was then finished with removal of
ProTEK and buried oxide layer.
The work reported here validates the CONTACT US:
MIP-coated microcantilever sensing
1.207.892.8899
concept and demonstrates the feasibil-
ity of this MEMS sensor for the detec- TUBEHOLLOWS.COM

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-784 37


Intro Cov ToC + A

Application Briefs

Design Software
Collier Research Corporation
Newport News, VA
757-825-0000
http://hypersizer.com

W hen announcing the completion of the Bell V-280 tiltro-


tor fuselage at a press conference, Bell Helicopter leader-
ship applauded the Bell Helicopter/Spirit AeroSystems team
for a job well done, ahead of schedule and within budget. This
event marked the culmination of a successful first-time collab-
oration between the two companies.
The sizing and analysis software Spirit used to prove out the
structural integrity of the V-280 was HyperSizer from Collier
Research, the first software package used by NASA to be made
available on the commercial market. Employed for both aircraft the JMR-TD program. A next generation tiltrotor, the Bell V-
and space-launch vehicles fabricated with composite or metal- 280 Valor advanced technology tiltrotor provides improved
lic materials, the software automatically performs design, stress speed, range and payload for expeditionary maneuvers.
analysis and sizing optimization, typically reducing the weight The unit was designed and assembled in Spirits rapid pro-
of structures by 20-40%. On the V-280 fuselage prototype pro- totyping facility in Wichita, Kansas in just 22 months. The
gram, Spirit AeroSystems employed HyperSizer for detailed siz- composite fuselage was shipped to Bell Helicopters facility in
ing of the fuselage. Important structural requirements include Amarillo, Texas for final assembly, and the build continues to-
strength, stability, stiffness and deflection/rotation limitations wards a first flight in the second half of 2017.
for severe flight, landing and ground load cases. To meet the aggressive V-280 schedule, HyperSizer was em-
The V-280 Valor is competing in the Department of De- ployed in a design-by-analysis approach that successfully
fenses Joint Multi-Role Technology Demonstrator (JMR TD) sized and analyzed the fuselage structure. HyperSizer also pro-
program. This is a science and technology precursor to the De- vided the engineers with automated stress-report generation
partment of Defenses Future Vertical Lift program, with the that enabled them to review and vet all relevant data in order
goal to replace 2,000 to 4,000 medium-class utility and attack to prove-out the structural soundness of the fuselage.
helicopters. The V-280 Valor is Bell Helicopters offering for For Free Info Visit http://info.hotims.com/61060-509

Night Vision Displays logistics, it is vital that


users are provided with a
Daisy Data Displays normalized interface in
York Haven, PA both daylight and with
717-932-9999 night-vision goggles. That
www.makeitdaisy.com made being able to transi-
tion from day to night vi-

U nited States Coast Guard officials required night-vision


goggle compatibility for the flat panel display systems
used in the Lockheed C-130 military aircrafts. To meet the re-
sion without the need for
add-on filters a priority.
The Fleetmate 7171CA
quirement, they recently purchased Fleetmate 7171CA Series features a 10.4" high res-
thin client flat panel displays with night-vision technology olution resistive touch
manufactured by Daisy Data Displays. screen that is pressure sensitive and responsive to any input
Daisys monitors feature a unique, new-to-market night-vi- device. Its one touch for night/day operating system provides
sion imaging system (NVIS) technology that gives users full- quick on the fly changeover and a built-in LCD heater en-
color readability in daylight and with night-vision goggles sures display operation across a broad temperature range. Up
without the need for add-on filters. The C-130Hs two-pilot to 500 NITs display with 100:1 brightness adjustment allows
flight station is currently equipped with digital avionics, head- precise brightness setting from bright to zero. The terminal
up displays, and a state-of-the-art navigation system. This features a PXA25 32-bit XScale processor, 16 MB RAM (ex-
fully-digital interface must be readable in all degrees of light. pandable up to 72 MB), 8 MB Flash ROM, Ethernet 10\100
The C-130H, in its role as the chief support aircraft for the Base-T, and VT200 terminal emulation. The enclosure is a
US Coast guard, serves in various applications that require dis- combination of aluminum 6061-T6 and cold rolled steel,
plays to support day to night transitions. In operations, such as nickel plated.
long-range search and rescues, homeland security patrols, and For Free Info Visit http://info.hotims.com/61060-507

38 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

Application Briefs
APPROVED for Critical
Bonding Applications by

Fuel Flow Meters EP30-2 EPOXY ADHESIVE


Hoffer Flow Controls
Elizabeth City, NC
252-331-1997
www.hofferflow.com

H offer Flow Controls, Inc. recently received a new contract


to supply 575 fuel flow meters as a part of the U.S. Navys
H-53 heavy lift helicopter fleet upgrade. The most powerful
helicopter in the U.S. Military, H-53 helicopters perform
many tasks within the U.S. Military including heavy lifting,
transport of supplies, combat search, rescue missions and
TESTED BY LIGO* FOR:
mine sweeping to clear vital shipping lanes. The current Low outgassing rates
H-53 helicopter fleet is slated to remain in service until Vacuum serviceability
mid-to-late 2020s. Advanced optical assemblies
Hoffer fuel measuring flow meters will be paired with How-
* The Laser Interferometer Gravitational-Wave Observatory
ell Instruments fuel flow indicators to comprise an upgraded
fuel flow indicating system for the helicopters. Howell Instru-
ments developed a custom indicator that requires no rewiring
and provides a fit, form, and function replacement to monitor
the fuel flow.
Hoffers 1/2" 3/8" custom liquid flow meters with tempera-
Hackensack NJ 07601, USA +1.201.343.8983 main@masterbond.com
ture compensation have special magnetic pickup coils for pair- www.masterbond.com
ing with the Howell indicators. Made with custom designed
Free Info at http://info.hotims.com/61060-785
housings that will fit within the footprint of the existing space,
the female MS 3/4" end fittings mate with the existing aircraft
interface connectors and fuel lines. The Hoffer 316 stainless
steel flow meters provide a repeatability of +/-0.1% of reading
and temperature compensation. Installation of the fuel flow
measuring systems is expected to begin in February of 2016.
The Sikorsky H-53 has flown in a variety of configurations A Furukawa Company
throughout its 50 year history with the U.S. military. In heavy Your Optical Fiber Solutions Partner
lift configuration (CH-53K), the latest generation features
three T408-GE-400 engines, auxiliary power unit (APU) with
pneumatic start, and integrated Engine Air Particle Protection
System (EAPPS), a Rockwell Collins Avionics Management Optical Fibers, Cables and Modules
System with fly-by-wire flight controls, and Aircraft Surviv- for Challenging Applications
ability Equipment (ASE).
The Navys specialized mine-sweeping version (MH-53E)
comes equipped with enlarged fuel sponsons enabling it to pro- Rad Hard GyroSil PM for Gyroscope Coils
vide long-range fleet support and stay aloft for extended peri-
linx MICRO Cables for Unmanned Craft
ods, using mechanical, magnetic, and acoustic sweep gear and
mine-hunting sonar to clear vital shipping lanes. The MH-53E FlightLink and FlightGuide for Avionics Systems
also performs the U.S. Navys vertical onboard delivery (VOD)
Yb & Er/Yb Optical Fiber and Modules
mission, transporting heavy equipment to and from ships.
for LADAR & Directed Energy
For Free Info Visit http://info.hotims.com/61060-508

SPEAK WITH THE EXPERTS!


New Orleans, LA, USA | 2 - 5 May 2016
Booth #631

www.ofsoptics.com /ofsoptics /ofs_defense /company/ofs /OFSoptics

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-786 39


Intro Cov ToC + A

New Products

Military Wide Band Amplifier 50 GHz Handheld Combination Analyzer


Lansdale Semiconductor, Inc. Keysight Technologies, Inc. (Santa Rosa, CA) has added six
(Phoenix, AZ) has announced millimeter-wave models to its family of FieldFox handheld an-
the continued availability of the alyzers. The flagship model is the industrys first handheld
ML1590/BGA military wide- combination analyzer to provide coverage to 50 GHz. Three
band RF amplifier, National combination-analyzer models cover 32, 44 or 50 GHz and pro-
Stock Number (NSN) 5962-01- vide spectrum analysis, vector network analysis, and cable
280-2203. The ML1590 is sup- and antenna testing in a rugged, portable unit. The three spec-
plied in (8) lead metal cans to Standard Microcircuit Drawing trum analyzer models cover the same frequency range.
(SMD) 5962-876570 integrated circuits (ICs), originally designed The FieldFox family is optimized for field testing. The fully
and built by Motorola/Freescale Semiconductor, Inc. sealed enclosure no fans or vents is compliant
Lansdale has single-source rights to both globally market with US MIL-PRF-28800F Class 2 standards
and continue to manufacture to the Department of Defense and is also type tested to meet MIL-STD-
Specification MIL-PRF-38535 Integrated Circuits Manufac- 810G requirements for operation in
turing, General Specification MIL-STD-883-test Method Stan- explosive environments (Method
dard Microcircuits, and MIL-STD-1835 Interface Standard 511.5, Procedure 1). FieldFox analyz-
Electronic Component Case Outlines. ers are also type tested to meet
The ML1590 operates over the full Mil. Temp. range of -55 IEC/EN 60529 IP53 requirements for
deg. C to +125 deg. C. Applications support mature circuit de- protection from dust and water.
signs in Military Systems as well as new designs for video am- For Free Info Visit http://info.hotims.com/61060-511
plifiers, mixers and staged IF amplifiers and can be used in
Navigation Test Instrumentation and Global Positioning Sys- Axial and Radial Seals
tems (GPS). Morgan Advanced Materials
For Free Info Visit http://info.hotims.com/61060-510 (Windsor, UK) Seals and Bear-
ings business offers quality axial
and radial seal components for
applications with severe service
www.hunterproducts.com conditions. Morgans compo-
nents are highly thermally conductive and resist corrosion due to
their rugged construction from carbon, graphite, and silicon car-
bon-based materials. They perform reliably under stress and can
be tailored to best fit individual applications.
The axial and radial seal components, like split seals for gas
seals, are suitable for use in the aerospace, chemical process-
ing, oil & gas, pharmaceutical industries, and more. They fea-
ture high mechanical strength, chemical inertness and dimen-
sional stability and are easy to install, leading to reliable
performance in nearly any application.
For Free Info Visit http://info.hotims.com/61060-513
MICRO-METALLIZER PLATING PENS MIL & QQ
Standards GOLD 14K, 18K, 24K, SILVER, RHODIUM,
PALLADIUM, NICKEL, COPPER, TIN, BLACK 3136 GHz Receiver
NICKEL, AND CHROME COLOR PENS AVAILABLE. Richardson RFPD (Geneva, IL), Inc.
announced the availability and full
Environmentally friendly, these low-cost disposable applicators design support capabilities for a new
permit instantaneous selection from a variety of plating receiver from M/A-COM Technology
possibilities without the preparation of solutions. Specially Solutions. The XR1020-QH is a 3136
formulated compounds and can be used for contact repair, GHz receiver with a noise figure of 3 dB
prototype development work, electronic instrument repair, and 14 dB conversion gain. It integrates a
medical instrument repair etc. low noise amplifier, image reject mixer and LO
buffer amplifier within a fully-molded, lead-free,
Hunter Products Inc. 4-millimeter, 24-lead PQFN package. The image reject mixer
792 Partridge Drive, P.O. Box 6795 eliminates the need for a bandpass filter after the LNA to re-
Bridgewater, NJ 08807-0795 move thermal noise at the image frequency. I and Q mixer out-
s&AX puts are provided, and an external 90 hybrid is required to se-
sales@hunterproducts.com lect the desired sideband. The XR1020-QH is suitable for
point-to-point radio, SATCOM and military applications.
For Free Info Visit http://info.hotims.com/61060-530

40 Free Info at http://info.hotims.com/61060-787 Aerospace & Defense Technology, April 2016


Intro Cov ToC + A

New Products

720W AC-DC Switching Power


Supplies

Acopian (Easton, PA) announced that


the 1U Switching Regulated 720W AC-
DC Power Supply family is now RoHS
Compliant and certified to UL Safety
Standards UL 60950 (Information Tech-
nology Equipment), and UL 508 (Indus-
trial Control Equipment). The power
supplies feature single output voltages
from 1V-135V, wide-adjust output volt-
ages from 0V-5V to 0V-135V and current
capabilities up to 70A. They offer 720W
of output power and are available with an How will your business adapt and grow?
optional auxiliary output (to 180 watts).
The Acopian power supplies accommo- The aerospace, defense (including arms) and medical device
date the universal AC input voltage of 95 industries face similar challenges; stringent regulations, mission-
to 265 VAC, 49-420 Hz, single phase.
critical quality control and the need for cutting-edge technology.
They feature active power factor correc-
tion (PFC) of 0.99 typical at 115VAC, 60
The demand for advanced manufacturing technologies is outpacing
Hz and full load to ensure operation in the traditional R&D model.
challenging AC environments and com-
pliance with EN61000-3-2.
For Free Info Visit Mfg4 is the Answer!
http://info.hotims.com/61060-512
Attend to find creative solutions and game-changing ideas from
RF Amplifier System other industries that can be applied to your specific manufacturing
Empower RF
Systems (Ingle-
challenges
wood, CA) has
begun shipping
Exhibit to engage with high-level buyers from diverse industries
the Model 2180
and expand your customer base into new markets
RF amplifier sys-
tem covering 1 The most promising manufacturing ideas and opportunities may be
to 2.5 GHz and just outside your industry
delivering 2 kW CW of broadband output
power in a 8U, air-cooled chassis. Features
include: user selectable configuration and To register or exhibit visit mfg4event.com
operation in three different modes - AGC
(Automatic Gain Control), ALC (Automatic
Level Control) and MGC (Manual Gain
Control); modern and multi-faceted Moni-
toring and Control (M&C) user interfaces,
including a Web browser, TCP/IP Ethernet,
RS-485 interface and a front panel touch- ENDLESS OPPORTUNITIES ARE JUST OUTSIDE YOUR INDUSTRY
screen display (optional IEEE-488 GPIB in-
terface available); and enhanced rugged-
ness using the latest in high voltage RF May 3-5, 2016
transistors (GaN).
For Free Info Visit
Connecticut Convention Center | Hartford, CT
http://info.hotims.com/61060-519

Aerospace & Defense Technology, April 2016 Free Info at http://info.hotims.com/61060-788 41


Intro Cov ToC + A

Product Spotlight
COMSOL CUSTOM RUBBER New Products
MULTIPHYSICS FOR MOLDING TO EXACT
SIMULATION APP SPECIFICATIONS
DESIGN You probably know us best as pro-
COMSOL Multiphysics delivers ducers of rubber molded parts.
tools for modeling, simulation, However, you may not know that
and application design. With the weve produced many parts that
Application Builder, simulation specialists can build other companies considered nearly impossible to
and share simulation apps within organizations, make. Our specialty? Precision custom molded parts
from design and development to production and at a competitive price with on time delivery. 12A POL DC-DC Converters
testing. See whats new in simulation technology at Injection, transfer and compression molding of TDK Corporation
Silicone, Viton, Neoprene, etc. Hawthorne Rubber
comsol.com/release/5.2
Manufacturing Corp., 35 Fourth Ave., Hawthorne,
(National City, CA)
NJ 07506; Tel: 973-427-3337, Fax: 800-643-2580, has introduced the
COMSOL, Inc. www.HawthorneRubber.com 12 Ampere TDK-
Hawthorne Rubber Lambda iCH
series of POL
Free Info at http://info.hotims.com/61060-790 Free Info at http://info.hotims.com/61060-791 (Point of Load)
non-isolated DC-
TE CONNECTIVITY SHX1 LONG- DC converters. Accept-
(TE) KILOVAC RANGE MULTI- ing a wide range input of 4.5 to
KHR500 HIGH- CHANNEL 14 VDC, the series can operate from either
VOLTAGE 600 AMP TRANSCEIVER a 5 VDC or 12 VDC bus. The iCH series can
CONTACTORS Lemos International offers provide output voltages from 0.7 to 8.5V,
the SHX1 Long-Range Multi-Channel Transceiver with efficiencies of up to 97%. A low inter-
The KILOVAC KHR500 (Bubba II) high-voltage, high-
that provides:
rupture, 600 AMP contactor is smaller, lighter, and
Unlicensed operation on MURS band frequencies nal power loss allows the iCH to deliver
switches significantly higher power than its predeces-
sor, the EV500 (Bubba I). It is capable of handling
(under FCC Part 95) 12A output current, without forced air
Data rates up to 5 kbps for standard module cooling, in ambient temperatures in excess
inrush currents as high as 4000 A. The new contactors
High-performance double superhet PLL synthesizer
are hermetically sealed for use in harsh and explosive
Usable range over 5km of 70 C.
environments. For more information, call 800-422-
3911 or visit www.connecticc.com. https://www.
Re-programmable via RS232 interface, fully The surface mount converters measure
screened, low profile, small footprint. 0.48 0.48 0.335 inches (12.2mm
connecticc.com/rpages/te-khr500-adt-april-2016
www.lemosint.com
Interstate Connecting 12.2mm 8.5mm) with a weight of just
Components Lemos International 2.5g. Product features include output
Free Info at http://info.hotims.com/61060-792 Free Info at http://info.hotims.com/61060-793 trim adjustment, power good, remote
sense and a choice of positive or negative
EPOXY logic remote on/off.
AVIONICS
PASSES For Free Info Visit
PANEL METER
HORIZONTAL http://info.hotims.com/61060-520
The Otek APM is a multi-
BURN TEST color LED indicator for
Flame retardant Master aircraft that accepts stan- AdvancedTCA Chassis
Bond EP90FR-HFL is dard 5-32 VDC plus other Pixus Technologies (Waterloo, Ontario,
low voltage/current options. Powerless design per-
a toughened epoxy that passes FAR standard 14 CFR
mits self-powering with only 5 VDC loop burden. Unit
Canada) now offers a 15U AdvancedTCA
25.853(a). It is suitable for use in many specialized
aviation applications including aircraft windows, can be custom scaled and fits a standard 1 hole. (ATCA) chassis that exceeds 400W/slot
lighting assemblies and baggage equipment areas, Night-vision compliant and mil-spec approved. The cooling capability
APM replaces NSN: 6620-00-083-8811 for Form & Fit.
among others. Since it has some flexibility, it is par-
Also RTCA-160F qualified. For more information:
and meets strin-
ticularly useful for bonding dissimilar substrates.
http://otekcorp.com/sites/default/files/apm_1.pdf gent NEBS re-
http://www.masterbond.com/tds/ep90fr-hfl
quirements. The
Pixus chassis lever-
Master Bond Otek Corporation ages the original
Kaparel design that
Free Info at http://info.hotims.com/61060-794 Free Info at http://info.hotims.com/61060-795 used patented Ri-
Cool II blowers for
WIRELESS A WORLD OF FIBER OPTIC 275W/slot of cool-
COMMUNICATION SOLUTIONS ing. Todays 15U unit pro-
PLANNING vides more air evacuation using the next
SOFTWARE generation of reverse impellar hot-plug
Wireless InSite is site-specif- cartridges. The new RiCool III blowers
ic radio propagation soft-
ware for the analysis of feature 185 CFM of airflow per fan with
wireless communication sys- T1/E1 & T3/E3 Modems, WAN 71mm H20 of static pressure.
tems, wireless networks, sensors, radars, and other RS-232/422/485 Modems and Multiplexers
Profibus-DP, Modbus Like the 13U ATCA chassis, the 15U
devices that transmit or receive radio waves. The
new version allows import of KMZ and COLLADA Ethernet LANs enclosure features specially designed
geometry files, making it easy to add single struc- Video/Audio/Hubs/Repeaters EMI filter trays above and below the
USB Modem and Hub
tures, such as bridges, high resolution buildings, or
Highly shielded Ethernet, USB (Tempest Case) card cage that help collimate airflow in
new construction, to a scene. Learn more at
www.remcom.com/wireless-insite. ISO-9001 the system. Both 40GbE and 10GbE
http://www.sitech-bitdriver.com backplane options are available.
Remcom S.I. Tech For Free Info Visit
Free Info at http://info.hotims.com/61060-796 Free Info at http://info.hotims.com/61060-797 http://info.hotims.com/61060-524

42 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


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Publisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Joseph T. Pramberger
Ad Index
Editorial Director TBMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Linda L. Bell For free product literature, enter advertisers reader service num-
Editorial Director SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .William Visnic bers at www.techbriefs.com/rs, or visit the Web site beneath their
Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bruce A. Bennett ad in this issue.
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Billy Hurley
Managing Editor, Tech Briefs TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kendra Smith Reader Service
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ryan Gehm Company Number Page
Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adam Santiago
Assistant Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kevin Coltrinari ACCES I/O Products . . . . . . . . . . . . . . . . . .775 . . . . . . . . . . . .23
Creative Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lois Erlacher Aurora Bearing Co. . . . . . . . . . . . . . . . . . . .783 . . . . . . . . . . . .36
Senior Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ayinde Frederick
Global Field Sales Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Marcie L. Hineman
C.R. Onsrud, Inc. . . . . . . . . . . . . . . . . . . . . .770 . . . . . . . . . . . . .11
Marketing Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Debora Rothwell Coilcraft CPS . . . . . . . . . . . . . . . . . . . . . . . .769 . . . . . . . . . . . . .9
Marketing Communications Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monica Bond
COMSOL, Inc. . . . . . . . . . . . . . . . . . . .790, 799 . . . .42, COV IV
Digital Marketing Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kaitlyn Sommer
Audience Development Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Marilyn Samuelsen CST of America, Inc. . . . . . . . . . . . . . . . . . .798 . . . . . . . .COV III
Audience Development Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stacey Nelson EMCOR Government Services . . . . . . . . .765 . . . . . . . . . . . . .3
Subscription Changes/Cancellations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nasa@omeda.com
ESTECH 2016 . . . . . . . . . . . . . . . . . . . . . . .806 . . . . . . . . . . . .17
TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY Gage Bilt Inc. . . . . . . . . . . . . . . . . . . . . . . . .780 . . . . . . . . . . . .35
261 Fifth Avenue, Suite 1901, New York, NY 10016
(212) 490-3999 FAX (646) 829-0800 Hawthorne Rubber Mfg. Corp. . . . . . . . . . .791 . . . . . . . . . . . .42
Chief Executive Officer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Domenic A. Mucchetti
Hunter Products, Inc. . . . . . . . . . . . . . . . . .787 . . . . . . . . . . .40
Executive Vice-President . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Luke Schnirring
Technology Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oliver Rockwell Imagineering, Inc. . . . . . . . . . . . . . . . . . . . .763 . . . . . . . . . . . . .1
Systems Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vlad Gladoun Interstate Connecting Components . . . . .792 . . . . . . . . . . . .42
Web Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Karina Carter
Digital Media Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Peter Bonavita
John Evans' Sons, Inc. . . . . . . . . . . . . . . . .764 . . . . . . . . . . . . .2
Digital Media Assistants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Keith McKellar, Peter Weiland, Anel Guerrero, Maria Sevilla Kaman Precision Products . . . . . . . . . . . .777 . . . . . . . . . . . .31
Digital Media Audience Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jamil Barrett Keysight Technologies . . . . . . . . . . . . . . . .771 . . . . . . . . . . . .15
Credit/Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Felecia Lahey
Accounting/Human Resources Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sylvia Bonilla Lemos International Co., Inc. . . . . . . . . . .793 . . . . . . . . . . . .42
Office Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alfredo Vasquez Lyons Tool & Die Co. . . . . . . . . . . . . . . . . . .779 . . . . . . . . . . . .33
Receptionist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Elizabeth Brache-Torres
Magnet Applications . . . . . . . . . . . . . . . . .782 . . . . . . . . . . . .36
ADVERTISING ACCOUNT EXECUTIVES Magnetic Component Engineering, Inc. . . . . .778 . . . . . . . . . . . .31
MA, NH, ME, VT, RI, Eastern Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ed Marecki Master Bond Inc. . . . . . . . . . . . . . . . .785, 794 . . . . . . . .39, 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tatiana Marshall
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(401) 351-0274
maxon precision motors, Inc. . . . . . . . . . .772 . . . . . . . . . . . .16
CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stan Greenfield Mfg4 2016 . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . .41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(203) 938-2418 Mini-Systems, Inc. . . . . . . . . . . . . . . . . . . . .776 . . . . . . . . . . . .29
NJ, PA, DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Murray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (973) 409-4685 MPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781 . . . . . . . . . . . .35
Southeast, TX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ray Tompkins New England Wire Technologies . . . . . . .774 . . . . . . . . . . . .21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(281) 313-1004
OFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786 . . . . . . . . . . . .39
NY, OH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ryan Beckman
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(973) 409-4687 Otek Corporation . . . . . . . . . . . . . . . . . . . .795 . . . . . . . . . . . .42
MI, IN, WI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Kennedy PI (Physik Instrumente) LP . . . . . . . . . . . .768 . . . . . . . . . . . . .8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 498-4520 ext. 3008
MN, ND, SD, IL, KY, MO, KS, IA, NE, Central Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bob Casey
Proto Labs, Inc. . . . . . . . . . . . . . . . . . . . . . .766 . . . . . . . . . . . . .5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 223-5225 Remcom . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . .42
Northwest, N. Calif., Western Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Craig Pitcher S.I. Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . .797 . . . . . . . . . . . .42
(408) 778-0300
CO, UT, MT, WY, ID, NM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tim Powers
Space Tech Expo . . . . . . . . . . . . . . . . . . . . .789 . . . . . . . . . . . .43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(973) 409-4762 Superior Tube Co. . . . . . . . . . . . . . . . . . . . .762 . . . . . . . .COV II
S. Calif. , AZ, NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tom Boris
TRENTON Systems . . . . . . . . . . . . . . . . . . .767 . . . . . . . . . . . . .7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (949) 715-7779
Europe Central & Eastern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sven Anacker Tube Hollows International . . . . . . . . . . . .784 . . . . . . . . . . . .37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-202-27169-11 Ulbrich Stainless Steels &
Joseph Heeg Special Metals, Inc. . . . . . . . . . . . . . . . . . . .773 . . . . . . . . . . . .19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-621-841-5702
Europe Western . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Shaw
W.L. Gore & Associates . . . . . . . . . . . . . . .866 . . . . . . . . . . . .13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-1270-522130
Integrated Media Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Patrick Harvey
Aerospace & Defense Technology, ISSN - pending, USPS Application to Mail at Periodicals
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (973) 409-4686
is published monthly in February, April, May, June, August, October, and December (7
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44 www.aerodefensetech.com Aerospace & Defense Technology, April 2016


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